Intake Manifold Gasket Replacement Opel Agila B

Remove

1. 1. Disconnect battery negative lead • Release nut
2. 2. Remove cap from radiator
3. 3. Raise vehicle

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

4. 4. Drain cooling system • Place collecting container below • Open radiator drain plug (1) • Allow coolant to drain into collecting container • Close radiator drain plug • Remove collecting container

5. 5. Lower vehicle
6. 6. Remove coolant expansion tank (1) from battery tray • Disconnect overflow hose from radiator – Release clip • Install 2x new blanking plug • Slide off

7. 7. Remove cap from coolant expansion tank

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

8. 8. Drain any fluid from coolant expansion tank • Clean inside of coolant expansion tank; flush it well with clean water and drain
9. 9. Install coolant expansion tank (1) to battery tray • Slide on • Remove 2x blanking plug • Connect overflow hose to radiator – Secure clip

10. 10. Release air cleaner assembly (1) from cylinder head cover • Pull off to release 2x rubber locator
11. 11. Remove cover and air cleaner element from air cleaner assembly • Release 2x clip (2), 2x locator

12. 12. Disconnect harness connector (1) from fuel tank evaporation solenoid valve

13. 13. Disconnect harness connector from mass air flow (MAF) meter (1)

14. 14. Release harness for fuel tank evaporation solenoid valve and engine harness from air cleaner assembly • Release 2x clip
15. 15. Release fuel tank evaporation solenoid valve (3) from air cleaner assembly (2) • Remove bolt
16. 16. Release fuel pipe assembly from air intake hose • Pull off
17. 17. Disconnect hose (5) for fuel tank evaporation solenoid valve from intake manifold • Release clip • Install 2x new blanking plug
18. 18. Disconnect air intake hose from throttle valve module • Release clip (1)
19. 19. Disconnect engine breather hose (6) from cylinder head cover • Release clip • Install 2x new blanking plug
20. 20. Remove air cleaner assembly from intake manifold • Remove bolt (4)

21. 21. Disconnect harness connector (1) from throttle valve module, then move to one side

22. 22. Disconnect inlet and outlet hose (1) from throttle valve module • Release 2x clip • Install 4x new blanking plug
23. 23. Remove throttle valve module (2) from intake manifold • Remove 2x nut (3), 2x bolt (4)

24. 24. Remove rubber seal (1) from intake manifold • Pull off

Note. The rubber seal has its own pull tag attached.

25. 25. Disconnect hose (1) for brake servo from intake manifold • Release clip • Install 2x new blanking plug

26. 26. Disconnect heater inlet hose from bracket for intake manifold • Release from clip (1) – Pull off
27. 27. Disconnect engine vent valve hose from intake manifold • Release from heater matrix outlet hose – Release from clip • Release clip (2) • Install 2x blanking plug
28. 28. Disconnect harness connector (3) from manifold absolute pressure (MAP) sensor
29. 29. Release harness for MAP sensor from intake manifold • Release clip

30. 30. Remove intake manifold bracket (1) from intake manifold • Remove bolt

31. 31. Remove intake manifold from intake manifold spacer • Remove 2x nut (1), 3x bolt (2)
32. 32. Remove rubber seal from intake manifold • Pull off

Note. The rubber seal has its own pull tag attached.

33. 33. Disconnect heater matrix outlet hose from water transfer pipe, then move to one side • Release clip (2) • Install 2x new blanking plug
34. 34. Disconnect outlet hose from water transfer pipe • Release clip (1) • Install 2x new blanking plug

35. 35. Disconnect lower radiator hose (2) from water transfer pipe • Release clip • Install 2x new blanking plug
36. 36. Disconnect heater matrix inlet hose (3) from thermostat housing assembly, then move to one side • Release clip • Install 2x new blanking plug
37. 37. Release harness for oxygen sensor from water transfer pipe • Release clip (1)

38. 38. Remove exhaust gas recirculation (EGR) valve (2) from cylinder head • Disconnect harness connector (1) • Remove 2x bolt • Remove gasket

39. 39. Remove water transfer pipe from thermostat housing assembly and engine block • Remove 2x bolt (1, 2)
40. 40. Remove seal ring from water transfer pipe • Prise off

41. 41. Remove intake manifold spacer from cylinder head • Remove 2x bolt (1) • Remove gasket
42. 42. Clean mating surfaces of cylinder head and intake manifold spacer for new intake manifold gasket. (cleaning both surfaces)

