Vauxhall Workshop Service and Repair Manuals

Open coolant drain bolt on radiator – collect coolant.

Detach wiring harness plug (3) from intake air temperature sensor and wiring harness plug (2) from hot film mass air flowmeter. Detach air intake hose (1) from throttle body and air cleaner housing.

Mark running direction of ribbed V-belt. Using ribbed V-belt tension roller and KM-913-A, release ribbed V-belt and remove ribbed V-belt.

Remove shackle (4) and support (5) from intake manifold and alternator. Loosen lower alternator fastening bolt – swing alternator aside.

Detach wiring harness plug (1) from throttle valve potentiometer and wiring harness plug (3) from idle speed adjuster.

Detach crankcase ventilation hose (2) from intake manifold.

Remove accelerator Bowden cable from Bowden cable bracket.

If present: Detach cruise control Bowden cable with bracket (5) from intake manifold.

Detach vacuum hose (4) from intake manifold – remove Bowden cable bracket.

Detach coolant hoses from throttle body.

Detach brake servo vacuum line (1) from intake manifold. Detach fuel lines (2) from fuel distributor pipe.

Caution

Fuel escapes. Observe safety regulations and national regulations. Depressurise fuel using Fuel Pressure Gauge KM-J-34730-91 via test connection – collect escaping fuel in suitable container.

  Remove

Detach wiring harness plug from DIS ignition module, wiring harness plugs from injectors, wiring harness plug (3) from exhaust gas recirculation valve and wiring harness plug from tank vent valve.

Detach ground cable from fuel distributor pipe.

I AT: Disconnect wiring harness plug (1) from output speed sensor, wiring harness plug (2) from transmission housing (7-pin), wiring harness plug (3) from oxygen sensor (X 20 SE), wiring harness plug (4) from intermediate housing (4-pin) and wiring harness plug (5) from selector lever position switch.

II MT: Disconnect wiring harness plug (1) from reversing lamps and wiring harness plug (2) from oxygen sensor (X 20 SE).

Detach wiring trough from camshaft housing cover and ground cable from camshaft housing. Lay wiring trough aside.

Remove crankcase vent hose (1) from camshaft housing cover.

Note:   When detaching the vacuum hoses, ensure that the valve connection is not damaged. Damaged valves must be replaced.

Caution

Damaged valve supports can cause a vehicle fire as a result of leaks.

  Remove

Disconnect vacuum hoses (2) from tank vent valve – seal off hose to active carbon canister. Detach coolant hoses from throttle body.

Remove intake manifold from cylinder head.

  Clean

Clean sealing surfaces and remove gasket remnants.

Attach inlet manifold with new seal to cylinder head – tightening torque 22 Nm / 16 lbf. ft.

Attach vacuum hoses to tank vent valve, crankcase ventilation hose to camshaft housing cover.

Attach ground cable to camshaft housing – tightening torque 20 Nm / 15 lbf. ft. Attach wiring trough (1) to camshaft housing cover – tightening torque 8 Nm / 6 lbf. ft. Connect wiring harness plug to reversing lamp switch.

For X 20 SE: Connect wiring harness plug for oxygen sensor and fasten to transmission.

Fasten wiring harness to transmission and to DIS ignition module bracket. Connect wiring harness plug to DIS ignition module. Attach ground cable (arrow) to fuel distributor pipe – tightening torque 4.4 Nm / 3.2 lbf. ft..

Connect wiring harness plug to tank vent valve, wiring harness plug to exhaust gas recirculation valve and wiring harness plugs to injectors.

Attach coolant hoses (1) to throttle body.

Attach fuel lines to fuel distributor pipe with new seal rings – tightening torque 22.5 Nm / 16.6 lbf. ft. Attach brake servo vacuum line to intake manifold – tightening torque 20 Nm / 14.7 lbf. ft.

If present: Attach cruise control Bowden cable with bracket to intake manifold – tightening torque 8 Nm / 6 lbf. ft. Attach vacuum hose to intake manifold. Insert accelerator Bowden cable (2) in Bowden cable bracket.

Attach crankcase ventilation hose to intake manifold.

Connect wiring harness plug to idle speed adjuster, wiring harness plug to throttle valve potentiometer.

Install support (1) and shackle (2) at intake manifold and alternator – tightening torque 20 Nm / 14.7 lbf. ft. Tighten lower alternator fastening bolt – tightening torque 35 Nm / 25.8 lbf. ft.

Install ribbed V-belt. Tension ribbed V-belt via ribbed V-belt tension roller. Ensure direction of travel of ribbed V-belt is correct.

Close coolant drain bolt on radiator.

Attach air intake hose to throttle body and air cleaner housing – tightening torque 3.5 Nm / 2.6 lbf. ft. Connect wiring harness plug to hot film mass air flowmeter and wiring harness plug to intake air temperature sensor.

Top up cooling system – see operations "Cooling System, Top Up and Bleed" and "Cooling System, Check for Leaks".