Replace Intake Manifold Opel Astra H

Remove

1. 1. Remove toothed belt
2. 2. Disconnect battery • Detach ground connection from ground terminal
3. 3. Detach wiring harness • Unscrew 4x bolts (1) • Disconnect 4x wiring harness plugs for injector (2)

4. 4. Detach 4x oil leak line (2) from injectors • Release 4x retaining clamp (3) from injector in direction of arrow – Pull off oil leak line Sealing plug 1) • Unclip 2x oil leak line from bracket (1)

Note. The oil leak line must not be detached from the fuel return damping case. It if is detached, it must be replaced.

Note. Close 4x injectors with suitable

5. 5. Disconnect 2x wiring harness plugs • From exhaust gas recirculation (1) • From boost pressure sensor (2)

6. 6. Remove fuel return damping case (1) with oil leak line • Unscrew 2x bolts • Return line with KM-796-A – Unclip line – Seal with KM-6015 • Detach 2x hoses – Undo 2 clamps

Note. Open fuel connections must be sealed with appropriate plugs 1)

7. 7. Detach accumulator high pressure line (1) to high pressure pump • Unscrew 2x union nuts sealed off with suitable sealing plugs 1)

Important. When releasing the retaining nut on the high pressure pump, counterhold with open-ended wrench.

Note. Opened fuel connections must be

8. 8. Detach 4x high pressure line - accumulator to injector • Unscrew 8x union nut (1)

Important. When releasing the retaining nut, counterhold with open-ended wrench against the injector

Note. Close opened fuel connections with appropriate plugs 1)

9. 9. Remove accumulator (1) • Unscrew 2x nut (arrows) • Disconnect 2x wiring harness plugs

10. 10. Detach fuel line of high-pressure pump (1) • Release clamp

Note. Close opened fuel connections with appropriate plugs 1)

11. 11. Disconnect high-pressure pump wiring harness plug (2)

12. 12. Release high-pressure pump drive gear • Counterhold with KM-6347 (1) in combination with KM-956-1 (2)

13. 13. Remove high-pressure pump gear • Attach EN-46790 (1) – Screw in 2x bolts • Pull off high-pressure pump drive gear – Counterhold with open-ended wrench (2)

14. 14. Remove high pressure pump • Unscrew 3x nuts (1)

15. 15. Raise vehicle by its full height
16. 16. Place collecting basin underneath.
17. 17. Drain coolant • Open drain bolt on radiator (1) • Collect coolant • Close drain bolt

18. 18. Detach 2x coolant hoses (1) from coolant pipe • Undo 2 clamps

19. 19. Lower vehicle by its full height
20. 20. Remove battery • Detach positive terminal (3) from positive pole – Slacken nut • Remove bracket 1) – Unscrew bolt (2) • Remove battery insulation

21. 21. Remove battery support. • Remove pre-glow system control unit (4) • Unclip coolant hose bracket (5) • Detach wiring harness – Undo cable tie (1) – Unclip 2x brackets • Unscrew 3x bolts (2)

22. 22. Detach vacuum line • Detach 4x vacuum hose from vacuum line • Unscrew 2x bolts (arrows)

Note. Mark the assignment of the hoses

23. 23. Detach EGR valve • EGR valve (3) – Unscrew 3 bolts • EGR metal tube to throttle valve module (1) – Unscrew 2x bolts • Exhaust gas recirculation (EGR) cooler (4) – Unscrew 2x bolts • Remove 2x engine transport shackle seal (2)

24. 24. Detach intercooler charge air hose (1) from throttle body • Undo 2 clamps

25. 25. Detach vacuum line from vacuum pump • Disconnect quick-release fitting (2) • Unclip 2x vacuum line from bracket (1)

26. 26. Remove throttle valve module (1) • Unscrew 3x bolts (2) • Disconnect wiring harness connector. • Remove seal

27. 27. Unclip coolant return line (2) • Unscrew bolt (1) • Remove 3x hoses (arrows) – Undo 3x clamps – Unclip hose

28. 28. Remove 4x wiring harness plugs from glow plugs (arrows)

29. 29. If present: remove vacuum reservoir (3) with retaining plate • Unscrew 3x bolts (1) and (2)

30. 30. Remove coolant pipe (2) • Unclip 2x coolant hoses from bracket (4) • Detach from bracket on transmission (3) – Unscrew 2x nuts • Detach from bracket on thermostat housing (1) – Unscrew nut • Detach 2x coolant hoses – Undo 2 clamps

31. 31. Remove EGR cooler (1) • Unscrew bolt, nut (arrows) • Release clamp • Detach 2x coolant hoses – Undo 2 clamps

Note. Remove EGR cooler rearward

32. 32. Release alternator bracket • Unscrew 2x bolts (1)

Note. Note different bolts

33. 33. Detach alternator • Unscrew bolt (1)

Note. Set alternator aside

Important. Note guide sleeves

34. 34. Detach high-pressure pump bracket (1) • Unscrew 6x bolts

Note. Note different bolt lengths

35. 35. Remove intake manifold (1) • Unscrew 9x nuts • Detach gasket

36. 36. Detach charge pressure sensor • Unscrew bolt
37. 37. Unscrew coolant hose connection port

