How to Replace the Intake Manifold, Lower Opel Vivaro A

Remove

1. 1. Release coolant pipe (1) from 2x integral clip (2)

2. 2. Release resonance box assembly, then move to one side • Release retaining strap (2) from support bracket • Release hose (1) from cover for air cleaner housing

3. 3. Remove cover (2) from air cleaner housing • Remove 2x screw (1)

4. 4. Remove air cleaner housing (1) from intake manifold • Remove 2x bolt

5. 5. Disconnect harness connector (1) from throttle valve housing

6. 6. Release breather pipe (1) from throttle valve assembly (2), then move to one side

7. 7. Remove throttle valve housing (1) from cylinder head • Remove 3x bolt

8. 8. Disconnect harness connector (1) from vacuum sensor (2)

9. 9. Remove brake servo hose (1) from intake manifold (2) • Release clip

10. 10. Disconnect 4x harness connector (1) from 4x ignition coil • Release harness from 4x integral clip

11. 11. Disconnect harness connector (1) from air temperature sensor (2)

12. 12. Remove upper intake manifold from lower intake manifold • Remove 7x bolt, 5x seal ring

13. 13. Disconnect harness connector (1) from sensor for power steering pressure

14. 14. Remove cover (1) from fuel rail • Remove 2x nut

15. 15. Release fuel rail (1) from lower intake manifold, then move to one side • Remove 2x bolt (2)

16. 16. Release harness from intake manifold • Remove bolt (1), bracket

17. 17. Release power steering reservoir from front panel, then move to one side • Release integral clip (1)

18. 18. Remove lower intake manifold (1) from cylinder head • Remove 12x bolt • Remove intake manifold gasket (2)

Install

19. 19. Install new gasket for lower intake manifold to cylinder head • Clean mating face of cylinder head
20. 20. Loosely install new lower intake manifold to cylinder head • Loosely install 12x bolt • Ensure 2x lug on intake manifold (arrowed) align with 2x lug on cylinder head (arrowed)

21. 21. Secure lower intake manifold • Tighten 10x bolt 21 Nm in sequence shown • Tighten 2x bolt 21 Nm

Note. Components removed from illustration for clarity.

22. 22. Install fuel rail (1) to lower intake manifold • Install 4x new seal, 2x bolt (2) 9 Nm

23. 23. Install harness to lower intake manifold • Install bracket, bolt (1)

24. 24. Install cover (1) to fuel rail • Install 2x nut 25 Nm

Note. Secure harness with 2x integral clip on fuel rail cover.

25. 25. Install harness connector (1) to sensor for power steering pressure

26. 26. Install power steering reservoir to front panel • Secure integral clip (1)

27. 27. Install upper intake manifold to lower intake manifold • Install 5x new seal ring • Tighten 7x bolt ( 9 Nm ) in sequence shown

28. 28. Install 4x harness connector (1) to 4x ignition coil • Secure harness to 4x integral clip on upper intake manifold

29. 29. Connect brake servo hose (1) to intake manifold (2) • Secure clip

30. 30. Install harness connector (1) to air temperature sensor (2)

31. 31. Install harness connector (1) to vacuum sensor (2)

32. 32. Install throttle valve housing (1) to cylinder head • Install 3x bolt ( 13 Nm )

33. 33. Install breather pipe (1) to throttle valve assembly (2)

34. 34. Install harness connector (1) to throttle valve housing

35. 35. Install air cleaner housing (1) to intake manifold • Install 2x bolt ( 9 Nm )

36. 36. Install cover (2) to air cleaner housing • Install 2x screw (1)

37. 37. Install resonance box assembly • Install hose (1) to air cleaner housing • Secure strap (2) to support bracket

38. 38. Secure coolant pipe (1) to 2x integral clip (2)