Vauxhall Workshop Service and Repair Manuals

 

Intake Manifold, Remove and Install (X 16 SZR)     Important!    Fuel escapes - observe safety measures and national legislation. Collect escaping fuel in a suitable container. Fuel system is pressurised.     Remove, Disconnect    Remove fuel pump relay - see operation "Fuel Pump Relay, Remove and Install".   Start engine for at least 5 sec - fuel pressure reduction.   Remove lower coolant hose from radiator. Collect escaping coolant.   Disconnect vacuum hoses (1) from air intake cover (2). Detach air intake cover (2) from throttle valve injection housing. Remove engine vent hoses (3) and (4) from camshaft housing cover. Detach air intake hose from air cleaner housing.   Remove air cleaner housing - see illustration "Air Cleaner Housing, Air Flow Guide (X 16 SZR)".

  Remove, Disconnect   

Detach or remove wiring harness plug from Multec central fuel injection - see illustration "Cable Routing - Multec Central Fuel Injection".  

Remove wiring trough from camshaft housing and alternator and lay aside.  

Remove shackle (1) and support (2) from wiring trough bracket. Unclip throttle linkage at throttle valve actuation. Remove Bowden cable bracket from intake manifold and set aside with Bowden cable for throttle valve actuation. Detach coolant hose (4) from intake manifold. Detach vacuum hose for intake pipe pressure sensor (5) from throttle valve injection housing. Detach fuel lines (6) from throttle valve injection housing. Detach vacuum hose for tank vent valve (7) from throttle valve injection housing and seal off. Detach brake servo vacuum line (8) from intake manifold.   Remove intake manifold from cylinder head.     Clean    Remove gasket remnants and clean sealing surfaces.

  Install, Connect   

Attach intake manifold to cylinder head with new gasket and new fastening nuts - tightening torque 22 Nm / 16 lbf. ft.   Attach brake servo vacuum line to intake manifold - tightening torque 18 Nm / 13 lbf. ft.   Attach vacuum hose for tank vent valve to intake manifold. Attach vacuum hose for intake pipe pressure sensor to throttle valve injection housing.   Attach coolant hose to intake manifold.   Attach Bowden cable bracket to intake manifold - tightening torque 9 Nm / 6.6 lbf. ft.   Clip throttle linkage to throttle valve control.   Install fuel lines at throttle valve injection housing 15 Nm / 11 lbf. ft.   Install fuel pump relay - see operation "Fuel Pump Relay, Remove and Install".   Attach shackle and support with wiring trough bracket to intake manifold and to alternator - tightening torque 20 Nm / 15 lbf. ft.

  Install, Connect   

Attach cable trough to camshaft housing cover - tightening torque 8 Nm / 6 lbf. ft.  

Connect/attach wiring harness plug for Multec central injection - see illustration "Multec Central Injection Wiring Harness Routing".  

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   

Install air cleaner housing - see illustration "Air Cleaner Housing, Air Flow Guide (X 16 SZR)".  

  Install, Connect   

Attach air intake cover (2) to throttle valve injection housing.   Connect vacuum hoses (1) to air intake cover.   Attach air intake hose to air cleaner housing.   Attach engine vent hoses (3) and (4) to camshaft housing cover.   Install lower coolant hose on radiator.   Top up cooling system - see operations "Cooling System, Top up and Bleed" and "Cooling System, Check for Leaks".