Intake manifold (Opel Frontera B)

Removal

Disconnect the connector from the engine air temperature sensor located on the air intake tube.

Disconnect the resonator hose from the air intake tube.

Remove the air intake tube and air filter housing cover as an assembly.

Remove the lower engine compartment protection.

Drain the coolant from the engine cooling system.

Disconnect the cooling system hoses from the throttle body.

Disconnect the connector from the throttle position potentiometer located on the throttle body.

Disconnect the connector from the idle air control valve located on the throttle body.

Remove the hollow bolts and disconnect the fuel lines from the fuel rail.



Remove the generator (see the relevant chapter).

Disconnect the connectors from the fuel injectors.

Disconnect the hose from the fuel pressure regulator.

Remove the fuel rail from the intake manifold.

Disconnect the accelerator cable from the throttle body.

Remove the support bracket (1) and the generator mounting bracket (2).



Disconnect the coolant hose from the intake manifold.



Disconnect the support (1) from the intake manifold and cylinder block.



Remove the ignition coil bracket mounting bolts.

Remove the exhaust manifold (2) from the cylinder head.

Installation

Clean the mating surfaces of the cylinder head and intake manifold.

Install the intake manifold with a new gasket and secure with new nuts, tightening them to a torque of 22 N·m.

Screw in the ignition coil bracket mounting bolts.

Install the intake manifold support (1) and secure with bolts, tightening them to a torque of 22 Nm.



Connect the cooling system hoses to the throttle body.



Install the support bracket (1) and the generator mounting bracket (2) and tighten the long bolts to 35 Nm and the short bolts to 20 Nm.



Install the fuel injectors into the intake manifold and the fuel rail onto the intake manifold. Secure the fuel rail with bolts and tighten them to a torque of 8 Nm.

Connect the hose to the fuel pressure regulator.

Connect the fuel lines to the fuel rail and secure them with the hollow bolts, tightening them to a torque of 25 N·m.

Connect the connectors to the fuel injectors.

Connect the connector to the idle air control valve located on the throttle body.

Connect the connector to the throttle position potentiometer located on the throttle body.

Connect the cooling system hoses to the throttle body.

Install the air intake tube (1) and air filter housing cover (2) together (see the relevant chapter). Tighten the air intake pipe bracket mounting nut to 16 N·m.



Connect the resonator hose to the air intake tube (1).



Connect the connector to the engine air temperature sensor located on the air intake tube.

Connect the accelerator cable to the throttle assembly, then adjust the accelerator cable play so that it is within 5.7-6.3 mm.

Install the lower engine compartment protection.

Fill the engine cooling system with coolant and check the cooling system for leaks (see the relevant chapter).