Vauxhall Workshop Service and Repair Manuals

Replace intake manifold gasket (Z 12 XE, Z 12 XEP, Z 14 XEP, with air conditioning, LHD)

Note:   In vehicles as of model year 04 onwards with ESP - the steering angle sensor loses its basic adjustment each time the battery is disconnected, and must be recalibrated

  Remove

4.   Drain coolant •   Place collecting basin underneath. •   Open drain bolt (arrow) 5.   Lower vehicle

6.   Remove suction pipe •   Detach engine vent hose (3) •   Remove air intake hose (1) •   Unscrew 2 nuts (2) •   For Z 12 XEP, Z 14 XEP: detach air intake hose – Release clamp

Important:   Observe safety precautions and national regulations 7.   Release fuel pressure with KM-J-34730-91 •   Unscrew test connection protective cap (2) from fuel rail (1) Note:   Test connection is on top of fuel rail in Z 12 XEP and Z 14 XEP

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

9.   Detach coolant hoses •   Detach 2 throttle valve module preheater hoses (1) – Release 2x clamp •   Detach coolant hose (2) from coolant pump – Release clamp

10.   Detach engine vent hose from cylinder head 11.   Unclip brake servo vacuum line (3)

13.   Remove wiring harness for engine management •   For Z 12 XEP, Z 14 XEP: remove fuel rail cover – Unscrew 2 bolts •   Disconnect 5 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) •   Unclip wiring harness – Open 2 brackets •   Unclip wiring trough (4) •   Set wiring harness to one side 14.   Detach engine wiring harness •   Remove cable ties. 15.   Raise vehicle

16.   Detach engine wiring harness •   Remove 2 cable ties 17.   Unclip wiring harness for engine management •   Open 2 brackets

21.   Remove intake manifold •   Unscrew 6 nuts (arrows) 22.   Clean sealing surfaces

  Install

23.   Install intake manifold •   Replace 4x seal ring •   Tighten 6 nuts 10 Nm 24.   Attach exhaust gas recirculation pipe •   Replace gasket •   Tighten 2 bolts 8 Nm 25.   Attach wiring harness for engine management •   Route wiring harness •   Clip-in wiring trough •   Connect wiring harness for engine management – Attach ground cable – Connect 7 wiring harness plugs •   Attach wiring harness – Open 2 brackets •   For Z 12 XEP, Z 14 XEP: attach fuel rail cover – Tighten 2 bolts