Replace Intake Manifold Opel Astra H

Important: When working on the fuel system maintaining cleanliness is essential, as even the smallest of dirt particles may result in engine operating faults or fuel system faults. Open fuel connections must be sealed off with suitable sealing plugs from the Opel parts catalogue. Sealing plugs are designed for single use only.

Remove

1. 1. Open bonnet
2. 2. Disconnect battery • Detach negative connection from ground terminal – Slacken nut
3. 3. Remove battery • Detach positive terminal (3) from positive pole – Slacken nut • Remove bracket 1) – Unscrew bolt (2)

4. 4. Remove battery support. • Unclip control unit of pre-heating system (4) • Unclip coolant hose bracket (5) • Detach wiring harness – Unclip 2x from battery support (1) • Unclip wiring harness plug (3) • Unscrew 3x bolts (2)

5. 5. Unscrew coolant expansion tank closure cap
6. 6. Remove engine cover
7. 7. Detach fuel return line (2) • Unscrew banjo bolt (3) • Detach bracket – Unscrew bolt (1)

8. 8. Remove high-pressure line (3) from high pressure pump to pressure chamber • Remove bracket – Unscrew bolt (4) • Disconnect wiring harness plug, sheathed glow plug (2) of cylinder 1 • Unscrew 2x union nuts (1) • Seal off connections with sealing caps

Note. Release wiring harness plug with EN-48558 and pull off by hand

9. 9. Detach 4x high-pressure lines from pressure chamber to injector • Unscrew 8x union nut (1) • Seal off connections on pressure chamber with suitable sealing plugs • Seal off connections on injectors with EN-48559

10. 10. Detach vacuum hose (1) of wastegate unit for exhaust gas recirculation cooler • Unclip 4x • Set vacuum hose aside

11. 11. Detach engine management wiring trough (1) from camshaft housing cover • Unscrew 3 bolts (arrows)

12. 12. Disconnect engine management wiring harness plugs • Disconnect 12x wiring harness plugs – Air mass flow meter – Camshaft sensor – Compressor – 4x injector – 3x sheathed glow plugs – Air intake temperature – Coolant temperature sensor • Unclip 2x wiring harnesses

Note. Release with EN-48558 and pull off by hand

13. 13. Detach charge air hose for throttle valve connection (1) • Release clamp

14. 14. Remove exhaust gas recirculation valve (1) • Disconnect wiring harness connector. • Detach EGR cooler pipe (2) – Unscrew 2x bolts – Remove gasket • Unscrew 4x bolts – Remove gasket

15. 15. Detach intake pipe rear bracket (2) from intake pipe (6) • Unscrew 2x bolts (1)
16. 16. Remove intake pipe together with throttle valve module • Disconnect wiring harness plug for throttle valve module – Unclip wiring harness • Remove intake pipe lower bracket (5) – Unscrew bolt (3) – Unscrew nut (4) • Unscrew 3 bolts (arrows) • Unclip vacuum hose • Remove gasket

17. 17. Remove intake pipe rear bracket • Unscrew 2x bolts
18. 18. Remove accumulator (1) • Disconnect wiring harness plug (arrow) • Unscrew 2x bolts (2)

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

22. 22. Detach oil return hose (2) • Release clamp (1)
23. 23. Release oil filter housing with heat exchanger • Unscrew banjo bolt (3)

24. 24. Lower vehicle by its full height
25. 25. Detach coolant hose (1) from heat exchanger • Release clamp (2)

26. 26. Remove oil filter housing with heat exchanger (1) • Disconnect wiring harness plug (2) • Unclip 2x wiring harnesses • Unscrew bolt (3)

27. 27. Detach 2x solenoid valves • Disconnect 2x wiring harness plugs (2) • Release 2x bolts (1) • Unscrew 2x bolts (1) • Unclip 4x vacuum hoses from intake manifold

28. 28. Remove intake manifold (1) • Unclip 5x vacuum hoses • Detach wiring harness from intake manifold • Unclip fuel return line from bracket (3) • Detach hose from vacuum unit • Unscrew 8x bolts (2) • Unscrew 2x nuts (4) • Remove gasket

