21.1a Components of the exhaust system for Z14XEP / Z16XEP engines
1 exhaust pipe
2 Additional silencer
3 Exhaust connections
4 Central muffler
6 Downpipe
7 Flexible downpipe section
8 Lambda probe
21.1b Z17DT engine exhaust system components (L/H)
1 exhaust pipe
2 Additional muffler
3 Exhaust connections
4 Central muffler
6 Catalyst
7 Downpipe
8 Flexible downpipe section
21.1c Z18XE engine exhaust system components
1 exhaust pipe
2 Additional muffler
3 Exhaust connections
4 Central muffler
6 Downpipe
7 Flexible downpipe section
8 Lambda probe
21.1d Z20LEL engine exhaust system components
1 exhaust pipe
2 Additional muffler
3.5 Exhaust connections
4 Central muffler
6 Lambda probe
7 Downpipe
8 Flexible downpipe section
2. Regularly inspect the entire system for signs of corrosion, deformation and mechanical damage. Check fastener tightness. Violation of the tightness of the components and their joints is fraught with the ingress of exhaust gases into the vehicle interior. Defective components and sections must be replaced.
3. When carrying out work on the exhaust system, the following instructions must be followed:
- a) Lubricate the fasteners to be loosened with penetrating oil or other rust-dissolving agent.
- b) Prepare the necessary replacement gaskets, hanging loops, clamps and fasteners in advance; when removing all seals and fastening elements, they must be replaced;
- c) The sealing surfaces of parts to be reinstalled must be cleaned with a wire brush or sandpaper. Lubricate the threaded part of the fastener with an anti-seize sealant before installation;
- d) When installing components, make sure that there is sufficient clearance between the sections of the system and nearby suspension / body elements. Pay special attention to the correct installation and secure fastening of heat shields (with appropriate equipment).
Note: If the system is severely corroded, a cutting torch may be required to separate sections of the system (alternatively, you can use a hacksaw or a pneumatic chisel - do not forget to wear safety goggles and gloves.
4. When removing or disconnecting the downpipe, it must not be allowed to hang on the flexible section of the pipe (see resist. illustration). Bending the flexible section at an angle of 5-10°and twisting at an angle of±0.5°can lead to its damage and failure. For this reason, when carrying out the relevant work, the downpipe must be fixed with a wire to the rigid elements of the bottom, if necessary, use the help of an assistant.
Removal and installation of a reception pipe / catalytic converter
Withdrawal
5. To perform a number of works in the engine compartment, only the exhaust pipe needs to be removed. To dismantle it, lift and place the car on stands, if equipped, remove the engine crankcase protection (see chapter 2).
6. Z20LE engine (L/R/H): Disconnect the lambda probe harness connector (see resist. illustration) and release the wire from the retaining clips.
7. Disconnect the downpipe (see resist. illustration) from catalytic converter (with appropriate equipment), for which loosen 3 nuts.
Note: On some models, the catalytic converter is included in the intake section and removed with it.
8. Fasten the center muffler to the bottom with wire.
9. Disconnect a reception pipe from the central muffler. If necessary, remove the lambda probe from the pipe.
Installation
10. Lubricate the threads of the lambda probe with a thin layer of Opel heat-resistant mounting paste (petrol engine: black grease, diesel engine: white grease), put it in place.
Attention: Mounting paste should only be applied to the thread, do not allow it to get on the body of the lambda probe!
Note: If the lambda probe is installed without the use of a heat-resistant lubricant, the thread will begin to stick over time. As a result, it will not be possible to unscrew the probe at the next service. New sensors already have the necessary lubrication.
11. Further installation is carried out in the reverse order of removal. Don't forget to replace the gas seals
Removal and installation of system of release of the fulfilled gases
Withdrawal
12. Raise and place the car on stands, if equipped, remove the engine crankcase protection (see chapter 2). If the central section of the exhaust tract does not have holders, it must be fixed with a wire to the bottom of the vehicle.
13. First of all, remove the rear section of the exhaust system, to do this, disconnect the rear docking connection and remove the section from the holders (see resist. illustration).
14. Then disconnect the downpipe from the catalytic converter, if necessary, remove the lambda probe (see above).
15. Remove the central muffler from the holders (see resist. illustration) and remove it together with the downpipe. If necessary, disconnect the downpipe from the center muffler by disconnecting the front exhaust tract docking joint.
Installation
16. Fix a reception pipe on the catalyst with new consolidation, do not tighten fixing nuts.
17. Install the center muffler in the holders (hang with wire) and connect to the downpipe, do not tighten the fastening.
18. Establish the back muffler and insert into holders and without tightening fastening connect to the central muffler.
19. Check that the exhaust system is installed in accordance with the profile of the bottom and that there is no bending stress on the exhaust pipes. At the same time, make sure that there is a sufficient distance between the exhaust system and the body everywhere, the holders with elastic rubber elements must be evenly loaded.
20. Tighten the release system fasteners.
21. Reinstall the lambda probe and crankcase protection if they were removed and lower the car.
Removal and installation of the particulate filter (DPF) (Z19DT engine (H))
22. Remove the rear section of the exhaust system (see above).
23. Mark the position of the differential pressure hoses (see resist. illustration) particulate filter and disconnect them.
24. Loosen the union nut, remove the temperature sensor and move it aside (see illustration 21.23), and then unscrew the 3 fixing bolts and remove the central muffler from the holders together with the filter.
24. Installation is carried out in the reverse order.
Attention: If the particulate filter has been replaced, it is necessary to reprogram the engine management system - contact an Opel workshop!
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