Warning! Before performing the operation, be sure to read the section "Safety precautions for maintenance and repair of the engine management system".
Note: The throttle assembly can be removed without draining the coolant. This will require two M10 bolts as plugs. Work should only be started after the engine has cooled to a temperature of no more than 40°C due to the risk of getting burned.
Recommendation: It is better to replace the gasket with a new one, even if it has no visible damage, since after reinstallation of the throttle assembly it will not provide the proper sealing of the connection.
Sequence of execution on the 1.6 DOHC engine (electronic throttle assembly)
1. Prepare the car for work (see "Preparing the car for maintenance and repair").
2. By unscrewing the expansion tank cap, we release excess pressure in the engine cooling system.
3. Disconnect the wiring harness connector from the cylinder air temperature sensor (see "Cylinder air temperature sensor for 1.4 and 1.6 DOHC engines - checking and replacing").
4. We remove the purge valve tube from one of the...
...and the second holder on the air supply pipe.
5. Using pliers, loosen the clamp and disconnect the crankcase ventilation hose.
6. Disconnect the air supply pipe from the air filter (see "Air filter - removal and installation").
7. Using a 7 mm socket wrench, loosen the clamp securing the air supply pipe to the throttle assembly.
8. Remove the air supply pipe.
9. Using pliers, loosen the clamp on the coolant supply hose to the throttle assembly and move the clamp slightly along the hose.
10. Disconnect the hose and screw an M10 bolt into it to prevent coolant from leaking out.
11. In the same way, disconnect and plug the coolant drain hose.
12. Disconnect the hose supplying crankcase gases to the throttle body space.
13. Disconnect the purge valve tube of the adsorber.
14. Using a slotted screwdriver, pry up the throttle assembly wiring harness connector retainer and remove it.
15. Disconnect the wiring harness connector from the throttle assembly.
16. Using the TORX E10 key, unscrew the four bolts securing the throttle assembly to the receiver.
17. Remove the throttle assembly by lifting it upward.
18. Remove the gasket. It must be replaced during assembly.
19. Install the parts in the reverse order. Check the level and add coolant if necessary (see "Checking the coolant level").
Sequence of execution on the 1.8 DOHC engine (throttle assembly with cable throttle drive)
1. Prepare the car for work (see "Preparing the car for maintenance and repair").
2. By unscrewing the expansion tank cap, we release excess pressure in the engine cooling system.
3. Press the lock and disconnect the wiring harness connector from the mass air flow sensor (see "1.8 DOHC Engine Mass Air Flow Sensor - Checking and Replacing").
4. Remove the wiring harness and the purge valve tube from one...
Information taken from the website [opelbook.ru]
...and the second holder on the air supply pipe.
5. Disconnect the air supply pipe from the air filter (see "Air filter - removal and installation"),
6. Using a 7 mm socket wrench, loosen the clamp securing the air supply pipe to the throttle assembly and remove the pipe.
7. Turn the throttle lever slightly to the right to loosen the cable tension and fix it (for example, with a screwdriver or a hex key).
8. Using a slotted screwdriver, move the throttle cable retainer in the direction indicated by the arrow.
9. Disconnect the cable.
10. Using a slotted screwdriver, remove the locking bracket of the cruise control drive cable (if installed).
11. Disconnect the cable.
12. Press the side clamps of the cruise control system drive cable guide...
...and remove the cable from the bracket on the throttle body.
13. Remove the throttle cable from the bracket.
14. Using pliers, loosen the clamp on the hose that supplies crankcase gases to the space in front of the throttle valve and move the clamp slightly along the hose.
15. Disconnect the hose by pulling it off the fitting.
16. Similarly, loosen the clamp and disconnect the hose supplying crankcase gases to the throttle body space.
17. Disconnect the purge valve tube of the adsorber.
18. Disconnect the two cooling system hoses and screw M10 bolts into them to prevent coolant from leaking out.
19. Press the locking device on the throttle assembly wiring harness connector and disconnect the connector from the throttle assembly.
20. Using the TORX E10 key, unscrew the four bolts securing the throttle assembly to the receiver.
21. Remove the throttle assembly by lifting it upward.
22. During assembly, replace the throttle assembly gasket.
We install the parts in the reverse order. We check the level and, if necessary, add coolant (see "Checking the coolant level").
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