Replace Intake Manifold Gasket — Opel Vectra C (2002-2008)

Replace Intake Manifold Gasket Opel Vectra C

DOHC Petrol Engine 14 illustrations ~557 words

1. Open bonnet
2. Disconnect battery.
3. Raise vehicle by its entire height
4. Detach intake manifold support (3) from intake manifold • Remove bolt (2) • Pull off vacuum hose (1)
5. Disconnect wiring harness plug (5) from tank vent valve (4)

6. Lower vehicle by its entire height
7. Remove air intake hose (3) • Disconnect intake air temperature sensor wiring harness plug (2) • Release 2x clamp (1)

8. Detach tank vent valve hose (1) from tank vent valve • Release in direction of arrow

9. Expose wiring harness • Unclip wiring duct from cylinder head cover • Disconnect EGR valve (1) wiring harness plug • Unclip intake pipe pressure sensor wiring harness (2) • Detach ground cable (4) from intake manifold flange – Remove bolt (3)

10. Detach engine vent pipe (1) from cylinder head cover (3) • Release retaining clip (2)

11. Reduce fuel pressure via test connection (1) with KM-J-34730-91 (2) • Catch emerging fuel in suitable container - follow safety regulations and country-specific regulations

12. Detach fuel line (2) from fuel distribution pipe • Disconnect using KM-796-A (1) • Unclip fuel line from bracket • Close fuel line and fuel distributor pipe with KM-807

14. Detach engine control unit from intake manifold • Remove ground cable (2) – Remove bolt (1) • Unscrew 3x bolt (3)

19. Place collecting basin underneath.
20. Detach coolant hose (2) from heater core (1) • Release clamp – Unclip coolant hose

22. Detach intake manifold (2) from cylinder head • Unscrew 5 bolts (1 and 3) • Remove intake manifold upwards • Remove gasket.

23. Install intake manifold • Replace gasket • Tighten 5x bolt 8 Nm
24. Route engine wiring harness • Close clip • Attach ground cable to intake manifold flange – Tighten bolt 20 Nm • Connect EGR valve wiring harness plug • Connect wiring harness plug for intake pipe pressure sensor – Attach wiring harness
25. Attach brake servo vacuum line
26. Attach engine control unit to intake manifold • Tighten 3x bolt 8 Nm • Connect ground cable. – Tighten bolt 8 Nm • Connect 2x wiring harness plug
27. Attach 2x coolant hoses to heater core • Secure 2x clamp
28. Connect heater core wiring harness plug
29. Attach fuel line to fuel distribution pipe
30. Attach engine venting pipe • Ensure correct seating
31. Attach tank vent valve hose • Clip in line
32. Clip in wiring duct
33. Install air intake pipe. • Secure 2x clamp 3.5 Nm • Connect intake air temperature sensor wiring harness plug – Attach wiring harness
34. Raise vehicle by its entire height
35. Attach intake manifold support to intake manifold • Tighten bolt 8 Nm
36. Attach vacuum hose to intake manifold
37. Connect tank vent valve wiring harness plug
38. Lower vehicle by its entire height
39. Check coolant level, correct if necessary
40. Connect battery.
41. Program volatile memories
42. Close bonnet

Replace Intake Manifold Gasket Opel Vectra C