Replace Exhaust Gas Recirculation Valve Opel Astra H

Warning: When working on the Common Rail system, wait for one minute after switching off the engine. The system reduces the pressure automatically.

Important: When working on the fuel system, cleanliness is vital as even very small particles of dirt can lead to faults in engine operation or in the fuel system. Seal open fuel connections with suitable sealing plugs 1) . Sealing plugs must only be used once.

Remove

1. 1. Remove cowl trim
2. 2. Disconnect battery • Detach ground connection from ground terminal – Slacken nut
3. 3. Remove battery • Detach positive connection (3) from positive terminal • Remove bracket 1) • Unscrew bolt (2)

4. 4. Remove battery support. • Remove pre-heating system control unit (4) • Remove wiring harness plug (3) • Detach coolant hose • Unclip clip (5) • Detach wiring harness – Detach 2x cable ties (1) • Unscrew 3x bolts (2)

5. 5. Disconnect wiring harness plug, fuel preheating (2)
6. 6. Disconnect wiring harness plug, water level display
7. 7. Unclip wiring harness from crash box (1) • Unclip 4x from bracket
8. 8. Disconnect 2x fuel lines (3) and (4) from fuel filter • Disconnect 2x quick-release fitting with KM-796-A • Seal with closure plug KM-6015 or KM-6320 • Unclip 2x from bracket

Note. Lift fuel filter housing out of crash box

9. 9. Take fuel filter housing out of crash box (1)

10. 10. Remove crash box (1) • Unscrew 2x nut (3) • Take out reinforcing plate (2)

11. 11. Raise vehicle by its full height
12. 12. Place collecting basin underneath.
13. 13. Drain coolant • Open drain bolt on radiator (1) • Drain coolant • Close drain bolt

14. 14. Lower vehicle by its full height
15. 15. Remove charge air hose from intercooler to connection port, throttle valve housing (1) • Undo 2 clamps

16. 16. Remove air cleaner housing (4) with air intake hose • Disconnect mass air flow sensor wiring harness (2) • Unclip 2x vacuum line (5) • Detach air intake hose from air intake pipe – Release clamp (3) • Detach air cleaner housing from wheel housing – Unscrew bolt (1) • Detach water drain hose (6) from air cleaner housing – Release clamp

17. 17. Remove engine cover (1)
18. 18. Detach coolant expansion tank • Take out retaining clips • Set coolant expansion tank aside
19. 19. Remove throttle valve housing (1) • Disconnect wiring harness connector. • Unclip wiring harness • Detach vacuum line (2) from solenoid valve • Unscrew 3 bolts

20. 20. Detach 2x coolant hose for heating (1) from coolant hose • Undo 2 clamps

21. 21. Remove coolant hose (1) from thermostat housing • Release clamp • Remove from bracket]

22. 22. Remove exhaust gas recirculation valve (1) • Detach metal tube for exhaust gas recirculation from intake manifold – Release clamp (2) • Detach bracket for exhaust gas recirculation valve from cylinder block – Unscrew bolt (3) • Unscrew 2x bolts • Remove valve and exhaust gas recirculation cooler assembly

23. 23. Detach exhaust gas recirculation valve (1) from exhaust gas recirculation cooler (2) • Detach coolant pipe from exhaust gas recirculation valve – Unscrew bolt • Unscrew 3 bolts

Install

Important. Charge air hoses and connection ports must be free from oil and grease.

24. 24. Clean sealing surfaces.
25. 25. Attach exhaust gas recirculation valve to exhaust gas recirculation cooler • Replace seal • Tighten 3x bolt 25 Nm – Attach coolant pipe to exhaust gas recirculation valve – Tighten bolt
26. 26. Install exhaust gas recirculation valve • Use new seal • Tighten 2x bolt 22 Nm • Attach metal tube for exhaust gas recirculation to intake manifold – Tighten clamp • Attach bracket for exhaust gas recirculation valve to cylinder block – Tighten bolt • Connect wiring harness plug
27. 27. Attach coolant hose to thermostat housing. • Tighten clamp • Mount in bracket
28. 28. Attach 2x coolant hose for heating to coolant pipe • Tighten 2x clamps
29. 29. Attach throttle valve housing • Tighten 3x bolts • Attach vacuum line to solenoid valve • Connect wiring harness plug – Clip into bracket
30. 30. Attach coolant compensation tank • Attach retaining clips
31. 31. Install engine cover • Clip in 4x
32. 32. Install air cleaner housing with air intake hose • Attach air cleaner housing to wheelhouse – Tighten bolt • Attach air intake hose to air intake pipe – Tighten clamp 3.5 Nm • Connect mass air flow meter wiring harness plug – Clip on bracket
33. 33. Install charge air hose, intercooler to connection port, throttle valve housing • Tighten 2x clamp 3.5 Nm
34. 34. Install crash box • Insert reinforcing plate • Tighten 2x nuts 25 Nm
35. 35. Insert fuel filter housing in crash box
36. 36. Attach 2x fuel lines to fuel filter • Connect 2x quick-release fittings • Clip 2x in bracket
37. 37. Attach wiring harness to crash box
38. 38. Connect wiring harness, water level display
39. 39. Connect wiring harness plug, fuel preheating
40. 40. Install battery holder • Tighten 3x bolts • Attach pre-glow system control unit • Attach wiring harness plug • Clip in coolant hose • Attach wiring harness – Connect 2x cable ties
41. 41. Install battery • Install bracket – Tighten fastening bolt • Attach positive connection to positive terminal – Tighten nut
42. 42. Connect battery • Attach ground connection to ground terminal – Tighten nut
43. 43. Install cowl trim
44. 44. Top up coolant or ensure correct quantity is present.
45. 45. Programme transient memory
46. 46. Close bonnet

1

) Protective caps are available in the Opel parts catalogue under catalogue number: 45 06 154 / part number: 9201697