Vauxhall Workshop Service and Repair Manuals

J315600 Oil Cooler/Heat Exchanger, Replace (Y 17 DTL, without AC, LHD)

1. Open bonnet

Caution!

On vehicles from model year 04 with ESP - the steering angle sensor loses its basic adjustment each time the battery is disconnected. It must be recalibrated.

2. Disconnect battery

• Detach ground cable

3. Drain coolant Place collecting basin underneath. Open drain bolt

4. Remove air cleaner housing (1)

• Remove wiring harness plug for hot film mass air flow meter (3)
• Release in direction of arrow
• Remove air intake hose (4)
• Loosen hose clamp (5)
• Remove bolt (2)

5. Remove wiring harness plug for engine control unit 3 off Release 2 wiring harness plugs in direction of arrow Unclip wiring harness

6. Remove air intake pipe Remove 3 bolts Remove vent hose (1) From cylinder head cover Detach air intake pipe from turbocharger

7. Remove wiring harness for engine management

• Disconnect wiring harness plug
• 2 off
• Detach wiring harness bracket
• Remove bolt
• Unclip wiring harness

8. Detach starter/alternator wiring harness bracket

• From exhaust recirculation valve
• Remove 2 nuts

9. Remove charge air hose

• From centre charge air pipe
• Loosen hose clamp

10. Remove centre charge air pipe

• Loosen hose clamp
• Unscrew studs, 2 bolts

11. Close coolant drain bolt

12. Remove oil filter element Place collecting basin underneath. Unscrew oil filter housing cover (1)

13. Detach oil filter housing cover return hose

• Remove hose clamps

14. Expose starter/alternator wiring harness Unclip wiring harness Set wiring harness to one side

15. Detach coolant hoses

• From heater radiator
• Detach retaining clip
• From heat exchanger (1)

16. Remove oil filter housing (1) Remove bolt

17. Remove heat exchanger

• Remove 4 bolts

18. Install heat exchanger Renew seal rings Tighten 4 bolts (12 Nm / 8.9 lbf. ft.)

19. Attach oil filter housing

• Renew seal rings
• 2 off
• Tighten bolt (25.5 Nm / 18.8 lbf. ft.)

20. Attach coolant hoses

21. Attach oil filter housing cover return hose

22. Install oil filter insert

• Tighten oil filter housing cover (25 Nm/18.5 lbf. ft.)

23. Install centre charge air pipe

• Clean sealing surface
• Tighten studs, 2 bolts
• Replace gasket

24. Attach charge air hose

25. Attach starter/alternator wiring harness bracket

• Tighten 2 nuts

26. Attach wiring harness for engine management

• Install wiring harness bracket
• Tighten bolt
• Connect wiring harness plug.
• 2 off
• Attach wiring harness

27. Install air intake pipe

• Tighten 3 bolts
• Fasten hose clamp
• Attach engine vent hose
• Fasten hose clamps
• Attach wiring harness

28. Attach engine control unit wiring harness plug

• Route wiring harness
• Connect wiring harness plug.
• Attach wiring harness

29. Install air cleaner housing

• Tighten bolt
• Fasten air intake hose.
• Connect wiring harness plug to hot film mass air flow meter

30. Connect battery

31. Calibrate steering angle sensor

• Switch on ignition

Note:   Rotate the steering wheel one time from its right-hand to its left-hand stop.

32. Top up coolant

• Note! Top up and bleed cooling system – see operation "Cooling System, Top up and Bleed"
• Observe specified coolant quantity

33. Check and correct engine oil level

• Observe specified engine oil quantity
• Start engine and allow to run until oil pressure telltale extinguishes.
• Check engine oil level, if necessary correct.

34. Program volatile memories

35. Close bonnet