vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Exhaust manifold > < Check and adjust valve play

Astra H

Replace intake manifold

  Remove

1.   Remove toothed belt
2.   Disconnect battery
•   Detach ground connection from ground terminal
3.   Detach wiring harness
•   Unscrew 4x bolts (1)
•   Disconnect 4x wiring harness plugs for injector (2)
Object Number: 8230688 Size: DEFAULT


4.   Detach 4x oil leak line (2) from injectors
Note:   The oil leak line must not be detached from the fuel return damping case. It if is detached, it must be replaced.
•   Release 4x retaining clamp (3) from injector in direction of arrow
– Pull off oil leak line
Note:   Close 4x injectors with suitable

Sealing plug 1)
•   Unclip 2x oil leak line from bracket (1)
Object Number: 8230689 Size: DEFAULT


5.   Disconnect 2x wiring harness plugs
•   From exhaust gas recirculation (1)
•   From boost pressure sensor (2)
Object Number: 8230699 Size: DEFAULT


6.   Remove fuel return damping case (1) with oil leak line
Note:   Open fuel connections must be sealed with appropriate plugs 1)  
•   Unscrew 2x bolts
•   Return line with KM-796-A
– Unclip line
– Seal with KM-6015
•   Detach 2x hoses
– Undo 2 clamps
Object Number: 2408163 Size: DEFAULT


7.   Detach accumulator high pressure line (1) to high pressure pump
Important:   When releasing the retaining nut on the high pressure pump, counterhold with open-ended wrench.
•   Unscrew 2x union nuts
Note:   Opened fuel connections must be

sealed off with suitable sealing plugs 1)  
Object Number: 2408157 Size: DEFAULT


8.   Detach 4x high pressure line - accumulator to injector
Important:   When releasing the retaining nut, counterhold with open-ended wrench against the injector
•   Unscrew 8x union nut (1)
Note:   Close opened fuel connections with appropriate plugs 1)  
Object Number: 2408161 Size: DEFAULT


9.   Remove accumulator (1)
•   Unscrew 2x nut (arrows)
•   Disconnect 2x wiring harness plugs
Object Number: 2408164 Size: DEFAULT


10.   Detach fuel line of high-pressure pump (1)
•   Release clamp
Note:   Close opened fuel connections with appropriate plugs 1)  
11.   Disconnect high-pressure pump wiring harness plug (2)
Object Number: 3446031 Size: DEFAULT


12.   Release high-pressure pump drive gear
•   Counterhold with KM-6347 (1) in combination with KM-956-1 (2)
Object Number: 7360968 Size: DEFAULT


13.   Remove high-pressure pump gear
•   Attach EN-46790 (1)
– Screw in 2x bolts
•   Pull off high-pressure pump drive gear
– Counterhold with open-ended wrench (2)
Object Number: 7360969 Size: DEFAULT


14.   Remove high pressure pump
•   Unscrew 3x nuts (1)
Object Number: 3446034 Size: DEFAULT


15.   Raise vehicle by its full height
16.   Place collecting basin underneath.
17.   Drain coolant
•   Open drain bolt on radiator (1)
•   Collect coolant
•   Close drain bolt
Object Number: 3446550 Size: DEFAULT


18.   Detach 2x coolant hoses (1) from coolant pipe
•   Undo 2 clamps
Object Number: 8230700 Size: DEFAULT


19.   Lower vehicle by its full height
20.   Remove battery
•   Detach positive terminal (3) from positive pole
– Slacken nut
•   Remove bracket 1)
– Unscrew bolt (2)
•   Remove battery insulation
Object Number: 7360933 Size: DEFAULT


21.   Remove battery support.
•   Remove pre-glow system control unit (4)
•   Unclip coolant hose bracket (5)
•   Detach wiring harness
– Undo cable tie (1)
– Unclip 2x brackets
•   Unscrew 3x bolts (2)
Object Number: 3446570 Size: DEFAULT


22.   Detach vacuum line
•   Detach 4x vacuum hose from vacuum line
Note:   Mark the assignment of the hoses
•   Unscrew 2x bolts (arrows)
Object Number: 2408150 Size: DEFAULT


