There might be a support strut attached to the manifold that attaches low down on the block.

Follow the vacuum pipe along and you may find there is a joint under the engine cover.

 

I can't remember if the z16xep has the support bracket underneath like the z16xe does. I'll have a look on tis tomorrow. If it does then it's accessed from under the car.

 

Thanks, please let me know if you need anymore photos. Has anyone got any thoughts on the the p020... codes?

 

The vacuum pipe connector on the inlet manifold has a small black 'button' on the side, push this in and the pipe will pull off,.... there is definitely a support bracket under the manifold, T30 Torx, which will be holding the upper manifold in place, remove it and the upper manifold can be removed.

 

The vacuum pipe connector on the inlet manifold has a small black 'button' on the side, push this in and the pipe will pull off,.... there is definitely a support bracket under the manifold, T30 Torx, which will be holding the upper manifold in place, remove it and the upper manifold can be removed.

Thanks Andy, I've taken the inlet manifold off now. I'm at the last hurdle. I think I've removed 7 or bolts but can't work out how to remove the final section. I'm guessing I have to remove the pipe but just can't work out (due to poor visibility and access) how it actually comes off. Any tips?

 

There are 2 T30 torx bolts on the joint of the pipe at the egr valve, i normally remove these and then the pipe will come off with the lower section of manifold, the bolts in question can just be seen in your 1st picture above.

 

Cheers Andy, I presume that the two are on the right hand side of the pipe/first picture. I'll give it a go tomorrow. Are you familiar with how i remove the brackets to access the egr channels?

 

Once you remove the lower section of manifold just turn it over, remove the gasket if its stuck to the manifold and you will see the channels carved into the manifold, the first picture also shows the egr pipe still attached to the manifold and shows the end where the 2 T30 have been removed,....

 

Had to down tools for a few weeks but got back to this yesterday.

I have removed the 2 torx screws for the egr pipe and almost any screw or bolt that could possible hold this thing in place. I just can't get it to budge. Is there a mechanism with the metal bar that runs along side with the black support brackets?

 

Actually it seems that mechanism is not related to removing it. Still at a complete loss. A few more pictures from different angles.

On another note, there is a connector with pink markings close to the injectors which I think I might have loosened. Worried that I might have damaged it. Does anyone know what it is?

 

On the bottom picture. Is there a torx bolt you missed towards the right of the picture

 

I can;t see it, which one are you referring to?

 

Bottom pic between cylinder 1 and 2.

 

View attachment 78347

 

Yes that's the one

 

Thanks, there are actually two. The head has a tiny hole on the head of it, I can;t find anything to fit it. It's tiny.

 

If you have new gaskets look at the bolt holes to confirm you have removed all of them

 

Those torx that you are referring are not the issues. A previous poster posed this. I think it slides out from that.

https://www.vauxhallownersnetwork.c...ixture-p0170-obd2-code-egr-vacuum-maf-throttle-body-fuel-pressure.387088/page-3

moved.

 

Well if all the bolts are out you need to use a mallet to remove the manifold. It's probably just stuck from many years of not being moved.

 

The lower section in your picture is held on by 2 nuts and 8 bolts so if thats what you've removed then give it a tap with a mallet as mark suggests.

 

In my country there is an saying: "If cannot be fixed, take a sledge hammer and fix it."
Just kidding of course.

Well, as I can see and as I can remember because I done the same and alone in the late afternoon (poor visibility) and it was at least 2 years ago, maybe more.
You done all right, its simply unscrew all the screws you can see and 2-3 you cannot but you can touch them by fingers.
You dont need to touch TP system itself (lever and motor which push and pull it) to avoid any other problems.
As Z16XEP engine has pretty high working temperature (you can see on few my YT videos, search "zdravo user"), its about 105 celsius mostly.
So that part you have to remove by bit of force, hammer is OK, but use a piece of wood between hammer and metal parts.
Hit it from one side and the other, from up and down if you anyway can reach it from floor.

I will post a link to one russian forum (use google translate as its in cyrillic) where man made great tutorial step by step with all tools needed and all notices about what you must be careful etc:

http://astraclub.ru/threads/109328-...ятие-ремонт-доработка-впускного-коллектора-и-планки-твинпорта-z16xep.-Фотоотчет

I hope this can help you.
Wish you good luck

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Marks152, Andy and Zdravo, thank you all very much. Your help has been greatly appreciated.
I was able to get it off and now getting down to cleaning it.

Few questions.
1. Brake cleaner is a slightly better option than carb cleaner?
2. Finish off with cleaning with some degreaser?
3. The gasket seems in good nick, I don't have a new one. What would be the best way to clean it before sealing it back up again?
4. Should I clean the egr valve, if so, any pointers?

Thanks again.

 

No problem, if I can help with my knowledge and experiance I will help.
Glad to hear that you removed the part.
Now to give you answers to your questions

1. You can use brake cleaner, engine degreeser, carb cleaner, gas (petrol), nitro thinner (for colors).
Oh yes, put some protective gloves on because this things eat skin.
2. Just wipe it down well and let it evaporate.
3. If gasket is OK, just put it on again.
4. You can clean it, but you will see when you open it, its made a bit wired, all is sealed and there is nothing much to clean.
But check the metal tube the one with ribbs on it, it can be clogged.

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No problem, if I can help with my knowledge and experiance I will help.
Glad to hear that you removed the part.
Now to give you answers to your questions

1. You can use brake cleaner, engine degreeser, carb cleaner, gas (petrol), nitro thinner (for colors).
Oh yes, put some protective gloves on because this things eat skin.
2. Just wipe it down well and let it evaporate.
3. If gasket is OK, just put it on again.
4. You can clean it, but you will see when you open it, its made a bit wired, all is sealed and there is nothing much to clean.
But check the metal tube the one with ribbs on it, it can be clogged.

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Thanks Zdravo,

In regards to the gasket, do I need to use sealant?
In regards to the egr, should i remove battery and tray to gain access?

 

Dont have to use sealant.
And about EGR, you dont have to take out battery or its holder.
Just unplug + and -

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Put some pictures of dirt and cleaning progress?

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Hi, I have some time today for putting it all back together. I have the manifold re attached, it's been so long since I started this process there are a few things I have forgotten or unsure about.

1. This thin black wire that I think feeds to the back of the manifold. What is this? it was loose, but it seems to fit nicely in back of manifold (black rubber slot). It doesn't seem that firmly in place. Should I stick some tape around it to be sure?

2. I can see on the vauxhall instructions that the earth cable (left hand side) goes o the top left of the ecu, where does this cable go (on the right hand side beside ecu bracket).

3.
There is a large hole on top f the manifold whee the ecu is positioned, before reattaching the ecu, I was curious if I a missing something with this hole?