Intake Manifold Replacement Opel Agila B

Remove

1. 1. Remove 2x wiper arm assembly (1) from vehicle • Remove 2x cap (2) – Pull off • Remove 2x nut (3)

2. 2. Remove battery from vehicle • Disconnect battery negative lead (3) – Release nut • Disconnect battery positive lead – Release cover (1) – Release nut (2) • Remove bracket from battery tray – Remove bolt (4)

3. 3. Disconnect hose (5) from mass air flow (MAF) meter (6) • Release clip
4. 4. Disconnect harness connector (3) from MAF meter
5. 5. Disconnect hose (1) from air cleaner assembly • Release from clip
6. 6. Remove air cleaner assembly (2) from vehicle • Remove 2x bolt (4) • Release 2x locator from battery tray – Pull up

7. 7. Release glow plug control unit (1) from battery tray, then move to one side • Release from 2x clip

8. 8. Remove battery tray (1) from vehicle • Remove 4x bolt

9. 9. Disconnect 2x harness connector from ECM • Pull out 2x lock (1), then release 2x clip (2)

10. 10. For left drive vehicle, release harness from ECM • Disconnect harness connector (3) from harness • Remove bracket (2) from ECM – Remove bolt (1)

11. 11. For left drive vehicle, remove bracket (2), earth lead (3) and ECM (1) from lower cowl panel • Remove 3x bolt

12. 12. For right drive vehicle, remove ECM (1) and bracket (3) from cowl panel grille • Remove 4x bolt
13. 13. For right drive vehicle, remove ECM and earth lead (2) from bracket • Remove 4x bolt

14. 14. Remove cowl grille panel (1) from vehicle • Remove 5x clip, then release 14x clip, 3x locator – Use suitable tool
15. 15. Remove windshield wiper motor (2) from vehicle • Disconnect harness connector • Remove 3x bolt (3)

16. 16. Remove lower cowl panel (2) from vehicle • Remove 6x nut (1)

17. 17. Raise vehicle

Important. Observe the relevant environmental regulations when disposing of used coolant.

18. 18. Drain cooling system • Place collecting container below • Open radiator drain plug • Allow coolant to drain into collecting container • Close radiator drain plug • Remove collecting container
19. 19. Lower vehicle
20. 20. Remove heater outlet pipe with turbo pipe assembly from EGR cooler (2) • Release 5x clip, 3x bolt
21. 21. Release intake manifold elbow from intake manifold • Remove 3x bolt, clip
22. 22. Disconnect harness connector from EGR valve (1)
23. 23. Disconnect 2x hose from EGR cooler • Release 2x clip
24. 24. Remove EGR valve and cooler from cylinder head • Remove gasket • Remove 2x bolt • Release 2x clip
25. 25. Clean mating surfaces of cylinder head and EGR valve

26. 26. Remove 2x wiring harness bracket (2) from intake manifold (1) • Remove 2x bolt

27. 27. Remove oil separator (3) from intake manifold • Remove bolt (4)
28. 28. Release oil level dipstick (2) from intake manifold • Remove bolt
29. 29. Disconnect connector from boost pressure sensor (1)

30. 30. Remove intake manifold (1) from cylinder head • Remove 9x bolt (2)
31. 31. Remove rubber gasket from intake manifold
32. 32. Remove wiring harness support bracket from intake manifold • Remove 2x bolt

Install

33. 33. Install wiring harness support bracket to intake manifold (1) • Install 2x bolt
34. 34. Install new rubber gasket to intake manifold
35. 35. Clean mating surface of cylinder head
36. 36. Install intake manifold to cylinder head • Install 9x bolt (2) 28 Nm

37. 37. Connect connector to boost pressure sensor (1)
38. 38. Secure oil level dipstick (2) to intake manifold • Install bolt 9 Nm
39. 39. Install oil separator (3) to intake manifold • Install bolt (4)

40. 40. Install 2x wiring harness bracket (2) to intake manifold (1) • Install 2x bolt

41. 41. Install EGR valve and cooler to cylinder head • Install new gasket • Install 2x bolt 28 Nm • Secure 2x clip
42. 42. Connect 2x hose to EGR cooler • Secure 2x clip
43. 43. Connect harness connector to EGR valve (1)
44. 44. Secure intake manifold elbow to intake manifold • Install 3x bolt, clip
45. 45. Install heater outlet pipe with turbo pipe assembly to EGR cooler (2) • Install 3x bolt, secure 5x clip

46. 46. Install lower cowl panel (2) to vehicle • Install 6x nut (1)

47. 47. Secure harness to lower cowl panel • Secure clip
48. 48. Install windscreen wiper motor (2) to vehicle • Install 3x bolt (3) 8 Nm
49. 49. Connect harness connector to windscreen wiper motor
50. 50. Install cowl panel grille (1) to vehicle • Secure 3x locator, 14x clip, then install 7x clip

51. 51. For right drive vehicle, install ECM and earth lead (2) to bracket • Install 4x bolt 10 Nm
52. 52. For right drive vehicle, install ECM (1) and bracket (3) to cowl panel grille • Install 4x bolt 10 Nm

53. 53. For left drive vehicle, install ECM (1), bracket (2) and earth lead (3) to lower cowl panel • Install 3x bolt 10 Nm

54. 54. For left drive vehicle, secure harness to ECM • Install bracket (2) to ECM – Install bolt (1) 10 Nm • Connect harness connector (3) to harness

55. 55. Connect 2x harness connector to ECM • Push in 2x lock (1), then secure 2x clip (2)

56. 56. Install battery tray (1) to vehicle • Install 4x bolt

57. 57. Install glow plug control unit (1) to battery tray • Secure to 2x clip

58. 58. Install air cleaner assembly (2) to vehicle • Push down to secure 2x locator to battery tray • Install 2x bolt (4)
59. 59. Connect hose (5) to mass air flow MAF meter (6) • Secure clip
60. 60. Connect harness connector (3) to MAF meter
61. 61. Connect hose (1) to air cleaner assembly • Secure to clip

62. 62. Install battery to vehicle • Install bracket to battery tray – Install bolt (4) • Connect battery positive lead – Secure nut (2) 11 Nm – Secure cover (1) • Connect battery negative lead (3) – Secure nut 11 Nm

63. 63. Install 2x wiper arm assembly (1) to vehicle • Adjust and align wiper arm as specified in service instructions • Install 2x nut (3) 18 Nm • Install 2x cap (2)

64. 64. Fill system with coolant – see operation “Engine Coolant Replacement”
65. 65. Program all volatile memories – see operation “Program Volatile Memories”