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Intake Manifold Flange, Replace > < Intake Manifold, Remove and Install

Astra H

Intake Manifold, Replace (Z16XEP)

  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 from throttle valve module
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: 3446341 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


  Install

22.   Attach intake manifold to cylinder head
•   Replace gasket
•   Tighten 5x bolt 8 Nm
23.   Attach engine vent pipe to cylinder head cover
•   Ensure correct fitting
24.   Lay engine wiring harness
•   2 clips
25.   Connect wiring harness plug, throttle valve body
26.   Fit brake force amplifier vacuum line
27.   Connect intake pipe pressure sensor wiring harness plug
28.   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
29.   Attach coolant hoses, throttle valve body
•   Attach 2x clamps
30.   Attach fuel line to fuel rail
31.   Connect hose, tank vent valve
•   1 clip
32.   Install air cleaner housing
•   Tighten bolt
•   Fasten clamp 3.5 Nm
•   Attach air intake pipe
•   Disconnect intake air temperature sensor wiring harness plug
33.   Raise vehicle
34.   Attach intake manifold support to cylinder block
•   Tighten bolt 8 Nm
•   Attach vacuum hose
•   Connect tank vent valve wiring harness plug
35.   Lower vehicle
36.   Top up coolant, correct if necessary
37.   Close bonnet

Intake Manifold Flange, Replace > < Intake Manifold, Remove and Install