Replace Intake Manifold Flange Seal Opel Astra G

Remove

1. 1. Open bonnet
2. 2. Disconnect battery
3. 3. Raise vehicle
4. 4. Place collecting basin underneath.
5. 5. Drain coolant • Open radiator drain plug • Collect coolant • Close drain plug
6. 6. Remove intake manifold bracket (3) from intake manifold • 1 bolt (2) • Detach 1 vacuum hose (1).
7. 7. Detach wiring harness plug (5) from tank vent valve (4) • 1 wiring harness plug

8. 8. Lower vehicle
9. 9. Remove air cleaner housing (5) and air intake manifold (3) • 1 mass air flow meter wiring harness plug (4) • Unclip tank ventilation hose (1) • 1 fastening bolt (2) • 1 clip

10. 10. Detach tank vent valve hose (1) • 1 clip • Disengage tank vent valve hose in direction of arrow

11. 11. Lower fuel pressure • Via test connector (1) in conjunction with KM-J-34730-91 (2) – Collect exiting fuel in a suitable container - observe safety regulations and national legislation

12. 12. Remove fuel line (2) from fuel distribution pipe • Detach using KM-796-A (1)

13. 13. Remove coolant hose (2) from throttle body (1) • 1 clip – Expose coolant hose – 3 clips

14. 14. Remove coolant hose (1) from coolant flange (2) • 1 clip

15. 15. Remove engine control unit with engine control unit bracket from intake manifold • Remove ground cable (8) – 1 bolt (9) • Wiring harness plugs, engine control unit (1) and (3) – Detach in direction of arrow and remove • Disconnect wiring harness plug (2) • Remove 1 wiring harness plug bracket – 2 bolts (5) • 3 tightening bolts (4), (6) and (7)

16. 16. Remove wiring harness plug (1) from suction pipe pressure gauge (2) • 1 wiring harness plug

17. 17. Remove brake force amplifier vacuum line (1) • From intake manifold – 1 hose
18. 18. Remove throttle body wiring harness plug (2) • 1 wiring harness plug

19. 19. Expose engine wiring harness • 2 clips (1) and (2) • Unclip cable channel (3) – Lay engine wiring harness to one side

20. 20. Remove engine vent pipe (1) • From cylinder head cover (3) – Detach safety clamp (2)

21. 21. Remove intake manifold (2) from cylinder head • Bolts (1) and (3) • Lift intake manifold up and off • Remove seal

22. 22. Remove PDA system vacuum dashpot wiring harness plug (1)

23. 23. Remove injection valve wiring harness plug (1)

24. 24. Remove intake manifold flange • 8 bolts (3) 2 nuts (2) from intake manifold flange (1) – Remove seal

Install

25. 25. Install intake manifold flange • Use new seal • 8 bolts – Tightening torque 20Nm • 2 nuts – Tightening torque 20Nm • Insert injection valve wiring harness plugs • Insert PDA system vacuum dashpot wiring harness plug
26. 26. Fit intake manifold to cylinder head • Replace seal • 5 bolts – Tightening torque 8 Nm
27. 27. Fit engine vent pipe • On cylinder head – Ensure correct fitting
28. 28. Route engine wiring harness • Route engine wiring harness • 2 clips • Clip in cable channel
29. 29. Install throttle body wiring harness plug • 1 wiring harness plug – Lock wiring harness plug
30. 30. Fit brake force amplifier vacuum line • on intake manifold – 1 hose
31. 31. Install throttle body wiring harness plug • 1 wiring harness plug
32. 32. Install engine control unit with engine control unit support on intake manifold • 3 fastening bolts – Tightening torque 8 Nm • 1 install ground cable – 1 bolt • 1 wiring harness plug bracket – 2 bolts • Attach engine control unit wiring harness plug and lock
33. 33. Install throttle body coolant hoses • on throttle body • 1 clip – Expose coolant hose – 3 clips • On thermostat housing – 1 clip
34. 34. Attach fuel line to fuel distribution pipe
35. 35. Connect tank vent valve hose • 1 clip
36. 36. Install air cleaner housing and air intake manifold • Place 1 mass air flow meter wiring harness plug • Clip in tank ventilation hose • 1 fastening bolt • 1 clip – Tightening torque 3.5Nm
37. 37. Raise vehicle
38. 38. Raise vehicle • 1 bolt – Tightening torque 8 Nm • Attach 1 vacuum hose • Attach tank vent valve wiring harness plug
39. 39. Lower vehicle
40. 40. Top up coolant or ensure correct quantity is present.
41. 41. Programme transient memory
42. 42. Close bonnet