vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Illustration - Coolant Hoses (Z 20 LEL, Z 20 LER) > < Coolant flange, remove and install

Astra H

Coolant Pipe, Remove and Install

  Remove

1.   Open bonnet
2.   Disconnect earth cable from battery
•   Slacken nut
3.   Raise vehicle
4.   Detach front exhaust pipe (2) from catalytic converter
•   Unscrew 3x nuts (1)
Object Number: 3446323 Size: DEFAULT


5.   Remove gasket and clean sealing surface
6.   Detach catalytic converter support from catalytic converter
•   Unscrew 2x bolts (1)
Object Number: 2412785 Size: DEFAULT


7.   Drain coolant
•   Place collecting basin underneath.
•   Attach suitable hose to drain connection (2)
•   Open coolant drain screw (1)
– Drain coolant
•   Close coolant drain screw
Object Number: 3446245 Size: DEFAULT


8.   Lower vehicle
9.   If present: detach cover (2)
•   Detach heat protection sheath
– Undo cable tie
•   Disconnect wiring harness plug, cylinder head oil pressure sensor (4)
– Unclip wiring harness, cylinder head oil pressure sensor (3)
•   Unscrew 2x bolts (1)
Object Number: 3446324 Size: DEFAULT


10.   If present: remove cylinder head oil pressure sensor (1)
11.   Remove mixture regulator oxygen sensor (3) with KM-6179
•   Unclip wiring harness plug for mixture regulator oxygen sensor
– Disconnect wiring harness connector.
•   Remove mixture regulator oxygen sensor
12.   Remove engine transport shackle (4)
•   Unscrew bolt (5)
13.   Detach heat shield (2) from exhaust manifold
•   Unscrew 3 bolts
Object Number: 2412789 Size: DEFAULT


14.   Remove heat shield.
15.   Detach exhaust manifold (2) from cylinder head
•   Unscrew 11x nuts (1)
Object Number: 2412790 Size: DEFAULT


16.   Remove exhaust manifold gasket
17.   Clean sealing surfaces.
18.   Remove coolant pipe (1)
•   Unscrew 5x bolts (2), (3) and (4)
Object Number: 2412807 Size: DEFAULT


  Install

19.   Install coolant pipe
•   Tighten 5x bolt 10 Nm
20.   Install exhaust manifold gasket
•   Observe correct fitting position
21.   Attach exhaust manifold to cylinder head.
Note:   Tighten nuts in a spiral, working from inside to outside
•   Tighten 11x nut 15 Nm
– Use new nuts
22.   Replace heat shield
23.   Attach heat shield to exhaust manifold
•   Tighten 3x bolt 8 Nm
24.   Fit engine transport shackle
•   Tighten bolt 25 Nm
25.   Install mixture regulator oxygen sensor 30 Nm
•   Coat mixture regulator oxygen sensor with special grease
•   Fix wiring harness plug
•   Lay mixture regulator oxygen sensor wiring harness
26.   If present: install cylinder head oil pressure sensor 20 Nm
•   Replace seal ring
27.   If present: attach cover
•   Tighten 2x bolts
•   Connect wiring harness plug, cylinder head oil pressure sensor
– Lay wiring harness, oil pressure sensor - cylinder head
28.   Raise vehicle
29.   Attach catalytic converter support to catalytic converter
•   Tighten 2x bolt 15 Nm
30.   Attach front exhaust pipe to catalytic converter
•   Use new gasket and nuts
•   Tighten 3x nut 20 Nm
31.   Lower vehicle
32.   Fill with coolant and bleed
33.   Connect earth cable to battery
•   Tighten nut
34.   Program volatile memories
35.   Close bonnet

Illustration - Coolant Hoses (Z 20 LEL, Z 20 LER) > < Coolant flange, remove and install