vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Intake Manifold Gasket, Replace > < Replace all valve stem seals (cylinder head installed)

Corsa D

Intake Manifold Gasket, Replace

  Remove

1.   Open bonnet
2.   Connect battery
•   Detach earth terminal
3.   Raise vehicle by its full height
4.   Drain coolant
•   Place collecting basin underneath.
•   Push on suitable hose (2)
•   Open drain cock (1) in the direction of the arrow
•   Collect coolant
•   Close drain cock
Object Number: 10678410 Size: DEFAULT


5.   Lower vehicle by its full height
6.   Remove air cleaner housing
7.   Remove bulkhead closing part LUREF_1.gif
Important:   Observe safety measures and national legislation
8.   Release fuel pressure with KM-J-34730-91 (2) via test connection
Note:   Collect escaping fuel in a suitable container.
•   Unscrew protective cap (1)
Object Number: 3446128 Size: DEFAULT


9.   Detach fuel line (2) from fuel rail with KM-996-A (1)
Object Number: 3446308 Size: DEFAULT


10.   Detach 2x coolant hoses (1) from throttle valve module
•   Place collecting basin underneath.
•   Undo 2x clamps
– Seal 2 hoses using KM-807
11.   Unclip heater core return hose (2)
•   Open intake manifold bracket (arrow)
Object Number: 10679226 Size: DEFAULT


12.   Remove throttle valve module LUREF_1.gif
13.   Disconnect brake servo vacuum line from intake manifold
•   Open quick-release fitting
14.   Detach cylinder head vent hose from intake manifold
15.   Disconnect tank vent valve wiring harness plug (1)
Object Number: 3446292 Size: DEFAULT


16.   Detach fuel vent line from tank vent valve
•   Open quick-release fitting
•   Unclip from bracket
17.   Detach engine-control wiring harness connector
•   Disconnect wiring harness connector, pressure sensor intake pipe and twinport vacuum unit
•   Unclip 2x from bracket
•   Detach engine wiring trough from cylinder head cover
18.   Detach fuel rail cover (1)
Object Number: 10686709 Size: DEFAULT


19.   Disconnect 3x injector wiring harness plug
•   Unclip 2x from bracket
•   Set wiring harness to one side
20.   Detach exhaust gas recirculation pipe from exhaust gas recirculation valve
•   Unscrew 2 bolts (arrows)
Object Number: 2410466 Size: DEFAULT


21.   Remove intake manifold
•   Unscrew 5x screw (arrows)
•   Remove 3x gaskets
Object Number: 2410535 Size: DEFAULT


  Install

22.   Clean sealing surfaces.
23.   Replace intake manifold gasket
24.   Install intake manifold
•   Tighten 5x bolt
– Tightening torque 10 Nm .
25.   Attach exhaust gas recirculation pipe to exhaust gas recirculation valve
•   Tighten 2x bolts
– Tightening torque 8 Nm .
26.   Connect 3 injector wiring harness connectors
•   Clip 2x in bracket
27.   Attach fuel rail cover
28.   Attach engine management wiring harness connector
•   Attach engine wiring trough to cylinder head cover
•   Clip 2x in bracket
•   Connect wiring harness connector, pressure sensor intake pipe and twinport vacuum unit
29.   Attach fuel vent line to tank vent valve
•   Clip into bracket
•   Connect quick-release fitting
30.   Connect wiring harness plug, tank vent valve
31.   Attach cylinder head vent hose to intake manifold
32.   Attach brake servo vacuum line to intake manifold
•   Connect quick-release fitting
33.   Install throttle valve module LUREF_1.gif
34.   Clip in heater core return hose
•   Close intake manifold bracket
35.   Attach fuel line to fuel rail
36.   Install bulkhead closing part LUREF_1.gif
37.   Install air cleaner housing LUREF_1.gif
38.   Connect battery
•   Attach earth terminal
39.   Fill and bleed cooling system LUREF_1.gif
40.   Program volatile memories
41.   Close bonnet

Intake Manifold Gasket, Replace > < Replace all valve stem seals (cylinder head installed)