Removing and Installing Intake Manifold Opel Astra H

DOHC Petrol Engine 11 illustrations ~1031 words

3. Remove air filter casing (5) with air intake manifold • Unscrew bolt (1) • Disconnect mass air flow meter wiring harness plug (2) • Release clamp (3) • Remove engine vent hose – Release clamp (4)

4. Mark direction of travel of ribbed V-belt.
5. Release tension in toothed V-belt tensioner (1) using hex. (size 15) in direction of arrow (anticlockwise) and remove ribbed V-belt I Version without AC. II Version with AC.

Note. Ensure running direction and installation position of ribbed V-belt is correct

6. Release lower alternator fastening bolt (2).
7. Remove alternator lug (1) • Swivel alternator to rear
8. Slacken intake manifold support (3) • Detach from intake manifold – Unscrew bolt • Undo from cylinder block – Loosen bolt • Swivel intake manifold support to side

9. Detach engine vent hose (4) from cylinder head cover.
10. Detach tank vent valve line (1) from throttle valve module
11. Detach coolant hoses (3) from throttle valve module • Place collecting basin underneath. • Undo 2x clamps
12. Detach coolant line (5) from intake manifold and cylinder head cover • Unscrew 2x bolts • Put coolant line to side
13. Detach brake servo vacuum line (2) from intake manifold • Push locking mechanism together • Remove vacuum line from above
14. Disconnect throttle valve module wiring harness plug

15. Disconnect the following wiring harness plugs: 1. Tank vent valve 2. Camshaft sensor 3. Switchover valve solenoid valve 4. Oxygen sensor for catalytic converter control 5. Coolant temperature sensor

16. Disconnect engine control module wiring harness plug (1)
17. Disconnect knock sensor wiring harness plug (2)
18. Detach bracket (4) and ground cable (3) from engine control unit • Unscrew bolt
19. Detach bolt (5) from engine transport shackle
20. Detach injector plug strip with cable trough • Detach from injectors • Set to one side
21. Reduce fuel pressure with pressure gauge KM-J-34730-91 via test connection • Collect escaping fuel in a suitable container
22. Detach fuel supply line (6) from fuel rail • Undo fastening nuts

23. Detach heater core coolant hose (2) • Place collecting basin underneath. • Release quick-release fitting (1)

24. Detach rear engine transport shackle (1) from cylinder head • Unscrew bolt
25. Detach intake manifold • Unscrew 7x fastening nuts (2) • Remove intake manifold from above
26. Modify attaching parts when replacing intake manifold.

28. Attach intake manifold to cylinder head • Use new seal • Tighten 7x fastening nut 20 Nm – Use new fastening nuts
29. Attach rear engine transportation shackle to cylinder head • Tighten bolt 25 Nm
30. Connect brake servo vacuum line to intake manifold

Note. Check for correct engagement

31. Attach coolant line to intake manifold and cylinder head cover -. • Tighten 2x bolt 8 Nm
32. Attach coolant hoses to throttle valve module and intake manifold • Attach 2x clamps
33. Attach heater core coolant hose

Note. Check for correct engagement

Note. Plug strip must audibly engage

40. Attach plug strip to engine transportation shackle • Tighten bolt
41. Connect or plug in all cable connections that are attached to the injector plug strip
42. Attach engine vent hose to cylinder head cover • Fasten clamp
43. Attach intake manifold support to intake manifold • Tighten bolt 20 Nm
44. Attach intake manifold support to cylinder block • Tighten bolt 35 Nm
45. Install alternator lug • Tighten fastening nut 20 Nm
46. Tighten lower alternator fastening bolt • Tighten bolt 35 Nm
47. Release tension in toothed V-belt tensioner (1) using hex. (size 15) in direction of arrow (anticlockwise), put on ribbed V-belt and tension using ribbed V-belt tensioning device. I Version without AC. II Version with AC.

Note. Ensure running direction and installation position of ribbed V-belt is correct

48. Install air cleaner housing and air intake manifold • Tighten bolt • Fasten clamp 3.5 Nm • Attach engine vent hose – Fasten clamp • Connect mass air flow meter wiring harness plug
49. Install engine cover • Tighten 2x bolts • Attach oil filler cap
50. Cooling System, Charge and Bleed
51. Always use antifreeze 19 40 650 / 9194431 (red) and ensure that the concentration is 50% water and 50% antifreeze. The antifreeze does not just protect the entire cooling system from freezing, but also protects all coolant-flushed parts from rust-corrosion/calcium deposits. It is therefore important to add antifreeze, even in tropical countries.
52. The water quality also plays an important role in addition to the mix ratio. Water of drinkable quality usually meets these requirements. The quality of purified sea water is inadequate!
53. Damage may also be caused to the engine if unauthorised anti-freeze agent is used!
54. If radiator, cylinder head or cylinder head gasket have been replaced the old coolant must not be re-used.

Important. Vehicles with air conditioning: switch air conditioning off and set to ECO mode with ECC

55. Open cooling system Warning: Cooling system is under pressure • Unscrew coolant expansion tank cover
56. Fill with coolant up to lower venting line (1) at coolant expansion tank
57. Seal off cooling system • Screw in coolant expansion tank cover
58. Start engine and allow to warm up • Allow engine to warm up at idling speed of up to 2500 rpm until first radiator fan setting switches on
59. Vent cooling system • Allow engine to run for approximately 2 minutes at 2000 to 2500 rpm

Note. The air in the cooling system is removed via the venting lines

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