Replace Exhaust Manifold Gasket Opel Vectra C

Remove

1. 1. Open bonnet
2. 2. Disconnect battery.
3. 3. Detach engine cover. • Unscrew 2x bolt • Unscrew oil filler cap • Remove engine cover • Screw in oil filler cap
4. 4. Remove pollen filter housing
5. 5. Drain coolant • Unscrew coolant compensation tank closure cap Warning: Only open coolant compensation tank once engine has cooled down • Place collecting basin underneath. • Open drain bolt (arrow)

6. 6. Detach vacuum line • Unscrew 2x bolt (arrows) • Disconnect 2x hose

7. 7. Remove charge air pipe (1) • Release 2x clamp

8. 8. Detach engine vent hose • Release clamp (1)

9. 9. Remove air intake hose (1) • Remove bolt • Release clamp
10. 10. Detach upper coolant hose • Release clamp
11. 11. Release oil dipstick guide tube at the top • Remove bolt (arrow)
12. 12. Remove connection hose from charge air pipe to intercooler • Release 2x clamp
13. 13. Detach cover • Unscrew 3x bolt
14. 14. Remove coolant pipe assembly (2) • Unscrew 5x bolt, nut • Release 5x clamps • Detach engine transport shackle, – Unscrew 2x bolt
15. 15. Release catalytic converter heat shield (3) • Unscrew 2x bolt

16. 16. Raise vehicle
17. 17. Detach lower engine compartment cover and right-hand engine splash protection if necessary
18. 18. Detach catalytic converter heat shield • Unscrew 2x nut, bolt

Note. Unhook heat shield from stud bolt.

19. 19. Lower vehicle
20. 20. Remove catalytic converter heat shield
21. 21. Release metal pipe, exhaust gas recirculation (1) • Unscrew 2x bolt • Release clamp

22. 22. Raise vehicle
23. 23. Remove front exhaust pipe • Unscrew 6x nut • Release exhaust pipe bracket – Unscrew 2x bolt • Remove 2x gasket

Important. When removing the central silencer, a catalytic converter, an exhaust manifold or an exhaust manifold with catalytic converter, the part of the exhaust system remaining in the vehicle must be secured to prevent it sagging. To do this, the section of the exhaust system with the flex pipe contained in it can be fastened to the substructure of the vehicle with suitable means such as e.g. wire or the transportation fittings for a new flex pipe. Bends of as little as 5 - 10 degrees in the flex pipe can lead to damage resulting in total failure of the flex pipe.

24. 24. Release catalytic converter at the bottom • Unscrew 2x bolt (2), nut (3)
25. 25. Remove catalytic converter • Disconnect wiring harness plug (1) • Release clamp (arrow)

26. 26. Remove turbocharger oil return line (1) • Unscrew 4x bolt

27. 27. Detach turbocharger oil feed line (1) • Unscrew banjo bolt (2) – From cylinder block • Remove 2x seal ring

28. 28. Detach vacuum hose for waste gate unit
29. 29. Lower vehicle
30. 30. Remove exhaust manifold (1) • Unscrew 8x nut • Remove gasket.

Install

31. 31. Cleaning work
32. 32. Install exhaust manifold • Replace 8x nut • Replace gasket • 8x nuts 25 Nm

Note. Pour 0.4ml clean engine oil into the oil feed line opening of the turbocharger

33. 33. Raise vehicle
34. 34. Attach turbocharger oil feed line • Banjo bolt 15 Nm – At cylinder block • Replace 2x seal ring
35. 35. Install turbocharger oil return line • Replace 2x gasket • 2x bolts 9 Nm • 2x bolts 25 Nm
36. 36. Connect vacuum hose for waste gate unit
37. 37. Attach catalytic converter • Screw on clamp lightly • Connect wiring harness plug.

Note. Ensure correct positioning.

38. 38. Attach front exhaust pipe • Replace 6x nut • Replace 2x gasket – 6x nuts 20 Nm • Fasten exhaust pipe bracket – Tighten 2x bolt
39. 39. Attach catalytic converter • Tighten clamp • Tighten 2x bolt, nut
40. 40. Lower vehicle
41. 41. Fasten metal pipe, exhaust gas recirculation • Replace gasket • 2x bolts 25 Nm • Tighten clamp
42. 42. Attach catalytic converter heat shield
43. 43. Raise vehicle
44. 44. Fasten catalytic converter heat shield • Tighten 2x nut, bolt
45. 45. Attach engine cover.
46. 46. Lower vehicle
47. 47. Fasten catalytic converter heat shield • Tighten 2x bolt
48. 48. Install coolant pipe assembly • Attach engine transport shackle. – Tighten 2x bolt • 5x bolt, nut 9 Nm • Secure 4x clamp
49. 49. Attach cover • 3x bolts 9 Nm
50. 50. Attach upper coolant hose • Fasten clamp
51. 51. Attach oil dipstick guide tube at the top • Bolt 9 Nm
52. 52. Install connection hose from charge air pipe to intercooler • 2x clamps 3,5 Nm
53. 53. Attach air intake pipe to turbocharger • Place seal on the turbocharger connection • Attach air intake pipe – Tighten clamp 3.5 Nm • Tighten bolt 9 Nm

Important. Adhere to the following installation sequence

54. 54. Attach engine vent hose • Fasten clamp
55. 55. Fit charge air pipe • 2x clamps 3,5 Nm
56. 56. Attach vacuum line • 2x bolts 9 Nm • Connect 2x hose
57. 57. Install air cleaner housing
58. 58. Attach engine cover. • Unscrew oil filler cap • Place engine cover in position • Screw in oil filler cap • 2x bolts 9 Nm
59. 59. Connect battery.
60. 60. Program volatile memories
61. 61. Check engine oil level and correct if necessary. • Observe specified engine oil quantity
62. 62. Close bonnet