Vauxhall Workshop Service and Repair Manuals

Intake Plenum, Remove and Install (X 25 XE)  

  Remove, Disconnect   

Detach air intake hose from throttle body.   Remove intake pipes - see operations "Intake Pipe (Above Cylinders 1-3-5), Remove and Install (X 25 XE)" and "Intake Pipe (Above Cylinders 2-4-6), Remove and Install (X 25 XE)".   Detach coolant hoses (1) from coolant lines - collect escaping coolant.   Detach Bowden cable for accelerator pedal (2) and, if in place, Bowden cable for cruise control (3) from ball end. Remove Bowden cables from Bowden cable bracket (4) and lay aside to rear.   Detach wiring harness plug (5) from throttle valve potentiometer. Disconnect vacuum hose (6) and engine vent hoses (7) and (8) from throttle body.

  Remove, Disconnect   

Remove exhaust gas recirculation corrugated pipe (1) from exhaust gas recirculation adapter and intake manifold bracket from exhaust gas recirculation adapter - 1 fastening bolt (arrow).   Detach and remove intake manifold from intake bridge and (4 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    When replacing intake plenum: Convert attaching parts.   Attach intake plenum to intake bridge - tightening torque 8 Nm / 6 lbf. ft.

  Install, Connect   

Secure intake manifold bracket and corrugated pipe to exhaust gas recirculation adapter - insert union nut with mounting paste (white) - tightening torque 25 Nm / 18 lbf. ft.  

Attach vacuum hose and engine vent hoses to throttle body.  

Connect wiring harness plug to throttle valve potentiometer.  

If in place, attach cruise control Bowden cable to Bowden cable bracket and to ball head.  

Attach cruise control Bowden cable to Bowden cable bracket and to ball head.  

Attach coolant hoses to coolant lines.  

Install intake pipes - see operations "Intake Pipe (Above Cylinders 1-3-5), Remove and Install (X 25 XE)" and "Intake Pipe (Above Cylinders 2-4-6), Remove and Install (X 25 XE)".  

Connect air intake hose to throttle valve connection.  

  Inspect   

Top up cooling system - see operations "Cooling System, Top up and Bleed" and "Cooling System, Check for Leaks".