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Replace intake manifold > < Intake Manifold, Replace (Z16XEP)

Astra H

Intake Manifold Flange, Replace

  Remove

1.   Open bonnet
2.   Raise vehicle
3.   Place collecting basin underneath.
4.   Drain coolant
•   Open drain bolt on radiator
•   Collect coolant
•   Close drain bolt
5.   Detach intake manifold support (3) from intake manifold
•   Unscrew bolt (2)
•   Detach vacuum hose (1)
6.   Disconnect wiring harness plug (5) from tank vent valve (4)
Object Number: 2412791 Size: DEFAULT


7.   Lower vehicle
8.   Remove air cleaner housing (4) with air intake pipe (2)
•   Disconnect intake air temperature wiring harness plug (3)
•   Unscrew bolt (1)
•   Release clamp
•   Detach air intake pipe
Object Number: 3446321 Size: DEFAULT


9.   Disconnect tank vent valve hose (1)
•   Unlatch tank vent valve hose in the direction of the arrow
Object Number: 2412771 Size: DEFAULT


10.   Release fuel pressure via test connection (1) using KM-J-34730-91 (2)
•   Collect exiting fuel in a suitable container - observe safety regulations and national legislation
Object Number: 2412772 Size: DEFAULT


11.   Detach fuel line (2) from fuel rail
•   Disconnect with KM-796-A (1)
Object Number: 2412773 Size: DEFAULT


12.   Detach coolant hose (2) from throttle valve body (1)
•   Release clamp
– Unclip coolant hose
Object Number: 2412774 Size: DEFAULT


13.   Detach coolant hose (1) from coolant flange (2)
•   Release clamp
Object Number: 2412792 Size: DEFAULT


14.   Disconnect wiring harness plugs from engine control unit (1)
Object Number: 3446342 Size: DEFAULT


15.   Detach engine control unit from intake manifold
•   Remove earth cable (2)
– Unscrew bolt (1)
•   Detach bracket for wiring harness plug
– Unscrew 2x bolts (5)
•   Unscrew 3x fastening bolt (4), (6) and (7)
Object Number: 3446337 Size: DEFAULT


16.   Disconnect wiring harness plug (1) from intake pipe pressure sensor (2)
Object Number: 2412794 Size: DEFAULT


17.   Detach brake servo vacuum line (1) from intake manifold
18.   Disconnect throttle valve body wiring harness plug (2)
Object Number: 2412795 Size: DEFAULT


19.   Expose engine wiring harness
•   Open 2x clip (1) and (2)
•   Unclip wiring trough (3)
– Set engine wiring harness aside
Object Number: 2412796 Size: DEFAULT


20.   Detach engine vent pipe (1) from cylinder head cover (3)
•   Unlatch fuse clamp (2)
Object Number: 2412797 Size: DEFAULT


21.   Detach intake manifold (2) from cylinder head
•   Unscrew 5x bolts (1) and (3)
•   Take out intake manifold upwards
•   Remove gasket
Object Number: 2412798 Size: DEFAULT


22.   Disconnect wiring harness plug, PDA system vacuum unit (1)
Object Number: 2412852 Size: DEFAULT


23.   Disconnect 4x wiring harness plug with injectors (1)
Object Number: 2412851 Size: DEFAULT


24.   Detach intake manifold flange (1)
•   Unscrew 8x bolts (3)
•   Unscrew 2x nuts (2)
•   Remove gasket
Object Number: 2412805 Size: DEFAULT


  Install

25.   Attach intake manifold flange
•   Use new gasket
•   Tighten 8x bolt 20 Nm
•   Tighten 2x nut 20 Nm
•   Connect wiring harness plug, injectors
•   Connect wiring harness plug, PDA system vacuum unit
26.   Attach intake manifold to cylinder head
•   Replace gasket
•   Tighten 5x bolt 8 Nm
27.   Attach engine vent pipe to cylinder head cover
•   Ensure correct fitting
28.   Lay engine wiring harness
•   2 clips
29.   Connect wiring harness plug, throttle valve body
30.   Fit brake force amplifier vacuum line
31.   Connect intake pipe pressure sensor wiring harness plug
32.   Attach engine control unit with engine control unit bracket to intake manifold
•   Tighten 3x fastening bolt 8 Nm
•   Install earth cable
– Tighten bolt
•   Bracket for wiring harness plug
– Tighten 2x bolts
•   Connect 2x wiring harness plug, engine control unit
33.   Attach coolant hoses, throttle valve body
•   Attach 2x clamps
34.   Attach fuel line to fuel rail
35.   Connect hose, tank vent valve
•   1 clip
36.   Install air cleaner housing
•   Tighten bolt
•   Fasten clamp 3.5 Nm
•   Attach air intake pipe
•   Disconnect intake air temperature sensor wiring harness plug
37.   Raise vehicle
38.   Attach intake manifold support to cylinder block
•   Tighten bolt 8 Nm
•   Attach vacuum hose
•   Connect tank vent valve wiring harness plug
39.   Lower vehicle
40.   Top up coolant, correct if necessary
41.   Close bonnet

Replace intake manifold > < Intake Manifold, Replace (Z16XEP)