Exhaust manifold — removal and installation (Opel Vectra B)

1.7L engines

1. The exhaust manifold is removed together with the turbocharger. Raise the front of the car and secure it on stands. Remove the engine splash guard.

2. Remove the radiator fan.

3. Remove the turbocharger air intake duct.

4. Unscrew the bolts securing the heat exchanger air intake pipe to the manifold and cylinder head and separate the pipe from the manifold. Loosen the clamp and remove the air intake pipe from the engine.

5. Loosen the clamps and remove the pipe connecting the turbocharger to the heat exchanger.

6. Loosen the clamps and remove the turbocharger coolant supply pipes from the water pump and thermostat housing. Release the hoses from the mounting brackets so that they can be removed together with the manifold.

7. Remove the bolts and turbocharger heat shield.

8. Remove the nuts and disconnect the exhaust pipe from the turbocharger.

9. Remove the bolt and the turbocharger oil feed pipe from the cylinder block. Loosen the clamp and remove the oil return hose.

10. Remove the bolts and support bracket from the side of the turbocharger.



11. Evenly and gradually in a diagonal sequence, unscrew the bolts and nuts securing the exhaust manifold (indicated by arrows). Remove the exhaust manifold together with the turbocharger.



12. Installation is carried out in the reverse order of removal, taking into account the following points:

• replace all gaskets;
• check engine oil and coolant levels;
• before starting the engine for the first time, disconnect the electrical connector from the engine stop solenoid valve and crank the engine with the starter until the oil pressure light goes out, which will supply engine oil to the turbocharger bearings before starting the engine. Reconnect the electrical connector of the engine stop solenoid valve.

2.0L engines

1. Remove the ground cable from the battery. Unscrew the screws and remove the plastic cover from the top of the cylinder head.

2. Remove the air supply pipe from the air cleaner housing and remove the metal pipe connecting the turbocharger to the heat exchanger.



3. Unscrew the nuts (A) and remove the wires (B) from the glow plugs.



4. Unscrew the screws securing the heat-resistant screen (indicated by arrows).





5. Remove the heat shield from the top of the manifold.



6. Remove the nuts securing the exhaust inlet pipe to the manifold and move the pipe away from the manifold.

7. Under the vehicle, unscrew the bolts and remove the starter heat shield.

8. Remove the bolts and remove the wiring harness guide from the rear of the cylinder block.

9. Unscrew the turbocharger oil pipes from the cylinder block.



10. Remove the bolts and bracket that supports the manifold. Disconnect the vacuum hose from the turbocharger flap diaphragm.





11.Loosen the exhaust manifold mounting nuts evenly and in a diagonal sequence. Remove the exhaust manifold together with the turbocharger.



12. Remove the exhaust manifold gasket.

13. Installation is carried out in the reverse order of removal, taking into account the following points:

• replace all gaskets;
• check and, if necessary, top up engine oil and coolant;
• when you first start the engine, the engine should idle for a few minutes to allow oil to flow to the turbocharger bearings.