Vauxhall Workshop Service and Repair Manuals

J303000 Intake manifold gasket, replace (Z 14 XE, Z 16 YNG with AC, RHD)

1. Open bonnet

Caution

On vehicles as of 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 engine cover.

• Unscrew oil filler pipe cap
• Remove 2 bolts
• Screw on oil filler pipe cap

4. Raise vehicle

5. Loosen exhaust system

Note:   When removing the centre muffler, a catalytic converter, an exhaust manifold or an exhaust manifold with catalytic converter, the exhaust system piece remaining in the vehicle must be prevented from swinging uncontrollably.

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.

Caution

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.

• Detach front exhaust pipe
• Remove 3 nuts

6. Lower vehicle

7. Remove heated oxygen sensor for mixture regulation Disconnect wiring harness plug (1) Screw out carefully using KM-6179 (2)

8. Remove exhaust manifold heat shield Remove 3 bolts 9. Remove exhaust manifold Remove oil dipstick Remove 9 nuts Carefully remove exhaust manifold upwards. Caution: Pay attention to upper radiator hose Remove Seal ring 10. Clean sealing surfaces Cylinder head, exhaust manifold 11. Attach exhaust manifold Insert seal. Carefully install exhaust manifold Caution: Pay attention to upper radiator hose Replace nuts Tighten nuts (22 Nm / 16 lbf. ft.) Insert oil dipstick

12. Attach exhaust manifold heat shield

• Tighten bolts (8 Nm / 6 lbf. ft.)

13. Install oxygen sensor, mixture regulation, heated

• Note: Apply special grease (black) to the threads
• Tighten using KM-6179-E (30 Nm / 22 lbf. ft.)
• Connect wiring harness plug.

14. Raise vehicle

15. Attach exhaust system

• Replace gasket
• Replace nuts
• Tighten nuts (25 Nm / 18 lbf. ft.)

16. Lower vehicle

17. Install engine cover.

• Unscrew oil filler pipe cap
• Tighten bolts (8 Nm / 6 lbf. ft.)
• Screw on oil filler pipe cap

18. Connect battery

19. Calibrate steering angle sensor

• Switch on ignition

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

20. Program volatile memories

21. Close bonnet