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 owners' backbox choices and swaps see Exhaust backbox: swapping it.
Silencer replacement
Turbo (Z20LET)
Remove
- Disconnect oxygen sensor for secondary catalytic converter (Disconnect engine harness connector)
- 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 left subframe for oxygen sensor
- Release clip from rear silencer heatshield
- Remove secondary catalytic converter for exhaust (Remove 3x front nut, then discard; Release rubber mount bracket; Release rubber mount; Remove gasket from front joint, then discard)
- Remove intermediate pipe and heatshield from rear silencer (Release clamp)
- Release rear silencer, left support bracket from silencer (Remove 2x nut, then discard)
- Remove rear silencer, left flexible support from subframe (Remove 2x bolt; Remove clamp)
- Release rear silencer, right support bracket from silencer (Remove 2x nut, then discard)
- Remove rear silencer, right flexible support from subframe (Remove 2x bolt; Remove clamp)
- Remove silencer from vehicle (Pull off)
Install
- Install silencer to vehicle (Push fit)
- Install rear silencer, right flexible support to subframe (Install clamp; Install 2x bolt)
- Secure rear silencer, right support bracket to silencer (Install 2x new nut)
- Install rear silencer, left flexible support to subframe (Install clamp; install 2x bolt)
- Secure rear silencer, left support bracket to silencer (Install 2x new nut)
- Install intermediate pipe and heatshield to rear silencer
- Install secondary catalytic converter for exhaust (Install new gasket to front joint; Position bracket for rubber mount; Install 3x new rear nut; Position rubber mount)
- Install harness to rear silencer heatshield for oxygen sensor installed to secondary catalytic converter (Secure clip to heatshield; Install harness to subframe; Secure 2x clip)
- 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 to engine harness (Connect harness connector)
NA (Z22SE)
Remove
- Open engine cover.
- Harness connectors for oxygen sensors.
- 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.
- Catalytic converter from exhaust manifold – 3 nuts.
- Catalytic converter from mounting.
- Intermediate pipe from silencer – clamp.
- Support bracket, right side – 2 nuts, 2 bolts.
- Harness connectors for oxygen sensors.
- Close engine cover.
- Chocks from front wheels.
Install
- Chocks to front wheels.
- Raise vehicle.
- Support bracket, left side – 2 nuts, 2 bolts.
- Silencer from vehicle.
- Silencer to vehicle.
- Support bracket, left side – 2 nuts, 2 bolts.
- Caution !
- Do not tighten nuts and bolts.
- Support bracket, right side – 2 nuts, 2 bolts.
- Torque
- Support bracket, left side – 2 nuts, 2 bolts.
- Support bracket, right side – 2 nuts, 2 bolts.
- Intermediate pipe to silencer – clamp.
- Important: Do not tighten clamp.
- Catalytic converter to exhaust manifold – 3 nuts.
- Catalytic converter to mounting.
- Catalytic converter to intermediate pipe – 3 nuts.
- Torque
- Clamp for intermediate pipe to silencer – 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.
Rear silencer heat shield (Turbo)
Turbo (Z20LET) only.
Remove
- Remove rear clamshell - see “Rear Clamshell, Remove and Install”
- Release intermediate pipe from secondary catalytic converter (Remove 3x nut, then discard; Release mounting bracket)
- Release heat shield for rear silencer from rear subframe
- Remove 3x bolt, 3x spring washer, 3x flat washer, clip
- Remove rear silencer and heat shield from rear subframe (Remove 6x bolt; Remove 4x bolt, 2x clamp)
- Remove intermediate pipe from rear silencer (Release clamp)
- Remove rear silencer from heat shield (Pull out)
Install
- Install rear silencer to new heat shield (Push fit)
- Install intermediate pipe to rear silencer (Secure clamp)
- Install rear silencer and heat shield to rear subframe (Install 6x bolt; Install 4x bolt, 2x clamp)
- Secure heatshield for rear silencer to rear subframe
- Install 3x bolt, 3x spring washer, 3x flat washer, clip
- Secure intermediate pipe to secondary catalytic converter (Secure mounting bracket; Install 3x new nut)
- Install rear clamshell - see “Rear Clamshell, Remove and Install”