9.1. Upper part of the intake manifold
Removal
1. Disconnect the battery, starting with the negative cable.
2. Remove the injectors, high pressure accumulator, high pressure accumulator protection.
3. Disconnect the wiring connectors from the glow plugs.
4. Unhook the harness guard 1 (figure 4.46).
Figure 4.46. Unhook the wire harness guard 1.
5. Move the wire harness to the side.
6. Remove the exhaust gas recirculation pipe 2 with seals, bracket 3 between the air distributor and the power steering pump (figure 4.47). Loosen clamp 4 of the damper/intake manifold connecting pipe.
Figure 4.47. Remove exhaust gas recirculation pipe 2 with seals, bracket 3 between the air distributor and the power steering pump.
7. Install the engine lifting tool Mot. 1367.
8. Remove the support, unscrew the bolts securing the upper part of the intake manifold and remove the upper part of the manifold (figure 4.48).
Figure 4.48. The order of unscrewing the bolts securing the upper part of the intake manifold.
Installation
9. Replace the upper intake manifold gaskets with new ones (figure 4.49).
Figure 4.49. Replace the upper intake manifold gaskets with new ones.
The source is on the online website (OpelBook.ru)
10. Apply Rhodorseal 5661 to the camshaft bearing cap mounting surfaces (figure 4.50a, b).
Figure 4.50a. Timing belt side.
Figure 4.50b. Flywheel side.
11. Install the rocker arm cover/intake manifold. Tighten the upper intake manifold mounting bolts to 12 Nm in the order shown in Figure 4.51.
Figure 4.51. Tightening order of the bolts securing the upper part of the intake manifold.
12. Further installation is carried out in the reverse order of removal.
9.2. Lower part of the intake manifold
Removal
1. Remove the upper intake manifold and air distributor.
2. Unscrew the bolts securing the lower part of the intake manifold and remove it (figure 4.52).
Figure 4.52. Unscrew the bolts securing the lower part of the intake manifold and remove it.
Installation
3. Replace the lower intake manifold gaskets with new ones.
4. Install the lower intake manifold and install the bolts, but do not tighten them.
5. Tighten the lower intake manifold mounting bolts to 12 Nm (figure 4.53).
Figure 4.53. Tighten the lower intake manifold mounting bolts.
Visitor comments