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vauxhall Workshop Repair Guides

Vauxhall Workshop Manuals

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Replace intake manifold

  Remove

1.   Open bonnet
2.   Remove engine cover
3.   Remove battery tray
4.   Detach bulkhead closing part LUREF_1.gif
5.   Remove brake force amplifier vacuum line
6.   Detach coolant expansion tank and set aside
7.   Detach charge air pipe (1) from throttle valve module (3)
•   Unscrew 2x bolts (2)
8.   Detach charge air pipe (1)
•   Detach hose clamp from transmission
Unscrew bolt
Object Number: 10680814  Size: DEFAULT


9.   Remove throttle valve module (1)
•   Disconnect wiring harness connector (2)
•   Unscrew 3x bolts (3)
•   Unscrew bolt for wiring harness bracket (arrow)
Object Number: 10677357  Size: DEFAULT


10.   Remove dipstick guide tube
•   Unscrew bolt
11.   Detach oil separator hose
•   Unscrew 2x bolts
•   Detach vacuum hose, charge air control
12.   Remove 2x fuel line
•   Seal fuel line connections with KM-6015
13.   Detach engine management wiring harness
•   Disconnect 2x wiring harness connectors from engine control unit (1)
•   Unclip wiring harness
Object Number: 10679180  Size: DEFAULT


14.   Disconnect wiring harness plug for mixture regulator oxygen sensor
15.   Detach 2x wiring harness brackets from intake manifold
•   Unscrew 4x bolts
•   Remove wiring harness connector and hose from differential pressure sensor
•   Unclip wiring harness
16.   Disconnect wiring harness connector for charge pressure sensor
17.   Raise vehicle by its full height
18.   Drain coolant
•   Open drain bolt on radiator (1)
•   Collect coolant
•   Close drain bolt
Object Number: 10678616  Size: DEFAULT


19.   Detach vacuum reservoir (1) with bracket (2)
•   Unscrew 4x bolts
•   Set aside vacuum reservoir and bracket
Object Number: 10677334  Size: DEFAULT


20.   Detach wiring harness from alternator
•   Unscrew nut
21.   Lower vehicle by its full height
22.   Detach exhaust gas recirculation pipe (3)
•   Unscrew 2x bolts (1) from flange of exhaust gas recirculation valve
•   Unscrew 3x bolts (5) from intake manifold
•   Remove gasket (4)
•   Remove seal ring (2)
Object Number: 10681673  Size: DEFAULT


23.   Detach exhaust gas recirculation valve (2)
•   Detach coolant hose from heater core
•   Unscrew 3x bolts (3)
•   Remove gasket (1)
•   Remove 2x wiring harness plug
•   Remove vacuum hose
Note:   Set aside exhaust gas recirculation valve. The exhaust gas recirculation valve cannot be removed.
Object Number: 10681674  Size: DEFAULT


24.   Raise vehicle by its full height
25.   Detach oil separator
•   From intake manifold
•   Unscrew 2x bolts
26.   Lower vehicle by its full height
27.   Detach oil separator hose from timing case
•   Detach clamp
28.   Detach intake manifold (1)
•   Unscrew 9x bolts (2, 3)
Object Number: 8125665  Size: DEFAULT


29.   Detach throttle valve connector adapter
•   Unscrew 3 bolts
30.   Detach charge pressure sensor
•   Unscrew bolt

  Install

31.   Detach charge pressure sensor
•   Tighten bolt 9 Nm
32.   Attach throttle valve connector adapter
•   Tighten 3x bolt 8 Nm
33.   Install intake manifold
•   Replace 4 gaskets
•   Tighten 9x bolts 25 Nm
34.   Connect wiring harness connector for charge pressure sensor
35.   Attach oil separator to cylinder head
•   Tighten 2x bolt 9 Nm
36.   Attach exhaust gas recirculation valve
•   Replace gasket
•   Attach coolant hose to heater core
•   Tighten 3 bolts 22 Nm
•   Push on 2x wiring harness plug
•   Attach vacuum hose
37.   Attach exhaust gas recirculation pipe
•   Replace 2x seals
•   Tighten 2x bolts on flange of exhaust gas recirculation valve 9 Nm
•   Tighten 3x bolts on intake manifold 9 Nm
38.   Install throttle valve module
•   Replace gasket
•   Tighten bolt, wiring harness bracket
•   Tighten 3x bolt 8 Nm
•   Connect wiring harness plug
39.   Attach oil separator hose to timing case
•   Fasten clamp
40.   Attach 2x wiring harness brackets to intake manifold
•   Tighten 4x bolts
•   Connect wiring harness connector and hose from differential pressure sensor
•   Attach wiring harness
41.   Raise vehicle by its full height
42.   Attach wiring harness to alternator
•   Tighten nut
43.   Insert dipstick guide tube
44.   Attach vacuum reservoir bracket
•   Tighten 2x bolt 20 Nm
45.   Attach vacuum reservoir to vacuum reservoir bracket
•   Tighten 2x bolt 9 Nm
46.   Lower vehicle by its full height
47.   Fasten oil dipstick guide tube
•   Tighten bolt 9 Nm
48.   Fit charge air pipe at throttle valve module
•   Replace gasket
•   Tighten 2x bolt 8 Nm
49.   Fasten charge air pipe
•   Attach hose clamp to transmission
Tighten bolt
50.   Install 2x fuel line
•   Remove sealing plug
51.   Connect wiring harness connector for mixture regulation oxygen sensor
52.   Connect vacuum line for brake force amplifier
53.   Install battery holder
54.   Attach coolant expansion tank
•   Tighten bolt
55.   Install bulkhead closing part LUREF_1.gif
56.   Connect battery
•   Attach earth clamp to earth terminal
Tighten nut
57.   Fill and bleed cooling system LUREF_1.gif
58.   Install engine cover
59.   Program volatile memories
60.   Close bonnet

J Engine and Engine Aggregates > DOHC diesel engine > Cylinder Head > Intake manifold > Repair Instructions > Replace intake manifold

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