Intake Manifold Replace Opel Antara I

Intake Manifold Replace

Remove

1. Disconnect the negative battery cable.
2. Remove the beauty cover. Refer to Beauty Cover Replace .
3. Remove the charge air system hoses and ducts. Refer to Charging Air System Replace .

4. Disconnect the radiator lower hose and drain coolant. Refer to Draining and Refilling the Cooling System .

5. Remove the accessory belt. Refer to Accessory Belt and Tensioner Replace .

6. Remove the fuel pipe-to-injection pump from the fuel injection pump.
7. Remove the power steering pump fastener and pull it left side.
8. Remove the coolant hose from intake manifold.
9. Remove the radiator upper hose.
10. Remove the injection pump return hose.
11. Remove the oil level indicator tube.
12. Remove the fuel pipe-to-common rail between common rail and fuel injection pump.
13. Remove the wiring splice pack tightening bolt from intake manifold.
14. Remove the glow plug fuse box retaining bolts.
15. Remove the engine wiring.
16. Remove the engine wiring harness guide.

17. Remove the coolant by-pass hose.
18. Remove the EGR cooler outlet pipe.
19. Remove the intake manifold with the gasket.

Install

1. Install the intake manifold with a new gasket.
2. Install the EGR cooler outlet pipe.

Tighten

Tighten the intake manifold bolts and nuts 23 N•m (17 lb-ft).

Tighten the EGR cooler outlet pipe bolts and nuts 20 N•m (14.8 lb-ft).

3. Install the engine wiring.
4. Install the glow plug fuse box retaining bolts.
5. Install the engine wiring splice pack tightening bolt to intake manifold.
6. Install the fuel pipe-to-common rail between common rail and fuel injection pump.
7. Install the oil level indicator tube.
8. Install the power steering pump.
9. Install the fuel pipe-to-injection pump to the fuel injection pump.

Tighten

Tighten the glow plug fuse box bolts to 10 N•m (88.5 lb-in).

Tighten the engine wiring splice pack tightening bolt to 15 N•m (11.1 lb-ft).

Tighten the fuel pipe-to-common rail to 20 N•m (14.8 lb-ft).

Tighten the fuel pipe-to-common rail retaining bolt to 10 N•m (88.5 lb-in).

Tighten the oil level indicator tube bolts to 11 N•m (97.4 lb-in).

Tighten the power steering pump bolts to 25 N•m (18.4 lb-ft).

Tighten the fuel pipe-to-injection pump retaining bolt(to intake manifold) to 9 N•m (79.7 lb-in).

Tighten the fuel pipe-to-injection pump retaining bolt to 25 N•m (18.4 lb-ft).