Intake manifold — removal and installation (Opel Vectra B)

Removal and installation

SOCH 1.6L Engines

1. Relieve the pressure in the fuel system and remove the ground cable from the battery.

2. Remove the accessory drive belt and drain the coolant from the cooling system.

3. Remove the air cleaner housing and air intake duct.

4. Disconnect the hoses from the throttle body housing, remove the screws and remove the housing from the top of the throttle body.

5. Disconnect the electrical connectors from the throttle potentiometer, idle speed control engine, fuel injector, coolant temperature sensor, and exhaust gas re-combustion system valve.

6. Unscrew the generator mounting bolt on the right side of the manifold.

7. Unscrew the union nuts and remove the fuel hoses from the throttle body.

8. Remove the mounting bracket and separate the accelerator body from the ball joint. Remove the accelerator cable housing from the bracket.

9. Disconnect the vacuum hose and crankcase ventilation hose from the throttle body.

10. Loosen the clamp and remove the coolant hose from the rear of the manifold.

11. Unscrew the union nut and remove the brake booster vacuum hose from the manifold.

12. Check that all hoses are disconnected and unscrew the manifold mounting nuts.

13. Remove the intake manifold.

14. Installation is carried out in the reverse order of removal, and it is necessary to install a new intake manifold gasket.

DOCH 1.6L Engines



15. Remove the bolts securing the plastic wiring harness bracket to the rear of the intake manifold.



16. Disconnect the electrical connectors from the oxygen sensors, ignition module, purge valve and other connectors on the left front side of the manifold. Unscrew the nut securing the ground bus to the cylinder head and manifold.



17. Remove the fuel vapor purge valve (indicated by the arrow) from the left front end of the manifold and disconnect the valve hose from the manifold.

18. Unscrew the union nut and remove the manifold brake booster vacuum hose. Disconnect the vacuum hose and engine crankcase ventilation hose from the manifold.



19. Disconnect the vacuum hose from the pressure regulator.

20. Loosen the clamps and remove the hose connecting the throttle body to the upper section of the manifold.





21. Unscrew the bolts securing the upper section of the manifold (indicated by arrows). Remove the upper section of the manifold and the gasket.

22. To remove the lower section of the intake manifold, first relieve the pressure in the fuel system.

23. Unscrew the union nuts and disconnect the fuel hoses from the fuel line.

24. Loosen the lower mounting bracket and remove the connecting part from the throttle body.

25. Disconnect the electrical connector from the crankshaft sensor and remove it from the manifold.

26. Remove the accelerator body from the throttle body and disconnect the electrical connectors from the idle speed control motor and throttle potentiometer.

27. Unscrew the bolts and remove the throttle body.

28. Remove the bolts from the throttle body bracket protrusions and remove the bracket from the manifold.

29. Remove the auxiliary drive belt and unscrew the bolt securing the generator to the right side of the manifold.

30. Unscrew the nuts and remove the lower section of the manifold.

31. Installation is performed in the reverse order of removal. In this case, it is necessary to install a new intake manifold gasket, fill the cooling system with coolant and adjust the accelerator torso.



Engines 1.8 and 2.0 l

32. Remove the auxiliary drive belt.

33. Relieve the pressure in the fuel system and remove the ground cable from the battery.

34. Disconnect the electrical connectors from the engine air temperature sensor and air flow meter.

35. Loosen the clamp and remove the crankcase ventilation hose from the rear of the cylinder head cover.

36. Loosen the clamps and remove the air intake duct from the air cleaner and throttle body.

37. Remove the retaining bracket and separate the accelerator cable from the throttle cam ball joint.

38. Remove the bolts and remove the accelerator cable bracket from the throttle body.

39. Clamp the coolant supply hoses to the rear of the throttle body, loosen the clamps and remove both hoses.

40. Remove the electrical connectors from the throttle potentiometer and idle speed control ball motor.

41. Mark the location and disconnect the hoses from the throttle body, then remove the nuts and remove the throttle body from the intake manifold.

42. Unscrew the union nuts and remove the fuel hoses from the fuel line.

43. Disconnect the electrical connectors from the ignition module, purge valve, manifold valve, coolant temperature sensor, EGR valve and oxygen sensor.

44. Release the retaining clips and remove the cover with electrical wires from the rear of the cylinder head. Disconnect the electrical connectors of the crankshaft sensor and the knock sensor.

45. Unscrew the union nut and remove the manifold brake booster vacuum hose. Disconnect the manifold vacuum hose and engine crankcase ventilation hose. Disconnect the vacuum hose from the pressure regulator



46. Remove the upper generator mounting bolt from the right side of the intake manifold.

47. Unscrew the bolts and remove the manifold base support bracket.

48. Unscrew the nuts and remove the manifold from the engine.

Installation

Installation is carried out in the reverse order of removal.