23.   Detach EGR valve
•   EGR valve (3)
– Unscrew 3 bolts
•   EGR metal tube to throttle valve module (1)
– Unscrew 2x bolts
•   Exhaust gas recirculation (EGR) cooler (4)
– Unscrew 2x bolts
•   Remove 2x engine transport shackle seal (2)
Object Number: 3446036 Size: DEFAULT


24.   Detach intercooler charge air hose (1) from throttle body
•   Undo 2 clamps
Object Number: 8230696 Size: DEFAULT


25.   Detach vacuum line from vacuum pump
•   Disconnect quick-release fitting (2)
•   Unclip 2x vacuum line from bracket (1)
Object Number: 8230704 Size: DEFAULT


26.   Remove throttle valve module (1)
•   Unscrew 3x bolts (2)
•   Disconnect wiring harness connector.
•   Remove seal
Object Number: 7361582 Size: DEFAULT


27.   Unclip coolant return line (2)
•   Unscrew bolt (1)
•   Remove 3x hoses (arrows)
– Undo 3x clamps
– Unclip hose
Object Number: 9007525 Size: DEFAULT


28.   Remove 4x wiring harness plugs from glow plugs (arrows)
Object Number: 3446037 Size: DEFAULT


29.   If present: remove vacuum reservoir (3) with retaining plate
•   Unscrew 3x bolts (1) and (2)
Object Number: 9007530 Size: DEFAULT


30.   Remove coolant pipe (2)
•   Unclip 2x coolant hoses from bracket (4)
•   Detach from bracket on transmission (3)
– Unscrew 2x nuts
•   Detach from bracket on thermostat housing (1)
– Unscrew nut
•   Detach 2x coolant hoses
– Undo 2 clamps
Object Number: 8230701 Size: DEFAULT


31.   Remove EGR cooler (1)
Note:   Remove EGR cooler rearward
•   Unscrew bolt, nut (arrows)
•   Release clamp
•   Detach 2x coolant hoses
– Undo 2 clamps
Object Number: 3446039 Size: DEFAULT


32.   Release alternator bracket
•   Unscrew 2x bolts (1)
Note:   Note different bolts
Object Number: 3446040 Size: DEFAULT


33.   Detach alternator
Note:   Set alternator aside
•   Unscrew bolt (1)
Object Number: 2408168 Size: DEFAULT


Important:   Note guide sleeves
34.   Detach high-pressure pump bracket (1)
•   Unscrew 6x bolts
Note:   Note different bolt lengths
Object Number: 3446041 Size: DEFAULT


