Vauxhall Workshop Service and Repair Manuals

  Remove

Disconnect ground cable from battery.

Disconnect wiring harness plug (1) for oxygen sensor on transmission.

Remove front exhaust pipe.

Detach air duct hose (3) from secondary air non-return valve (2).

Remove fastening bolts (1) from exhaust manifold and secondary air non-return valve bracket (2).

Remove heat shield from exhaust manifold.

Remove crankcase ventilation hose from cylinder head cover and crankcase ventilation flange from cylinder block.

Remove fastening bolts (3) from exhaust manifold and remove secondary air metal pipe (4) from exhaust manifold. Remove oil dipstick.

Detach exhaust manifold from cylinder head.

  Clean

Clean sealing surfaces and remove gasket remnants.

Attach exhaust manifold with new gasket and new fastening nuts to cylinder head.

Torque

For version with single-layer gasket – 22 Nm / 16 lbf. ft.

For version with multi-layer metal-layer gasket:

Step 1 – in the sequence 9 7 8 2 4 3 9 7 2 4 – 14 Nm / 10 lbf. ft.

Step 2 – in the sequence 1 2 3 4 5 6 7 8 9 10 – 22 Nm / 16 lbf. ft.

Step 3 – in the sequence 1 2 3 4 5 6 7 8 9 10 – 22 Nm / 16 lbf. ft.

Insert oil dipstick.

Coat fastening bolts for secondary air metal pipe with assembly paste (white). Insert secondary air metal pipe with new seal rings into exhaust manifold and fasten – tightening torque 20 Nm / 15 lbf. ft.

Attach crankcase ventilation flange with new gasket to cylinder block – tightening torque 25 Nm / 18 lbf. ft. Attach crankcase ventilation hose to cylinder head cover.

Attach baffle plate and secondary air non-return valve bracket to exhaust manifold – tightening torque 8 Nm / 6 lbf. ft.

Secure air guide hose with spring strip clamp to secondary air non-return valve.

Install front exhaust pipe.

Connect wiring harness plug for oxygen sensor and secure on transmission.

Connect ground cable to battery.