Vauxhall Workshop Service and Repair Manuals

Exhaust Manifold for Cylinders 1-3-5, Remove and Install (X 25 XE, X 30 XE)

Caution Leaks in secondary air system can cause damage to catalytic converter and engine.   Remove Disconnect ground cable from battery. Remove coolant intake pipe – see operation "Coolant Intake Pipe, Remove and Install". Disconnect wiring harness plug for oxygen sensor. Remove front exhaust pipe. Detach heat shields (1) and (2) from exhaust manifold. Remove union nuts (3) and (4) – counterhold on screw-on port. Remove exhaust gas recirculation corrugated pipe.

Detach fastening bolts for secondary air metal pipe (1) from exhaust manifold. Separate secondary air metal pipe (2) from hose connection of centre metal pipe. Remove secondary air metal pipe. Detach exhaust manifold from cylinder head.   Clean Remove gasket remnants and clean sealing surfaces.

  Install

Attach exhaust manifold with new gasket and new nuts to cylinder head – tightening torque 20 Nm / 15 lbf. ft. Attach secondary air metal pipe to exhaust manifold and attach to hose connection of centre metal pipe – insert fastening bolts with installation paste (white) – tightening torque 20 Nm / 15 lbf. ft. Install exhaust gas recirculation corrugated pipe – before installing union nuts, coat thread of screw-in connection with installation paste (white) – tightening torque 25 Nm / 18.5 lbf. ft. Attach lower and upper heat shields to exhaust manifold. Install front exhaust pipe. Connect wiring harness plug for oxygen sensor. Install coolant intake pipe – see operation "Coolant Intake Pipe, Remove and Install". Connect ground cable to battery.