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Catalytic Converter Replacement - 2.0L Diesel LBQ, LBR, LBS and LBX > < Starting and Charging Schematics

Astra J

  • Engine
  • Engine Exhaust
  • Repair Instructions
  • Exhaust System Replacement - 1.7L Diesel LPL and LPV

Exhaust System Replacement (1.7L Diesel LPL and LPV)

Special Tools

CH-6129   Remover / Installer Oxygen Sensor

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Remove the front compartment insulator. Refer to Front Compartment Insulator Replacement .
Warning:  Refer to Exhaust Service Warning .
2. Remove the exhaust rear muffler. Refer to Exhaust Rear Muffler Replacement .

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Note:  Avoid cable or wiring damage when removing the heated oxygen sensor.
3. Remove the heated oxygen sensor (1), using the CH-6129   remover and hang aside.
4. Remove the exhaust pressure sensor (2) and hang aside.

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5. Remove the exhaust temperature sensor (1) and hang aside.

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6. Remove the 3 nuts (1) and fix the flex pipe in order to avoid damage.
7. Separate the exhaust front pipe and particulate filter assembly (2) from the catalytic converter (4) and remove the exhaust front pipe and particulate filter assembly gasket (3).

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Note:  A second technician is required.
8. Remove the 2 nuts (1) and the gasket (2).
9. Remove and DISCARD the 2 bolts (4).
10. Remove the 2 nuts (3).
11. Remove the 2 nuts (7).
12. Remove and DISCARD the 2 bolts (5).
13. Remove the 2 bolts (6).
14. Remove the exhaust system.

Installation Procedure


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Note:  A second technician is required.
1. Install the exhaust system.
2. Install a NEW gasket (2).

Caution: Refer to Fastener Caution .
3. Install the 2 nuts (1) and tighten to 22 N·m (16 lb ft) .
4. Install 4 NEW bolts (4, 5) and tighten in two passes:
  4.1 First pass: 60 N·m (44 lb ft) .
  4.2 Second pass: Tighten to additional +30° .
5. Install the 2 nuts (3) and tighten to 22 N·m (16 lb ft) .
6. Install the 2 nuts (7) and tighten to 22 N·m (16 lb ft) .
7. Install the 2 bolts (6) and tighten to 22 N·m (16 lb ft) .

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8. Install a NEW gasket (3).
9. Install the exhaust front pipe and particulate filter assembly (2) to the catalytic converter (4).
10. Install the 3 nuts (1) and tighten to 25 N·m (18 lb ft) .

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11. Install the exhaust temperature sensor (1) and tighten to 45 N·m (33 lb ft) .

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Note:  Avoid cable or wiring damage when installing the heated oxygen sensor.
12. Install the heated oxygen sensor (1) and tighten to 42 N·m (31 lb ft) , using the CH-6129   remover .
13. Install the exhaust pressure sensor (2) and tighten to 45 N·m (33 lb ft) .
14. Install the front compartment insulator. Refer to Front Compartment Insulator Replacement .
15. After the replacement of the exhaust particulate filter, use a scan tool to perform the appropriate reset function. Refer to Engine Control Module Programming and Setup .

  • Engine
  • Engine Exhaust
  • Repair Instructions
  • Exhaust System Replacement - 1.7L Diesel LPL and LPV

Catalytic Converter Replacement - 2.0L Diesel LBQ, LBR, LBS and LBX > < Starting and Charging Schematics