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Vauxhall Workshop Service and Repair Manuals

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Removing and installing exhaust manifold with turbocharger > < Replace intake manifold

Astra H

Replacing exhaust manifold

  Remove

1.   Open bonnet
2.   Disconnect earth cable from battery
•   Slacken nut
3.   Raise vehicle
4.   Expose wiring harness of catalytic converter control oxygen sensor (1)
•   Unfasten cable tie (2)
•   Disconnect wiring harness connector (3)
Object Number: 2412787 Size: DEFAULT


5.   Detach front exhaust pipe (2) from catalytic converter
•   Unscrew 3x nuts (1)
Object Number: 3446323 Size: DEFAULT


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


8.   Lower vehicle
9.   In design with oil pressure switch on cylinder head: Remove 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.   For design with cylinder head oil pressure switch: 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.

  Install

18.   Insert exhaust manifold gasket
•   Observe correct fitting position
19.   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
20.   Replace heat shield
21.   Attach heat shield to exhaust manifold
•   Tighten 3x bolt 8 Nm
22.   Fit engine transport shackle
•   Tighten bolt 25 Nm
23.   Install mixture regulator oxygen sensor
•   Coat mixture regulator oxygen sensor with special grease
•   Screw in mixture regulator oxygen sensor with KM-6179 30 Nm
•   Fix wiring harness plug
•   Lay mixture regulator oxygen sensor wiring harness
24.   For design with cylinder head oil pressure switch: install cylinder head oil pressure sensor with new gasket 20 Nm
25.   In design with oil pressure switch on cylinder head: Attach cover
•   Tighten 2x bolts
•   Connect wiring harness plug, cylinder head oil pressure sensor
– Lay wiring harness, cylinder head oil pressure sensor
26.   Raise vehicle
27.   Attach catalytic converter support to catalytic converter
•   Tighten 2x bolt 20 Nm
28.   Attach front exhaust pipe to catalytic converter
•   Use new gasket and nuts
•   Tighten 3x nut 20 Nm
29.   Lower vehicle
30.   Connect battery
31.   Program volatile memories
32.   Close bonnet

Removing and installing exhaust manifold with turbocharger > < Replace intake manifold