vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Replace turbocharger > < Removing and installing charge air pipe

Astra H

Exhaust Manifold with Turbocharger, Replace

  Remove

1.   Open bonnet
2.   Disconnect battery
3.   Remove engine cover (2)
•   Detach oil filler port closure cap (1)
•   Pull off engine cover
Note:   Rubber retainers (3) must remain on engine cover
•   Attach oil filler port closure cap
Object Number: 2412632 Size: DEFAULT


4.   Raise vehicle by its full height
5.   Remove engine splash protection right or engine compartment cover lower
6.   Drain coolant
•   Open drain bolt on radiator (1)
•   Collect coolant
•   Close drain bolt
Object Number: 3446550 Size: DEFAULT


7.   Remove ribbed V-belt
•   Mark direction of rotation
•   Apply tension to ribbed V-belt tensioner via bolt (1) in the direction of the arrow
•   Fix ribbed V-belt tensioner to bore (2)
•   Remove ribbed-V-belt
Object Number: 3447354 Size: DEFAULT


8.   Detach front exhaust pipe
•   From start-up catalytic converter
– Unscrew 3x bolts (1)
Object Number: 2413387 Size: DEFAULT


9.   Place collecting basin underneath.
10.   Drain engine oil
•   Unscrew oil drain bolt (1)
•   Replace gasket
•   Tighten oil drain bolt 78.4 Nm
Object Number: 2413383 Size: DEFAULT


11.   Detach oil dipstick guide tube from upper part of oil pan
•   Unscrew 2x bolts (1)
Object Number: 2413384 Size: DEFAULT


12.   Detach turbocharger oil return hose (1) from turbocharger
•   Unscrew 2x bolts
Object Number: 2412719 Size: DEFAULT


13.   Detach turbocharger oil feed line (1) from cylinder block
•   Unscrew nut (2)
Object Number: 2412720 Size: DEFAULT


14.   Detach start-up catalytic converter from bracket
•   Unscrew 2x bolts (1)
Object Number: 2413388 Size: DEFAULT


15.   Disconnect vacuum hose (2) from turbocharger control unit (1)
Object Number: 3447359 Size: DEFAULT


16.   Lower vehicle by its full height
17.   Release compressor (1)
•   Disconnect wiring harness connector.
•   Unscrew 3 bolts
Note:   Note different bolt lengths
– Attach compressor top to vehicle front
Object Number: 2413385 Size: DEFAULT


18.   Remove compressor bracket (1)
•   Unscrew 3 bolts
Object Number: 2413386 Size: DEFAULT


19.   Remove air intake manifold (1)
•   Detach wiring harness
– Release 3x clip
•   Undo 2 clamps
•   Unscrew 2x bolts
Object Number: 2412653 Size: DEFAULT


20.   Remove bracket, oil dipstick guide tube (1)
•   Unclip vacuum line
– Unclip 2x clips
•   Remove oil dipstick guide tube
– Release clamp
•   Detach bracket, oil dipstick guide tube, from camshaft housing
– Unscrew 2x bolts
Object Number: 2412713 Size: DEFAULT


21.   Remove upper charge air hose (1)
•   Undo 2 clamps
Object Number: 2413389 Size: DEFAULT


22.   Remove lower charge air hose
•   Release clamp
Object Number: 10679756 Size: DEFAULT

23.   Release heat exchanger, exhaust gas recirculation
•   Remove from bracket
– Unscrew 2x bolts (3)
•   Detach from camshaft housing
– Unscrew bolt (2)
•   Detach from exhaust gas recirculation port
– Unscrew 2x bolts (4)
•   Detach from intake manifold
– Unscrew 2x bolts (arrow)

24.   Remove heat exchanger, exhaust gas recirculation
•   Cut 2x hoses (arrows)
Object Number: 10679757 Size: DEFAULT


25.   Remove exhaust manifold heat shield
•   Unscrew 4x bolts (1)
Object Number: 2413390 Size: DEFAULT


26.   Detach turbocharger oil feed line from turbocharger
•   Unscrew banjo bolt (1)
Object Number: 2412717 Size: DEFAULT


27.   Remove exhaust manifold (1) with turbocharger
•   Unscrew 2x bolts
•   Unscrew 7x nuts
Object Number: 2413391 Size: DEFAULT


