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Contents Wiring diagrams Section: DOHC Petrol Engine All sections

Replace Intake Manifold Opel Astra H

DOHC Petrol Engine 19 illustrations ~827 words

Spezialwerkzeugliste:

KM-6151

Remove

  1. 1. Detach fuel pressure regulator (high-pressure)
  2. 2. Remove air intake pipe (2) • Undo 2x clamps (1)
  1. 3. Detach engine control unit • Detach wiring harness bracket – Unscrew 2x nuts (1) • Release and unplug 2x wiring harness plug (2) • Release and disconnect throttle valve module wiring harness plug (5) • Unclip wiring harness • Detach earth cable (3) – Unscrew bolt • Detach engine control unit – Unscrew 3 bolts
  1. 4. Detach throttle valve module • Unscrew 4x bolts – Remove gasket
  2. 5. Remove resonator (2) • Detach air intake pipe • Unscrew bolt (3) • Unclip resonator mountings (1) in direction of arrow
  1. 6. Release oil dipstick guide tube (1) • Pull out oil dipstick • Unscrew bolt (2) • Pull the oil dipstick guide tube up out of the oil pan. • Set oil dipstick guide tube to one side

Note. Wiring harnesses will be removed later

  1. 7. Loosen alternator from above • Unscrew 2x bolts (1)
  1. 8. Raise vehicle by its full height
  2. 9. Remove lower engine compartment cover (2) • Unscrew 4x bolts (1) • Remove 2x body-bound rivets (3)
  1. 10. Remove ribbed V-belt • Mark direction of rotation of ribbed V-belt • Tension the ribbed V-belt tensioner using KM-6151 in the direction of the arrow – Remove ribbed-V-belt
  1. 11. Unclip 2x wiring harness (2) and (3) from oil dipstick guide tube (1) • Take out oil dipstick guide tube
  1. 12. Detach intake manifold support (1) from intake manifold (2) • Unscrew bolt
  1. 13. Detach alternator • Unscrew 2x bolts (1) • Put alternator to one side

Note. Wiring harness remains in situ

  1. 14. Lower vehicle by its full height
  2. 15. Remove tank vent valve (3) • Release and disconnect wiring harness plug (4) • Unclip tank vent line (1) – Open 2x clip • Pull off hose (2) from intake manifold • Open (arrow) latch • Place tank vent valve on cylinder head cover
  1. 16. Release and disconnect the brake servo vacuum line at the joint • Open quick-release fitting (1) • Unclip from bracket
  1. 17. Remove intake pipe pressure sensor (3) • Unscrew bolt (2) – Remove bracket (1) • Pull out intake pipe pressure sensor from intake manifold – Set intake pipe pressure sensor to one side
  1. 18. Remove engine vent valve (1) • Release 2x clamp (2) and (3) • Unclip engine vent valve upward – Loosen latch with screwdriver (4)
  1. 19. Detach wiring harness • Release and disconnect 3x wiring harness plug (1)
  1. 20. Remove tank vent valve bracket (1) • Unscrew 4x bolts (2)
  1. 21. Remove engine cover bracket • Unscrew 2x nuts (1)
  1. 22. Remove intake manifold • Unscrew 7x bolts (arrows) • Unscrew 2x nuts (1)
  1. 23. Remove 4x switchover valve (1)
  2. 24. Remove cylinder 1 intake duct gasket (2)
  3. 25. Insert cylinder 1 intake duct gasket
  4. 26. Insert 4x swirl flap

Install

  1. 27. Clean sealing surfaces.
  2. 28. Install intake manifold • Use new gasket • Tighten 7x bolt 9 Nm • Tighten 2x nut 9 Nm
  3. 29. Install resonator • Insert resonator • Tighten bolt
  4. 30. Attach engine cover bracket • Tighten 2x nuts
  5. 31. Attach tank vent valve bracket • Tighten 4x bolts
  6. 32. Attach wiring harness • Connect and lock 3x wiring harness plug • Attach wiring harness • Attach cable ties
  7. 33. Install intake pipe pressure sensor • Insert bracket • Tighten bolt 10 Nm
  8. 34. Install engine vent valve • Clip engine vent valve to wiring trough • Attach 2x clamps
  9. 35. Connect the brake servo vacuum line at the joint • Connect quick release fitting • Clip into bracket
  10. 36. Attach tank vent valve • Connect and lock wiring harness plug • Clip in tank vent line – Close 2x clip • Push hose onto intake manifold
  11. 37. Raise vehicle by its full height
  12. 38. Attach alternator • Screw in 4x bolts • Tighten 2x bolt 20 Nm
  13. 39. Insert ribbed V-belt • Position ribbed V-belt • Tension the ribbed V-belt tensioner using KM-6151 in the direction of the arrow

Note. Note direction of rotation and installation position of ribbed V-belt

  1. 40. Fasten intake manifold support • Tighten bolt
  2. 41. Insert oil dipstick guide tube into oil pan • Clip 2x wiring harnesses to oil dipstick guide tube
  3. 42. Install lower engine compartment cover • Tighten 4x bolts • Install 2x body-bound rivets
  4. 43. Lower vehicle by its full height
  5. 44. Attach alternator at top • Tighten 2x bolt 20 Nm
  6. 45. Install throttle valve module • Insert gasket flange • Tighten 4x bolt 9 Nm
  7. 46. Attach oil dipstick guide tube to intake manifold • Tighten bolt
  8. 47. Install engine control unit • Tighten 3x bolt 9 Nm • Install earth cable – Tighten bolt 8 Nm • Connect and lock 4x wiring harness plug • Install wiring harness bracket – Tighten 2x nuts
  9. 48. Install air intake pipe. • Attach 2x clamps
  10. 49. Attach fuel pressure regulator (high-pressure)

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