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Turbocharger Replacement > < Engine Replacement - 1.4L LUH and LUJ - M32

Astra J

Intake Manifold Replacement (LUH, LUJ w. El. Returnless Fuel Syst.)

Special Tools

•  EN-34730-91   Pressure Tester
•  EN-6015   Closure Plugs

For equivalent regional tools, refer to Special Tools

Removal Procedure

1. Open the hood.
2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
3. Remove the engine sight shield.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

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5. Unclip the heater outlet hose from retainer clip (1).
6. Unclip the engine control module wiring harness from 2 retainer clips (2).
7. Lower the vehicle.
8. Remove the charge air cooler outlet air hose from the throttle body. Refer to Charge Air Cooler Outlet Air Hose Replacement .

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9. Disconnect the throttle body wiring harness plug (1).

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10. Disconnect the evaporative emission canister purge solenoid valve wiring harness plug (3).

Note:  Make note of the installed position of the manifold absolute pressure sensor and the barometric pressure sensor wiring harness plugs to ensure they will be connected in their original position.
11. Disconnect the manifold absolute pressure sensor wiring harness plug (2) and the barometric pressure sensor wiring harness plug (1).
12. Disconnect the 4 fuel injector wiring harness plugs (4).
13. Unclip the engine control module wiring harness from the camshaft cover.

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14. Disconnect the turbocharger wastegate regulator solenoid valve wiring harness plug (3).
15. Unclip the engine control module wiring harness from 2 intake manifold retainer clips (2) and from 2 fuel injection rail retainer clips (1).

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Warning: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.


16. Remove the fuel injector rail cap (1).

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17. Relieve the fuel pressure, using the EN-34730-91   pressure tester (1).

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18. Remove the fuel feed pipe (4) from fuel injector rail.
19. Unclip the fuel feed pipe from retainer clip (1).
20. Remove the fuel ventilation pipe (2) from evaporative emission canister purge solenoid valve.
21. Unclip the fuel ventilation pipe from retainer clip (1).
22. Close the vents with the EN-6015   closure plugs .
23. Disconnect the brake booster vacuum pipe (3) from the intake manifold.

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Note:  The intake manifold bolts remain in intake manifold.
24. Remove the 6 intake manifold bolts (1).

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25. Remove the intake manifold (1) in compound with the intake manifold gasket.
26. Remove the assembly parts from intake manifold as necessary. Refer to Intake Manifold Disassemble .

Installation Procedure

1. Install the assembly parts to intake manifold as necessary. Refer to Intake Manifold Assemble .
2. Clean the sealing surfaces.

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3. Install the intake manifold (1) along with a NEW intake manifold gasket.

Caution: Refer to Fastener Caution .

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4. Install the 6 intake manifold bolts (1) and tighten to 20 N·m (15 lb ft) .

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5. Connect the fuel ventilation pipe (2) to the evaporative emission canister purge solenoid valve.
6. Clip in the fuel ventilation pipe to the retainer clip (1).
7. Connect the fuel feed pipe (4) to the injector rail.
8. Clip in the fuel feed pipe to the retainer clip (1).
9. Connect the brake booster vacuum pipe (3) to the intake manifold.

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10. Install the fuel injector rail cap (1).

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11. Connect the turbocharger wastegate regulator solenoid valve wiring harness plug (3).
12. Clip in the engine control module wiring harness to 2 intake manifold retainer clips (2) and from 2 fuel injection rail retainer clips (1).

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13. Clip in the engine control module wiring harness to the camshaft cover.
14. Connect the 4 fuel injector wiring harness plugs (4).
15. Connect the manifold absolute pressure sensor wiring harness plug (2) and the barometric pressure sensor wiring harness plug (1).
16. Disconnect the evaporative emission canister purge solenoid valve wiring harness plug (3).

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17. Connect the throttle body wiring harness plug (1).
18. Install the charge air cooler outlet air hose to the throttle body. Refer to Charge Air Cooler Outlet Air Hose Replacement .
19. Raise and support the vehicle.

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20. Clip in the heater outlet hose to retainer clip (1).
21. Clip in the engine control module wiring harness to 2 retainer clips (2).
22. Lower the vehicle.
23. Install the engine sight shield.
24. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
25. Close the hood.

Turbocharger Replacement > < Engine Replacement - 1.4L LUH and LUJ - M32