Vauxhall Workshop Service and Repair Manuals

Replace intake manifold gasket (Z 10 XE, Z 10 XEP, with air conditioning, LHD)

Note:   On vehicles as of model year 04 with ESP - every time the battery is disconnected, the steering angle sensor loses its basic setting. It must be recalibrated.

  Remove

3.   Drain coolant Note:   With model variant "ECO" - remove lower engine compartment cover •   Place collecting basin underneath. •   Open drain bolt (arrow)

4.   Remove suction pipe (4) •   Unscrew 2 nuts •   Detach engine vent hose (5) – From cylinder head cover •   On Z 10 XEP: Remove air intake hose – Release clamp •   Disconnect 2 wiring harness plugs – Hot film mass air flow sensor (2), tank vent valve (1) •   Remove hot film mass air flow meter (3) – From air cleaner housing

5.   Detach fuel evaporation hose •   Detach hose (1) from intake manifold and set to one side

Important:   Observe safety precautions and national regulations 6.   Reduce fuel pressure •   Unscrew test connection protective cap (2) Note:   Test connection for Z 10 XEP at upper fuel rail •   Fit KM-J-34730-91 to fuel rail (1)

7.   Detach fuel line (arrow) with KM-796-A •   Unclip fuel line •   Seal using KM-807

8.   Detach coolant hoses •   Detach 2x throttle body preheater hoses (1) – Release 2x clamp •   Detach coolant hose (2) from coolant pump – Release clamp 9.   Detach engine venting hose from cylinder head cover •   Release clamp 10.   Unclip brake servo vacuum line (3)

11.   Remove wiring harness plug for engine management •   On Z 10 XEP: Remove fuel rail cover – Unscrew 2 bolts •   Disconnect 2 wiring harness plugs – Injection valves (3), throttle valve module (2) •   Disconnect engine control unit wiring harness plug – Release in direction of arrow •   Remove ground cable (1) – Remove bolt •   Unclip 3x wiring harnesses from bracket •   Close brackets •   Unclip wiring trough (4) – Set to one side 12.   Raise vehicle

13.   Remove wiring harness for engine management •   Detach starter wiring harness – Unscrew 2 nuts (1) – Release cable ties •   Unclip 2x wiring harnesses from brackets (arrows) 14.   Lower vehicle

15.   Detach exhaust gas recirculation pipe from exhaust gas recirculation coolant flange •   Unscrew 2 bolts (arrows)

16.   Remove intake manifold •   Unscrew 5x nuts (arrows) 17.   Clean sealing surfaces

  Install

18.   Install intake manifold •   Replace 3x seal rings •   Tighten 5x nuts 10 Nm 19.   Attach exhaust gas recirculation pipe •   Exhaust gas recirculation coolant flange •   Tighten 2 bolts 8 Nm

29.	Lower vehicle Note:   With "ECO" model variant - install lower engine compartment cover

32.	Fill and bleed cooling system