Intake manifold (single point injection Multec) — removal and installation (Opel Astra F)

Removal

Procedure for carrying out work: as indicated in the section "Multec Single Point Injection System Components", subsection "Injection device, removal", first nine points.

Release the clamp, then disconnect the swivel joint at the end of the cable from the throttle lever. Remove the rubber cable grommet from the bracket on the intake manifold and set the cable aside.

Remove the nut and disconnect the brake booster vacuum hose from the intake manifold (fig. 4.116).



On 1.6L engines, disconnect the hose from the EGR valve.

Disconnect the wire from the temperature gauge sensor.

If necessary, disconnect the wire from the coolant temperature sensor.

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Disconnect the halves of the plug connector located at the bracket on the left side of the intake manifold. Separate the connector from the bracket.

Partially drain the coolant from the system, then disconnect the coolant hose from the rear of the intake manifold. Coolant may leak, so clamp the hose to reduce coolant loss.

Remove the top nut and bolt securing the generator, noting the location of the ground wire on the bolt (fig. 4.117).





Make sure all hoses, tubes and wires are disconnected.

Unscrew the nuts and remove the manifold from the cylinder head. Remove the gasket.

It is also possible to remove several manifold studs from the cylinder head after removing the manifold nuts. In this case, the studs should be screwed back into the cylinder head after removing the manifold using the nuts.

If desired, auxiliary components can be removed from the manifold, in accordance with the contents of the relevant sections of this chapter.

Installation

Installation is carried out in the reverse order of removal, taking into account the following.

Where required, install auxiliary components on the manifold.

If the alternator mounting bracket is removed from the manifold, install it before installing the manifold as access will be limited after the manifold is installed.

Install the manifold with a new gasket and tighten the nuts to the required torque

Check that all hoses, tubes and wires are connected correctly.

After completing the work, check and, if necessary, top up the coolant to the required level.

Check and, if necessary, adjust the throttle cable free play.