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Exhaust Rear Silencer Heat Shield Replacement > < Exhaust Rear Auxiliary Silencer Replacement - 1.6L LLU

Astra J

Exhaust System Replacement (1.4L LDD, LUH, and LUJ)

Removal Procedure

Warning: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.


Warning: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury.


1. Remove the exhaust rear muffler. Refer to Exhaust Rear Muffler Replacement .

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Note:  A second technician is required.
2. Remove the 2 exhaust pipe front hanger bracket bolts (4).
3. Remove and DISCARD 2 exhaust pipe front hanger bracket bolts (5).
4. Remove the 2 exhaust pipe front hanger bracket insulator nuts (3).
5. Remove the exhaust pipe front hanger bracket (2).
6. Remove the 2 exhaust pipe front hanger bracket insulators (1).

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Note:  A second technician is required.
7. Remove the heated oxygen sensor (1).
8. Remove the 3 catalytic converter nuts (3).
9. Remove the exhaust front pipe gasket (4) from the catalytic converter and exhaust front pipe (2).
10. Remove the exhaust system.

Installation Procedure


Note:  A second technician is required.
1. Install the exhaust system.

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2. Install the NEW exhaust front pipe gasket (4).

Caution: Refer to Fastener Caution .
3. Install the 3 NEW catalytic converter nuts (3) to the exhaust front pipe (2) and tighten to 17 N·m (13 lb ft) .
4. Install the heated oxygen sensor (1) and tighten to 40 N·m (30 lb ft) .

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5. Install the 2 exhaust pipe front hanger bracket insulators (1).
6. Install the exhaust pipe front hanger bracket (2).
7. Install the 2 exhaust pipe front hanger bracket insulator nuts (3) and tighten to 20 N·m (15 lb ft) .
8. Install the 2 exhaust pipe front hanger bracket bolts (4) and tighten to 25 N·m (18 lb ft) .
9. Install 2 NEW exhaust pipe front hanger bracket bolts (5) and tighten in two passes:
  9.1 First pass to 60 N·m (44 lb ft) .
  9.2 Second pass to additional 30° - 45° .
10. Install the exhaust rear muffler. Refer to Exhaust Rear Muffler Replacement .

Exhaust Rear Silencer Heat Shield Replacement > < Exhaust Rear Auxiliary Silencer Replacement - 1.6L LLU