28.   Clamp exhaust manifold (1) in vice
29.   Remove heat shield, start-up catalytic converter (4)
•   Unscrew 3 bolts
30.   Detach catalytic converter (3) from turbocharger
•   Unscrew 3x nut
31.   Detach turbocharger (2) from exhaust manifold
•   Unscrew 3x nut
Object Number: 2413423 Size: DEFAULT


  Install

32.   Clean sealing surface
33.   Attach turbocharger to exhaust manifold
Note:   Fill 0.4 ml clean engine oil into the aperture of the oil feed line
•   Replace gasket
•   Tighten 3x new nuts 26.5 Nm
34.   Attach catalytic converter to turbocharger
•   Replace gasket
•   Tighten 3x nuts
35.   Install heat shield, start-up catalytic converter
•   Tighten 3x bolt 11.7 Nm
36.   Remove exhaust manifold from vice
37.   Insert exhaust manifold with turbocharger
•   Replace gasket
38.   Attach turbocharger oil feed line to cylinder block
•   Replace 2x gaskets
•   Fit hollow bolt
39.   Attach exhaust manifold with turbocharger
•   Tighten 2x bolts 69 Nm
•   Tighten 7x nut 69 Nm
40.   Attach turbocharger oil feed line to turbocharger
•   Replace 2x gaskets
•   Tighten bolt 20.6 Nm
41.   Install exhaust manifold heat shield
•   Tighten 4x bolt 11.7 Nm
42.   Attach vacuum hose to turbocharger control unit
43.   Install heat exchanger, exhaust gas recirculation
•   Replace 2x gaskets
•   Attach to exhaust manifold
– Tighten 2x bolts 28.5 Nm
•   Attach to exhaust gas recirculation port
– Tighten 2x bolts 28.5 Nm
•   To camshaft housing
– Tighten bolt 24 Nm
•   To bracket
– Tighten 2x bolts
– Attach 2x clamps
44.   Install lower charge air hose
Important:   Groove (1) must engage in projection (2)
•   Tighten 2x clamp 3.5 Nm
Object Number: 2415955 Size: DEFAULT


45.   Install upper charge air hose
•   Tighten 2x clamp 3.5 Nm
46.   Attach upper coolant hose to heat exchanger exhaust gas recirculation
•   Fasten clamp
47.   Install bracket, oil dipstick guide tube
•   Attach bracket, oil dipstick guide tube, to camshaft housing
– Tighten 2x bolts
•   Attach vacuum line
– Clip in 2x clips
•   Attach dipstick guide tube
– Fasten clamp
48.   Install air intake pipe.
•   Fasten 2x clamp 3.5 Nm
•   Tighten 2x bolts
•   Attach wiring harness
– Clip in 3x clips
49.   Install compressor bracket
•   Tighten 3x bolts
50.   Install compressor
•   Suspend compressor
•   Tighten 3x bolt 24.5 Nm
•   Fix wiring harness plug
51.   Install engine cover
•   Detach oil filler port closure cap
•   Refit engine cover
•   Attach oil filler port closure cap
52.   Raise vehicle by its full height
53.   Attach turbocharger oil feed line to cylinder block
•   Tighten banjo bolt 27.5 Nm
54.   Attach oil return hose to turbocharger
•   Replace gasket
•   Tighten 2x bolts
55.   Attach oil dipstick guide tube to upper part of oil pan
•   Replace gasket
•   Tighten 2x bolts 9.8 Nm
56.   Attach start-up catalytic converter to bracket
•   Tighten 2x bolts
57.   Attach front exhaust pipe to start-up catalytic converter
•   Replace gasket
•   Tighten 3x new nuts
58.   Insert ribbed V-belt
Note:   Note running direction of ribbed V-belt
•   Position ribbed V-belt
– I. Ribbed V-belt without air conditioning
– II. Ribbed V-belt with air conditioning
•   Apply tension to ribbed V-belt tensioner via bolt (1) in the direction of the arrow
•   Take out fixing
•   Release ribbed V-belt tensioner
Object Number: 2415977 Size: DEFAULT


59.   Install lower engine cover and right engine splash guard
60.   Lower vehicle by its full height
61.   Cooling System, Charge and Bleed
62.   Top up engine oil, check oil level
63.   Connect battery
64.   Program volatile memories
65.   Close bonnet

Replace turbocharger > < Removing and installing charge air pipe