The steps below are shortened from the Vauxhall TIS pages for the Speedster. The VX220 shares the same engines and most of the car, but check anything unusual against your own car. The TIS pictures and the full wording aren't reproduced, so use the workshop manual if you are doing the job. We haven't seen owners' accounts of this job, so there are no owner tips here.
For sports cats and pre-cat removal see Sports cats and NA pre-cat removal.
Converter removal and refitting
The TIS steps are the same for the Turbo and the NA.
Remove
- Open engine cover.
- Harness connectors for oxygen sensors.
- Chocks to front wheels.
- Raise vehicle.
- Rear undertray – 13 bolts.
- Diffuser panel – 7 bolts, 2 clips.
- Wiring harness from rear subframe – clip.
- Wiring harness from heatshield – cable ties, clip.
- Wiring harness from wheelarch liner.
- Lower heatshield from exhaust manifold – 3 bolts, clip.
- Catalytic converter from intermediate pipe – 3 nuts.
- Harness connectors for oxygen sensors.
- Close engine cover.
- Chocks from front wheels.
Install
- Catalytic converter from exhaust manifold – 3 nuts.
- Catalytic converter from mounting.
- Catalytic converter to exhaust manifold – 3 nuts.
- Catalytic converter to mounting.
- Catalytic converter to intermediate pipe – 3 nuts.
- Lower heatshield to exhaust manifold – 3 bolts, clip.
- Wiring harness through wheelarch liner.
- Wiring harness to rear subframe – clip.
- Wiring harness to heatshield – cable ties, clip.
- Diffuser panel – 7 bolts, 2 clips.
- Important: Do not tighten bolts.
- Rear undertray – 13 bolts.
- Tighten diffuser and undertray bolts.
- Lower vehicle.
Clean
- Gasket faces.
Turbo primary converter
Turbo (Z20LET) only.
Remove
- Remove engine cover - see “Engine Cover, Remove and Install”
- Disconnect air intake hose from mass air flow meter and turbocharger (Release 2x clip; Move air intake hose to one side)
- Remove support bracket with engine lifting eye from cylinder head (Remove bolt)
- Remove heat shield from support bracket on cylinder head (Remove 4x bolt, 4x washer)
- Remove support bracket for heat shield from cylinder head (Remove bolt, 2x washer; Remove bolt)
- Disconnect harness connector from switchover valve on turbocharger (Release integral clip)
- Disconnect vacuum hose from turbocharger (Pull off)
- Remove guide tube for oil level dipstick from engine cylinder block (Remove oil level dipstick; Remove bolt; Remove 2x O ring, then discard)
- Disconnect harness connector for primary oxygen sensor from engine harness (Release integral clip; Release cable tie, then discard)
- Disconnect harness connector for secondary oxygen sensor from engine harness
- Release integral clip
- Lower harness through aperture in left rear inner wheel
- Release heat shield for turbocharger from transmission housing (Remove bolt)
- Remove engine undertray (Raise vehicle; Remove 13x bolt, 13x washer)
- Remove exhaust undertray (Remove 12x bolt, 12x washer, 2x clip)
- Remove secondary catalytic converter
- Remove 6x nut, then discard
- Remove gasket, then discard
- Release harness from clip (Release 2x cable tie, then discard)
- Remove hose from turbocharger and intercooler (Release 2x clip; Remove cable tie, then discard)
- Release heat shield for turbocharger from engine cylinder block (Remove bolt, washer)
- Disconnect oil return pipe from engine cylinder block (Position suitable collecting container; Install blanking plug (Discard 2x seal ring))
- Disconnect oil feed pipe from engine cylinder block (Remove bolt; Disconnect pipe union)
- Lower vehicle
- Disconnect coolant feed hose from turbocharger, then secure to one side (Position suitable collecting container; Install clamp; Discard 2x seal ring)
- Disconnect coolant return hose from turbocharger (Release clip)
- Remove exhaust manifold with turbocharger from cylinder head (Remove 10x nut, then discard; Remove gasket, then discard)
