Vauxhall Workshop Service and Repair Manuals

Lower Part of Intake Manifold, Remove and Install (X 16 XEL)  

  Remove, Disconnect   

Remove air cleaner housing - see operation "Air Cleaner Housing, Remove and Install". Remove upper part of intake manifold - see operation "Upper Part of Intake Manifold, Remove and Install".  

Reduce fuel pressure with Fuel Pressure Gauge KM-J-34730-91 via checking connection - collect escaping fuel in suitable reservoir - note safety regulations and national legislation.  

Detach fuel lines (1) from fuel distributor pipe or from fuel pressure regulator. Detach connection port (2) from throttle body. Remove wiring harness plug for crankshaft pulse pick-up (3) from bracket and pull through downwards (between intake manifold ducts) - note cable routing.   Remove cable duct (4) from throttle-valve housing and place to rear. Detach Bowden transmission cable and place to rear.   Remove fastening bolts (5) and lay throttle body aide downwards.

  Remove, Disconnect   

Disconnect wiring harness plug (1) from idle speed stepper motor and wiring harness plug (2) from throttle valve potentiometer.   Remove throttle body flange (3) from lower part of intake manifold - note different bolt lengths.   Remove lower radiator hose from radiator - collect coolant.   Use KM-913-A to tighten ribbed V-belt tension roller in clockwise direction and remove ribbed V-belt from generator belt pulley.   Remove alternator shackle. Loosen lower alternator fastening bolt and swing alternator to rear.

  Remove, Disconnect   

Detach wiring trough bracket from lower part of intake manifold and lay aside to rear with lower wiring trough.  

Remove coolant hose from intake manifold, lower part (arrow) and intake manifold, lower part from cylinder head. Remove coolant flange (1) from cylinder head and set aside to the rear.     Clean    Clean sealing surfaces and remove sealant remnants.     Install, Connect    Install coolant flange (1) and intake manifold, lower part with new gasket at cylinder head - tightening torque 20 Nm/15 lbf. ft. Install coolant hose on intake manifold, lower part (arrow) - note correct seating.

  Install, Connect   

Attach cable duct bracket to lower part of intake manifold. Fasten generator shackle to coolant flange & generator to lower part of intake manifold - tightening torque 20 Nm. Use KM-913-A to tighten ribbed V-belt in clockwise direction and lay aside ribbed V-belt. Note direction of rotation of ribbed V-belt.  

Attach throttle-valve housing to lower part of intake manifold, watching out for varying bolt lengths - tightening torque 8 Nm. Plug in wiring harness plug to idling speed stepper motor and throttle-valve potentiometer. Attach throttle-valve housing with new seal to throttle-valve housing flange tightening torque 8 Nm. Attach cable duct to throttle-valve housing. Replace Bowden transmission cable.  

Pull wiring harness plug for crankshaft pulse pick-up between intake manifold ducts and engage in bracket - note cable routing. Fasten connection port with hose clamp to throttle body. Attach fuel feed line to fuel distributor pipe and fuel return line to fuel pressure regulator.  

Install upper part of intake manifold - see operation "Upper Part of Intake Manifold, Remove and Install". Install air cleaner housing - see operation "Air Cleaner Housing, Remove and Install". Attach lower radiator hose to radiator.  

  Inspect   

Cooling system - see operations "Cooling System, Top Up and Bleed" and "Cooling System, Check for Leaks".