Install

38. 38. Tighten coolant hose connection port

Note. coat with sealant

39. 39. Attach charge pressure sensor • Replace seal • Tighten bolt
40. 40. Clean sealing surface
41. 41. Install intake manifold • Install new gasket – Clip on 2x to intake manifold • Tighten 9x new nut 25 Nm

Important. Note guide sleeves

42. 42. Attach high-pressure pump bracket • Tighten 6x bolt 25 Nm
43. 43. Attach alternator • Screw in bolt
44. 44. Fasten alternator bracket • Tighten 2x bolt 25 Nm

Note. Note different bolts

45. 45. Fasten alternator • Tighten bolt 60 Nm
46. 46. Install EGR cooler • Tighten bolt 25 Nm • Tighten nut • Tighten clamp • Attach 2x coolant hoses – Attach 2x clamps
47. 47. Install coolant pipe • Attach 2x coolant hoses – To thermostat housing – To coolant pipe – Attach 2x clamps • Fasten 2x brackets – Tighten 3x nut 9 Nm • Clip 2x coolant hoses into bracket
48. 48. If present: install vacuum reservoir with retaining plate • Tighten 3x bolt 25 Nm
49. 49. Connect 4x wiring harness plug, sheathed glow plug
50. 50. Install coolant return line • Attach 3x hoses – Attach 3x clamps – Clip in hose • Tighten bolt
51. 51. Install throttle valve module • Replace seal • Tighten 3x bolts • Fix wiring harness plug

Note. Attach wiring harness bracket to throttle valve module

52. 52. Attach vacuum line to vacuum pump • Connect quick release fitting • Clip 2x vacumhoses into bracket

Important. Quick-release fitting must audibly engage

53. 53. Fit intercooler charge air hose to throttle valve connection • Tighten 2x clamp 3.5 Nm

Note. Charge air hose and connection piece must be free from oil and grease

54. 54. Install EGR valve • Replace 2x seals • Fit engine transport shackle • EGR valve – Tighten 3x bolt 25 Nm • EGR metal tube to throttle valve module – Tighten 2x bolt 25 Nm • Exhaust gas recirculation (EGR) cooler – Tighten 2x bolt 25 Nm
55. 55. Install vacuum line • Tighten 2x bolt 9 Nm • Attach 4x vacuum hose to vacuum line

Note. Note the assignment of the hoses

56. 56. Raise vehicle by its full height
57. 57. Attach 2x coolant hoses to coolant pipe • Attach 2x clamps
58. 58. Lower vehicle by its full height
59. 59. Install battery holder • Tighten 3x bolt 15 Nm • Attach wiring harness – Connect cable ties – Clip on 2x brackets • Attach pre-glow system control device • Clip on coolant hose bracket
60. 60. Install battery • Install bracket – Tighten bolt 7 Nm • Insert battery insulation • Attach positive connection to positive terminal – Tighten nut
61. 61. Install high pressure pump • Tighten 3x nut 25 Nm
62. 62. Fit high pressure pump wheel • Tighten nut 50 Nm • Counterhold with KM-6347 in conjunction with KM-956-1
63. 63. Connect high-pressure pump wiring harness plugs
64. 64. Attach fuel line to high-pressure pump • Remove closure plugs • Fasten clamp
65. 65. Install accumulator • Tighten 2x nuts 25 Nm • Connect 2x wiring harness plugs

Important. High-pressure lines must not be installed more than once. When fastening the retaining nut counterhold against the injector with an open-ended wrench.

66. 66. Install 4x new high-pressure line, accumulator to injector • Remove closure plugs • Tighten 4x retaining nut (M14) 23 Nm • Tighten 4x retaining nut (M12) 23 Nm

Important. High-pressure lines must not be installed more than once. When fastening the retaining nut counterhold against the injector with an open-ended wrench.

67. 67. Attach new high pressure line - accumulator to high pressure pump • Remove closure plugs • Tighten union nut (M14) 23 Nm • Tighten union nut (M12) 23 Nm
68. 68. Install fuel return damping case with oil leak line • Tighten 2x bolts – Attach wiring harness bracket to fuel return damping case • Attach 2x hoses – Attach 2x clamps • Attach return line – Clip in line
69. 69. Connect 2x wiring harness plugs • To exhaust gas recirculation • To boost pressure sensor
70. 70. Attach wiring harness • Tighten 4x bolts • Connect 4x injector wiring harness plug
71. 71. Attach 4x oil leak line to injector • Remove closure plugs • Clip 4x oil leak line to injector • Clip 2x oil leak line in bracket
72. 72. Connect battery • Attach ground connection to ground terminal – Tighten nut
73. 73. Fuel System, Check for Leaks • Start engine.

Important. Wear protective goggles and protective gloves.

Note. Check fuel system for escaping fuel.

74. 74. Top up coolant or ensure correct quantity is present.
75. 75. Install toothed belt

1

) protective caps are available in the opel parts catalogue under catalogue number 45 06 154 / part number 9201697/