Vauxhall Workshop Service and Repair Manuals

Gasket between Intake Manifold and Cylinder Head, Replace (15 DT, X 15 DT)  

  Remove, Disconnect   

Remove air cleaner housing with air intake hose. Remove crankcase vent from cylinder head cover. Detach hose clamps from air intake pipe on intake manifold and from intake pipe (see illus.). Remove hose completely.

Unbolt charge air pipe from intake manifold.

  Remove, Disconnect   

Unbolt bracket for air intake pipe and charge air pipe from cylinder head (see illus. I).   Remove oil dipstick guide tube from cylinder block.   Unbolt air intake pipe from bracket on charge air pipe (see illus. II).   Detach hose clamp from charge air pipe on turbocharger and remove charge air pipe from engine compartment (see illus. III).   Detach wiring harness from bracket on intake manifold (see illus. IV).

  Remove, Disconnect   

Disconnect pressure hose from intake manifold to pressure unit on distributor injector pump (see illus. I).   Unscrew intake manifold fastening bolts (1).   Loosen outer fastening bolts and remove intake manifold (2).     Clean    Clean sealing surfaces on intake manifold and cylinder head.     Install, Connect    Install new gasket. Attach intake manifold and fasten (1 and 2).     Tighten (Torque)    Intake manifold to cylinder head - 25 Nm / 18 lbf. ft.

  Install, Connect   

Connect pressure hose from intake manifold to pressure unit of distributor injector pump. Fasten wiring harness to bracket on intake manifold (see illus.). Press oil dipstick guide tube with new seal ring into cylinder block.

Bolt charge air pipe to intake manifold. Fasten hose clamp to turbocharger. Fasten bracket for charge air pipe to cylinder head.   Install air intake pipe and bolt to bracket of charge air pipe.   Connect crankcase ventilation to cylinder head cover. Install air cleaner housing with air intake hose.