Vauxhall Workshop Service and Repair Manuals

Intake Manifold, Remove and Install (Z 16 SE)

Caution

Fuel leak – observe safety regulations and national legislation. Reduce fuel pressure with Pressure Tester KM-J-34730-91 via testing port – collect escaping fuel in suitable container.

Remove Disconnect ground cable from battery. Open coolant drain bolt – collect escaping coolant. Remove engine vent hoses (4) and (5) from camshaft housing cover. Disconnect wiring harness plug (3) from intake air temperature sensor. Disconnect wiring harness plug (1) from tank vent valve (2). Detach tank vent valve from air cleaner housing. Remove air cleaner housing and air intake hose – see illustration "Air Cleaner Housing (Z 16 SE)".

Remove ribbed V-belts – see operation "Ribbed V-belts, Remove and Install". Detach tank vent valve hose (6) from throttle body. Remove brake servo vacuum line (5) from intake manifold. Detach coolant hoses (7) from throttle body and lay aside. Release wiring harness plugs (2) in direction of arrow and detach from engine control unit. Remove intake pipe pressure sensor wiring harness bracket (1) and exhaust gas recirculation valve from engine control unit. Disconnect wiring harness plugs (3) and (4) from intake pipe pressure sensor and exhaust gas recirculation valve.

Remove ground cable (2) from engine control unit. Disconnect wiring harness plug (4) from oxygen sensor, throttle body (5), camshaft sensor (7) and injectors. Detach wiring harness bracket (1) from intake manifold and lay wiring harness aside. Remove alternator support (3) from alternator and intake manifold. Release alternator from alternator shackle (6) and swing alternator rearwards. Detach coolant hose from intake manifold – place collecting basin underneath. Detach fuel lines from fuel distributor pipe. Unclip fuel line from bracket and lay aside. Remove intake manifold from cylinder head.   Clean Clean sealing surfaces and remove gasket residues.

  Install

Attach intake manifold to cylinder head with new gasket – tightening torque 22 Nm / 16 lbf. ft. 1)

Attach fuel line to fuel distributor pipe and clip in bracket.

Attach coolant hose to intake manifold.

Attach alternator to alternator shackle – tightening torque 20 Nm / 15 lbf. ft.

Attach alternator support to alternator and intake manifold – tightening torque 20 Nm / 15 lbf. ft.

Route wiring harness and attach wiring harness bracket to intake manifold – tightening torque 20 Nm / 15 lbf. ft.

Connect wiring harness plug to injectors, camshaft sensor, throttle body and oxygen sensor.

Attach ground cable to engine control unit.

Connect wiring harness plug to exhaust gas recirculation valve and intake pipe pressure sensor.

Attach exhaust gas recirculation valve wiring harness bracket and intake pipe pressure sensor to engine control unit.

Connect wiring harness plug to engine control unit and lock.

Attach coolant hoses to throttle body.

Attach brake servo vacuum hose to intake manifold.

Attach tank vent valve hose to throttle body.

Install ribbed V-belt – see operation "Ribbed V-belt, Remove and Install".

Install air cleaner housing with air intake hose – see illustration "Air Cleaner Housing (Z 16 SE)".

Attach tank vent valve to air cleaner housing and connect wiring harness plug to tank vent valve.

Attach engine vent hoses to camshaft housing cover.

Close coolant drain bolt. Connect ground cable to battery.

  Inspect

Charge cooling system – see operations "Cooling System, Charge and Bleed" and "Cooling System, Check for Leaks".