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Sump Replacement - 1.4L LDD > < Drive Belt Tensioner Replacement

Astra J

Intake Manifold Replacement (1.4L LDD)

Special Tools

•  EN-34730-91   Pressure Tester
•  EN-6015   Closure Plugs

Removal Procedure

1. Open the hood.
2. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection
3. Remove air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement
4. Remove engine sight shield.
5. Remove dash upper extension panel opening cover. Refer to Dash Upper Extension Panel Opening Cover Replacement
6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle

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7. Unclip heater outlet hose from retainer clip (1, 2).
8. Unclip engine control module wiring harness from retainer clip (3).
9. Lower the vehicle.

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10. Remove engine control module wiring harness (1) from camshaft cover:
  •  Disconnect intake camshaft position sensor wiring harness plug (7).
  •  Disconnect intake camshaft position actuator solenoid valve wiring harness plug (6).
  •  Disconnect exhaust camshaft position sensor wiring harness plug (4).
  •  Disconnect exhaust camshaft position actuator solenoid valve wiring harness plug (5).
  •  Disconnect engine coolant temperature sensor wiring harness plug (3).
  •  Disconnect engine oil pressure indicator switch wiring harness plug (2).
  •  Unclip engine control module wiring harness (1) from camshaft cover.

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11. Disconnect engine control module wiring harness from intake manifold upper:
  •  Disconnect throttle body wiring harness plug (1).
  •  Disconnect evaporative emission canister purge solenoid valve wiring harness plug (2).
  •  Disconnect intake manifold runner solenoid valve wiring harness plug (4).
  •  Unclip engine control module wiring harness from intake manifold (3)..
  •  Disconnect the 4 fuel injector wiring harness plugs (5).

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12. Disconnect the engine control module wiring harness from retainer clip (1).
13. Disconnect brake booster vacuum pipe from intake manifold connector (2).
14. Disconnect mass air flow sensor wiring harness plug (3).
15. Lay engine control module wiring harness aside.
16. Place collecting basin underneath.

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17. Remove fuel injector rail cap (1).

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18. Relief fuel pressure. Use EN-34730-91   pressure tester (1).

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19. Remove fuel feed pipe (2) from fuel injector rail.
20. Unclip fuel feed pipe from retainer clip (1).
21. Remove fuel ventilation pipe (4) from evaporative emission canister purge solenoid valve.
22. Unclip fuel ventilation pipe from retainer clip (3).

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23. Remove the 6 intake manifold bolts (1).

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24. Remove the intake manifold (1) in compound with the 5 seal rings.
25. Remove assembly parts from intake manifold. Refer to Intake Manifold Disassemble

Installation Procedure

1. Clean sealing surfaces.
2. Install assembly parts to intake manifold. Refer to Intake Manifold Assemble

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3. Install the intake manifold (1) in compound with 5 NEW seal rings.

Caution: Refer to Fastener Caution


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4. Install the 6 intake manifold bolts (1) and tighten to 20 N·m(15 lb ft) .

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5. Clip fuel ventilation pipe to retainer clip (3).
6. Connect fuel ventilation pipe (4) to evaporative emission canister purge solenoid valve.
7. Clip fuel feed pipe to retainer clip (1).
8. Connect fuel feed pipe (2) to injector rail.

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9. Install fuel injector rail cap (1).

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10. Connect the engine control module wiring harness to retainer clip (1).
11. Connect mass air flow sensor wiring harness plug (3).
12. Connect brake booster vacuum pipe to intake manifold connector (2).

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13. Connect engine control module wiring harness to intake manifold upper:
  •  Connect the 4 fuel injector wiring harness plugs (5).
  •  Clip the engine control module wiring harness to intake manifold (3).
  •  Connect intake manifold runner solenoid valve (4).
  •  Connect the evaporative emission canister purge solenoid valve wiring harness plug (2).
  •  Connect the throttle body wiring harness plug (1).

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14. Install engine control module wiring harness to camshaft cover:
  •  Clip engine control module wiring harness (1) to camshaft cover.
  •  Connect engine oil pressure indicator switch wiring harness plug (2).
  •  Connect engine coolant temperature sensor wiring harness plug (3).
  •  Connect exhaust camshaft position actuator solenoid valve wiring harness plug (5).
  •  Connect exhaust camshaft position sensor wiring harness plug (4).
  •  Connect intake camshaft position actuator solenoid valve wiring harness plug (6).
  •  Connect intake camshaft position sensor wiring harness plug (7).
15. Raise the vehicle.

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16. Clip engine control module wiring harness to retainer clip (3).
17. Clip heater outlet hose to 2 retainer clips (1) and (2).
18. Lower the vehicle.
19. Install dash upper extension panel opening cover. Refer to Dash Upper Extension Panel Opening Cover Replacement
20. Install engine sight shield.
21. Install air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement
22. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection
23. Close the hood.

Sump Replacement - 1.4L LDD > < Drive Belt Tensioner Replacement