Vauxhall Workshop Service and Repair Manuals

J303000 Exhaust Manifold Gasket, Replace (Z 18 XE, with Air Conditioning, LHD)

  Remove

1.   Open bonnet 2.   Disconnect battery Note:   In vehicles from model year 04 onwards with ESP - the steering angle sensor loses its basic adjustment each time the battery is disconnected and must be recalibrated. •   Detach ground cable 3.   Raise vehicle 4.   Detach front exhaust pipe Note:   Bends in the flex pipe with an angle as little as 5 – 10 degrees from the intended installation position may result in damage with subsequent total failure of the flex pipe. •   When removing the centre muffler, a catalytic converter, an exhaust manifold or an exhaust manifold with catalytic converter, the exhaust system piece remaining in the vehicle must be prevented from swinging uncontrollably. Note:   The exhaust system piece with the flex pipe inside can be secured for this purpose using suitable means, such as a wire on the vehicle underbody. •   Unscrew 3 nuts 5.   Lower vehicle 6.   Remove engine cover. •   Unscrew oil filler pipe cap •   Unscrew 2 bolts •   Screw on oil filler pipe cap 7.   Remove intake pipe •   Remove bolt (arrow) •   Pull intake pipe out of bracket

8.   Remove mixture regulation heated oxygen sensor (2) •   Disconnect wiring harness plug (3) •   Remove cable ties. •   Screw out carefully using KM-6129 (1) 9.   Detach upper radiator hose from thermostat housing •   Place collecting basin underneath. 10.   Remove exhaust manifold heat shield •   Unscrew 3 bolts 11.   Detach oil dipstick guide tube •   Remove bolt •   Swivel the oil dipstick guide tube to one side

12.   Remove exhaust manifold •   Unscrew 10x nut – Remove engine transport shackle •   Remove gasket.

  Install

14.   Install exhaust manifold •   Replace gasket •   Replace nuts •   Position engine transport shackle •   Tighten 10x nuts 12 Nm + 12 Nm Note:   The nuts must be tightened in two stages in accordance with the tightening sequence

26.	Check and correct coolant level