How to Replace the Intake Manifold Gasket Opel Combo C

Remove

1. 1. Open bonnet

Important. In vehicles as of model year 04 with ESP - every time the battery is disconnected, the steering angle sensor loses its basic setting and must be recalibrated

2. 2. Disconnect battery
3. 3. Remove air cleaner housing
4. 4. Remove charge air pipe to turbocharger (1) • Release 2x clamp • Unscrew 2x bolt (arrows) • Unclip wiring harness • Detach hose

5. 5. Remove oil dipstick guide tube (1) • Withdraw oil dipstick • Remove bolt (2)

6. 6. Disconnect MAP sensor wiring harness plug • Release wiring harness plug in direction of arrow • Expose wiring harness
7. 7. Release engine vent hose • To timing case • Release clamp • Remove bracket – Remove bolt • Expose wiring harness
8. 8. Remove fuel filter housing (2) • Disconnect 4 lines (1) and (4) – Use KM-796-A • Disconnect 2 wiring harness plugs – Housing cover (3) – Housing bottom (arrow) • Close 4 fuel lines

9. 9. Loosen coolant compensation tank • Unclip coolant compensation tank
10. 10. Remove crash box • Remove nut • Remove nut
11. 11. Remove charge air pipe at intake manifold (1) • Release clamp • Unscrew 4 bolts (arrows)

12. 12. Drain coolant • Place collecting basin underneath. • Open drain bolt

13. 13. Detach 2 heating hoses • Open 2 quick-release fittings

14. 14. Loosen upper EGR valve • Loosen EGR valve metal pipe – Release clamp • Unscrew 2 bolts (1) • Detach coolant hose – Loosen clamp (2)
15. 15. Raise vehicle
16. 16. Remove lower engine compartment cover / splash protection
17. 17. Loosen oil separator (3) • Unscrew 2x bolt (arrows)
18. 18. Loosen lower EGR valve • From bracket – Remove bolt (4)
19. 19. Lower vehicle
20. 20. Attach EGR valve
21. 21. Remove intake manifold (1) • Unscrew 9 bolts
22. 22. Cleaning work • At cylinder head
23. 23. Install intake manifold • Replace gasket (3) • Tighten 9 bolts 25 Nm

Note. Note differing bolt lengths (2).

Install

24. 24. Attach EGR valve • Replace gasket • Tighten 2 bolts 22 Nm • Attach coolant hose – Fasten clamp • Attach EGR valve metal pipe – Replace gasket – Fasten clamp
25. 25. Raise vehicle
26. 26. Attach lower EGR valve • To bracket • Tighten bolt 22 Nm
27. 27. Attach oil separator • Tighten 2 bolts 15 Nm
28. 28. Install lower engine compartment cover / splash protection
29. 29. Lower vehicle
30. 30. Fit charge air pipe to intake manifold • Replace seal ring • Tighten 4 bolts • Fasten clamp 3.5 Nm
31. 31. Attach 2x heater hose • Attach 2 quick-release fittings
32. 32. Install crash box • Tighten 2 nuts 25 Nm
33. 33. Install fuel filter housing • Connect 2 wiring harness plugs • Connect 4 lines
34. 34. Fasten coolant compensation tank • Clip in coolant compensation tank
35. 35. Attach engine vent hose • To timing case • Fasten clamp • Attach bracket – Tighten bolt 9 Nm • Fasten cable harness
36. 36. Connect MAP sensor wiring harness plug • Lock wiring harness plug
37. 37. Install oil dipstick guide tube • Tighten bolt 9 Nm • Insert oil dipstick
38. 38. Install charge air pipe at turbocharger • Screw in 2x bolt • Attach 2 clamps 3.5 Nm • Attach wiring harness • Attach hose
39. 39. Install air cleaner housing
40. 40. Connect battery
41. 41. Top up coolant
42. 42. Program volatile memory
43. 43. Close bonnet