Intake manifold — removal and installation (Opel Vectra B)

1.7L engines

1. Remove the ground cable from the battery.

2. Loosen the clamps securing the air intake duct to the air cleaner housing and remove it from the engine.

3. Loosen the clamps and unscrew the bolts securing the turbocharger air intake duct and remove it from the cylinder head.

4. Remove the bolts securing the heat exchanger air intake pipe to the cylinder head manifold and disconnect the pipe from the manifold. Loosen the clamp securing the other side of the pipe and remove the pipe from the engine.

5. Loosen the clamp and remove the fuel pump vacuum hose from the rear of the manifold.

6. Remove the screws and remove the wiring harness bracket from the manifold.

7. Evenly and gradually loosen the bolts and nuts securing the intake manifold to the cylinder head.

8. Remove the intake manifold together with the gasket.

9. Check that the mating surfaces of the intake manifold and cylinder head are clean and dry and install a new gasket on the manifold struts.

Install the manifold and, working in a diagonal sequence, tighten the manifold mounting nuts and bolts evenly and gradually to the specified torque.

Install the wiring harness bracket.

Connect the fuel pump vacuum hose to the manifold.

Install the heat exchanger air intake pipe using a new gasket. Tighten the pipe mounting bolts and connect the inlet hose.

Install the intake ports and connect the battery.

2.0L engines

1. Remove the ground cable from the battery. Unscrew the screws and remove the plastic cover from the top of the cylinder head.



2. On low pressure turbo engines, remove the metal and flexible pipe connecting the exhaust manifold to the turbocharger, and on high pressure turbo engines, remove the pipe connecting the manifold to the heat exchanger.



3. Unscrew the screws (indicated by arrows) securing the wiring harness bracket to the top of the intake manifold.



4. Disconnect the electrical connectors from the coolant sensors, high pressure fuel pump, crankshaft sensor and manifold overpressure sensor and move the wiring harness bracket away from the manifold.



5. Remove the vacuum line from the EGR valve located on the top of the manifold.





6. Unscrew the connecting nut securing the fuel supply pipe to the injector.



7. Unscrew the connecting nut securing the fuel supply pipe to the fuel pump.



8. Remove the fuel supply lines from the fuel pump to the fuel injectors.



9. Loosen the bolts gradually and evenly and remove the upper part of the manifold.





10. To remove the lower section of the intake manifold, disconnect the vacuum pipe from the diaphragm valve.



11. Unscrew the bolt securing the electrical connector bracket.



12. Evenly and gradually unscrew the mounting nuts and remove the lower section of the manifold with the gasket from the cylinder head.





13. Install the lower section of the intake manifold together with the gasket onto the cylinder head and secure with nuts, tightening them in a diagonal sequence.

14. Connect the diaphragm valve vacuum hose and install the bracket with the electrical connector.

15. Install the upper section of the intake manifold together with the gasket and secure with bolts.

16. Install the wiring harness bracket to the top of the manifold and secure with bolts. Connect the electrical connectors and connect the vacuum line to the EGR valve.

17. Install the air intake duct and install the plastic cover onto the cylinder head.

18. Connect the battery, start the engine and check the fuel system for leaks.