Removal and installation air intake tract components (Opel Astra G)

Removal

Petrol models

Astra Models

1. Loosen the clamp securing the intake air duct to the throttle body. Release the latches securing the air duct to the air cleaner housing, loosen the mounting screw/nut and remove the air cleaner assembly from the engine compartment.



2. Release the carbon adsorber purge valve from the bracket on the air cleaner housing.



On models with central injection, you will also need to disconnect the vacuum hose and warm air supply hose from the air cleaner housing.



3. In some cases, dismantling the air cleaner involves disconnecting the crankcase ventilation hoses and disconnecting the electrical wiring connectors. Sometimes the air duct is bolted to the bracket.

Zafira Models

1. Remove the engine compartment sealing strip and the cowl cover installed under the lower edge of the windshield.

2. To gain access to the air intake duct, loosen the mounting nuts/bolts and remove the upper front panel cover.



3. Remove the air cleaner and air ducts (see above).

Diesel models

Models 1.7 l

Connection diagram of the components of the air intake tract (1.7L SOHC models)





Connection diagram of the components of the air intake tract (1.7L DOHC models)



1. Loosen the clamp and remove the air intake duct from the rear of the air cleaner housing (see illustrations Connection diagram of the components of the air intake tract (1.7L SOHC models) and Connection diagram of the components of the air intake tract (1.7L DOHC models)).

2. Remove the screws (with TORX type heads) fastening the air cleaner bracket to the body and remove the air cleaner from the engine, - note that there is a protrusion at the bottom of the air cleaner housing, which during installation must be correctly aligned with the corresponding recess in the mudguard.

3. The other air ducts leading to the turbocharger, intercooler and intake manifold can be removed by loosening the corresponding clamps and unscrewing the mounting screws. Note that the air duct connecting the air cleaner housing to the intake jack has a built-in mass air flow (MAF) sensor - disconnect the wiring and remove the sensor before removing the intake duct.

2.0L models

Connection diagram of the components of the air intake tract (2.0L low-pressure turbo models)



Connection diagram of the components of the air intake tract (2.0L high-pressure turbo models)





1. On Zafira models, remove the engine bay weather strip and the cowl cover located under the lower edge of the windscreen. To gain access to the air intake duct, loosen the retaining nuts/bolts and remove the upper front panel cover.

2. On all models, disconnect the negative wire from the battery, as well as the electrical wiring from the MAF sensors and, if installed, the intake air temperature (IAT).

(Material copied from this website: OpelBook)



3. Disconnect the crankcase ventilation hose from the intake air duct, loosen the mounting clamp and remove the air duct assembly together with the air mass meter sensor and remove it from under the hood.

4. Release the clamps, remove the air cleaner housing cover and remove the filter element - try to remember the installation position of the components. Unscrew the mounting bolt and remove the air cleaner housing, disconnecting it from the air intake duct.

5. On models with low-pressure turbocharging (x20DTL/Y20DTL engines) (see illustration Connection diagram of the components of the air intake tract (2.0L low-pressure turbo models)) To remove the air ducts leading to the turbocharger and intake manifold, first unscrew the mounting screws and remove the plastic protective cover from the engine. Release the air duct fastening clamp connecting the metal sleeve to the pipeline. Unscrew the bolts securing the tube to the cylinder head cover, loosen the mounting clamp and disconnect the sleeve from the turbocharger. Remove the sleeve and air duct assembly from the top of the engine and remove the sealing ring installed between the sleeve and the compressor.



6. On models with high-pressure turbocharging (y2ODTH engine) (see illustration Connection diagram of the components of the air intake tract (2.0L high-pressure turbo models)) loosen the clamps/bolts and remove the air ducts connecting the intercooler and the intake manifold, as well as the turbocharger sleeve. To remove the metal sleeve, disconnect the air duct from it, then loosen the clamp securing the sleeve to the turbocharger. Unscrew the mounting bolt and remove the sleeve from the engine, - pay attention to the sealing ring installed.

Installation

All models

Installation is carried out in the reverse order of dismantling the components.

1. Make sure that the air duct clamps are tightened securely 2.0L diesel engines don't forget to replace the sealing ring at the junction of the metal sleeve with the turbocharger (if the sleeve was disconnected).