Vauxhall Workshop Service and Repair Manuals

Coolant Pipe, Remove and Install (X 16 XEL, Y 16 XE, Z 16 XE)  

Notice: 

Illustration F 9971 shows X 16 XEL with Secondary Air System.  

  Remove, Disconnect   

For X 16 XEL without secondary air system, Y 16 XE, Z 16 XE: Remove intake manifold - see operation "Intake Manifold, Remove and Install (X 16 XEL without Secondary Air System)" or "Intake Manifold, Remove and Install (Z 16 XE)".   For X 16 XEL with secondary air system: remove upper part of inlet manifold - see operation "Inlet Manifold - Upper Part, Remove and Install (X 16 XEL with Secondary Air System)". Remove air intake pipe - see operation "Air Intake Pipe, Remove and Install (X 16 XEL with Secondary Air System)". Remove accelerator Bowden cable (1) from bracket and detach from curved disc. Remove unions from throttle body.   Unscrew fastening bolts (arrows) for throttle body and lay throttle body aside. Remove gasket for throttle body.

  Clean   

Remove gasket remnants and clean sealing surfaces.  

  Remove, Disconnect   

For X 16 XEL with secondary air system: remove throttle body flange (1) from lower part of inlet manifold - note different bolt lengths.   Remove alternator - see operation "Alternator, Remove and Install".   For version with automatic transmission: Disconnect multiplug (2) (twist lock). Unclip compensation tank coolant hose from bracket. Detach relay and fuse box (4) from battery support. Remove battery (3).   Unclip bracket (5) from battery carrier (6) and lay aside. Remove battery carrier.

  Remove, Disconnect   

Version with AT: remove hose clamp (1) from transmission.   Remove coolant compensation tank.   Detach cable tie for wiring loom on coolant hose for radiator.   Detach lower coolant hose (2) from radiator - collect escaping coolant.   Release coolant hose (5) in direction of arrow and detach from heater core. Detach coolant hose (6) from coolant compensation tank, coolant hose (3) from coolant pump and coolant hose (4) from coolant flange.   Unscrew fastening bolt (arrow) for coolant pipe and remove coolant pipe upwards.

  Important!   

When replacing the coolant pipe, ensure that no cables or wiring harness plugs are pinched - ensure correct hose routing and correct seating.  

  Install, Connect   

Insert coolant pipe and attach using the fastening bolt. Attach coolant hoses to coolant flange, to coolant pump and to coolant compensation tank.  

Attach and lock coolant hose to heater core.  

Attach coolant hose to radiator - secure cable bundle with cable tie on coolant hose.  

Attach coolant compensation tank.  

For version with automatic transmission: Fasten coolant compensation tank hose to transmission with hose clamp. Install battery support. Clip cable bundle bracket to battery support. Install battery. Attach relay and fuse box to battery support. Clip compensation tank coolant hose to cable bundle bracket. Connect multiplug (twist lock).  

  Install, Connect   

Install alternator - see operation "Alternator, Remove and Install".  

For X 16 XEL without secondary air system, Y 16 XE, Z 16 XE: Install intake manifold - see operation "Intake Manifold, Remove and Install (X 16 XEL without Secondary Air System)" or "Intake Manifold, Remove and Install (Z 16 XE)".  

For X 16 XEL with secondary air system: attach throttle body flange to lower part of inlet manifold - note different bolt lengths - tightening torque 8 Nm / 6 lbf. ft.  

Attach throttle valve connection with new gasket to throttle body flange - tightening torque 8 Nm / 6 lbf. ft.  

For X 16 XEL with secondary air system: attach accelerator Bowden cable into curved disc and attach to bracket. Attach union to throttle body.  

Install air intake pipe - see operation "Air Intake Pipe, Remove and Install (X 16 XEL with Secondary Air System)", Install upper part of inlet manifold - see operation "Inlet Manifold - Upper Part, Remove and Install (X 16 XEL with Secondary Air System)".  

Top up cooling system - see operations "Cooling System, Top up and Bleed" and "Cooling System, Check for Leaks".