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Crankshaft and Bearing Cleaning and Inspection - LDE, LED, LFJ, LXV, 2H0, LUW, LFH > < Engine Mount Bracket Replacement

Astra J

Intake Manifold Replacement (1.6L LLU)

Special Tools

•  EN-6015   Closure Plugs
•  EN-34730-91   Fuel Gauge

For equivalent regional tools, refer to Special Tools .

Removal Procedure

Warning:  Refer to Gasoline/Gasoline Vapors Warning .

1. Open the hood.
2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .

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3. Loosen the clamp.
4. Remove the charger air cooler outlet air hose (2) from the throttle body (1).
5. Disconnect the booster vacuum pipe from the intake manifold.
6. Unclip the engine wiring harness conduit.
7. Remove the positive crankcase ventilation hose and pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement .
8. Remove the manifold pressure sensor. Refer to Manifold Absolute Pressure Sensor Replacement .

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9. Remove the ECM wiring harness bracket bolt (2) from the intake manifold (1).
10. Disconnect the 4 fuel injection wiring harness plugs.
11. Disconnect the throttle body wiring harness
12. Unclip the fuel injection wiring harness.
13. Put the fuel injection wiring harness aside.
14. Place a collecting basin underneath.
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.


15. Release the fuel pressure using the test connection with EN-34730-91   gauge . Refer to Fuel Pressure Measurement .

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16. Remove the evaporative emission vent pipe (5) from the intake manifold (4).
  16.1 Disconnect the wiring harness (6) from the evaporative emission vent purge valve (1).
  16.2 Release the quick connector (3). Refer to Plastic Collar Quick Connect Fitting Service .
  16.3 Close the vents with the EN-6015   plugs .
  16.4 Remove the evaporative emission vent pipe retainer bolt (2).

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17. Disconnect the fuel filler pipe (1) from the fuel rail (3).
  17.1 Release the quick connector (2).
  17.2 Close the vents with the EN-6015   plugs .

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18. Disconnect the fuel return pipe (1) from the fuel rail (3).
  18.1 Release the quick connector (2).
  18.2 Close the vents with the EN-6015   plugs .

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19. Remove the 3 engine wiring harness bracket bolts (4).
20. Remove the engine wiring harness bracket (1) with the fuel pipes (3) from the intake manifold (2).
21. Remove the engine lift bolt.
22. Remove the engine lift intake side.
23. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

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24. Loosen the intake manifold (3) from the cylinder head (5) (bottom).
  24.1 Remove 2 bolts (1).
  24.2 Remove 2 nuts (2).
25. Lower the vehicle.
26. Remove the intake manifold (3) from the cylinder head (5) (top).
  26.1 Remove 3 bolts (1).
  26.2 Remove the nut (2).
  26.3 Remove the gasket (4).

Disassemble Procedure

1. Remove the throttle body. Refer to Throttle Body Assembly Removal .
2. Disassemble the intake manifold. Refer to Intake Manifold Disassemble .

Cleaning and Inspection Procedure

Clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection .

Assemble Procedure

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

Installation Procedure


Caution: Refer to Fastener Caution .

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1. Install the intake manifold (3) to the cylinder head (5) (top).
  1.1 Install the gasket (4).
  1.2 Install the nut (2) and tighten to 20 N·m (15 lb ft) .
  1.3 Install 3 bolts (1) and tighten to 20 N·m (15 lb ft) .
2. Raise the vehicle.
3. Install the intake manifold (3) to the cylinder head (5) (bottom).
  3.1 Install 2 bolts (1) and tighten to 20 N·m (15 lb ft) .
  3.2 Install 2 nuts (2) and tighten to 20 N·m (15 lb ft) .
4. Lower the vehicle.
5. Install the engine lift intake side.
6. Install the engine lift bolt and tighten to 22 N·m (16 lb ft) .

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7. Install the engine wiring harness bracket (1) with the fuel pipes (3) to the intake manifold (2).
8. Install the 3 engine wiring harness bracket bolts (4) and tighten to 8 N·m (71 lb in) .

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9. Connect the fuel return pipe (1) to the fuel rail (3).
  9.1 Remove the EN-6015   plugs .
  9.2 Install the quick connector (2).

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10. Connect the fuel filler pipe (1) to the fuel rail (3).
  10.1 Remove the EN-6015   plugs .
  10.2 Install the quick connector (2).

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11. Install the evaporative emission vent pipe (5) to the intake manifold (4)
  11.1 Connect the wiring harness (6) to the evaporative emission vent purge valve (1).
  11.2 Install the quick connector (3). Refer to Plastic Collar Quick Connect Fitting Service .
  11.3 Remove the EN-6015   plugs .
  11.4 Install the evaporative emission vent pipe retainer bolt (2) and tighten to 8 N·m (71 lb in) .
12. Position the fuel injection wiring harness.
13. Connect the throttle body wiring harness.

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14. Install the ECM wiring harness bracket bolt (2) to the intake manifold (1) and tighten to 8 N·m (71 lb in) .
15. Connect the 4 fuel injection wiring harness plugs.
16. Install the manifold pressure sensor. Refer to Manifold Absolute Pressure Sensor Replacement .
17. Clip in the wiring harness.
18. Install the positive crankcase ventilation hose and pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement .
19. Connect the booster vacuum pipe to the intake manifold.
20. Clip in the engine wiring harness conduit.

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21. Install the charger air cooler outlet air hose (2) to the throttle body (1).
22. Install the clamp.
23. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
24. Close the hood.

Crankshaft and Bearing Cleaning and Inspection - LDE, LED, LFJ, LXV, 2H0, LUW, LFH > < Engine Mount Bracket Replacement