Vauxhall Workshop Service and Repair Manuals

Oil Return Line, Remove and Install  

Notice: 

G 0009 shows X 20 DTL.  

  Remove, Disconnect   

Remove engine cover and charged air tube (1).   Detach conduction bridges (2) or rear wiring trough from glow plugs together with wiring connections.   Remove fastening bolts (3) and central heat shield.   Remove fastening bolts (4) and left and right heat shield.

  Remove, Disconnect   

Remove fastening bolts (4) and fastening nuts (3) and lower heat shield (starter).   Remove wiring trough from cylinder block (3 fastening bolts) and carefully push away downwards.   Remove exhaust manifold support (2) from exhaust manifold and release from cylinder block - swing support to side.   Disconnect oil return line (1) from cylinder block and from turbocharger - collect escaping engine oil.

  Install, Connect   

Attach oil return line with new seal to turbocharger - 8 Nm / 6 lbf. ft.  

Attach oil return line to cylinder block - thereby ensuring that oil return line is not damaged when tightening to torque - tightening torque 20 Nm / 15 lbf. ft.  

Attach exhaust manifold support to exhaust manifold and cylinder block - tightening torque 25 Nm / 18.5 lbf. ft.  

Attach wiring trough to cylinder block (3 fastening bolts).  

Install all heat shields.  

Notice: 

Before assembling components of the intake system (hoses, connections, etc.), they must be cleaned of any possible contamination (grease, oil, etc.). When tightening the hose clamps, be sure to observe exactly the tightening torque of 3.5 Nm / 2.6 lbf. ft.  

  Important!   

It is only ensured that the intake system is free of leaks, thus ensuring operational safety of the engine, if the hose clamps are tightened correctly to the prescribed tightening torque.  

  Install, Connect   

Attach air intake hose to turbocharger - ensure correct seating.  

Attach conduction bridges or rear wiring trough to glow plugs together with wiring connections.  

Install charge air pipe with new seal ring.  

Install engine cover on cylinder head cover.  

Check engine oil level, if necessary correct.