How to Replace the Intake Manifold Opel Vivaro A

Remove

1. 1. Disconnect battery negative lead
2. 2. Remove engine cover insulation • Remove 3x cap (1), 3x bolt

3. 3. Disconnect air intake ducting from air cleaner (1) • Release 2x clip

4. 4. Disconnect harness connector (1) from mass air flow meter and release harness (2) from air cleaner housing

5. 5. Disconnect air intake hose for turbocharger from mass air flow meter • Release clip (1)

6. 6. Release wiring harness and fuel lines from 2x clip of air cleaner housing
7. 7. Remove air cleaner housing from 2x support bracket • Remove front nut, washer (1) • Remove rear nut, washer (2)

8. 8. For vehicles up to MY2006, disconnect hose (1) from intercooler, then move to one side • Release bracket from upper front panel – Remove bolt • Release clip
9. 9. For vehicles as of MY2007, remove pipe (2) from intercooler and intake manifold • Release 2x clip

10. 10. Disconnect hose for charge pressure sensor from intake manifold • Release hose clamp (1)

11. 11. Disconnect harness connector (1) from exhaust gas recirculation (EGR) valve

12. 12. Remove breather pipe (1) from between air intake hose and engine oil separator (2) • Release 2x clip (3)

13. 13. Raise vehicle
14. 14. Remove engine and transmission undershield from vehicle
15. 15. Remove right splash shield • Release wash pipe from support clip (1) • Remove 2x bolt (2) • Remove Torx head screw (3)

16. 16. Disconnect front silencer from catalytic converter • Remove 2x nut (1)
17. 17. Remove front silencer from intermediate pipe • Remove clamp nut (2)

18. 18. Remove heat shield (1) from sub-frame • Remove 2x bolt

19. 19. Disconnect earth lead from support bracket for catalytic converter • Remove nut (1)

20. 20. Remove support bracket (1) from transmission, starter, and catalytic converter • Remove 3x bolt, nut

21. 21. Remove support bracket (1) from engine and catalytic converter • Remove nut (1), bolt (2)

22. 22. Remove catalytic converter (1) from turbocharger • Remove 4x nut (2), gasket

23. 23. Disconnect air intake hose (1) from turbocharger, then remove • Release clip (2)
24. 24. Disconnect air outlet hose (3) from turbocharger • Release clip (4)

25. 25. Release support bracket for oil pressure pipe from inlet manifold • Remove bolt (1)

26. 26. Disconnect oil supply pipe from turbocharger union adapter • Release union nut (1) • Discard sealing ring

27. 27. Remove oil supply pipe from cylinder block • Release union nut (1) – Discard sealing ring

28. 28. Disconnect oil return pipe from turbocharger • Remove 2x bolt (1), gasket

29. 29. Disconnect vacuum hose (1) from wastegate vacuum actuator • Move hose to one side

30. 30. Remove turbocharger (1) from exhaust manifold • Remove 3x nut (2), gasket

31. 31. Remove lifting eye (1) from exhaust manifold • Remove 2x bolt (2)

32. 32. Disconnect EGR pipe from exhaust manifold • Release clamp (1)

33. 33. Remove exhaust manifold (1) from engine • Remove 9x nut

34. 34. Remove intake manifold (1) and gasket from cylinder head • Discard gasket

35. 35. Remove EGR pipe from intake manifold • Remove clamp (1)

36. 36. Remove EGR valve from intake manifold • Remove 3x bolt (1) – Discard gasket

Install

37. 37. Install exhaust gas recirculation (EGR) valve to new intake manifold • Install new gasket • Install 3x bolt (1) 8 Nm

38. 38. Install EGR pipe to intake manifold • Secure clamp (1)

Important. Locking compound must be applied to the manifold stud on installation to the cylinder head to prevent coolant loss – see “Sealants, Lubricants and Locking Compounds”

39. 39. Install new gasket and intake manifold (1) to cylinder head

Important. Locking compound must be applied to the manifold stud on installation to the cylinder head to prevent coolant loss – see “Sealants, Lubricants and Locking Compounds”

40. 40. Install exhaust manifold (1) to cylinder head • Install new gasket, 9x new nut 28 Nm

41. 41. Install lifting eye (1) to exhaust manifold • Install 2x bolt (2) 20 Nm

42. 42. Connect EGR pipe to exhaust manifold • Secure clamp (1)

43. 43. Install turbocharger (1) to exhaust manifold with new gasket • Secure 3x nut (2) 26 Nm

44. 44. Connect vacuum hose (1) to wastegate vacuum actuator

45. 45. Install oil pressure pipe to cylinder block with new sealing ring • Secure union nut (1) 22 Nm

46. 46. Install oil pressure pipe to adapter union with new sealing ring • Secure union nut (1) 22 Nm

47. 47. Secure support bracket for oil pressure pipe to inlet manifold • Install bolt (1)

48. 48. Connect oil return pipe to turbocharger • Install new gasket • Install 2x bolt (1) 12 Nm

49. 49. Connect air outlet hose (3) to turbocharger • Secure clip (4)
50. 50. Install air intake hose (1), then connect to turbocharger • Secure clip (2)

51. 51. Install primary exhaust catalyst (1) with new gasket to turbocharger • Secure 4x nut (2) 24 Nm

52. 52. Install support bracket to engine and catalytic converter • Install nut (1) 30 Nm , bolt (2) 44 Nm

53. 53. Install support bracket (1) to transmission, starter, and catalytic converter • Install 3x bolt 21 Nm , nut 21 Nm

54. 54. Connect earth lead to support bracket for catalytic converter • Install nut (1) 21 Nm

55. 55. Install heat shield (1) to sub-frame • Install 2x bolt

56. 56. Install front silencer to catalytic converter with new gasket • Install 2x nut (1)
57. 57. Install front silencer to intermediate pipe • Secure clamp nut (2)

58. 58. Install right splash shield • Install and secure 2x bolt (2) 8 Nm • Install and secure Torx head screw (3) • Secure wash pipe to support clip (1)

59. 59. Install engine and transmission undershield to vehicle
60. 60. Lower vehicle
61. 61. Install breather pipe (1) to between air intake hose and engine oil separator (2) • Secure 2x clip (3)

62. 62. Connect harness connector (1) to EGR valve

63. 63. Connect hose for charge pressure sensor to intake manifold • Secure hose clamp (1)

64. 64. For vehicles up to MY2006, connect hose (1) to intercooler • Secure clip • Secure bracket to upper front panel – Install bolt
65. 65. For vehicles as of MY2007, install pipe (2) to intake manifold and intercooler • Secure 2x clip

66. 66. Install air cleaner to 2x support bracket • Install rear washer, nut (2) 8 Nm

67. 67. Secure wiring harness and fuel lines to 2x clip of air cleaner housing
68. 68. Connect air intake hose for turbocharger to mass air flow meter • Secure clip (1)

69. 69. Connect harness connector (1) to mass air flow meter and secure harness (2) to air cleaner housing

70. 70. Connect air intake ducting to air cleaner (1) • Secure 2x clip

71. 71. Install engine cover insulation • Install 3x bolt, 3x cap (1)

72. 72. Connect battery negative lead
73. 73. Remove engine immobiliser/instrument panel fuse from interior fuse box • Remove left ashtray housing from instrument panel – Release 4x clip • For vehicles up to MY2006, remove fuse (2) • For vehicles from MY2007, remove fuse (1)

74. 74. Crank engine for five seconds
75. 75. Install engine immobiliser/instrument panel fuse to interior fuse box
76. 76. Install left ashtray housing to instrument panel • Secure 4x clip
77. 77. Program all volatile memories