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Replace intake manifold > < Replace intake manifold

Astra H

Intake Manifold, Replace - Petrol Engines

  Remove

1.   Open bonnet
2.   Disconnect battery
•   Detach earth connection from earth terminal
– Slacken nut
3.   Detach wiring harness for engine control unit
•   Disconnect 2x wiring harness plugs (3), (4)
•   Detach ground connection
– Unscrew bolt (5)
•   Unclip 2x wiring harnesses
4.   Detach engine control wiring harness
•   Detach wiring harness plug (2) from engine control unit
•   Detach wiring harness plug (1) from tank vent valve
Object Number: 9008391 Size: DEFAULT


5.   Unclip fuel supply and return lines
•   Open clip
6.   Detach fuel supply line (2)
•   Undo quick-release fitting with KM-796-A
•   Seal off fuel line
7.   Detach fuel return line (1)
•   Undo quick-release fitting with KM-796-A
•   Seal off fuel line
Object Number: 9008392 Size: DEFAULT


8.   Disconnect tank venting line from tank vent valve
9.   Detach wiring harness for mixture regulator oxygen sensor (1) from bracket
•   Disconnect wiring harness plug (2)
•   Unclip 2x wiring harnesses
Object Number: 9008474 Size: DEFAULT


10.   Disconnect camshaft sensor wiring harness plug (1)
Object Number: 9008475 Size: DEFAULT


11.   Remove wiring trough (1)
•   Pull upwards
Object Number: 9008476 Size: DEFAULT


12.   Detach earth cable from cylinder head
•   Unscrew bolt (1)
13.   Disconnect ignition module wiring harness plug (2)
Object Number: 9008477 Size: DEFAULT


14.   Detach throttle valve module wiring harness
•   Disconnect wiring harness plug (2)
•   Unclip wiring harness (1)
Object Number: 9008478 Size: DEFAULT


15.   Detach wiring harness for coolant temperature sensor
•   Disconnect wiring harness connector.
•   Unclip bracket from coolant line
16.   Detach wiring harness bracket (1) from engine control unit
•   Unscrew 2x bolts (2)
Object Number: 9008479 Size: DEFAULT


17.   Remove engine control unit (2)
•   Unscrew 2x bolts (1)
Object Number: 9008480 Size: DEFAULT


18.   Detach fuel injection wiring harness
•   Remove wiring trough (1)
•   Disconnect 4x wiring harness plugs for injectors (2)
Object Number: 9008481 Size: DEFAULT


19.   Detach wiring harness bracket from intake manifold
•   Unscrew 3 bolts
20.   Disconnect atmospheric pressure sensor wiring harness plug
21.   Set engine control wiring harness aside
22.   Detach venting line for cylinder head cover (4)
•   Undo quick-release fitting (1)
•   Unclip line
•   Detach quick-release fitting (2) from cylinder head cover
– Detach retaining clamp (3)
Object Number: 9008482 Size: DEFAULT


23.   Remove engine control unit bracket (1)
•   Unscrew 4x bolts (2)
Note:   Note different bolt lengths
Object Number: 9008483 Size: DEFAULT


24.   Raise vehicle by its full height
25.   Detach wiring harness for vacuum control solenoid valve (1)
•   Disconnect wiring harness plug (2)
•   Unclip wiring harness (4)
26.   Detach vacuum line for air recirculation control (3)
•   Disconnect line from solenoid valve
•   Unclip line
Object Number: 9008484 Size: DEFAULT


27.   Detach intake manifold at bottom
•   Unscrew 2x nuts (1)
•   Unscrew 2x bolts (2)
Object Number: 9008485 Size: DEFAULT


28.   Lower vehicle by its full height
29.   Detach charge air hose (1) from throttle housing (3)
•   Release clamp (2)
Object Number: 9008400 Size: DEFAULT


30.   Remove tank vent valve (1)
•   Undo quick-release fitting (3)
•   Detach bracket
– Unscrew bolt (2)
Object Number: 9008486 Size: DEFAULT


31.   Detach intake manifold at top
•   Unscrew nut
•   Unscrew 3 bolts
•   Place intake manifold down
32.   Detach engine transport shackle (1)
•   Unscrew bolt
Object Number: 9008487 Size: DEFAULT


33.   Remove intake manifold

  Install

34.   Insert intake manifold
35.   Fit engine transport shackle
•   Tighten bolt 25 Nm
36.   Attach intake manifold at top
•   Tighten nut 20 Nm
•   Tighten 3x bolt 20 Nm
37.   Install tank vent valve
•   Connect quick release fitting
•   Attach bracket
– Tighten bolt
38.   Attach charge air hose to throttle valve module
•   Tighten clamp 3.5 Nm
39.   Raise vehicle by its full height
40.   Attach intake manifold at bottom
•   Tighten 2x nut 20 Nm
•   Tighten 2x bolt 20 Nm
41.   Attach vacuum line for air recirculation control
•   Push line onto solenoid valve
•   Clip in line
42.   Attach wiring harness for vacuum control solenoid valve
•   Fix wiring harness plug
•   Attach wiring harness
43.   Lower vehicle by its full height
44.   Install engine control unit bracket
•   Tighten 4x bolt 8 Nm
Note:   Note different bolt lengths
45.   Attach venting line for cylinder head cover
•   Attach quick-release fitting to cylinder head cover
– Attach retaining clamp
•   Connect quick release fitting
•   Clip in line
46.   Connect atmospheric pressure sensor wiring harness plug
47.   Attach wiring harness bracket to intake manifold
•   Tighten 3x bolts
48.   Attach fuel injection wiring harness
•   Connect 4x wiring harness plugs for injectors
•   Attach wiring trough
49.   Install engine control unit
•   Tighten 2x bolt 8 Nm
50.   Attach wiring harness bracket to engine control unit
•   Tighten 2x bolt 8 Nm
51.   Attach wiring harness for coolant temperature sensor
•   Fix wiring harness plug
•   Clip bracket onto coolant line
52.   Attach throttle valve module wiring harness
•   Fix wiring harness plug
•   Attach wiring harness
53.   Connect ignition module wiring harness plug
54.   Attach earth cable to cylinder head
•   Tighten bolt
55.   Attach wiring trough
56.   Connect camshaft sensor wiring harness plug
57.   Attach wiring harness for mixture regulator oxygen sensor to bracket
•   Clip in 2x wiring harnesses
•   Fix wiring harness plug
58.   Attach tank venting line to tank vent valve
59.   Attach fuel return line
•   Connect quick release fitting
60.   Attach fuel supply line
•   Connect quick release fitting
61.   Clip in fuel supply and return lines
62.   Attach engine control wiring harness
•   Connect wiring harness plug to engine control unit
•   Attach wiring harness plug to tank vent valve
63.   Attach engine control unit wiring harness
•   Attach ground connection
– Tighten bolt
•   Connect 2x wiring harness plugs
•   Clip in 2x wiring harnesses
64.   Connect battery
65.   Program volatile memories
66.   Close bonnet

Replace intake manifold > < Replace intake manifold