Install

43. 43. Install intake manifold spacer to cylinder head • Install new gasket • Install 2x bolt (1)

44. 44. Install water transfer pipe to thermostat housing assembly and engine block • Install new seal ring – Apply suitable lubricant • Install 2x bolt (1, 2)

45. 45. Clean mating surface for EGR valve
46. 46. Install EGR valve (2) to cylinder head • Install new gasket • Install 2x bolt 23 Nm • Connect harness connector (1)

47. 47. Secure harness for oxygen sensor to water transfer pipe • Secure clip (1)
48. 48. Connect heater matrix inlet hose (3) to thermostat housing assembly • Remove 2x blanking plug • Secure clip
49. 49. Connect lower radiator hose (2) to water transfer pipe • Remove 2x blanking plug • Secure clip

50. 50. Connect outlet hose to water transfer pipe • Remove 2x blanking plug • Secure clip (1)
51. 51. Connect heater matrix outlet hose to water transfer pipe • Remove 2x blanking plug • Secure clip (2)

52. 52. Clean mating surfaces of intake manifold and intake manifold spacer for new rubber seal (cleaning both surfaces)
53. 53. Install new rubber seal to intake manifold • Apply suitable lubricant to rubber seal, then push on
54. 54. Install intake manifold to intake manifold spacer • Install 2x nut (1), 3x bolt (2)

55. 55. Install intake manifold bracket (1) to intake manifold • Install bolt

56. 56. Secure harness for MAP sensor to intake manifold • Secure clip
57. 57. Connect harness connector (3) to MAP sensor
58. 58. Connect engine vent valve hose to intake manifold • Remove 2x blanking plug • Secure clip (2) • Connect engine vent valve hose to heater matrix outlet hose – Secure clip
59. 59. Connect heater matrix inlet hose to bracket (1) for intake manifold • Secure to clip – Push on

60. 60. Connect hose (1) for brake servo to intake manifold • Remove 2x blanking plug • Secure clip

61. 61. Clean mating surfaces of intake manifold and throttle valve module (cleaning both surfaces)
62. 62. Install new rubber seal (1) to intake manifold • Apply suitable lubricant to rubber seal, then push on

63. 63. Install throttle valve module (2) to intake manifold • Install 2x nut (3), 2x bolt (4) 23 Nm
64. 64. Connect inlet and outlet hose (1) to throttle valve module • Remove 4x blanking plug • Secure 2x clip

65. 65. Connect harness connector (1) to throttle valve module

66. 66. Install air cleaner assembly to intake manifold • Install bolt (4)
67. 67. Connect engine breather hose (6) to cylinder head cover • Remove 2x blanking plug • Secure clip
68. 68. Connect air intake hose to throttle valve module assembly • Secure clip (1)
69. 69. Connect hose (5) for fuel tank evaporation solenoid valve to intake manifold • Remove 2x blanking plug • Secure clip
70. 70. Secure fuel pipe assembly to air intake hose • Push on
71. 71. Secure fuel tank evaporation solenoid valve (3) to air cleaner assembly (2) • Install bolt

72. 72. Secure harness for fuel tank evaporation solenoid valve and engine harness to air cleaner assembly • Secure 2x clip
73. 73. Connect harness connector to MAF meter (1)

74. 74. Connect harness connector (1) to fuel tank evaporation solenoid valve, then secure to 2x clip

75. 75. Install air cleaner element and cover to air cleaner assembly (1) • Secure cover to air cleaner assembly – Secure 2x locator, then secure 2x clip (2)
76. 76. Secure air cleaner assembly to cylinder head cover • Push on to secure 2x rubber locator

Important. Only use coolant approved by the manufacturer and ensure a concentration of 50% water and 50% anti-freeze.

77. 77. Fill coolant expansion tank with new coolant fluid up to maximum level mark
78. 78. Install cap to coolant expansion tank
79. 79. Fill radiator with new coolant fluid up to bottom of radiator filler neck
80. 80. Install cap to radiator
81. 81. Connect battery negative lead • Secure nut 11 Nm
82. 82. Program all volatile memories – see operation “Program Volatile Memories”
83. 83. Start engine and allow it to run at idle speed until thermostat opens

Note. Cooling system bleeds itself automatically during the warm-up phase.

84. 84. Switch off engine
85. 85. Check and correct coolant fluid level