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Removing and Installing Throttle Valve Module Opel Astra H

Fuel Injection Systems 6 illustrations ~527 words

Remove

  1. 1. Disconnect ground cable from battery
  2. 2. Remove air intake manifold • Unscrew bolt (2)
  3. 3. Remove engine vent hose from cylinder head cover • Release clamp (4)
  4. 4. Detach air intake pipe from air intake hose • Release clamp (1) – Release clamp
  5. 5. Detach air intake pipe from turbocharger • Release clamp (3)

Note. Seal air intake pipe at turbocharger

  1. 6. Remove air intake pipe
  1. 7. Remove charge air hose (2) • Undo 2x clamps (1) • Remove charge air hose
  1. 8. Detach charge air deflection pipe • Unscrew 4x bolts (1) • Unclip vacuum line from bracket (2) • Remove charge air deflection pipe
  1. 9. Drain coolant • Open drain bolt on radiator (1) • Collect coolant • Close drain bolt
  1. 10. Close coolant drain screw
  2. 11. Detach throttle body coolant line (2) from throttle body
  3. 12. Disconnect throttle body wiring harness plug (1)
  4. 13. Remove throttle body

Install

  1. 14. Replace throttle body seal rings and attach throttle body coolant lines to throttle body
  2. 15. Install charge air deflection pipe • Screw in 4x bolt 9 Nm • Clip vacuum line into bracket
  3. 16. Fit charge air hose • Insert charge air hose • Fasten 2x clamp 3.5 Nm
  4. 17. Connect ground cable to battery
  5. 18. Always use antifreeze 19 40 650 / 9194431 (red) and ensure that the concentration is 50% water and 50% antifreeze. The antifreeze does not just protect the entire cooling system from freezing, but also protects all coolant-flushed parts from rust-corrosion/calcium deposits. It is therefore important to add antifreeze, even in tropical countries.
  6. 19. The water quality also plays an important role in addition to the mix ratio. Water of drinkable quality usually meets these requirements. The quality of purified sea water is inadequate!
  7. 20. Damage may also be caused to the engine if unauthorised anti-freeze agent is used!
  8. 21. If radiator, cylinder head or cylinder head gasket have been replaced the old coolant must not be re-used.

Important. Vehicles with air conditioning: switch air conditioning off and set to ECO mode with ECC

  1. 22. Open cooling system Warning: Cooling system is under pressure • Unscrew coolant expansion tank cover
  2. 23. Fill with coolant up to lower venting line (1) at coolant expansion tank
  3. 24. Seal off cooling system • Screw in coolant expansion tank cover
  4. 25. Start engine and allow to warm up • Allow engine to warm up at idling speed of up to 2500 rpm until first radiator fan setting switches on
  5. 26. Vent cooling system • Allow engine to run for approximately 2 minutes at 2000 to 2500 rpm

Note. The air in the cooling system is removed via the venting lines

  1. 27. Switch engine off and allow to cool
  2. 28. Check coolant level and also top up coolant to "COLD" mark
  1. 29. Re-teach throttle valve module

Note. For engines with throttle body module (E-Gas) it is necessary to perform a relearning procedure after throttle body module (E-Gas) replacement. To do so, turn on ignition and wait at least 10 seconds. Under no circumstances should starting occur during the waiting period as this would interrupt the relearning procedure.

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