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Thread: Inlet Manifold / Swirl Valve DIY Replacement

  1. #1
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    Vehicle : Vectra Estate

    Trim : Elite

    Engine : 1.9 CDTi Z19DTH

    Year : 2004

    Mileage : 139000

    Default Inlet Manifold / Swirl Valve DIY Replacement

    Hi Everyone,

    I have decided to replace my own inlet manifold as it is leaking around the flaps and the link rod is on its last legs. Since the car is at 84K miles so I shall be replacing the cam belt at the same time.
    I have made a shopping list of parts using the TIS 2000 instructions, if anyone is aware of other bits that would also need replacing please let me know. If anyone has had this job carried out at the dealers and has the invoice showing the all the parts required, I'd really appreciate a copy, I really don’t want to get half way through re-assembly have to stop because I forgot a gasket. My fax no is 01202 812401 or email me, thanks.

    Parts list-
    Intake manifold
    Intake manifold to cylinder head gasket
    Intake manifold nuts x 9
    EGR valve Gaskets x2
    High pressure pump fuel line
    Leaked oil hose on damping case (I assume this gets brittle)
    Toothed belt
    Toothed belt tensioner (is this necessary)
    Sealant
    Sealing plugs from kit 45 06 154

    Are there any non-reusable clamps that I have missed?

    The swirl actuator appears to still be functioning (it appears to move freely); do I have to replace this and its linkage as well? Is the old actuator compatible with the new inlet manifold? If I replace the actuator do I need to have it adapted by Tech 2 or similar?

    Does anyone have any thoughts on the water pump needing replacing at the same time as the cam belt?

    Tooling wise I have fabricated a pulley locking tool for the high pressure pump (as per the recommendation in the Haynes manual) and shall use a harmonic balance puller for the pulley. I have identified a timing locking tool from Franklin part FTA559 to set the cam shaft timing. Hopefully that will cover the required Special Service Tools.

    Anything else?
    Thanks in advance
    Jon Page

  2. #2
    Regular Member DeanF's Avatar
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    Default

    I believe the actuator is the same, but to replace it after the job if it were to fail is the removal of the inlet again !!! is it worth the risk ??

    You need to add the actuator arm onto your list as these are plastic with cups either end which become brittle & break upon removal.

    All the best

    Dean

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    Default

    I have a brand new inlet manifold and motor if you want to buy?

  4. #4
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    Vehicle : Vectra Estate

    Trim : Elite

    Engine : 1.9 CDTi Z19DTH

    Year : 2004

    Mileage : 139000

    Default Thanks

    Hi North,

    Thanks for the offer of the parts, I would want to use parts from Vx so that I have the 12 month warranty. It's a big job if they fail.

    Jon

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    Admin plasma's Avatar
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    Vehicle : Vectra

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    Engine : 150

    Year : 05

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    Default

    I've got a complete breakdown of all parts and part numbers when they did mine if u want me to list it?

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    Year : 2004

    Mileage : 139000

    Default

    Hi Plasma,

    Thats just what the doctor ordered! I would be very greatful if you could list the parts.

    Many thanks
    Jon

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    Regular Member baztheman's Avatar
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    Hi jon if you are replacing the cam belt there is a kit to go with it (tentioner change is good practice) and while your there you should consider changing the water pump.

    thats what i did on my 1.9 cdti

    ps did you know that i was chatting with a vauxhall fitter and they have renamed the swirl valve to a @rsehole valve at bristol st newcastle (i take it is as reliable as the duel mass fly wheels,gearboxes.....ect ) LOL... baz

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    Sent jon a full list of all parts changed/required as per dealer job under warranty would do

  9. #9
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    Year : 2004

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    Default

    Thanks Dean,
    Time to spend some money!

    Jon

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    Vehicle : Vectra Estate

    Trim : Elite

    Engine : 1.9 CDTi Z19DTH

    Year : 2004

    Mileage : 139000

    Default Z19DTH - PIERBURG service info SI009 -Inlet manifold

    Everyone with a 1.9 CDTi 150BHP,

    I have just found this document published by Pierburg, it is very informative regarding the inlet manifold well worth a look if you have this engine.

    http://www.ms-motor-service.com/xima...093_en_web.pdf

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