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Astra J

Intake Manifold Replacement (1.7L Diesel LPL, LPV and LUB)

Removal Procedure

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Drain the cooling system. Refer to Cooling System Draining and Filling .
3. Remove the fuel injection fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement .
4. Remove the exhaust gas recirculation valve. Refer to Exhaust Gas Recirculation Valve Replacement .

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5. Detach the vacuum hose (1) from the exhaust gas recirculation cooler.
6. Unclip the vacuum hose from the 4 retainer clips see arrows and set the vacuum hose aside.

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7. Remove the 3 wiring harness bolts (2) from the wiring harness (1).
8. Disconnect the following engine wiring harness plugs:
  •  Coolant temperature sensor wiring harness plug
  •  Throttle body wiring harness plug
  •  4 Injector wiring harness plugs
  •  4 glow plug wiring harness plugs
  •  Camshaft sensor wiring harness plug
  •  Air intake temperature sensor wiring harness plug
  •  2 solenoid valve wiring harness plugs
  •  Engine control module wiring harness plug
  •  Glow plug controller wiring harness plug
  •  Wiring harness connection plug
9. Unclip the wiring harness from the 6 retainer clips and set the wiring harness (1) aside.

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10. Disconnect the charge air cooler outlet air hose (2) from the throttle body (1).
11. Remove the engine oil cooler. Refer to Oil Filter Adapter and Oil Cooler Assembly Replacement .

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12. Detach the 2 vacuum hoses (3) from the 2 vacuum regulator solenoid valves (2).
13. Unclip the vacuum hoses from 5 clips (1).
14. Remove the intake manifold assembly with the intake pipe and the throttle body. Refer to Intake Manifold Removal .
15. Disassemble the intake manifold. Refer to Intake Manifold Disassemble .

Installation Procedure

1. Clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection .
2. Assemble the Intake manifold. Refer to Intake Manifold Assemble .
3. Install the intake manifold. Refer to Intake Manifold Installation .

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4. Attach the 2 vacuum hoses (3) to 2 vacuum regulator solenoid valves (2).
5. Clip in the vacuum hoses to 5 clips (1).
6. Install the engine oil cooler. Refer to Oil Filter Adapter and Oil Cooler Assembly Replacement .

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7. Connect the charge air cooler outlet air hose (2) to the throttle body (1).

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8. Connect the following engine wiring harness plugs:
  •  Coolant temperature sensor wiring harness plug
  •  Throttle body wiring harness plug
  •  4 Injector wiring harness plugs
  •  4 glow plug wiring harness plugs
  •  Camshaft sensor wiring harness plug
  •  Air intake temperature sensor wiring harness plug
  •  2 solenoid valve wiring harness plugs
  •  Engine control module wiring harness plug
  •  Glow plug controller wiring harness plug
  •  Wiring harness connection plug
9. Clip in the wiring harness (1) to the 6 retainer clips.

Caution: Refer to Fastener Caution .
10. Install the 3 wiring harness bolts (2) to the wiring harness (1) and tighten to 9 N·m (80 lb in) .

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11. Clip in the vacuum hose to the 4 retainer clips see arrows.
12. Attach the vacuum hose (1) to the exhaust gas recirculation cooler.
13. Install the exhaust gas recirculation valve. Refer to Exhaust Gas Recirculation Valve Replacement .
14. Install the fuel injection fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement .
15. Filling the cooling system. Refer to Cooling System Draining and Filling .
16. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .

Timing Belt Tensioner Pulley Replacement > < Camshaft Timing Pulley Replacement