Vauxhall Workshop Service and Repair Manuals

Inlet Manifold Replacement - with Start/Stop System

Removal Procedure

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Remove the engine sight shield. Refer to Engine Sight Shield Replacement .
3. Drain the cooling system. Refer to Cooling System Draining and Filling .





4. Remove the 2 charge air cooler outlet air hose bolts (3).
5. Remove the charge air cooler outlet air hose bolt from the radiator inlet hose bracket.
6. Remove the charge air cooler outlet air hose (4) from the throttle body (1) and hang aside.
7. Remove the charge air cooler outlet air hose seal (2).





8. Remove the 2 exhaust pressure pipe clamps (2, 6).
9. Remove the exhaust pressure pipe bolt (5) from the throttle body support.
10. Remove the exhaust pressure pipe bolt (3) from the exhaust pressure sensor bracket (1).
11. Unclip the vacuum hose from the exhaust pressure pipe (4).
12. Remove the exhaust pressure pipe (4).
13. Remove the auxiliary water pump outlet hose. Refer to Auxiliary Water Pump Outlet Hose Replacement .





14. Remove the 2 exhaust gas recirculation pipe bolts (1) from the exhaust gas recirculation valve cooler.
15. Remove the 3 exhaust gas recirculation pipe bolts (5) from the exhaust manifold.
16. Remove the exhaust gas recirculation pipe (3).
17. Remove the exhaust gas recirculation pipe seal (2).
18. Remove the exhaust gas recirculation pipe gasket (4).





19. Remove the 2 throttle body support bolts (2).
20. Remove the throttle body support (1).





21. Unclip the heater inlet hose (1) from the heater outlet hose clip (4).
22. Remove the heater outlet hose clamp (2).
23. Remove the heater outlet hose (1) from the exhaust gas recirculation valve cooler (3).
24. Disconnect the exhaust gas recirculation valve wiring harness plug.
25. Disconnect the exhaust gas recirculation valve actuator wiring harness plug.
26. Remove the exhaust gas recirculation valve actuator vacuum hose.





27. Remove the 3 exhaust gas recirculation valve cooler bolts (3).
28. Remove the exhaust gas recirculation valve cooler (2).
29. Remove the exhaust gas recirculation valve cooler gasket (1).





30. Unclip the wiring harness from the oil level indicator tube (1).
31. Remove the oil level indicator.
32. Remove the oil level indicator tube bolt (2).
33. Remove the oil level indicator tube (1)
34. Remove the oil level indicator gasket from the cylinder block.





35. Disconnect the positive crankcase ventilation pipe connector (3) from the positive crankcase ventilation oil separator.
36. Disconnect the positive crankcase ventilation pipe connector wiring harness plug.
37. Remove the vacuum hose from the turbocharger wastegate actuator vacuum control solenoid valve.
38. Remove the 2 positive crankcase ventilation pipe bracket bolts (2).
39. Remove the positive crankcase ventilation pipe (1).
40. Remove the exhaust gas recirculation valve vacuum tank . Refer to Exhaust Gas Recirculation Valve Vacuum Tank Replacement .





41. Unclip the positive crankcase ventilation oil separator hose from the hose clamp (1).
42. Remove the positive crankcase ventilation oil separator hose clamp (2).
43. Remove the positive crankcase ventilation oil separator hose from the oil filler tube.
44. Remove the 2 positive crankcase ventilation oil separator bolts (4).
45. Remove the 2 positive crankcase ventilation tube bolts (5).
46. Remove the positive crankcase ventilation oil separator (3).
47. Remove the positive crankcase ventilation tube gasket (6).





48. Disconnect the oxygen sensor wiring harness plug (2).
49. Disconnect the exhaust pressure sensor wiring harness plug (3) from the exhaust pressure sensor (4).
50. Unclip the oxygen sensor wiring harness (1) from the exhaust pressure sensor bracket (5).





51. Disconnect the manifold absolute pressure sensor wiring harness plug (1) from the manifold absolute pressure sensor (2).
52. Unclip the wiring harness from the intake manifold bracket.
53. Disconnect the throttle body wiring harness plug.
54. Unclip the fuel feed pipe and fuel return pipe from the intake manifold.





55. Remove the 5 intake manifold upper bolts (3).
56. Remove the 4 intake manifold lower bolts (4).
57. Remove the intake manifold (2).
58. Remove the 4 inlet manifold gaskets (1).
59. Remove the throttle body assembly. Refer to Throttle Body Assembly Removal .
60. Disassemble the intake manifold. Refer to Inlet Manifold Disassemble .

Installation Procedure

1. Assemble the intake manifold. Refer to Inlet Manifold Assemble .
2. Install the throttle body assembly. Refer to Throttle Body Assembly Installation .





3. Install the 4 NEW intake manifold gaskets (1).
4. Install the inlet manifold (2).

Caution: Refer to Fastener Caution in the Preface section.

