Vauxhall Workshop Service and Repair Manuals

Intake Manifold, Remove and Install (X 16 SZR)

Caution

Fuel escapes – observe safety measures and national legislation. The fuel system is under pressure. Remove fuel pump relay – see operation "Fuel Pump Relay, Remove and Install". Start engine for at least 5 sec. to reduce fuel pressure.

Remove Open coolant drain bolt – collect escaping coolant. Disconnect vacuum hoses (1) from air intake cover. Remove engine bleeding hose (2) from camshaft housing cover. Remove air cleaner housing with air intake cover – see illustration "Air Ducts (X 16 SZR)". Remove ribbed V-belts – see operation "Ribbed V-belts, Remove and Install".

Detach vacuum hose for intake manifold pressure sensor (1) and tank vent valve hose (2) from throttle valve injection housing. Detach brake servo vacuum line (3) from intake manifold. Remove engine bleeding hose (4) from camshaft housing cover. Detach injector wiring harness plug (5), throttle valve potentiometer (6), exhaust gas recirculation valve (7), idle speed stepper motor (8) and coolant temperature sensor (9).

Disconnect wiring harness plug (1) from tank vent valve and expose wiring harness. Disconnect crankshaft pulse pickup wiring harness plug (2) from cable trough. Remove ground cable (3 cables) from camshaft housing and intake manifold. Disconnect wiring harness plug (3) from intake manifold pressure sensor. Remove cable trough (4) from camshaft housing cover and set aside.

Unclip accelerator (2) at throttle valve actuator. Detach Bowden cable retainers (3) from intake manifold and lay aside with accelerator Bowden cable. Remove support (1) from alternator and intake manifold. Release alternator from alternator shackle (4) and swing alternator rearwards. Detach fuel lines (5) from throttle body. Remove coolant hose (6) from intake manifold – place collection pan underneath. Remove intake manifold from cylinder head.   Clean Clean sealing surfaces and remove gasket residues.

  Install

Attach intake manifold to cylinder head with new gasket – tightening torque 22 Nm / 16 lbf. ft. 1) .

Attach coolant hose to intake manifold.

Attach fuel lines to throttle valve guards – tightening torque 15 Nm / 11 lbf. ft.

Attach alternator to alternator shackle – tightening torque 20 Nm / 15 lbf. ft.

Attach support to alternator and intake manifold – tightening torque 20 Nm / 15 lbf. ft.

Attach Bowden cable bracket to intake manifold – tightening torque 9 Nm / 6.6 lbf. ft. Clip accelerator to throttle valve actuator.

Attach cable trough to camshaft housing cover – tightening torque 8 Nm / 6 lbf. ft.

Connect wiring harness plug to intake pipe pressure sensor. Attach ground cable (3 units) to camshaft housing and intake manifold.

Connect crankshaft pulse pickup wiring harness plug to cable trough and tank vent valve wiring harness plug to tank vent valve – note cable routing.

Connect wiring harness plug to coolant temperature sensor, idle speed stepper motor, exhaust gas recirculation valve, throttle valve potentiometer and injector.

Attach engine bleeding hose to camshaft housing cover.

Attach brake servo vacuum line to intake manifold.

Connect vacuum hose for intake manifold pressure sensor and tank vent valve hose to throttle valve injection housing.

Install ribbed V-belt – see operation "Ribbed V-belt, Remove and Install".

Install air cleaner housing with air intake cover – see illustration "Air Ducts (X 16 SZR)".

Connect vacuum hoses to air intake cover and attach engine bleeding hose to camshaft housing cover.

Close coolant drain bolt.

  Inspect

Charge cooling system – see operations "Cooling System, Charge and Bleed" and "Cooling System, Check for Leaks".