Vauxhall Workshop Service and Repair Manuals

J 470200 Return Manifold, 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. Remove oil dipstick guide tube Remove upper bolt (1) Unclip vacuum hoses 4. Raise vehicle 5. Remove oil dipstick guide tube Remove 2 lower bolts (arrows) Remove oil dipstick guide tube

6. Remove front exhaust pipe

Note:   When removing the centre muffler, a catalytic converter, an exhaust manifold, or an exhaust manifold with catalytic converter, secure that portion of the exhaust system remaining on the vehicle against uncontrolled suspension.

For this purpose, the exhaust system portion including the flexpipe may be fastened to the vehicle underbody using suitable means, e.g. wire.

Caution!

Angular dislocations of the flexpipe as small as 5 to 10 degrees offset from the intended installation position can already cause damage and subsequent complete failure of the flexpipe.

• Remove 2 nuts

7. Loosen turbocharger bracket Remove bolt (1) 8. Remove turbocharger oil return hose (2). Remove 2 clamps

9. Remove turbocharger oil feed line Unscrew nut (1) Note! Counterhold at threaded port (2) 10. Detach vacuum hose from waste gate unit 11. Loosen air intake pipe. From turbocharger Release clamp

12. Lower vehicle

13. Remove charge air hose

• From turbocharger, centre charge air pipe
• Release 2 clamps

14. Remove exhaust manifold heat shield Remove 4 bolts

15. Remove air intake pipe Remove 3 bolts Detach engine vent hose (1) From cylinder head cover Detach air intake pipe from turbocharger Release 2 clamps Unclip wiring harness 16. Remove oil dipstick guide tube bracket Remove 2 bolts

17. Remove turbocharger oil feed line Unscrew banjo bolt (1) Remove seal rings

18. Remove exhaust recirculation pipe Remove 2 bolts (1) Remove gasket.

19. Detach exhaust manifold Remove 7 bolts, remove 2 nuts (1) 20. Remove turbocharger heat shield Remove 3 bolts

21. Detach return manifold (1) Remove 4 nuts 22. Clean sealing surfaces Exhaust manifold, connection 23. Attach return manifold Tighten nuts (26.5 Nm / 19.5 lbf. ft.)

24. Install turbocharger heat shield

• Tighten bolts (11.7 Nm / 8.6 lbf. ft.)

25. Install exhaust manifold

• Replace gasket
• Tighten bolts, nuts (23.5 Nm/17.3 lbf. ft.)

26. Attach exhaust gas recirculation pipe

• Replace gasket
• Tighten bolts (28.4 Nm / 20.9 lbf. ft.)

27. Install turbocharger oil feed line

• Renew seal rings
• Tighten banjo bolt (9.8 Nm / 7.2 lbf. ft.)

28. Attach exhaust manifold heat shield

• Tighten bolts (11.7 Nm / 8.6 lbf. ft.)

29. Install oil dipstick guide tube bracket

• Tighten nuts
• Clip in vacuum hoses

30. Raise vehicle

31. Fasten turbocharger oil feed line

• Renew seal rings
• Note! Counterhold at threaded port
• Tighten nut (9.8 Nm/7.2 lbf. ft.)

32. Install turbocharger oil return hose

33. Attach turbocharger bracket

• Tighten bolt (26.5 Nm / 19.6 lbf. ft.)

34. Connect waste gate unit vacuum hose

35. Attach front exhaust pipe

• Replace gasket, nuts
• Tighten nuts (65 Nm / 48 lbf. ft.)

36. Install oil dipstick guide tube

• Replace seal ring
• Tighten lower bolts (9.8 Nm / 7.2 lbf. ft.)

37. Lower vehicle

38. Install oil dipstick guide tube

• Tighten upper bolt (9.8 Nm / 7.2 lbf. ft.)
• Clip in vacuum hoses

39. Install air intake pipe

• Tighten bolts
• Tighten clamps (3.5 Nm / 2.5 lbf. ft.)
• Attach engine vent hose
• Fasten clamp
• Attach wiring harness

40. Attach charge air hose

• Tighten clamps (3.5 Nm / 2.5 lbf. ft.)

41. Check and correct engine oil level

• Observe specified engine oil quantity

42. Connect battery

43. Calibrate steering angle sensor

• Switch on ignition

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

44. Program volatile memories

45. Close bonnet