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Thread: Is there a how2 for removing the intake manifold on a 1.9cdti

  1. #1
    Regular Member Gavin2.6's Avatar
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    Vehicle : 1.9 cdti SRI & 2.6 Vec B & Mk1 Fiesta XR2

    Trim : 2 batteries. 2k RMS. 2x 15 SPL's

    Engine : CDTI 200 16V


    Default Is there a how2 for removing the intake manifold on a 1.9cdti

    Hey guys,

    Just wondering if anyone knows if there is a how2 or if someone can give me a quick guide on removing the intake manifold on my 1.9 cdti 150.

    The swirl bar has popped off and i want to refit it but also clean out all the insides of the intake, TB and egr etc.

    I know i will need a few gaskets for the intake manifold and the egr but do i need anything else. Got a full kit of tools and loads of engine cleaning stuff.

    Just never worked on a diesel vx before.

  2. #2
    Regular Member nokiaman1978's Avatar
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    just had mine done at the garage under waranty and the guy said it was a huge job took him 4 hrs.

  3. #3
    Regular Member Gavin2.6's Avatar
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    Vehicle : 1.9 cdti SRI & 2.6 Vec B & Mk1 Fiesta XR2

    Trim : 2 batteries. 2k RMS. 2x 15 SPL's

    Engine : CDTI 200 16V


    Default

    4 hours is not a huge job lol. Try changing the gearbox and alternator on a v6 vectra b. Took me and a friend the whole weekend lol. 4 hours on a nice afternoon working on the car is my idea of relaxing haha.

    Just need to know if there are any points i need to be aware off. If its just nuts and bolts then sweet i will have it off in no time but i dont know anything about the 1.9 cdti so not sure whats what.

  4. #4
    Regular Member lofty's Avatar
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    Vehicle : Vectra C Estate

    Trim : Elite

    Engine : 1.9 CDTi


    Default

    not a how2 but some info here

  5. #5
    Regular Member Gavin2.6's Avatar
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    Vehicle : 1.9 cdti SRI & 2.6 Vec B & Mk1 Fiesta XR2

    Trim : 2 batteries. 2k RMS. 2x 15 SPL's

    Engine : CDTI 200 16V


    Default

    Quote Originally Posted by lofty View Post
    not a how2 but some info here

    Cheers bud.


    So the cam cover has to come off then. As for the fuel pump. Do i remove it totally or just remove the pulley? I know there are 2 bolt holes in the pump that you can lock up with the egr nuts but why do you need to do this.

    Once i get my head around the fuel pump i think i should be go to tackle it lol.

  6. #6
    Regular Member Gavin2.6's Avatar
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    Vehicle : 1.9 cdti SRI & 2.6 Vec B & Mk1 Fiesta XR2

    Trim : 2 batteries. 2k RMS. 2x 15 SPL's

    Engine : CDTI 200 16V


    Default

    Do we know if the part number 55210201 is the new manifold or the old one ?

    Also if the old actuator moves the swirls in the full range I should not need another one. Is it only if the current actuator moves a small amount then i need it resetting ?.

    Slowly getting an understanding lol. Hate getting to know my new cars.

  7. #7
    Regular Member P3tchy's Avatar
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    Default

    The pump has to come off completly to gain access to the manifold. Don't drop the woodruff key.

    The 2 bolts are used to lock the cam belt in place, they screw into the cam cover and not the pump itself.

    55210201 is the modified manifold. You will need the actuator as well p/n 55199915


    I got mine from doram@rowcliffes.co.uk or 01823 250423 ask for David (Vauxhall dealer)

    £150.42 Inc vat and delivery
    Last edited by P3tchy; 7th April 2010 at 13:08.

  8. #8
    Regular Member the-wizard's Avatar
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    Vehicle : vectra-c

    Trim : sri

    Engine : cdti

    Year : 2004

    Mileage : 98,000

    Default

    If you do a litle looking into some of my recent threads ive just done mine!!, you will need 1 new manifold, 1 new manifold gasket, antifreeze or catch the old and filter back in after, i also used 1 new type fiat EGR semi blanking gasket, THATS IT!!, RUNS 100% FANTASTIC!!!!!!!!!!!!!!!!!!!!!.

  9. #9
    Regular Member Gavin2.6's Avatar
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    Vehicle : 1.9 cdti SRI & 2.6 Vec B & Mk1 Fiesta XR2

    Trim : 2 batteries. 2k RMS. 2x 15 SPL's

    Engine : CDTI 200 16V


    Default

    Legend.

    So the pulley remains in place along with cambelt then the pump is removed from the back.

    Sounds straight forward to me. In terms of the actuator. As long as mine spins the swirls enough then im happy to leave the original inplace. Not checked yet tho so probs stuck and will need a new one lol.

    Does the new actuator need setting up at all or is it just plug and play and im presuming the swirl bar connector rod comes with the new manifold.

    Any other things i need to remove. Fuel pipes, glow plugs etc.

  10. #10
    Regular Member Gavin2.6's Avatar
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    Trim : 2 batteries. 2k RMS. 2x 15 SPL's

    Engine : CDTI 200 16V


    Default

    Quote Originally Posted by the-wizard View Post
    If you do a litle looking into some of my recent threads ive just done mine!!, you will need 1 new manifold, 1 new manifold gasket, antifreeze or catch the old and filter back in after, i also used 1 new type fiat EGR semi blanking gasket, THATS IT!!, RUNS 100% FANTASTIC!!!!!!!!!!!!!!!!!!!!!.

    Cheers bud. I think i have a good idea on what i need to get now. Its just doing the job i was unsure about especially around the fuel pump.

    Give me a petrol v6 and i can do anything to it but im lost on the oil burners lol.

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