vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

ABOUT US
Gasket, Exhaust Manifold, Replace (Z 17 DTH, with Air Conditioning, LHD) > < Check the cooling system for leaks

Corsa C

Turbocharger Gasket on Catalytic Converter Flange, Replace

  Remove

1.   Open bonnet
2.   Disconnect battery
3.   Drain coolant
•   Place collecting basin underneath.
•   Open drain bolt
Object Number: 2411059 Size: DEFAULT


4.   Detach turbocharger charge air pipe (3)
•   Release clamp
•   Open quick-release fitting
5.   Loosen heat exchanger coolant pipe (1)
•   Place collecting basin underneath.
•   Unscrew 3 bolts
Note:   Be careful of exhaust manifold heat shield (2).
6.   Remove oil feed line (4)
•   Place collecting basin underneath.
•   Unscrew 2 banjo bolts
Object Number: 2406310 Size: DEFAULT


7.   Remove oil filter housing/heat exchanger housing (1)
•   Disconnect lower radiator hose
– Release clamp
•   Unscrew 4 bolts
•   Close coolant drain bolt
Object Number: 2406311 Size: DEFAULT


8.   Loosen catalytic converter (1)
•   From turbocharger
•   Open retaining plate (2)
•   Unscrew 3 bolts
Object Number: 2406312 Size: DEFAULT


9.   Raise vehicle
Important:   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. The exhaust system piece with the flex pipe inside can be secured for this purpose using suitable means, such as a wire on the vehicle underbody. Bends in the flex pipe with an angle as little as 5 – 10 degrees from the intended installation position may result in damage with subsequent total failure of the flex pipe.
10.   Remove exhaust system
•   Release clamp
11.   Remove exhaust system
•   Detach exhaust system
Note:   2nd mechanic required.
– Detach 5 damper rings
•   Attach exhaust system
12.   Disconnect catalytic converter
•   Remove bolt
•   Remove catalytic converter downwards
13.   Cleaning work
•   Turbocharger, catalytic converter

  Install

14.   Fit catalytic converter
•   Fit bolt
15.   Lower vehicle
16.   Attach catalytic converter
•   To turbocharger
•   Replace gasket, retaining plate
•   Tighten 3x bolts 30 Nm
•   Fasten 3 bolts
17.   Cleaning work
•   On cylinder block, oil filter housing
18.   Install oil filter housing
•   Replace gasket
•   Tighten 4 bolts 9 Nm
•   Connect lower radiator hose
– Fasten clamp
19.   Install turbocharger oil feed line
•   Replace 4x seal ring
•   Tighten 2 banjo bolts 15 Nm
20.   Attach heat exchanger coolant pipe
•   Replace gasket
•   Tighten 3 bolts 9 Nm
21.   Attach turbocharger charge air hose
•   Fasten clamp 3.5 Nm
•   Close quick-release fitting
22.   Raise vehicle
23.   Fasten catalytic converter
•   Tighten bolt 25 Nm
24.   Attach exhaust system
•   Fasten and tighten clamp 35 Nm
25.   Lower vehicle
26.   Connect battery
27.   Top up coolant
28.   Program volatile memory
29.   Close bonnet

Gasket, Exhaust Manifold, Replace (Z 17 DTH, with Air Conditioning, LHD) > < Check the cooling system for leaks