How to Replace the Intake Manifold (Petrol Engine) Opel Meriva A

Remove

1. 1. Open bonnet
2. 2. Disconnect battery • Detach ground clamp from ground terminal – Undo nut
3. 3. Remove air intake pipe with air intake hose • Release 2x clamp • Unscrew bolt
4. 4. Detach engine control unit wiring harness • Disconnect 2x wiring harness plugs (3), (4) • Detach ground connection – Remove bolt (5) • Unclip 2x wiring harnesses
5. 5. Detach engine control wiring harness • Detach wiring harness plug (2) of engine control unit • Detach wiring harness plug (1) from tank vent valve

6. 6. Unclip fuel feed and return lines • Open clip
7. 7. Detach fuel supply line (2) • Disconnect quick-release fitting with KM-796-A • Seal off fuel pipe
8. 8. Detach fuel return line (1) • Disconnect quick-release fitting with KM-796-A • Seal off fuel pipe

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

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

12. 12. Detach wiring trough (1) • Pull upwards

13. 13. Detach ground cable from cylinder head • Unscrew bolt (1)
14. 14. Disconnect wiring harness plug for ignition module (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 bracket from coolant pipe
17. 17. Detach wiring harness bracket (1) from engine control unit • Unscrew 2x bolt (2)

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

19. 19. Detach fuel injection system wiring harness • Detach wiring trough (1) • Disconnect 4x wiring harness plugs of injectors (2)

20. 20. Detach wiring harness bracket from intake manifold • Unscrew 3x bolt
21. 21. Disconnect wiring harness plug of atmospheric pressure sensor
22. 22. Place engine control wiring harness to one side
23. 23. Detach vent line for cylinder head cover (4) • Disconnect quick-release fitting (1) • Unclip line • Detach quick-release fitting (2) for cylinder head cover – Detach retaining clamp (3)

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

Note. Note differing bolt lengths

25. 25. Raise vehicle all the way
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, air recirculation control (3) • Detach line from solenoid valve • Unclip line

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

29. 29. Lower vehicle all the way
30. 30. Detach charge air hose (1) from throttle valve housing (3) • Release clamp (2)

31. 31. Remove tank vent valve (1) • Disconnect quick-release fitting (3) • Remove holder – Unscrew bolt (2)

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

34. 34. Remove intake manifold

Install

35. 35. Insert intake manifold
36. 36. Attach engine transport shackle • Tighten bolt 25 Nm
37. 37. Attach intake manifold at the top • Tighten nut 20 Nm • Tighten 3x bolts 20 Nm
38. 38. Install tank vent valve • Connect quick release fitting • Connect holder – Tighten bolt
39. 39. Attach charge air hose to throttle valve module • Tighten clamp 3.5 Nm
40. 40. Raise vehicle all the way
41. 41. Attach intake manifold at the bottom • Tighten 2x nut 20 Nm • Tighten 2x bolts 20 Nm
42. 42. Attach vacuum line, air recirculation control • Push line onto solenoid valve • Clip in line
43. 43. Attach wiring harness for vacuum control solenoid valve • Connect wiring harness plug • Clip wiring harness into position
44. 44. Lower vehicle all the way
45. 45. Install engine control unit bracket • Tighten 4 bolts 8 Nm

Note. Note differing bolt lengths

46. 46. Attach vent line for cylinder head cover • Attach quick-release fitting to cylinder head cover – Attach retaining clamp • Connect quick release fitting • Clip in line
47. 47. Connect wiring harness plug of atmospheric pressure sensor
48. 48. Attach wiring harness bracket to intake manifold • Tighten 3 bolts
49. 49. Attach fuel injection system wiring harness • Connect 4x injector wiring harness plugs • Attach wiring trough
50. 50. Install engine control unit • Tighten 2x bolt 8 Nm
51. 51. Attach wiring harness bracket to engine control unit • Tighten 2x bolt 8 Nm
52. 52. Attach wiring harness for coolant temperature sensor • Connect wiring harness plug • Clip bracket to coolant pipe
53. 53. Attach throttle valve module wiring harness • Connect wiring harness plug • Clip wiring harness into position
54. 54. Connect ignition module wiring harness plug
55. 55. Attach ground cable to cylinder head • Tighten bolt
56. 56. Attach wiring trough
57. 57. Connect wiring harness plug of camshaft sensor
58. 58. Attach wiring harness for mixture control oxygen sensor to bracket • Clip in 2x wiring harnesses • Connect wiring harness plug
59. 59. Attach tank vent line to tank vent valve
60. 60. Attach fuel return line • Connect quick release fitting
61. 61. Attach fuel supply line • Connect quick release fitting
62. 62. Attach fuel feed and return lines
63. 63. Attach engine control wiring harness • Attach wiring harness plug to engine control unit • Attach wiring harness plug to tank vent valve
64. 64. Attach engine control unit wiring harness • Attach ground connection – Tighten bolt • Connect 2 wiring harness plugs • Clip in 2x wiring harnesses
65. 65. Install air intake pipe with air intake hose • Tighten 2x bolts 3.5 Nm • Tighten bolt
66. 66. Connect battery
67. 67. Program volatile memory
68. 68. Close bonnet