Replace Intake Manifold - Petrol Engine Opel Corsa D

Warning: Exiting fuel - observe safety regulations and national legislation.

Note. The relevant fuel pressure is relieved only very slowly once the ignition is switched off. Before opening this pressurised part of the fuel system, therefore, the fuel pressure must be reduced via the test connection by means of a pressure gauge KM-J-34730-91 . Catch emerging fuel in a suitable container.

Remove

1. 1. Open bonnet
2. 2. Disconnect battery • Detach ground connection from ground terminal – Undo nut
3. 3. Remove bulkhead closing part
4. 4. Detach engine control unit wiring harness • Disconnect 2x wiring harness plugs (3), (4) • Detach earth connection – Unscrew bolt (5) • Unclip wiring harness (2x)
5. 5. Detach engine control wiring harness • Detach wiring harness plug (2) from engine control unit • Remove wiring harness plug (1) from tank vent valve

6. 6. Unclip fuel supply and return line • Open clip
7. 7. Remove fuel supply line (2) • Undo quick-release fitting with KM-796-A • Seal fuel supply line
8. 8. Detach fuel return line (1) • Undo quick-release fitting with KM-796-A • Seal fuel supply line

9. 9. Pull tank vent line from tank vent valve
10. 10. Detach wiring harness for oxygen sensor mixture control (1) from bracket • Disconnect wiring harness plug (2) • Unclip wiring harness (2x)

11. 11. Disconnect wiring harness plug for camshaft sensor (1)

12. 12. Remove wiring duct (1) • pull up

13. 13. Detach earth cable from cylinder head • Unscrew bolt (1)
14. 14. Disconnect ignition module wiring harness plug (2)

15. 15. Detach throttle valve module wiring harness • Disconnect wiring harness plug (2) • Unclip wiring harness (1)

16. 16. Detach wiring harness for coolant temperature sensor • Disconnect wiring harness connector. • Unclip holder from coolant line
17. 17. Detach wiring harness (1) from engine control unit • Unscrew 2x bolts (2)

18. 18. Remove engine control unit (2) • Unscrew 2x bolts (1)

19. 19. Detach wiring harness for fuel injection • Remove wiring duct (1) • Disconnect 4x injection valve wiring harness plugs (2)

20. 20. Detach wiring harness bracket from intake manifold • Unscrew 3x bolts
21. 21. Disconnect wiring harness plug for atmospheric pressure sensor
22. 22. Lay wiring harness for engine control aside
23. 23. Detach cylinder head cover vent line (4) • Undo quick-release fitting (1) • Unclip line • Remove quick-release fitting (2) from cylinder head cover – Detach locking bracket (3)

24. 24. Remove engine control unit bracket (1) • Unscrew 4x bolt (2)

Note. Note different bolt lengths.

25. 25. Raise vehicle by full height
26. 26. Detach wiring harness for vacuum control solenoid valve (1) • Disconnect wiring harness plug (2) • Unclip wiring harness (4)
27. 27. Detach vacuum line for recirculating air control (3) • Pull line from solenoid valve • Unclip line

28. 28. Detach intake manifold at bottom • Unscrew 2x nuts (1) • Unscrew 2x bolts (2)

29. 29. Lower vehicle by its full height
30. 30. Detach charge air hose (1) from throttle valve housing (3) • Release clamp (2)

31. 31. Detach tank vent valve (1) • Undo quick-release fitting (3) • Remove bracket – Unscrew bolt (2)

32. 32. Detach intake manifold at top • Unscrew nut • Unscrew 3x bolts • Lay intake manifold aside
33. 33. Detach engine transport shackle (1) • Unscrew bolt

34. 34. Remove intake manifold
35. 35. Transfer intake manifold attachments

Install

36. 36. Insert intake manifold
37. 37. Fit engine transport shackle • Tighten bolt 25 Nm
38. 38. Attach intake manifold at top • Tighten nut 20 Nm • Tighten 3x bolt 20 Nm
39. 39. Install tank vent valve • Connect quick-release fitting • Attach bracket – Tighten bolt
40. 40. Attach charge air hose to throttle module • Tighten clamp 3.5 Nm
41. 41. Raise vehicle by full height
42. 42. Attach intake manifold at bottom • Tighten 2x nut 20 Nm • Tighten 2x bolt 20 Nm
43. 43. Attach vacuum line for recirculating air control • Push line onto solenoid valve • Clip in line
44. 44. Attach wiring harness for vacuum control solenoid valve • Fix wiring harness plug • Attach wiring harness
45. 45. Lower vehicle by its full height
46. 46. Install engine control unit bracket • Tighten 4x bolt 8 Nm

Note. Note different bolt lengths.

47. 47. Attach cylinder head cover vent line • Attach engine vent hose to cylinder head cover – Attach locking bracket • Connect quick-release fitting • Clip in line
48. 48. Connect atmospheric pressure sensor wiring harness plug
49. 49. Attach wiring harness to intake manifold • Tighten 3x bolts
50. 50. Attach wiring harness for fuel injection • Connect 4 injector wiring harness plugs • Attach cable duct
51. 51. Install engine control unit • Tighten 2x bolt 8 Nm
52. 52. Attach wiring harness to engine control unit • Tighten 2x bolt 8 Nm
53. 53. Attach wiring harness for coolant temperature sensor • Fix wiring harness plug • Clip holder to coolant line
54. 54. Attach throttle valve module wiring harness • Fix wiring harness plug • Attach wiring harness
55. 55. Connect ignition module wiring harness
56. 56. Attach earth cable to cylinder head • Tighten bolt
57. 57. Attach cable duct
58. 58. Connect wiring harness plug, camshaft sensor
59. 59. Attach wiring harness for oxygen sensor mixture control to bracket • Clip in 2x wiring harnesses • Fix wiring harness plug
60. 60. Attach tank vent hose to tank vent valve
61. 61. Attach fuel return line • Connect quick-release fitting
62. 62. Attach fuel supply line • Connect quick-release fitting
63. 63. Clip in fuel supply and return line
64. 64. Attach engine control wiring harness • Attach wiring harness plug to engine control unit • Attach wiring harness plug to tank vent valve
65. 65. Attach engine control unit wiring harness • Attach earth connection – Tighten bolt • Connect 2x wiring harness plug • Clip in 2x wiring harnesses
66. 66. Install bulkhead closing part
67. 67. Connect battery
68. 68. Program volatile memories
69. 69. Close bonnet