Vauxhall Workshop Service and Repair Manuals

Intake Pipe (Above Cylinders 1-3-5), Remove and Install (X 25 XE)  

  Remove, Disconnect   

Connect Fuel Pressure Gauge KM-J-34730-91 to test connection on fuel distributor pipe. Reduce fuel pressure by opening valve on pressure gauge - collect escaping fuel in suitable container. Observe safety precautions and national regulations.   Detach fuel lines (1) from fuel pressure regulator and fuel distributor pipe.   Detach brake servo vacuum line (2) from intake manifold. Detach vacuum hoses from vacuum accumulator and remove vacuum accumulator from intake manifold (3).   Disconnect wiring harness plugs from idle speed adjuster (4) and from exhaust gas recirculation valve (5). Remove ventilation hose to engine ventilation housing from intake pipe and lay to one side. Disconnect vacuum hoses and wiring harness plug (7). Remove fastening bolts (6) and remove secondary air switchover valve.

  Remove, Disconnect   

Detach intake manifold (1) from intake bridge and intake plenum (5 fastening clamps).   Remove intake manifold from intake manifold bracket (3 fastening bolts).   Notice:  Before assembling components of the intake system (hoses, connections, etc.), they must be cleaned of any possible contamination (grease, oil, etc.). When tightening the hose clamps, be sure to observe exactly the tightening torque of 3.5 Nm / 2.6 lbf. ft.     Important!    It is only ensured that the intake system is free of leaks, thus ensuring operational safety of the engine, if the hose clamps are tightened correctly to the prescribed tightening torque.     Install, Connect    Attach intake manifold with fastening clamps to intake bridge and intake plenum. Attach intake manifold with fastening bolts to intake manifold bracket - ensure correct seating - tightening torque 8 Nm / 6 lbf. ft.   Attach secondary air switchover valve and fit fastening bolts. Attach vacuum hoses and wiring harness plug to secondary air switchover valve.

  Install, Connect   

Fasten engine ventilation housing ventilation hose at intake pipe.  

Connect wiring harness plug to idle speed adjuster and to exhaust gas recirculation valve.  

Attach vacuum accumulator to intake manifold and vacuum hoses to vacuum accumulator.  

Attach brake servo vacuum line to intake manifold and fuel lines to fuel pressure regulator or fuel distributor pipe.