Replace Coolant Pipe (Z 20 NET, AC, Rhd, Mt) Opel Vectra C

Remove

1. 1. Open bonnet
2. 2. Disconnect battery. • Detach ground cable
3. 3. Detach upper engine cover
4. 4. Raise vehicle
5. 5. Detach ribbed V-belt cover • Unscrew 4x bolt

6. 6. Release coolant pump coolant drain bolt

7. 7. Lower vehicle
8. 8. Remove pollen filter housing • Disconnect wiring harness plug for hot film mass air flow meter (1) • Unclip wiring harness (4) • Remove intake pipe – Release clamp (2)
9. 9. Remove air intake hose. • Release clamp (arrow) • Remove wastegate unit hose (3) • Detach tank vent line

10. 10. Drain coolant • Unscrew coolant compensation tank closure cap Warning: Only open coolant compensation tank once engine has cooled down • Place collecting basin underneath. • Open radiator drain plug (arrow)

11. 11. Unscrew coolant pump coolant drain bolt
12. 12. Remove turbo heat shield • Unscrew 2x bolt • Unclip shield

13. 13. Connect wiring harness plug for mixture regulation oxygen sensor (1)

14. 14. Remove engine vent hose • Release 2x clamp
15. 15. Disconnect 3x wiring harness plug • Catalytic converter control oxygen sensor (1), exhaust temperature sensor (1), solenoid charge pressure unit (2) • Unclip wiring harness plug

16. 16. Release catalytic converter • Unscrew 3x nut
17. 17. Raise vehicle
18. 18. Install coolant pump coolant drain bolt • Clean thread. • Use conventional Teflon tape – Tightening torque 20 Nm
19. 19. Remove charge air pipe • Release 2x clamp • Unscrew 2x bolt (1)

20. 20. Remove exhaust system • Remove front exhaust pipe – Unscrew 3x nut (1) • Expose wiring harness

Important. When removing the centre muffler, a catalytic converter, an exhaust manifold, or an exhaust manifold with catalytic converter, secure that portion of the exhaust system remaining on the vehicle against uncontrolled suspension. The exhaust system piece with the flex pipe inside can be secured for this purpose using suitable means, such as a wire on the vehicle underbody. Bends in the flex pipe with an angle as little as 5 – 10 degrees from the intended installation position may result in damage with subsequent total failure of the flex pipe.

Important. Secure front exhaust pipe from hanging over

21. 21. Remove exhaust system • Detach exhaust system – 6x damper ring

Note. 2nd and 3rd mechanics are required

22. 22. Remove catalytic converter support • Unscrew 2x nut • Unscrew 2x bolt
23. 23. Remove catalytic converter • Remove steering gear heat shield – Unscrew 3x bolt
24. 24. Remove turbo coolant return line • Unscrew 2x banjo bolt

25. 25. Detach thermostat housing • Unscrew 3x bolt

Note. Coolant hoses remain attached.

26. 26. Remove coolant pipe
27. 27. Clean sealing surfaces

Install

28. 28. Replace thermostat housing gasket

Note. Lightly coat gasket with silicone grease (white)

29. 29. Attach coolant pipe • Replace 2x coolant pipe seal ring • Insert coolant pipe. – In thermostat housing

Note. Lightly coat gasket with silicone grease (white)

Note. Lug on coolant pipe engages in recess on thermostat housing

30. 30. Attach thermostat housing • Tighten 3x bolt – Tightening torque 9 Nm
31. 31. Attach turbo coolant return line • Replace 4x seal ring • Tighten 2x banjo bolt – Tightening torque 40 Nm
32. 32. Fit catalytic converter • Attach steering gear heat shield – Tighten 3x bolt
33. 33. Refit radiator drain plug
34. 34. Lower vehicle
35. 35. Attach catalytic converter • Replace 3x nut • Screw in 1x nut (1) until dimension I is approx. 1 mm • Screw in 2x nut (2) • Tighten 3x nut – Tightening torque 25 Nm

Note. Use assembly paste.

Note. The tightening sequence must be observed; ensure that the catalytic converter flange and turbo flange do not touch at the edge.

36. 36. Raise vehicle
37. 37. Fit catalytic converter support • Tighten 2x nut – Tightening torque 40 Nm • Tighten 2x bolt – Tightening torque 25 Nm
38. 38. Position exhaust system • Replace gasket

Note. 2nd and 3rd mechanics are required

39. 39. Attach exhaust system • Replace 3x nut • Tighten 3x nut – Tightening torque 16 Nm . • Route wiring harness and clip in
40. 40. Fit charge air pipe • Tighten 2x clamp • Tighten 2x bolt
41. 41. Install ribbed V-belt cover • Screw in 4x bolt
42. 42. Lower vehicle
43. 43. Connect 3x wiring harness plug • Unclip 2x wiring harness plug • Catalytic converter control oxygen sensor, exhaust temperature sensor, solenoid
44. 44. Install engine vent hose.
45. 45. Disconnect wiring harness plug for oxygen sensor, mixture regulation
46. 46. Attach turbo heat shield • Fit heat shield • Tighten 3x bolt – Tightening torque 20 Nm
47. 47. Install air intake hose. • Attach tank vent line • Attach wastegate hose • Tighten clamp – Tightening torque 3,5 Nm
48. 48. Install air cleaner housing • Install intake pipe – Tighten clamp – Tightening torque 3,5 Nm • Connect wiring harness plug to hot film mass air flow meter • Attach wiring harness
49. 49. Attach upper engine cover
50. 50. Connect battery.
51. 51. Top up coolant • Observe specified coolant quantity

Note. Fill and bleed cooling system

52. 52. Close bonnet
53. 53. Program volatile memories