5. Install the 4 intake manifold lower bolts (4) and the 5 intake manifold upper bolts (3) and tighten to 25 N·m (18 lb ft) .
6. Clip in the fuel feed pipe and the fuel return pipe to the intake manifold.
7. Connect the throttle body wiring harness plug.
8. Clip in the wiring harness to the intake manifold bracket.





9. Connect the manifold absolute pressure sensor wiring harness plug (1) to the manifold absolute pressure sensor (2).





10. Connect the oxygen sensor wiring harness plug (2).
11. Connect the exhaust pressure sensor wiring harness plug (3) to the exhaust pressure sensor (4).
12. Clip in the oxygen sensor wiring harness (1) to the exhaust pressure sensor bracket (5).





13. Install the positive crankcase ventilation tube gasket (6).
14. Install the positive crankcase ventilation oil separator (3).
15. Install the 2 positive crankcase ventilation tube bolts (5) and tighten to 9 N·m (80 lb in) .
16. Install the 2 positive crankcase ventilation oil separator bolts (4) and tighten to  9 N·m (80 lb in) .
17. Install the positive crankcase ventilation oil separator hose to the oil filler tube.
18. Install the positive crankcase ventilation oil separator hose clamp (2).
19. Install the positive crankcase ventilation oil separator hose to the hose clamp (1).
20. Install the exhaust gas recirculation valve vacuum tank. Refer to Exhaust Gas Recirculation Valve Vacuum Tank Replacement .





21. Install the positive crankcase ventilation pipe (1).
22. Install the vacuum hose to the turbocharger wastegate actuator vacuum control solenoid valve.
23. Connect the positive crankcase ventilation pipe connector wiring harness plug.
24. Connect the positive crankcase ventilation pipe connector (3) to the positive crankcase ventilation oil separator.
25. Install the 2 positive crankcase ventilation pipe bracket bolts (2) and tighten to 8 N·m (71 lb in) .





26. Install a NEW oil level indicator gasket to the cylinder block.
27. Install the oil level indicator tube (1)
28. Install the oil level indicator tube bolt (2) and tighten to  9 N·m (80 lb in) .
29. Install the oil level indicator .
30. Clip in the wiring harness to the oil level indicator tube (1).





31. Install the NEW exhaust gas recirculation valve cooler gasket (1).
32. Install the exhaust gas recirculation valve cooler (2).
33. Install the 3 exhaust gas recirculation valve cooler bolts (3) and tighten to  22 N·m (16 lb ft) .
34. Install the exhaust gas recirculation valve actuator vacuum hose.
35. Connect the exhaust gas recirculation valve actuator wiring harness plug.
36. Connect the exhaust gas recirculation valve wiring harness plug.





37. Install the heater outlet hose (1) to the exhaust gas recirculation valve cooler (3).
38. Install the heater outlet hose clamp (2).
39. Clip in the heater inlet hose (1) to the heater outlet hose clip (4).





40. Install the throttle body support (1).
41. Install the 2 throttle body support bolts (2) and tighten to  9 N·m (80 lb in) .





42. Install a NEW exhaust gas recirculation pipe gasket (4) to the exhaust gas recirculation pipe.
43. Install the exhaust gas recirculation pipe seal (2) to the exhaust gas recirculation pipe.
44. Install the exhaust gas recirculation pipe (3).
45. Install the 3 exhaust gas recirculation pipe bolts (5) to the exhaust manifold and tighten to  9 N·m (80 lb in) .
46. Install the 2 exhaust gas recirculation pipe bolts (1) to the exhaust gas recirculation valve cooler and tighten to  25 N·m (18 lb ft) .
47. Install the auxiliary water pump outlet hose. Refer to Auxiliary Water Pump Outlet Hose Replacement .





48. Install the exhaust pressure pipe (4).
49. Install the exhaust pressure pipe bolt (3) to the exhaust pressure sensor bracket (1) and tighten to  9 N·m (80 lb in) .
50. Install the exhaust pressure pipe bolt (5) to the throttle body support and tighten to  9 N·m (80 lb in) .
51. Install the 2 exhaust pressure pipe clamp (2, 6).
52. Clip in the vacuum hose to the exhaust pressure pipe (4).





53. Install a NEW charge air cooler outlet air hose seal (2).
54. Install the charge air cooler outlet air hose (4) to the throttle body (1).
55. Install the charge air cooler outlet air hose bolt to the radiator inlet hose bracket and tighten to  10 N·m (89 lb in) .
56. Install the 2 charge air cooler outlet air hose bolts (3) and tighten to  10 N·m (89 lb in) .
57. Install the engine sight shield. Refer to Engine Sight Shield Replacement .
58. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
59. Fill the cooling system. Refer to Cooling System Draining and Filling .