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[terry paget]

I suspect removing the manifold will be a serious pain in the Arris. I'll bet a tidy sum that you'll end up having to drill out snapped studs and all sorts of other sh!te.

Is there an option of cutting the old hose to remove and then re-routing using a longer flexible coolant hose, such as used by kit car builders. E.g.

https://www.carbuilder.com/uk/38mm-id-x-450mm-long-vulcoflex-flexible-coolant-hose

Do you have experience of the Vectra, or maybe Astra, with this problem? On reflection, I had trouble with at least two 4 cylinder Omegas, but no trouble with 6 cylinder Omegas, or a Senator, or my Rover Streetwise. Not that it matters I shall find out soon enough. Iam aftraid your suggested rubber hose would not do, the metal pipe is shaped and the ends ar 'O' ring joints.

[Viral_Jim]

Sorry no, I haven't experienced either vehicle. I've only ever taken the manifolds of 3 cars I think. A Desmond omega, fiat 131 twin cam and a 1.3 escort. All cars were c15yrs old at the time and all were a complete sh!t to do. Perhaps I'm just cack handed. 

My thoughts were that you would cut the metal pipe leaving 1-2" on either end, potentially flare the pipe and then use a flexi between the two flared ends.

All that said, I can't really picture in my mind the layout of the problem pipe from the pics you've shared, so I might be barking up completely the wrong tree.

I just think I'd try a couple of avenues before trying to get the manifold off. One of which would definitely be the pressure test DG suggested 

[dave the builder]

Yep
find the leak BEFORE trying to fix it

[terry paget]

Above pic, from below, shows a drip leaking from the tube passing through tunnel in casting.

Pic showing pipe entering tube.
I am at a loss to know how to proceed. Please advise.

[terry paget]

This post should precede post. The exhaust manifold came off easily and without studs breaking off. Above pic shows the coolant pipe from coolant pump to thermostat.


Above pic shows coolant pipe passing through  a tube, part of a casting fixed to the head, also carrying other items including the oil filter assembly. This assembly looks tricky to remove. The coolant pipe was not expected to require attention; I am dismayed I have cracked it.  All I was doing was changing the thermostat holder to cure a minor coolant leak from below the LH end of the coolant pipe. I must have pulled it forward to remove the sealing ring. Please advise.

[Doctor Gollum]

A pipe of two halves

Remove it and replace both seals. No point doing anything less given the access.

[terry paget]

A pipe of two halves

Remove it and replace both seals. No point doing anything less given the access.

Do you mean if I remove the ends I can pull them out separately? That had not occurred to me. I will try it. Thank you.

[Doctor Gollum]

How else would it be fitted? 

[henryd]

As DG says it'll be two pieces pushed into o rings on both sides

[terry paget]

As DG says it'll be two pieces pushed into o rings on both sides

Like the Omega V6 thermostat pipe. Why didn't I think of that? Imagine my relief when he told me that. There was I wondering how I could remove the whole assembly, with oil filter and something else fixed behind the junction pipe.

[terry paget]

Another mystery on this car is the radiator drain tap. I fitted a new radiator about 6 months ago, not a Vx radiator, and the drain tap only turns a quarter of a turn, but seems to be closed in either position. It's not the end of the world, but pulling off the bottom hose to drain the radiator makes quite a mess. What am I doing wrong?

[Doctor Gollum]

Buying cheap radiators from random Chinese eBay suppliers notwithstanding...

Just pull the bottom hose

[terry paget]

Buying cheap radiators from random Chinese eBay suppliers notwithstanding...

Just pull the bottom hose

I bought the one you recommended, about £100. Next time I shall check the drain tap before I fit.

[Doctor Gollum]

Fair enough

Slept since then, was it an old stock VX one?

[terry paget]

I'm not surprised it leaked. This joint looks like it was not meant to be disturbed, felt spacer and black jointing compound. At least there is no need to get a pipe repaired. I note a hole in the middle section to the box behind, possibly to speed warm up.
Is there any point disturbing the other end, Doc?