Vauxhall Workshop Service and Repair Manuals

Throttle Body, Remove and Install  

  Remove, Disconnect   

Disconnect wiring harness plug (1) from intake air temperature sensor and wiring harness plug (2) from hot film mass air flow meter. Disconnect engine vent hoses (3) from cylinder head cover. Disconnect air intake hose (4) from throttle body and air filter housing upper part.   Connect Fuel Pressure Checking Unit KM-J-34730-91 to checking connection of the fuel distributor pipe. Reduce fuel pressure by opening the valve on the pressure checking unit - collect escaping fuel in a suitable vessel. Note safety regulations and country-specific regulations. Disconnect fuel return line (5) from fuel pressure regulator and Bowden cable bracket. Disconnect wiring harness plug (6) from idle speed stepper motor.   Remove retainer for accelerator Bowden cable (7) and unclip accelerator Bowden cable from ball head.   If available: Remove retaining clip for cruise control Bowden cable and remove cruise control Bowden cable from ball head.   Remove Bowden cable bracket (8) from throttle body and lay aside with Bowden cables to the rear.

  Remove, Disconnect   

Disconnect vacuum hose fuel pressure regulator (1) from throttle body. Seal coolant hoses (2) with commercially available hose clamps and disconnect from throttle body - collect escaping coolant if necessary. Disconnect engine vent hose (3) from throttle body. Disconnect wiring harness plug from throttle valve potentiometer.   Remove fastening nuts (arrows) for throttle body and take throttle body out of inlet manifold.     Important!    Carefully cover opening in the inlet manifold - foreign matter may cause serious damage to the engine.     Clean    Remove gasket remnants and clean sealing surfaces. Ensure utmost cleanliness - do not damage sealing surfaces.

  Install, Connect   

Attach throttle body to intake manifold with new gasket - tightening torque 9 Nm / 7 lbf. ft.  

Connect wiring harness plug to throttle valve potentiometer.  

Install coolant hoses and vacuum hose for fuel pressure regulator.  

Remove commercially available hose clamps.  

Connect Bowden cable bracket to throttle body and Bowden cables to ball head and secure.  

Attach fuel return line to fuel pressure regulator - tightening torque 15 Nm / 11 lbf. ft.  

Attach Bowden cable bracket and fuel feed line to fuel distributor pipe - tightening torque 15 Nm / 11 lbf. ft.  

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 air intake hose to throttle body and engine vent hoses to cylinder head cover.  

  Install, Connect   

Connect wiring harness plugs to intake air temperature sensor and to hot film mass air flow meter.  

Install air filter housing - see illustration "Air Filter Housing, Air Flow Guide".  

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