Vauxhall Workshop Service and Repair Manuals

Intake Manifold, Remove and Install (C 20 XE)  

  Remove, Disconnect   

Air cleaner housing - see operation "Air Cleaner Housing, Remove and Install".   Remove wiring harness plug (1) from mass air flow meter, hose (arrow) from prevolume chamber (2) and prevolume chamber with air intake hose. If present: remove wiring harness plug (3) from intake air temperature sensor.   C 20 XE up to MY '93: remove V-belt from alternator and tension shackle from intake manifold. Loosen lower alternator fastening bolt and swing alternator to rear.   C 20 XE MY '93 onwards: mark direction of rotation of ribbed V-belt. Tighten ribbed V-belt tension roller clockwise using KM-913-A and remove ribbed V-belt from generator belt pulley. Detach support (4) and shackle (5) from generator or intake manifold. Loosen lower generator extract and swing generator towards the rear.

  Remove, Disconnect   

Disconnect coolant hose (1) from coolant compensation tank and from intake manifold (2).   Detach brake servo vacuum line (arrow) from intake manifold.   Version with AC: detach vacuum line from intermediate piece for brake servo connection.   Remove intake manifold support from cylinder block and intake manifold   (accessible from underside).   Detach accelerator Bowden cable and lay aside to rear. Close off fuel lines with spring clamps and detach from fuel distributor pipe or from fuel pressure regulator.

Remove engine vent hoses from cylinder head cover.

  Remove, Disconnect   

Disconnect plug strip from injectors. Disconnect wiring harness plug (1) from throttle valve potentiometer, ground connections (2) from fuel distributor pipe and wiring harness plug (3) from tank vent valve.   Lay injector plug strip to the rear.

Remove fastening nuts from intake manifold. Detach vacuum lines (arrow) from tank vent valve and remove tank vent valve.

Lift intake manifold.  

  Remove, Disconnect   

Detach coolant hose (1) from coolant pipe and wiring harness plug (2) from idle speed adjuster. Remove intake manifold.     Clean    Clean sealing surfaces and remove sealant remnants.     Install, Connect    Attach intake manifold with new seal and new fastening nuts to cylinder head - tightening torque 22 Nm.

Connect wiring harness plug to idle speed adjuster and coolant hose to coolant pipe.   Insert tank vent valve and connect vacuum hose.

  Install, Connect   

Connect wiring harness plugs to tank vent valve and throttle valve potentiometer.  

Fasten ground connections to fuel distributor pipe. Place plug strip on injectors and engage - ensure correct seating.  

Attach engine vent hoses to cylinder head cover.  

Attach fuel lines to fuel distributor pipe or fuel pressure regulator.  

Attach accelerator Bowden cable to curved disc.  

Attach intake manifold support to cylinder block and intake manifold - accessible from underside of vehicle - 25 Nm/18 lbf. ft.  

Version with AC: connect vacuum line to intermediate piece for brake servo connection.  

Attach brake servo vacuum line to intake manifold - 20 Nm/15 lbf. ft.  

Connect coolant hose (1) to coolant compensation tank and to intake manifold.  

  Install, Connect   

C 20 XE from MY '93: Attach support and shackle to generator or intake manifold - tightening torque 20 Nm. Tighten lower generator extract - tightening torque 35 Nm. Tighten ribbed V-belt tension roller clockwise using KM-913-A and attach ribbed V-belt, noting direction of rotation and installation position of ribbed V-belt.  

C 20 XE up to MY '93: attach tension shackle to intake manifold. Install V-belt and tension - see operation "V-belt Tension, Check".  

Install prevolume chamber with air intake hose. Attach hose to prevolume chamber.  

Connect wiring harness plug to mass air flow meter and wiring harness plug to intake air temperature sensor.  

Air cleaner housing - see operation "Air Cleaner Housing, Remove and Install".  

  Inspect   

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