Note. Note different bolt lengths

29. 29. Detach intake air temperature sensor • Unscrew 2x bolts

Install

30. 30. Attach intake air temperature sensor • Tighten 2x bolts – Replace seal ring
31. 31. Install intake manifold • Use new gasket • Tighten 8x bolts 24 Nm • Tighten 2x nut 24 Nm • Clip in 5x vacuum hoses • Attach wiring harness to intake manifold • Clip in fuel return line • Attach hose to vacuum unit

Note. Tighten in the specified tightening sequence (1-10)

Note. Note different bolt lengths

32. 32. Attach 2x solenoid valves • Tighten 4x bolts 7 Nm • Connect 2x wiring harness plugs • Clip 4x vacuum hoses to intake manifold
33. 33. Install oil filter housing with heat exchanger • Screw in banjo bolt • Tighten bolt 46 Nm • Fix wiring harness plug • Clip in 2x wiring harnesses
34. 34. Attach coolant hose to heat exchanger • Fasten clamp
35. 35. Raise vehicle by its full height
36. 36. Fasten oil filter housing with heat exchanger • Tighten banjo bolt 110 Nm
37. 37. Attach oil return hose • Fasten clamp
38. 38. Lower vehicle by its full height
39. 39. Install accumulator • Tighten 2x bolt 25 Nm • Fix wiring harness plug
40. 40. Install intake pipe rear bracket • Tighten 2x bolt 24 Nm
41. 41. Install intake pipe together with throttle valve module • Replace gasket • Tighten 3x bolt 16 Nm • Connect wiring harness plug, throttle valve module – Attach wiring harness • Install intake pipe lower bracket – Tighten bolt – Tighten nut • Clip in vacuum hose
42. 42. Attach intake pipe bracket to intake pipe • Tighten 2x bolts
43. 43. Install exhaust gas recirculation valve • Replace gasket • Tighten 4x bolts 24 Nm • Attach exhaust gas recirculation cooler pipe – Tighten 2x bolts 29 Nm • Fix wiring harness plug

Note. Attach coolant hose bracket

44. 44. Attach charge air hose for throttle valve connection • Tighten clamp 3.5 Nm
45. 45. Connect engine management wiring harness plugs • Connect 12x wiring harness plugs – Air mass flow meter – Camshaft sensor – Compressor – 4x injector – 3x sheathed glow plugs – Air intake temperature – Coolant temperature sensor • Clip in 2x wiring harnesses
46. 46. Attach engine management wiring trough to camshaft housing cover • Tighten 3x bolts
47. 47. Attach vacuum hose to wastegate unit for exhaust gas recirculation cooler • Route vacuum hose • Clip in 4x
48. 48. Install 4x high-pressure lines from pressure chamber to injectors • Detach 4x sealing caps from pressure chamber • Detach 4x EN-48559 from injector • Tighten 8x union nut 25 Nm

Note. Attach first to injector, then to pressure chamber

49. 49. Attach high-pressure line from high pressure pump to pressure chamber • Attach union nut to pressure chamber with MKM-6600-207 and to high-pressure pump with MKM-6600-12 and MKM-6600-308 – Tighten 2x union nuts 25 Nm • Attach to bracket – Tighten bolt • Connect wiring harness plug, sheathed glow plug of cylinder 1
50. 50. Attach fuel return line • Tighten banjo bolt 10 Nm • Attach bracket – Tighten bolt 7 Nm
51. 51. Check and correct engine oil level
52. 52. Install battery holder • Tighten 3x bolts • Clip in wiring harness plug • Attach wiring harness – Clip 2x to battery support • Clip in bracket for coolant hose • Clip in control unit of pre-heating system
53. 53. Install battery • Install bracket – Tighten bolt • Attach positive connection to positive terminal – Tighten nut
54. 54. Connect battery • Attach negative connection to ground terminal – Tighten nut

Important. Wear protective goggles

55. 55. Carry out leak test on high pressure system • Carry out actuator test (fuel leak) • Visual inspection of high pressure system for fuel leak

Note. Engine must be at operating temperature

56. 56. Install engine cover
57. 57. Program volatile memories
58. 58. Fill and bleed cooling system
59. 59. Close bonnet