Catalytic Converter Replacement Opel Agila B

Remove

1. 1. Download data from engine control unit using Tech 2
2. 2. Perform “Reset” before replacement of catalytic converter • Use Tech 2
3. 3. Remove cap from coolant expansion tank
4. 4. Raise vehicle

Important. Observe the relevant environmental regulations when disposing of used coolant.

5. 5. Drain cooling system • Place collecting container below • Open radiator drain plug • Allow coolant to drain into collecting container • Close radiator drain plug • Remove collecting container
6. 6. Release 2x protective panelling from front panelling • Remove 4x clip (1)

7. 7. Release front panelling from lower front body panel • Remove 3x bolt (1)

8. 8. Lower vehicle
9. 9. Release front panelling from 2x front wing • Remove 2x screw (1)
10. 10. Release front panelling from upper front body panel • Remove 2x clip (3), 4x bolt (2)

11. 11. Remove front panelling from vehicle • Release front panelling from 2x side bracket (1) – Pull off • Disconnect 2x harness connector from 2x front fog lamp (if installed)

Note. 2x technician are required.

12. 12. Disconnect battery negative lead • Release nut
13. 13. Disconnect harness connector (3) from mass air flow meter (5)
14. 14. Release cover (2) from air cleaner assembly • Release 4x screw
15. 15. Remove air cleaner element from air cleaner assembly
16. 16. Release coolant hose (1) from air cleaner assembly • Release clip
17. 17. Release harness for mass air flow meter from air cleaner assembly • Release clip
18. 18. Remove air cleaner assembly from battery tray and upper front panel • Remove 2x bolt (4) • Pull up to release 2x locator from battery tray

19. 19. Remove cover (1) from engine • Remove 4x bolt

20. 20. Disconnect intercooler outlet hose (1) from intercooler (4) • Release clip
21. 21. Disconnect intercooler inlet hose (3) from intercooler • Release clip
22. 22. Remove intercooler from vehicle • Remove bolt (2), then lift upwards to release from 2x rubber mount

23. 23. For vehicles without diesel particulate filter (DPF), disconnect front body harness from mixture control oxygen sensor harness • Disconnect harness connector – Release harness connector lock
24. 24. For vehicles without DPF, release mixture control oxygen sensor harness connector from bracket • Release clip
25. 25. For vehicles without DPF, release mixture control oxygen sensor harness from upper front body panel • Release clip
26. 26. For vehicles without DPF, release mixture control oxygen sensor harness from intercooler outlet pipe • Release 2x clip (2) • Release from clip (1)

27. 27. For vehicles without DPF, remove mixture control oxygen sensor (1) from catalytic converter • Use Socket KM-6179

28. 28. Disconnect 4x harness connector (1) from 4x glow plug
29. 29. Release earth strap from exhaust manifold • Remove bolt (3)
30. 30. Remove engine lifting eye (2) from exhaust manifold • Remove bolt
31. 31. Remove heat shield (4) from exhaust manifold • Remove bolt

32. 32. Remove hose (1) from turbocharger • Remove 2x bolt • Release 2x clip

33. 33. Remove oil feed pipe (1) from turbocharger and oil cooler assembly • Remove 2x bolt (2), 4x washer

34. 34. Disconnect coolant feed pipe (1) from oil cooler assembly • Remove 2x bolt (2) • Remove gasket
35. 35. Release 2x harness from coolant feed pipe • Release from 2x clip

36. 36. Remove oil cooler assembly (1) from engine • Remove 4x bolt • Release harness from 2x clip • Remove seal

37. 37. For vehicles with DPF, remove heat shield (1) from catalytic converter • Remove 3x bolt (2)

38. 38. Raise vehicle
39. 39. For vehicles with DPF, disconnect differential pressure sensor hose from differential pressure sensor pipe (2) • Release clip (1)

40. 40. For vehicles with DPF, disconnect temperature sensor (1) from body harness • Release harness connector from bracket – Release clip, then slide off • Disconnect harness connector

41. 41. Release front exhaust pipe from catalytic converter • Release clamp (1) – Release nut

42. 42. For vehicles with DPF, release DPF (1) from centre exhaust pipe • Remove 2x nut (2) • Remove gasket
43. 43. For vehicles without DPF, release front exhaust pipe from centre exhaust pipe • Remove 3x nut • Remove gasket

44. 44. For vehicles with DPF, remove front exhaust pipe with DPF (2) from vehicle • Release from 2x rubber mount (1)
45. 45. For vehicles without DPF, remove front exhaust pipe from vehicle • Release from 2x rubber mount

46. 46. Release catalytic converter bracket (1) from transmission • Remove bolt (2)

47. 47. Lower vehicle
48. 48. Remove catalytic converter (2) from turbocharger • Release locking tab (1) from 3x bolt • Remove 3x bolt, locking tab • Remove gasket

Install

49. 49. Install new catalytic converter (2) to turbocharger • Clean mating surfaces • Install new gasket • Install new locking tab (1), 3x bolt 28 Nm • Secure locking tab to 3x bolt

50. 50. Raise vehicle
51. 51. Secure catalytic converter bracket (1) to transmission • Install bolt (2)

52. 52. For vehicles with DPF, install front exhaust pipe with DPF (2) to vehicle • Secure to 2x rubber mount (1)
53. 53. For vehicles without DPF, install front exhaust pipe to vehicle • Secure to 2x rubber mount

