Contents: Removal ⬇ Installation ⬇
All elements of the system can be replaced individually.
Removal
Raise the vehicle and place it on supports.
Lubricate all threaded connections with a rust dissolving agent and leave for a while.
Loosen the clamp on the rear (main) muffler.
Remove the main muffler from the rubber mounts and disconnect it from the additional muffler.
Place wooden shims under the exhaust system.
For vehicles with 2.0L engines with a catalytic converter: unscrew the lambda probe from the inlet pipe with a wrench, after disconnecting the connector.
Attention! The lambda probe and catalytic converter are sensitive to impacts. It is not recommended to hit them or drop them.
Loosen the bolts securing the intake pipe to the exhaust manifold (see Fig.). Fig. A shows the C16NZ engine flange, and Fig. B shows the E16NZ.
For vehicles with 1.7L turbodiesel engines and 2.0L turbopetrol engines: Loosen the bolts securing the intake pipe to the turbocharger.
Loosen, where necessary, the bolts securing the intake pipe to the body.
Remove the exhaust system mount in front of the additional muffler from the rubber mounts and remove the muffler.
(Original posted on the website: OpelBook)
Installation
Install the intake pipe of the new exhaust system, having previously cleaned the mating surfaces and laid new sealing and damping gaskets. Do not tighten the mounting bolts yet.
To ensure the possibility of subsequent disassembly, it is recommended to cover the threaded connections with a special anti-stick paste before assembly.
Raise the exhaust system with the help of an assistant or place it on wooden spacers.
Install an additional muffler on rubber suspensions.
Place a new gasket under the intake pipe flange and pre-secure the pipe with new bolts, without tightening them yet.
If necessary, tighten the exhaust pipe bracket mounting bolts.
Install the main muffler onto the exhaust pipe from behind, having first installed the clamp.
Adjust the position of the main muffler and install it on rubber suspensions.
Before tightening the bolts of the exhaust system, adjust the position of all its elements without distortions and deformations. Maintain the required distance between the system elements and the car body and ensure uniform load on the rubber suspensions.
Tighten the system mounting bolts to the following torques:
- the inlet pipe with the exhaust manifold - with a torque of 25 Nm,
- the inlet pipe with a turbocharger in cars with a 2.0 l turbo petrol engine - 12 Nm,
- the intake pipe with a turbocharger in cars with 1.7 l turbodiesel engines - 65 Nm,
- receiving pipe with support - 20 Nm,
- ball joint - 12 Nm,
- clamps - 25 Nm,
- exhaust manifold on cars with 16-valve engines - 20 Nm.
In cars with 2.0 l engines with a catalytic converter: before screwing in the lambda probe, lubricate its thread with Opel paste N1948602 (05613905). Screw in the lambda probe and tighten to a torque of 30 Nm. Connect the connector, routing the wire so that it does not come into contact with the exhaust system anywhere. Secure the wire with clamps.
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