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Contents Wiring diagrams Section: DOHC Petrol Engine All sections

Replace EGR Valve Opel Astra H

DOHC Petrol Engine 8 illustrations ~385 words

Remove

  1. 1. Open bonnet
  2. 2. Disconnect earth connection from battery • Slacken nut
  3. 3. Raise vehicle
  4. 4. Place collecting pan underneath.
  5. 5. Drain coolant • Place collecting pan underneath. • Attach suitable hose to drain connection (2) • Open coolant drain screw (1) – Drain coolant • Close coolant drain screw
  1. 6. Lower vehicle
  2. 7. Detach positive connection from positive terminal • Slacken nut
  3. 8. Remove battery • Unscrew bolt (1) – Remove retaining plate (2) • Remove battery
  1. 9. Remove battery support (2) • Unscrew 3x bolts (1) • Detach wiring harness – Undo cable ties
  1. 10. Remove coolant expansion tank (1) • Pull out of bracket in direction of arrow • Unclip coolant hose
  1. 11. Disconnect ignition module wiring harness plug (1)
  2. 12. Disconnect wiring harness plug of EGR valve (2)
  3. 13. Detach engine transport shackle (3) • Unscrew bolt (4)
  1. 14. Disconnect wiring harness plug for mixture regulation oxygen sensor (1)
  2. 15. Detach wiring harness bracket (2) • Unscrew 2x bolts
  1. 16. Disconnect wiring harness plugs (1) from engine control unit • Unlatch fuse (2)
  1. 17. Detach coolant hose (3) from EGR-valve • Release clamp
  2. 18. Detach exhaust gas recirculation pipe (1) from EGR-valve • Unscrew 2x bolts (2)
  3. 19. Remove EGR valve (4) • Unscrew 4x bolts

Install

  1. 20. Clean sealing surfaces.
  2. 21. Install EGR valve • Use new gaskets • Tighten 4x bolt 8 Nm
  3. 22. Attach exhaust gas recirculation pipe to EGR-valve • Tighten 2x bolt 8 Nm
  4. 23. Connect engine control unit wiring harness plugs • Latch fuse
  5. 24. Attach coolant hose to EGR-valve • Fasten clamp
  6. 25. Install wiring harness bracket • Tighten 2x bolt 60 Nm
  7. 26. Fit engine transport shackle • Tighten bolt 20 Nm
  8. 27. Connect wiring harness plug for mixture regulation oxygen sensor • Clip into bracket
  9. 28. Connect EGR valve wiring harness plug
  10. 29. Connect ignition module wiring harness plug
  11. 30. Insert coolant expansion tank into bracket • Clip coolant hose into bracket
  12. 31. Install battery holder • Tighten 3x bolts • Detach wiring harness from battery support – Attach cable ties
  13. 32. Install battery • Install battery bracket – Tighten bolt • Attach positive connection to positive terminal – Tighten nut
  14. 33. Top up coolant or ensure correct quantity is present.
  15. 34. Program volatile memories
  16. 35. Close bonnet

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