54. 54. Clean mating surfaces
55. 55. For vehicles with DPF, secure DPF (1) to centre exhaust pipe • Install new gasket • Install 2x nut (2) 60 Nm
56. 56. For vehicles without DPF, secure front exhaust pipe to centre exhaust pipe • Install new gasket • Install 3x nut 32 Nm

57. 57. Clean mating surfaces
58. 58. Secure front exhaust pipe to catalytic converter • Secure clamp (1) – Secure nut 55 Nm

59. 59. For vehicles with DPF, connect temperature sensor (1) to body harness • Connect harness connector • Secure harness connector to bracket – Slide on to secure clip

60. 60. For vehicles with DPF, connect differential pressure sensor hose to differential pressure sensor pipe (2) • Secure clip (1)

61. 61. Lower vehicle
62. 62. For vehicles with DPF, install heat shield (1) to catalytic converter • Install 3x bolt (2) 9 Nm

63. 63. Install oil cooler assembly (1) to engine • Install new seal • Install 4x bolt 9 Nm • Secure harness to 2x clip

64. 64. Connect coolant feed pipe (1) to oil cooler assembly • Clean mating surfaces • Install new gasket • Install 2x bolt (2)
65. 65. Secure 2x harness to coolant feed pipe • Secure to 2x clip

66. 66. Install oil feed pipe (1) to turbocharger and oil cooler assembly • Install 4x new washer, 2x bolt (2) 22 Nm

67. 67. Install hose (1) to turbocharger • Install 2x bolt • Secure 2x clip

68. 68. Install heat shield (4) to exhaust manifold • Install bolt 10 Nm
69. 69. Install engine lifting eye (2) to exhaust manifold • Install bolt 28 Nm
70. 70. Secure earth strap to exhaust manifold • Install bolt (3)
71. 71. Connect 4x harness connector (1) to 4x glow plug

72. 72. For vehicles without DPF, install mixture control oxygen sensor (1) 45 Nm to catalytic converter • Apply assembly paste to threads • Use Socket KM-6179

73. 73. For vehicles without DPF, secure harness for mixture control oxygen sensor to intercooler outlet pipe • Secure to clip (1) • Secure 2x clip (2)

74. 74. For vehicles without DPF, secure mixture control oxygen sensor harness connector to bracket • Secure clip
75. 75. For vehicles without DPF, secure mixture control oxygen sensor harness to upper front body panel • Secure clip
76. 76. For vehicles without DPF, connect front body harness to mixture control oxygen sensor harness • Connect harness connector – Secure harness connector lock
77. 77. Install intercooler (4) to vehicle • Position intercooler to 2x rubber mount • Install bolt (2)
78. 78. Connect intercooler outlet hose (1) to intercooler • Secure clip
79. 79. Connect intercooler inlet hose (3) to intercooler • Secure clip

80. 80. Install cover (1) to engine • Install 4x bolt 8 Nm

81. 81. Install air cleaner assembly to battery tray and upper front panel • Push down to secure 2x locator to battery tray • Install 2x bolt (4)
82. 82. Secure harness for mass air flow meter to air cleaner assembly • Secure clip
83. 83. Secure coolant hose (1) to air cleaner assembly • Secure clip
84. 84. Install air cleaner element to air cleaner assembly

Note. Before installing the air cleaner element, remove all debris from the air cleaner assembly.

85. 85. Secure cover (2) to air cleaner assembly • Secure 4x screw
86. 86. Connect harness connector (3) to mass air flow meter (5)

87. 87. Install front panelling to vehicle • Connect 2x harness connector to 2x front fog lamp (if installed) • Secure front panelling to 2x side bracket (1) – Push on

Note. 2x technician are required.

88. 88. Secure front panelling to upper front body panel • Install 4x bolt (2), 2x clip (3)
89. 89. Secure front panelling to 2x front wing • Install 2x screw (1)

90. 90. Raise vehicle
91. 91. Secure front panelling to lower front body panel • Install 3x bolt (1)

92. 92. Secure 2x protective panelling to front panelling • Install 4x clip (1)

93. 93. Lower vehicle

Important. Only use coolant approved by the manufacturer and ensure a concentration of 50% water and 50% anti-freeze.

94. 94. Fill coolant expansion tank with new coolant fluid up to maximum level mark
95. 95. Install cap to coolant expansion tank
96. 96. Connect battery negative lead • Secure nut 11 Nm
97. 97. Program all volatile memories – see operation “Program Volatile Memories”
98. 98. Start engine and allow it to run at idle speed until thermostat opens • Switch off engine

Note. Cooling system bleeds itself automatically during the warm-up phase.

99. 99. Check and correct coolant fluid level
100. 100. Check and correct engine oil level
101. 101. Program catalytic converter • Connect Tech 2 to diagnostic socket • Select F0: DIAGNOSTICS • Select corresponding vehicle identification • Select F1: ENGINE • Turn "ON" Ignition and press CONFIRM • Press CONFIRM again for catalytic converter • Select F5: Programming • Select Program catalytic converter; then select CONFIRM • Follow menu guide in Tech 2 to end of program
102. 102. Turn off Tech 2 then remove from vehicle • Disconnect Tech 2 from diagnostic socket