Vauxhall Workshop Service and Repair Manuals

Replace exhaust manifold gasket (conversion from cast manifold to sheet metal manifold)

  Remove

4.   Detach front exhaust pipe (1) Note:   With model variant "ECO" - remove lower engine compartment cover •   Unscrew 3 nuts

5.   Lower vehicle 6.   Remove intake pipe (1) •   Remove bolt (2)

7.   Detach oil dipstick guide tube •   Withdraw oil dipstick •   Remove bolt 8.   Remove heated oxygen sensor for mixture regulation •   Disconnect wiring harness plug •   Unclip cable •   Unscrew carefully using KM-6129 (1) 9.   Remove left engine transport shackle (2) •   Remove bolt 10.   Remove exhaust manifold heat shield •   Unscrew 2 bolts

11.   Remove exhaust manifold •   Unscrew 7x nuts •   Remove gasket. 12.   Remove oil dipstick guide tube 13.   Clean sealing surfaces •   Cylinder head, exhaust manifold

  Install

15.   Attach exhaust manifold brace Note:   On conversion from a cast manifold to a sheet metal manifold, the two-piece exhaust manifold brace and the corresponding bolts must be fitted otherwise the sheet metal manifold may be damaged. •   Attach adapter (2) of exhaust manifold brace to cylinder block – Tighten 2x bolts (1) 22 Nm •   Attach exhaust manifold brace (4) to adapter – Screw in 2x bolts (3)

16.   Lower vehicle 17.   Insert dipstick guide tube •   Replace 2 seal rings (1)

18.   Install exhaust manifold •   Replace gasket Note:   On conversion from a cast manifold to a sheet metal manifold, the correct gasket must be fitted. •   Replace nuts – Tighten 7 x nuts (1) 15 Nm

19.   Raise vehicle 20.   Attach catalytic converter to exhaust manifold brace •   Screw in 2x bolts (2) •   Tighten 2x bolts (1) 22 Nm •   Tighten 2x bolts (2) 22 Nm

21.	Attach front exhaust pipe Note:   With "ECO" model variant - install lower engine compartment cover •   Replace gasket •   Tighten 3x nuts 25 Nm – Replace nuts

22.   Lower vehicle 23.   Attach exhaust manifold heat shield Note:   On conversion from a cast manifold to a sheet metal manifold, the correct heat shield must be fitted. •   Screw in 2x bolts (1)