[andyl]

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.

 

[zdravo]

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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[Eimhear]

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.

 

[zdravo]

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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[Eimhear]

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?

 

[zdravo]

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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[zdravo]

Put some pictures of dirt and cleaning progress?

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[Eimhear]

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?

 

[Eimhear]

Could it be a spare earth cable on the right hand side?

 

[zdravo]

1st picture
It clips down under together with similar vacuum tube.

2nd picture
I believe it goes under the ECU
Later I will call man who I sold my H and will take a picture. He is close to me.

3rd picture
In the hole goes MAP sensor
Taka a look on the pictures (from the russian forum)

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[Eimhear]

Thanks Zdravo,

On all of the pictures I have seen the left earth cable attaches to the top left hand side of ecu (as shown in this picture) maybe I disconnected it
when looking at the egr valve?

 

[Eimhear]

Or perhaps the earth is for the map sensor.

I sent you a message Zdravo saying that I read through your astra ru removal guide. The google translation is not perfect, however at one point you mentioned using sealant. Should I have used sealant at any point when dismantling manifold or reassembly for example?

 

[zdravo]

Hmmm you can use it, but it will be OK without it

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[Eimhear]

Everything is on. Just one last connector that I can't find anywhere that it could go. Can anyone put me out of my misery. The green one.

 

[zdravo]

That one dont go anywhere on petrol cars.
Use zip tie to festen iz to firewall

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[zdravo]

Look at the photo
Its behind the ECU

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[zdravo]

Here is a bit "tuned" picture, to see better

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[Eimhear]

Thanks zdravo, you're a legend.

Car is not starting, any ideas. Everything is connected. Video on link.

http://sendvid.com/guw5702w

 

[andyl]

Is everything plugged in, check the coil pack plug.

 

[zdravo]

Check fuel line, blue pipe with part green connector.
Check all the injectors, I accidentaly unplugged one by miskate when was doing the same on my car. And of course chwck coil pack, its on battery side, big connector, must click

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[Eimhear]

Cheers Andy, I'll check now. Checked the even, and these codes are coming up.
014100
111306