35.   Remove intake manifold (1)
•   Unscrew 9x nuts
•   Detach gasket
Object Number: 3446043 Size: DEFAULT


36.   Detach charge pressure sensor
•   Unscrew bolt
37.   Unscrew coolant hose connection port

  Install

38.   Tighten coolant hose connection port
Note:   coat with sealant
39.   Attach charge pressure sensor
•   Replace seal
•   Tighten bolt
40.   Clean sealing surface
41.   Install intake manifold
•   Install new gasket
– Clip on 2x to intake manifold
•   Tighten 9x new nut 25 Nm
Important:   Note guide sleeves
42.   Attach high-pressure pump bracket
•   Tighten 6x bolt 25 Nm
43.   Attach alternator
•   Screw in bolt
44.   Fasten alternator bracket
•   Tighten 2x bolt 25 Nm
Note:   Note different bolts
45.   Fasten alternator
•   Tighten bolt 60 Nm
46.   Install EGR cooler
•   Tighten bolt 25 Nm
•   Tighten nut
•   Tighten clamp
•   Attach 2x coolant hoses
– Attach 2x clamps
47.   Install coolant pipe
•   Attach 2x coolant hoses
– To thermostat housing
– To coolant pipe
– Attach 2x clamps
•   Fasten 2x brackets
– Tighten 3x nut 9 Nm
•   Clip 2x coolant hoses into bracket
48.   If present: install vacuum reservoir with retaining plate
•   Tighten 3x bolt 25 Nm
49.   Connect 4x wiring harness plug, sheathed glow plug
50.   Install coolant return line
•   Attach 3x hoses
– Attach 3x clamps
– Clip in hose
•   Tighten bolt
51.   Install throttle valve module
•   Replace seal
•   Tighten 3x bolts
Note:   Attach wiring harness bracket to throttle valve module
•   Fix wiring harness plug
52.   Attach vacuum line to vacuum pump
Important:   Quick-release fitting must audibly engage
•   Connect quick release fitting
•   Clip 2x vacumhoses into bracket
53.   Fit intercooler charge air hose to throttle valve connection
Note:   Charge air hose and connection piece must be free from oil and grease
•   Tighten 2x clamp 3.5 Nm
54.   Install EGR valve
•   Replace 2x seals
•   Fit engine transport shackle
•   EGR valve
– Tighten 3x bolt 25 Nm
•   EGR metal tube to throttle valve module
– Tighten 2x bolt 25 Nm
•   Exhaust gas recirculation (EGR) cooler
– Tighten 2x bolt 25 Nm
55.   Install vacuum line
•   Tighten 2x bolt 9 Nm
•   Attach 4x vacuum hose to vacuum line
Note:   Note the assignment of the hoses
56.   Raise vehicle by its full height
57.   Attach 2x coolant hoses to coolant pipe
•   Attach 2x clamps
58.   Lower vehicle by its full height
59.   Install battery holder
•   Tighten 3x bolt 15 Nm
•   Attach wiring harness
– Connect cable ties
– Clip on 2x brackets
•   Attach pre-glow system control device
•   Clip on coolant hose bracket
60.   Install battery
•   Install bracket
– Tighten bolt 7 Nm
•   Insert battery insulation
•   Attach positive connection to positive terminal
– Tighten nut
61.   Install high pressure pump
•   Tighten 3x nut 25 Nm
62.   Fit high pressure pump wheel
•   Tighten nut 50 Nm
•   Counterhold with KM-6347 in conjunction with KM-956-1
63.   Connect high-pressure pump wiring harness plugs
64.   Attach fuel line to high-pressure pump
•   Remove closure plugs
•   Fasten clamp
65.   Install accumulator
•   Tighten 2x nuts 25 Nm
•   Connect 2x wiring harness plugs
Important:   High-pressure lines must not be installed more than once. When fastening the retaining nut counterhold against the injector with an open-ended wrench.
66.   Install 4x new high-pressure line, accumulator to injector
•   Remove closure plugs
•   Tighten 4x retaining nut (M14) 23 Nm
•   Tighten 4x retaining nut (M12) 23 Nm
Important:   High-pressure lines must not be installed more than once. When fastening the retaining nut counterhold against the injector with an open-ended wrench.
67.   Attach new high pressure line - accumulator to high pressure pump
•   Remove closure plugs
•   Tighten union nut (M14) 23 Nm
•   Tighten union nut (M12) 23 Nm
68.   Install fuel return damping case with oil leak line
•   Tighten 2x bolts
– Attach wiring harness bracket to fuel return damping case
•   Attach 2x hoses
– Attach 2x clamps
•   Attach return line
– Clip in line
69.   Connect 2x wiring harness plugs
•   To exhaust gas recirculation
•   To boost pressure sensor
70.   Attach wiring harness
•   Tighten 4x bolts
•   Connect 4x injector wiring harness plug
71.   Attach 4x oil leak line to injector
•   Remove closure plugs
•   Clip 4x oil leak line to injector
•   Clip 2x oil leak line in bracket
72.   Connect battery
•   Attach ground connection to ground terminal
– Tighten nut
73.   Fuel System, Check for Leaks
Important:   Wear protective goggles and protective gloves.
•   Start engine.
Note:   Check fuel system for escaping fuel.
74.   Top up coolant or ensure correct quantity is present. LUREF_1.gif
75.   Install toothed belt
1 ) protective caps are available in the opel parts catalogue under catalogue number 45 06 154 / part number 9201697/

Exhaust manifold > < Check and adjust valve play