Vauxhall Workshop Service and Repair Manuals

Heat Exchanger, Remove and Install (X 25 XE)  

  Remove, Disconnect   

Remove intake flange - see operation "Intake Flange, Remove and Install".   Remove secondary air metal pipe (cylinders 2-4-6) - see operation "Secondary Air Metal Pipe (Cylinders 2-4-6), Remove and Install (X 25 XE)" in group "L".   Remove DIS ignition module - see operation "DIS Ignition Module, Remove and Install (X 25 XE)".   Remove coolant bridge (1) from cylinder heads and lay aside towards rear.   Open fastening clamp (2) and remove oil lines (3) from heat exchanger.

  Remove, Disconnect   

Remove oil filter with KM-726-A - collect escaping engine oil.   Remove crankshaft pulse pick-up (1) from cylinder block and lay aside.   Detach oil lines (2) from cylinder block and remove.   Remove fastening bolts (4) from heat exchanger and fastening bolts (3) from heat exchanger cover.   Detach heat exchanger from cylinder block with wide spatula.     Clean    Remove gasket remnants and clean sealing surfaces.

Notice: 

The previous seal ring for the heat exchanger cover is now replaced by a bead of silicon sealing compound (light grey).  

  Install, Connect   

Apply an approx. 2 mm (dimension I) thick bead of silicon sealing compound (light grey) in groove of heat exchanger cover and install immediately while wet.   Install heat exchanger cover on heat exchanger - tightening torque 30 Nm / 22 lbf. ft.   Attach heat exchanger to cylinder block - tightening torque 20 Nm / 15 lbf. ft.   Connect oil lines with new seal rings to cylinder block and heat exchanger - 30 Nm / 22 lbf. ft.   Close fastening clamp for oil lines.

  Install, Connect   

Attach crankshaft pulse pick-up to cylinder block - 8 Nm / 6 lbf. ft.  

Lightly coat seal ring of new oil filter with engine oil and bolt to cylinder block with KM-726-A - tightening torque 15 Nm / 11 lbf. ft.  

Install secondary air metal pipe (cylinder 2-4-6) - see operation "Secondary Air Metal Pipe (cylinder 2-4-6), Remove and Install (X 25 XE)" in group "L".  

Connect coolant bridge with new seal rings to cylinder heads - 30 Nm / 22 lbf. ft.  

Install DIS ignition module - see operation "DIS Ignition Module, Remove and Install".  

Install intake flange - see operation "Intake Flange, Remove and Install".  

Check engine oil level and fill engine oil up to "MAX" mark on oil dipstick. Start engine and allow to run until oil pressure telltale is extinguished. Check engine oil level again and correct.