Removal and installation of thermal screens (Opel Astra J)

During engine operation, the exhaust system heats up to a high temperature. Therefore, in case of severe mechanical damage or significant corrosion of the heat shields installed on the system elements, be sure to replace them. In addition to reducing the comfort level in the cabin, a malfunction of the heat shields can lead to charring of the heat and noise insulation of the body floor.

Warning! The edges of the heat shield of the catalytic converter are very sharp, so when removing it, protect your hands from injury with a rag or gloves.

You will need: socket heads "10", TORX E10.

To remove the heat shield cat collector do the following.

1. Disconnect the wire from the negative terminal of the battery.



2. Squeeze the clamps of the oxygen sensor control wire harness connector…



3. …and disconnect the block.





4. Remove the engine crankcase guard (see Removal and installation mudguards and engine crankcase protection).



5. Remove the two bolts of the upper heat shield mount: the left bolt secures the oil level indicator (dipstick) guide tube, and the right bolt secures the oxygen sensor control wiring harness holder; move the harness holder aside..



6. …remove the guide tube seal from the cylinder block hole…





7. …and pick up the phone.



8. Unscrew the two bolts securing the heat shield to the exhaust manifold…



9. …and remove the heat shield of the catalytic converter, passing the wires and the connector of the control oxygen sensor through the hole in the shield.

10. Install the exhaust manifold heat shield in the reverse order of removal.



To remove the heat shield additional muffler do the following.

1. Remove the main and additional mufflers (see Replacing the main and additional mufflers).

Note: If you have sufficient skill, you can leave the main and additional mufflers in place, as the heat shield is quite flexible. After unscrewing the seven nuts that secure it and removing the body strut, remove the shield down from the studs and carefully turn it around the muffler.

2. Remove the four bolts securing the body strut…



3. ...and remove the spacer.



4. Unscrew the seven nuts securing the additional muffler heat shield to the body base and remove the heat shield.



5. Install the parts in the reverse order of removal.

To remove the heat shield exhaust pipe of additional muffler, installed on the fuel tank, do the following.



1. Remove the fuel tank…

Note: The fuel tank must be removed as its mounting clamps are located on top of the heat shield.

2. …remove the four mounting pins and remove the heat shield.

3. Install the parts in the reverse order of removal.

[Original posted on the website: opelbook.ru]

To remove the heat shield main muffler do the following.

1. Remove the main and additional mufflers (see Replacing the main and additional mufflers)



2. Unscrew the four nuts securing the heat shield of the main muffler and remove the heat shield.

3. Install the parts in the reverse order of removal.