Intake Manifold Assembly Replace Opel Antara I

Intake Manifold Assembly Replace

Note: The intake manifold comprises of an upper and lower section. Some service procedures only require the removal of the upper intake manifold (e.g. fuel injector/spark plug servicing), while other service procedures require the removal of both the upper and lower manifold as a complete assembly (e.g. cylinder head/s). If only the upper intake manifold needs to be removed, refer to Upper Intake Manifold Replace .

Remove

1. Depressurise the fuel system. Refer to Fuel System Pressure Relief
2. Disconnect the negative battery cable.
3. Remove the air intake duct.
4. Remove the engine dress cover. Refer to Engine Dress Cover Replace .

Note: The following precautions must be followed when disconnecting the throttle body wiring connector.

4. Retract the throttle body wiring connector lock (3).
5. While pressing the connector latch in the direction of the arrow (4), disconnect the throttle body wiring connector.

7. Disconnect the positive crankcase ventilation (PCV) hose (1), evaporative (EVAP) emission purge vacuum hose (2).
8. Remove the water outlet port-to-surge tank pipe bracket retaining bolts (3).
9. Remove the EVAP emission purge solenoid bracket retaining bolt (4).

10. Disconnect the wiring harness connector from the intake manifold tuning control (IMTC) solenoid.
11. Remove the engine wiring harness mount bracket.
12. Move all the necessary parts clear of the upper intake manifold assembly.

Important: Plug the fuel feed hose opening after removal to prevent dirt and other contaminants from entering the fuel system.

13. Disconnect the fuel feed line from the fuel rail.

14. Remove the wiring harness connector (2) from the EVAP valve (1).
15. Disconnect the quick connect (3) from the rear of the EVAP valve, as follows:

a. Squeeze the two barbed lugs together, push the quick connect into the valve, then pull out to separate the connection.

b. Plug both open ends to prevent the entry of foreign matter.

16. Remove the four long bolts securing the complete intake manifold to the cylinder heads.

Important: Do not loosen nor remove the shortest bolts (X) holding the upper intake manifold to the lower.

17. Remove the two short bolts securing the lower intake manifold to the cylinder heads.

Important: When the intake manifold is removed, plug each of the cylinder head intake openings with lint free cloth, to stop the entry of foreign material into the intake ports.

18. Remove the upper and lower intake manifold assembly from the engine.
19. Remove lower intake manifold to cylinder head gasket.

20. Remove the bolts attaching the upper intake manifold to the lower intake manifold.
21. Remove the upper intake manifold from the lower intake manifold.

Note: Do not reuse the upper to lower intake manifold gaskets.

22. Remove and discard the upper to lower intake manifold gaskets.

Note: The following precautions must be followed when removing the fuel rail and injector assembly (1):

a. Care must be taken when removing the fuel rail and injector assembly to prevent damage to the injector spray tips and injector harness connector terminals.

b. Support the fuel rail and injector assembly after removal.

c. Plug all fuel line and manifold openings after removal to prevent dirt and other contaminants from entering the fuel system.

Remove the fuel rail and injector assembly, if necessary. Refer to Fuel Rail and Injectors Replace . Clean

Important: Due to the aluminium alloy construction of the intake manifold, wire brushes and steel scrapers must not be used during the cleaning process, as damage to sealing surfaces may occur. Use of a wooden or plastic scraper is preferred.

1. Clean mating surfaces ensuring any gasket material is removed.
2. Clean the manifold using a suitable solvent.

Dry the timing components with compressed air. Inspect

1. Inspect the intake manifold for the following fault conditions:
2. Place a straight edge (1) across the upper intake manifold sealing surface (2).
3. Using a feeler gauge (3), measure the clearance between the manifold and the straight edge.
4. If the clearance between the upper intake manifold sealing surface and the straight edge exceeds the specified maximum warpage, replace the manifold.

5. Place a straight edge (1) across the lower intake manifold sealing surface (2).
6. Using a feeler gauge (3), measure the clearance between the manifold and the straight edge.
7. If the clearance between the lower intake manifold sealing surface and the straight edge exceeds the specified maximum warpage, replace the manifold.

Install

1. Install the fuel rail and injector assembly, if necessary. Refer to Fuel Rail and Injectors Replace
2. Install the lower intake manifold to the cylinder head.

Tighten

Tighten the lower intake manifold to cylinder head attaching bolts to 23 N•m (17 lb-ft).

3. Install the upper intake manifold to the lower intake manifold and cylinder head.

Tighten

Tighten the upper intake manifold to lower intake manifold attaching bolts to 23 N•m (17 lb-ft).

Tighten the upper intake manifold to cylinder head attaching bolts to 23 N•m (17 lb-ft).

4. Connect the fuel injector connector.
5. Connect the fuel feed line to the fuel rail.

6. Connect the EVAP emission canister purge solenoid valve connector and the quick connector.

7. Connect the IMTC connector.
8. Connect the throttle body connector.
9. Install the EVAP emission purge solenoid bracket retaining bolt.
10. Install the water outlet port-to-surge tank pipe bracket retaining bolts.
11. Connect the EVAP emission vacuum hose and PCV hose to the upper intake manifold.