vocky
Staff
this is a basic guide to fitting the 2.4 inlet manifold
firstly, disconnect the battery
remove the fuel pressure regulator vacuum pipe and fittings
disconnect the cam cover oil vapour pipe
disconnect the air temp sensor and remove the intake pipe (air filter to the throttle body)
disconnect the tb wiring plug then remove the throttle body
disconnect the map sensor and remove the sensor (sits behind the tb)
remove the egr pipe and blank off the egr valve
disconnect the fuel vent pipe
disconnect the servo vacuum hose
remove the dip stick and tube
remove the ecu
remove the bolts holding the inlet manifold to the head, remove the two nuts and also remove the two studs (Tx socket)
the engine wiring loom is held onto the inlet manifold from underneath, disconnect the clips from the inlet manifold (a pain to get at)
remove the inlet manifold from the car (a quick thanx to Jamee for nicking his pic
)
next remove the big red cable from the alternator - 13mm nut
then remove plastic cover from the back of the alternator, two 13mm nuts and a screw
refit the 13mm nut to the outer 8mm stud and reattach the big red cable with it's original nut
then fit the new suppressor to the other 8mm stud and the other end to the screw
fit the new gaskets to the 2.4 inlet manifold and fit the manifold to the engine
[ignore the adaptor plate, I required this for my 2.0sc tb, the 58mm + 2.4 tb do not require this]
then replace the servo pipe one way valve with one from an astra or corsa (90373359) and fit a new piece of servo hose from the valve to the inlet manifold (make sure it's servo hose not water hose)
make a bracket for the dipstick and refit it
connect up the fuel pressure regulator to the new servo one way valve with a new piece of tubing (vectra's have loads of this pipe under the bonnet, use a scrappy)
refit the map sensor and connect the plug
refit the 58mm throttle body using the 2.2 gasket (not the 2.4 gasket) and ensure it seals the tb or fit the new 2.4 tb and connect the plug
make a couple of brackets and refit the ecu, make sure the earth cable is bolted tight direct to the ecu
reconnect the fuel vent pipe
refit the intake pipe for a 58mm tb or fit a new 75mm intake for the new 2.4 tb
reconnect the air temp sensor
refit the cam cover oil vapour pipe (58mm tb) or fit an oil catch tank
make a final check and then reconnect the battery
remember to let the ecu settle by only driving with moderate revs for 25 miles or so
firstly, disconnect the battery
remove the fuel pressure regulator vacuum pipe and fittings
disconnect the cam cover oil vapour pipe
disconnect the air temp sensor and remove the intake pipe (air filter to the throttle body)
disconnect the tb wiring plug then remove the throttle body
disconnect the map sensor and remove the sensor (sits behind the tb)
remove the egr pipe and blank off the egr valve
disconnect the fuel vent pipe
disconnect the servo vacuum hose
remove the dip stick and tube
remove the ecu
remove the bolts holding the inlet manifold to the head, remove the two nuts and also remove the two studs (Tx socket)
the engine wiring loom is held onto the inlet manifold from underneath, disconnect the clips from the inlet manifold (a pain to get at)
remove the inlet manifold from the car (a quick thanx to Jamee for nicking his pic
next remove the big red cable from the alternator - 13mm nut
then remove plastic cover from the back of the alternator, two 13mm nuts and a screw
refit the 13mm nut to the outer 8mm stud and reattach the big red cable with it's original nut
then fit the new suppressor to the other 8mm stud and the other end to the screw
fit the new gaskets to the 2.4 inlet manifold and fit the manifold to the engine
[ignore the adaptor plate, I required this for my 2.0sc tb, the 58mm + 2.4 tb do not require this]
then replace the servo pipe one way valve with one from an astra or corsa (90373359) and fit a new piece of servo hose from the valve to the inlet manifold (make sure it's servo hose not water hose)
make a bracket for the dipstick and refit it
connect up the fuel pressure regulator to the new servo one way valve with a new piece of tubing (vectra's have loads of this pipe under the bonnet, use a scrappy)
refit the map sensor and connect the plug
refit the 58mm throttle body using the 2.2 gasket (not the 2.4 gasket) and ensure it seals the tb or fit the new 2.4 tb and connect the plug
make a couple of brackets and refit the ecu, make sure the earth cable is bolted tight direct to the ecu
reconnect the fuel vent pipe
refit the intake pipe for a 58mm tb or fit a new 75mm intake for the new 2.4 tb
reconnect the air temp sensor
refit the cam cover oil vapour pipe (58mm tb) or fit an oil catch tank
make a final check and then reconnect the battery
remember to let the ecu settle by only driving with moderate revs for 25 miles or so