Engine with single overhead camshaft
Removing
1. Disconnect the negative cable from the battery.
2. Loosen the clamp screws securing the main air line to the throttle body and air flow meter, then remove the main air line.
3. Loosen the clamp screw, disconnect the idle speed control hose from the throttle body.
4. Disconnect the breather hose from the camshaft cover to the throttle body.
5. Disconnect the coolant hoses from the throttle body. Seal the open ends of the hoses to prevent further loss of coolant.
6. Disconnect the electrical wiring from the throttle position sensor.
7. Unfasten the fixing bracket, then disconnect the ball end of the throttle cable from the lever.
8. Pull the throttle cable O-ring off the bracket on the intake manifold, then disconnect the throttle return spring from the bracket (see illustration).
9. Make a final check that all relevant hoses and wires have been disconnected and released from the throttle body.
10. Unscrew the four fixing nuts, remove the throttle body from the intake manifold (see illustrations). Access to the lower nuts is difficult and therefore the two fuel supply hoses may have to be moved to the side. Be careful not to deform the hoses.
11. Remove the gasket.
12. If required, the throttle position sensor can be removed from the throttle body, see illustration. Chapter 23.
Installation
13. Install in reverse order, paying attention to the following.
14. Where applicable, install the throttle position sensor as described in Chapter 23.
15. Install the throttle body using a new gasket (see illustration).
16. Make sure all hoses and wires are properly connected.
17. Check the coolant level and, if necessary, top up as described in Section 3.
18. Check and, if necessary, adjust the throttle cable play as described in Chapter 19.
Engine with two overhead camshafts
Removing
19. Disconnect the negative cable from the battery.
20. Loosen the clamp screw securing the main air line to the left side of the airflow meter.
21. Using a socket wrench, remove the four bolts securing the heater block to the throttle body. Lift the heater block off the throttle body, disconnect the hose from the base of the block, then remove the heater block.
22. Disconnect the wiring from the throttle position sensor.
23. Unscrew the fixing nut, remove the fuel supply hose bracket on the left side of the throttle body (see illustration).
24. Pull the cable from the throttle lever.
25. Disconnect the breather hose from the throttle body.
26. Disconnect the vacuum pipe from the top of the fuel pressure regulator.
27. Make a final check that all relevant hoses, pipes and wires have been disconnected and released from the throttle body.
28. Turn off four fixing nuts, remove the throttle case from an inlet collector. Remove the gasket.
29. If required, the throttle position sensor can be removed from the throttle body, if necessary, follow Chapter 31.
30. Never try to adjust the throttle linkage. If the linkage is defective, contact your Opel dealer.
Installation
31. Install in reverse order, paying attention to the following.
32. Where applicable, install the throttle position sensor as described in Chapter 23.
33. Install the throttle body using a new gasket.
34. Make sure that all hoses, pipes and wires are properly connected.
35. Finally, check and, if necessary, adjust the throttle cable play as described in Chapter 19.
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