Vauxhall Workshop Service and Repair Manuals

 

Exhaust Manifold, Remove and Install (X 16 XEL)     Remove, Disconnect    For X 16 XEL with secondary air system: Detach vacuum hose (1) and air duct hose (2) from secondary air combination valve.   Mark installation position of secondary air combination valve (3), unscrew fastening bolts (4) and remove secondary air combination valve from secondary air metal pipe.     Clean    Remove gasket remnants and clean sealing surfaces.

  Remove, Disconnect   

Remove fastening bolts for metal pipe support (2) from metal pipe bracket and exhaust manifold.   Remove fastening bolts (1) from exhaust manifold and take out heat shield.     Clean    Remove gasket remnants and clean sealing surfaces.     Remove, Disconnect    Remove fastening bolts (3) from exhaust manifold and take out secondary air metal pipe.   For X 16 XEL without secondary air system: remove heat shield from exhaust manifold.

  Remove, Disconnect   

Disconnect wiring harness plug for oxygen sensor (1).   Detach front exhaust pipe from exhaust manifold.   Unbolt exhaust manifold together with engine transport shackle from cylinder head and remove.   Remove oxygen sensor and coat thread with special grease (black) when replacing the exhaust manifold.     Clean    Remove gasket remnants and clean sealing surfaces.     Install, Connect    If removed, install oxygen sensor in exhaust manifold - tightening torque 30 Nm / 22 lbf. ft.   Attach exhaust manifold with new seal and new nuts together with engine transport shackle to cylinder head - tightening torque 22 Nm / 16 lbf. ft.   Attach front exhaust pipe with new gasket to exhaust manifold - tightening torque 25 Nm / 18 lbf. ft.   Connect wiring harness plug for oxygen sensor.

  Install, Connect   

For X 16 XEL without secondary air system: attach heat shield to exhaust manifold - tightening torque 8 Nm / 6 lbf. ft.   For X 16 XEL with secondary air system: Insert secondary air metal pipe with new gasket into exhaust manifold and lightly coat thread of fastening bolts (1) and (2) with special grease (black) - tightening torque (M6) 8 Nm / 6 lbf. ft., (M8) 20 Nm / 15 lbf. ft.   Attach heat shield to exhaust manifold using fastening bolts (3) - tightening torque 8 Nm / 6 lbf. ft.   Attach metal pipe support to exhaust manifold using fastening bolts (4) - tightening torque 8 Nm / 6 lbf. ft.

  Install, Connect   

Screw in fastening bolts (4) and attach secondary air combination valve (3) in correct installation position to secondary air metal pipe with new gasket - tightening torque 6 Nm / 4.5 lbf. ft.   Attach air duct hose (2) and vacuum hose (1) to secondary air combination valve.     Important!    Leaks in secondary air system can cause damage to catalytic converter and engine.