Exhaust Manifold Replacement Opel Agila B

Remove

1. 1. Remove cap from coolant expansion tank
2. 2. Raise vehicle

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

3. 3. 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
4. 4. Release 2x protective panelling from front panelling • Remove 4x clip (1)

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

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

9. 9. 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.

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

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

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

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

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

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

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

31. 31. Disconnect coolant feed pipe (1) from oil cooler assembly • Remove 2x bolt (2) • Remove gasket
32. 32. Release 2x harness from coolant feed pipe • Release from 2x clip
33. 33. Release coolant feed pipe from cylinder head • Remove bolt

34. 34. Remove coolant feed pipe from thermostat hose • Remove clip (1)

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

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

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

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

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

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

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

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

46. 46. Lower vehicle
47. 47. Release turbocharger oil return pipe (1) from cylinder block • Remove 2x bolt (2), gasket

48. 48. Remove intercooler inlet hose from turbocharger • Release clip
49. 49. Remove turbocharger (1) and catalytic converter (2) from exhaust manifold • Remove 3x nut

50. 50. Remove exhaust manifold (2) from cylinder head • Remove 10x nut (3)
51. 51. Remove exhaust manifold gasket (1) from cylinder head

Install

52. 52. Clean mating surfaces
53. 53. Install new exhaust manifold gasket (1) to cylinder head
54. 54. Install new exhaust manifold (2) to cylinder head • Install 10x new nut (3) 15 Nm + 30°

55. 55. Install turbocharger (1) and catalytic converter (2) to exhaust manifold • Clean mating surfaces • Install 3x new nut 28 Nm

56. 56. Install intercooler inlet hose to turbocharger • Secure clip
57. 57. Secure turbocharger oil return pipe (1) to cylinder block • Install new gasket • Install 2x bolt (2) 10 Nm

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

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

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

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

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

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

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

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

72. 72. Install coolant feed pipe to thermostat hose • Install new clip (1)

73. 73. Connect coolant feed pipe (1) to oil cooler assembly • Clean mating surfaces • Install new gasket • Install 2x bolt (2)
74. 74. Secure 2x harness to coolant feed pipe • Secure to 2x clip
75. 75. Secure coolant feed pipe to cylinder head • Install bolt

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

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

78. 78. Install heat shield (4) to exhaust manifold • Install bolt 10 Nm
79. 79. Install engine lifting eye (2) to exhaust manifold • Install bolt 28 Nm
80. 80. Secure earth strap to exhaust manifold • Install bolt (3)
81. 81. Connect 4x harness connector (1) to 4x glow plug

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

83. 83. For vehicles without DPF, secure mixture control oxygen sensor harness connector to bracket • Secure clip
84. 84. For vehicles without DPF, secure mixture control oxygen sensor harness to upper front body panel • Secure clip
85. 85. For vehicles without DPF, connect front body harness to mixture control oxygen sensor harness • Connect harness connector – Secure harness connector lock
86. 86. Install intercooler (4) to vehicle • Position intercooler to 2x rubber mount • Install bolt (2)
87. 87. Connect intercooler outlet hose (1) to intercooler • Secure clip
88. 88. Connect intercooler inlet hose (3) to intercooler • Secure clip

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

90. 90. Install air cleaner assembly to battery tray and upper front body panel • Push down to secure 2x locator to battery tray • Install 2x bolt (4)
91. 91. Secure harness for mass air flow meter to air cleaner assembly • Secure clip
92. 92. Secure coolant hose (1) to air cleaner assembly • Secure clip
93. 93. Install air cleaner element to air cleaner assembly

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

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

96. 96. 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.

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

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

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

102. 102. Lower vehicle

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

103. 103. Fill coolant expansion tank with new coolant fluid up to maximum level mark
104. 104. Install cap to coolant expansion tank
105. 105. Connect battery negative lead • Secure nut 11 Nm
106. 106. Program all volatile memories – see operation “Program Volatile Memories”
107. 107. 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.

108. 108. Check and correct coolant fluid level
109. 109. Check and correct engine oil level