- Remove heat shield from exhaust manifold (Remove bolt)
- Remove catalytic converter from exhaust manifold (Remove clamp)
- Remove oxygen sensor from primary catalytic converter
Install
- Install oxygen sensor to primary catalytic converter
- Install catalytic converter to exhaust manifold (Install clamp 8 Nm)
- Install heat shield to exhaust manifold (Install bolt)
- Install exhaust manifold with turbocharger to cylinder head (Install new gasket; Install 10x new nut)
- Install guide tube for oil level dipstick to engine cylinder block (Install 2x new O ring; Install bolt; Install oil level dipstick)
- Connect vacuum hose to turbocharger (Push fit)
- Connect harness connector to switchover valve on turbocharger (Secure integral clip)
- Connect coolant feed hose to turbocharger (Connect pipe union, 2x new seal ring; Remove clamp)
- Install support bracket for heat shield to cylinder head (Install bolt, 2x washer; Install bolt)
- Install heat shield to support bracket on cylinder head (Install 4x bolt, 4x washer)
- Secure heat shield for turbocharger to transmission housing (Install bolt)
- Install support bracket with engine lifting eye to cylinder head (Apply locking compound)
- Connect coolant return hose to turbocharger (Secure clip)
- Connect harness connector for primary oxygen sensor to engine harness (Secure integral clip; Secure new cable tie)
- Connect air intake hose to mass air flow meter and turbocharger (Secure 2x clip)
- Raise vehicle
- Connect oil feed pipe to engine cylinder block (Install bolt 35 Nm; Connect pipe union 20 Nm)
- Connect oil return pipe to engine cylinder block (Remove blanking plug, then discard)
- Secure heat shield for turbocharger to engine cylinder block (Install bolt, washer)
- Install hose to turbocharger and intercooler (Secure 2x clip; Install new cable tie)
- Install secondary catalytic converter
- Remove 6x new nut
- Install new gasket
- Secure 2x new cable tie (Secure harness to clip)
- Raise harness through aperture in left rear inner wheel
- Install engine undertray (Install 13x bolt, 13x washer)
- Install exhaust undertray (Install 12x bolt, 12x washer, 2x clip)
- Lower vehicle
- Connect harness connector for secondary oxygen sensor to engine harness (Secure integral clip)
- Install engine cover - see “Engine Cover, Remove and Install”
- Check coolant level, then top-up as required
- Program volatile memories
Turbo secondary converter
Turbo (Z20LET) only.
Remove
- Disconnect oxygen sensor for secondary catalytic converter
- Disconnect harness connector
- Release integral clip
- Lower harness through aperture in left rear inner wheel
- Remove engine undertray (Raise vehicle; Remove 13x bolt, 13x washer)
- Remove exhaust pipe undertray (Remove 12x bolt, 12x washer, 2x clip)
- Release harness for secondary catalytic converter (Release 2x clip from subframe; Release clip from rear silencer heatshield)
- Remove secondary catalytic converter (Remove 3x front nut, then discard; Release rubber mount bracket; Release rubber mount from bracket; Remove gasket from front joint, then discard)
- Remove oxygen sensor from secondary catalytic converter
Install
- Install oxygen sensor to secondary catalytic converter
- Install secondary catalytic converter (Install new gasket to front joint; Position bracket for rubber mount; Install 3x new rear nut; Secure rubber mount to bracket)
- Install harness for oxygen sensor to rear silencer heatshield
- Secure clip
- Install harness for oxygen sensor to subframe
- Secure 2x clip
- Raise harness through aperture in left rear inner wheel
- Secure clamp for intermediate pipe
- Install engine undertray (Remove 13x bolt, 13x washer)
- Install exhaust pipe undertray (Install 12x bolt, 12x washer, 2x clip)
- Lower vehicle
- Connect oxygen sensor for secondary catalytic converter (Connect harness connector; Secure integral clip)
- Program volatile memories