Vauxhall Workshop Service and Repair Manuals

J301500 Intake Manifold Gasket, Replace (Z 18 XE, with Air Conditioning, LHD)

  Remove

4.   Remove air cleaner housing (1) •   Disconnect 2 wiring harness plugs – Hot film mass air flow meter (4), tank vent valve (2) •   Unclip tank vent valve •   Detach intake hose •   Detach engine vent hose (3) •   Remove bolt (arrow)

5.   Raise vehicle 6.   Remove right-hand air duct •   Unscrew 3 bolts (arrows) 7.   Remove ribbed V-belt cover •   Unscrew 3 bolts (1) •   Remove clip (2)

8.   Remove ribbed V-belt Note:   Mark running direction. •   Tension ribbed V-belt tensioner in direction of arrow with KM-913-A (2) •   Use KM-6130 (1)

9.   Remove wiring harness for engine management •   Disconnect 3 wiring harness plugs – Catalytic converter control oxygen sensor (1), oil pressure switch (2), crankshaft sensor (3) •   Unclip wiring harness – 3 brackets

10.   Release alternator •   Release alternator support – Unscrew 2 bolts (1) •   Release nut (2)

11.   Detach intake manifold support •   Unscrew upper bolt •   Loosen lower bolt 12.   Lower vehicle

13.   Drain coolant •   Place collecting basin underneath. •   Open drain bolt (arrow) 14.   Lower vehicle 15.   Disconnect camshaft sensor wiring harness plug •   Unclip from bracket •   Disconnect wiring harness connector.

16.   Detach alternator shackle •   Remove ground cable (1) – Unscrew nut (2) •   Unscrew studs (3) •   Unscrew and remove lower bolt (4) •   Loosen upper bolt (5) •   Swing alternator backwards.

Important:   Observe safety precautions and national regulations 17.   Release fuel pressure with KM-J-34730-91 on fuel distributor pipe •   Unscrew test connection protective cap 18.   Detach fuel line from fuel distributor pipe 19.   Detach engine vent hose from cylinder head cover 20.   Pull fuel evaporation hose from throttle valve module

21.   Remove wiring harness for engine management •   Disconnect 8x wiring harness plugs – Throttle valve module (8), engine control unit (4), knock sensor (6), combination plug (7), EGR valve (3), ignition module (2), heated oxygen sensor for mixture regulation (1), coolant temperature sensor (arrow) •   Detach ground cable (5) •   Remove 6x cable ties •   Detach cable trough from engine transport shackle •   Remove wiring harness

22.   Remove fuel distributor pipe •   Unscrew 2x bolt (arrows) •   Pull out fuel distributor pipe with injectors and engine management wiring harness

23.   Release preheater line - throttle valve module •   Detach preheater hose (1) from throttle valve module – Release clamp •   Unscrew 2 bolts (arrows) 24.   Detach preheater return hose for throttle valve module (2) from throttle valve module •   Release clamp 25.   Detach heating return hose (3) from intake manifold 26.   Remove right rear engine transport shackle (4) •   Remove bolt

27.   Remove intake manifold •   Unscrew 7x nuts (arrows) •   Remove brake servo vacuum line

  Install