Replace Intake Manifold Gasket Opel Vectra C

Remove

Important. When working on the fuel system maintaining cleanliness is essential, otherwise small particles of dirt may result in engine operating faults or fuel system faults. Open fuel connections must be sealed off with suitable sealing plugs from the kit (45 06 154). Sealing plugs are designed for single use only.

1. 1. Remove toothed belt • Remove toothed belt
2. 2. Drain coolant Warning: Only open coolant compensation tank once engine has cooled down • Unscrew coolant compensation tank closure cap • Place collecting basin underneath. • Open drain bolt

3. 3. Detach wiring harness • Unscrew 4x bolt (1) • Disconnect 4x injector wiring harness plugs (2)

4. 4. Detach fuel pressure controller (1) of return system • Unscrew 2x bolt • Detach 4x hose KM-796-A

5. 5. Remove pressure line (1) • Unscrew 2x union nut

Important. Counterhold with open-ended wrench when releasing the lock nut on the high pressure diesel fuel pump.

6. 6. Remove 4x pressure lines • Release 8x lock nuts (1)

Important. When releasing the lock nut, counterhold at injector with open-ended wrench

7. 7. Remove pressure reservoir (1) • Unscrew 2x nut (arrows) • Disconnect 2x wiring harness plug

8. 8. Detach fuel line high pressure pump (1)
9. 9. Disconnect wiring harness plug, high pressure pump (2)

10. 10. Release high pressure pump wheel • Use KM-6347 (1) and KM-956-1 (2) • Attach KM-6347 and KM-956-1 – Tighten 2x fixing bolts • Release nut of high pressure pump wheel (4) • Detach KM-6347 , KM-956-1 . – Release 2x fixing bolts.

Note. Release fixing bolts (3) of KM-6347 , insert KM-6347 in high pressure pump wheel in conjunction with KM-956-1 . Grooves of KM-6347 must engage in the high pressure pump wheel (arrows). Ensure it is seated correctly. Turn KM-6347 with KM-956-1 in the direction of the arrow.

11. 11. Pull off high pressure pump wheel • Detach nut • Use EN-46790 (1) • 2nd mechanic required

12. 12. Remove high pressure pump • Unscrew 3x nut (1)

13. 13. Detach vacuum line • Unscrew 2x bolt (arrows) • Detach 2x vacuum hose

14. 14. Disconnect 2x wiring harness plug • from exhaust gas recirculation, charge pressure sensor
15. 15. Detach exhaust recirculation valve • Unscrew 3x bolt – Exhaust gas recirculation valve (3) • Unscrew 2x bolt – Metal pipe, exhaust gas recirculation, on throttle value module (1) • Unscrew 2x bolt – Cooler, exhaust gas recirculation (4) • Remove 2x gasket, engine transport shackle (2)

16. 16. Remove connection hose (3) on throttle valve module • Release 2x clamp
17. 17. Detach throttle valve module (1) • Unscrew 3x bolt (2) • Disconnect wiring harness plug • Remove gasket.

18. 18. Release coolant recirculation valve • Remove bolt • Detach 3x hoses
19. 19. Detach 4x wiring harness plug, sheathed glow plug (arrows)

20. 20. Remove vacuum reservoir with retaining plate (1) • Unscrew 3 bolts (arrows)

Note. If fitted

21. 21. Detach 3x coolant hose • Release 3x clamp – 2x cooler, exhaust gas recirculation – Thermostat housing
22. 22. Detach 2x coolant line • On the starter – Unscrew 2x bolt • Release bolt, nut
23. 23. Remove cooler, exhaust gas recirculation • Unscrew bolt, nut (arrows) • Release clamp

24. 24. Release alternator bracket • Unscrew 2x bolt (1)

Note. Note that the bolts are different lengths!

25. 25. Remove alternator • Remove bolt (1)

26. 26. Detach high pressure pump bracket (1) • Unscrew 6x bolt

27. 27. Remove intake manifold (1) • Unscrew 9x nut • Detach gasket

Install

28. 28. Cleaning work
29. 29. Install intake manifold • Replace gasket • Attach gasket • Tighten 9x nuts 25 Nm
30. 30. Attach high pressure pump bracket • Tighten 6x bolt 25 Nm
31. 31. Install alternator • Screw in bolt
32. 32. Fasten alternator bracket • Tighten 2x bolt 25 Nm

Note. Note that the bolts are different lengths!

33. 33. Fasten alternator • Tighten bolt 60 Nm
34. 34. Install cooler, exhaust recirculation • Tighten bolt 25 Nm • Tighten clamp
35. 35. Attach 2x coolant line • On the starter – Tighten 2x bolt • Tighten bolt, nut
36. 36. Attach 3x coolant hose • Secure 3x clamp
37. 37. Attach vacuum reservoir with retaining plate • Tighten 3x bolt 25 Nm

Note. If fitted

38. 38. Attach 4x wiring harness plug, sheathed glow plug
39. 39. Install throttle valve module • Replace gasket • Connect wiring harness plug • Tighten 3x bolt
40. 40. Attach exhaust recirculation valve • Replace 2x gasket, position engine transport shackle • Tighten 3x bolt 25 Nm – Exhaust gas recirculation valve • Tighten 2x bolt 25 Nm – Metal pipe, exhaust gas recirculation, on throttle valve module • Tighten 2x bolt 25 Nm – Cooler, exhaust gas recirculation
41. 41. Connect 2x wiring harness plug • on exhaust gas recirculation, charge pressure sensor
42. 42. Fasten coolant return line • Tighten bolt • Attach 2x hose
43. 43. Attach vacuum line • Attach 2x vacuum hose • Tighten 2x bolts 9 Nm
44. 44. Install connection hose on throttle valve module • Tighten 2x clamp 3,5 Nm
45. 45. Install high pressure pump • Tighten 3x nuts 25 Nm
46. 46. Attach high pressure pump wheel • Tighten nut 50 Nm • 2nd mechanic required • Counterhold with KM-6347 and KM-956-1
47. 47. Connect wiring harness plug of high-pressure pump
48. 48. Attach fuel line, high pressure pump
49. 49. Install pressure reservoir • Connect 2x wiring harness plug • Tighten 2x nut 25 Nm
50. 50. Install 4x pressure lines • Renew 4x pressure lines • Tighten 4x lock nut (M14) 30 Nm • Tighten 4x union nuts (M12) 22 Nm

Important. Pressure lines may only be installed once. When fastening the lock nuts, counterhold at the injector with an open-ended wrench.

51. 51. Install pressure line • Tighten union nut (M14) 30 Nm • Tighten lock nut (M12) 22 Nm

Important. Pressure line may only be fitted once. When fixing the lock nut to the high pressure diesel fuel pump, counterhold with open-ended wrench.

52. 52. Attach fuel pressure controller of return system • Attach 4x hoses – Replace leaked oil hose on damping case • Tighten 2x bolt
53. 53. Attach wiring harness • Tighten 4x bolt • Connect 4x injector wiring harness plugs
54. 54. Top up coolant • Observe specified coolant quantity

Note. Top up and bleed cooling system – see operation "Cooling System, Top up and Bleed".

55. 55. Check fuel system for leaks • Start engine.

Important. Wear protective goggles and gloves.

Note. Check fuel system for escaping fuel.

56. 56. Install toothed belt • Install toothed belt