Exhaust Gas Recirculation Valve Replacement Opel Agila B

Remove

1. 1. Remove 2x wiper arm from vehicle • Remove 2x cap, 2x nut
2. 2. Remove battery from vehicle • Disconnect battery negative lead (3) – Release nut • Disconnect battery positive lead – Release cover (1) – Release nut (2) • Remove bracket from battery tray – Remove bolt (4)

3. 3. Disconnect hose (5) from mass air flow (MAF) meter (6) • Release clip
4. 4. Disconnect harness connector (3) from (MAF) meter
5. 5. Disconnect hose (1) from air cleaner assembly • Release from clip
6. 6. Remove air cleaner assembly (2) from vehicle • Remove 2x bolt (4) • Release 2x locator from battery tray – Pull up

7. 7. Release glow plug control unit (1) from battery tray, then move to one side • Release from 2x clip

8. 8. Remove battery tray (1) from vehicle • Remove 4x bolt

9. 9. Disconnect 2x harness connector from ECM • Pull out 2x lock (1), then release 2x clip (2)

10. 10. For left drive vehicle, release harness from ECM • Disconnect harness connector (3) from harness • Remove bracket (2) from ECM – Remove bolt (1)

11. 11. For left drive vehicle, remove bracket (2), earth lead (3) and ECM (1) from lower cowl panel • Remove 3x bolt

12. 12. For right drive vehicle, remove ECM (1) and bracket (3) from cowl panel grille • Remove 4x bolt
13. 13. For right drive vehicle, remove ECM and earth lead (2) from bracket • Remove 4x bolt

14. 14. Remove cowl grille panel (1) from vehicle • Remove 7x clip, then release 14x clip, 3x locator – Use suitable tool
15. 15. Remove windshield wiper motor (3) from vehicle • Disconnect harness connector • Remove 3x bolt (2)
16. 16. Release harness from lower cowl panel • Release clip

17. 17. Remove lower cowl panel (2) from vehicle • Remove 6x nut (1)

18. 18. Remove cap from radiator
19. 19. Raise vehicle

Important. Observe the relevant environmental regulations when disposing of used coolant.

20. 20. Drain cooling system • Place collecting container below • Open radiator drain plug (1) • Allow coolant to drain into collecting container • Close radiator drain plug • Remove collecting container
21. 21. Lower vehicle

22. 22. Remove heater outlet pipe with turbo pipe assembly from EGR cooler (2) • Release 5x clip, 3x bolt
23. 23. Release intake manifold elbow from intake manifold • Remove 3x bolt, clip
24. 24. Disconnect harness connector from EGR valve (1)
25. 25. Disconnect 2x hose from EGR cooler • Release 2x clip
26. 26. Remove EGR valve and cooler from cylinder head • Remove gasket • Remove 2x bolt • Release 2x clip
27. 27. Clean mating surfaces of cylinder head and EGR valve

28. 28. Release coolant hose bracket (4) from EGR valve assembly • Remove bolt (3)
29. 29. Remove EGR cooler from EGR valve assembly • Remove 3x bolt (2) • Remove gasket (1)

Install

30. 30. Install EGR cooler to new EGR valve assembly • Install new gasket (1) • Install 3x bolt (2) 28 Nm
31. 31. Secure coolant hose bracket (4) to EGR valve assembly • Install bolt (3) 28 Nm

32. 32. Install new EGR valve and cooler to cylinder head • Install new gasket • Install 2x bolt 28 Nm • Secure 2x clip
33. 33. Connect 2x hose to EGR cooler • Secure 2x clip
34. 34. Connect harness connector to EGR valve (1)
35. 35. Secure intake manifold elbow to intake manifold • Install 3x bolt, clip
36. 36. Install heater outlet pipe with turbo pipe assembly to EGR cooler (2) • Install 3x bolt, secure 5x clip

37. 37. Install lower cowl panel (2) to vehicle • Install 6x nut (1)

38. 38. Secure harness to lower cowl panel • Secure clip
39. 39. Install windshield wiper motor (3) to vehicle • Install 3x bolt (2) 8 Nm • Connect harness connector
40. 40. Install cowl grille panel (1) to vehicle • Secure 3x locator, 14x clip, then install 7x clip

41. 41. For right drive vehicle, install new ECM and earth lead (2) to bracket • Install 4x bolt 10 Nm
42. 42. For right drive vehicle, install ECM (1) and bracket (3) to cowl panel grille • Install 4x bolt 10 Nm

43. 43. For left drive vehicle, install ECM (1), bracket (2) and earth lead (3) to lower cowl panel • Install 3x bolt 10 Nm

44. 44. For left drive vehicle, secure harness to ECM • Install bracket (2) to ECM – Install bolt (1) 10 Nm • Connect harness connector (3) to harness

45. 45. Connect 2x harness connector to ECM • Push in 2x lock (1), then secure 2x clip (2)

46. 46. Install battery tray (1) to vehicle • Install 4x bolt

47. 47. Secure glow plug control unit (1) to battery tray • Secure 2x clip

48. 48. Install air cleaner assembly (2) to vehicle • Secure 2x locator to battery tray – Push on • Install 2x bolt (4)
49. 49. Connect hose (1) to air cleaner assembly • Secure clip
50. 50. Connect harness connector (3) to (MAF) meter
51. 51. Connect hose (5) to mass air flow (MAF) meter (6) • Secure clip

52. 52. Install bracket to battery tray • Install bolt (4) • Connect battery positive lead – Secure nut (2) – Secure cover (1)
53. 53. Install battery to vehicle • Connect battery negative lead (3) – Secure nut 11 Nm

Important. Only use coolant approved by the manufacturer and ensure a concentration of 50% water and 50% anti-freeze.

54. 54. Fill coolant expansion tank with new coolant fluid up to maximum level mark
55. 55. Install cap to coolant expansion tank
56. 56. Install 2x wiper arm to vehicle • Adjust and align wiper arm • Install 2x nut 18 Nm • Install 2x cap
57. 57. Program all volatile memories – see operation “Program Volatile Memories”