Vauxhall Workshop Service and Repair Manuals

Replace intake manifold

Important:   When working on the fuel system maintaining cleanliness is essential, as even the smallest of dirt particles may result in engine operating faults or fuel system faults. Open fuel connections must be sealed off with suitable sealing plugs from the Opel parts catalogue. Sealing plugs are designed for single use only.

  Remove

3.   Remove battery •   Detach positive terminal (3) from positive pole – Slacken nut •   Remove bracket 1) – Unscrew bolt (2)

4.   Remove battery support. •   Unclip control unit of pre-heating system (4) •   Unclip coolant hose bracket (5) •   Detach wiring harness – Unclip 2x from battery support (1) •   Unclip wiring harness plug (3) •   Unscrew 3x bolts (2)

7.   Detach fuel return line (2) •   Unscrew banjo bolt (3) •   Detach bracket – Unscrew bolt (1)

8.   Remove high-pressure line (3) from high pressure pump to pressure chamber •   Remove bracket – Unscrew bolt (4) •   Disconnect wiring harness plug, sheathed glow plug (2) of cylinder 1 Note:   Release wiring harness plug with EN-48558 and pull off by hand •   Unscrew 2x union nuts (1) •   Seal off connections with sealing caps

9.   Detach 4x high-pressure lines from pressure chamber to injector •   Unscrew 8x union nut (1) •   Seal off connections on pressure chamber with suitable sealing plugs •   Seal off connections on injectors with EN-48559

10.   Detach vacuum hose (1) of wastegate unit for exhaust gas recirculation cooler •   Unclip 4x •   Set vacuum hose aside

11.   Detach engine management wiring trough (1) from camshaft housing cover •   Unscrew 3 bolts (arrows)

13.   Detach charge air hose for throttle valve connection (1) •   Release clamp

14.   Remove exhaust gas recirculation valve (1) •   Disconnect wiring harness connector. •   Detach EGR cooler pipe (2) – Unscrew 2x bolts – Remove gasket •   Unscrew 4x bolts – Remove gasket

15.   Detach intake pipe rear bracket (2) from intake pipe (6) •   Unscrew 2x bolts (1) 16.   Remove intake pipe together with throttle valve module •   Disconnect wiring harness plug for throttle valve module – Unclip wiring harness •   Remove intake pipe lower bracket (5) – Unscrew bolt (3) – Unscrew nut (4) •   Unscrew 3 bolts (arrows) •   Unclip vacuum hose •   Remove gasket

18.   Remove accumulator (1) •   Disconnect wiring harness plug (arrow) •   Unscrew 2x bolts (2)

21.   Drain coolant •   Open drain bolt on radiator (1) •   Collect coolant •   Close drain bolt

22.   Detach oil return hose (2) •   Release clamp (1) 23.   Release oil filter housing with heat exchanger •   Unscrew banjo bolt (3)

25.   Detach coolant hose (1) from heat exchanger •   Release clamp (2)

26.   Remove oil filter housing with heat exchanger (1) •   Disconnect wiring harness plug (2) •   Unclip 2x wiring harnesses •   Unscrew bolt (3)

27.   Detach 2x solenoid valves •   Disconnect 2x wiring harness plugs (2) •   Release 2x bolts (1) •   Unscrew 2x bolts (1) •   Unclip 4x vacuum hoses from intake manifold

28.   Remove intake manifold (1) •   Unclip 5x vacuum hoses •   Detach wiring harness from intake manifold •   Unclip fuel return line from bracket (3) •   Detach hose from vacuum unit •   Unscrew 8x bolts (2) Note:   Note different bolt lengths •   Unscrew 2x nuts (4) •   Remove gasket

  Install

31.   Install intake manifold Note:   Tighten in the specified tightening sequence (1-10) •   Use new gasket •   Tighten 8x bolts 24 Nm Note:   Note different bolt lengths •   Tighten 2x nut 24 Nm •   Clip in 5x vacuum hoses •   Attach wiring harness to intake manifold •   Clip in fuel return line •   Attach hose to vacuum unit

58.	Fill and bleed cooling system