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Replace EGR Valve Opel Astra H

Fuel Injection Systems 11 illustrations ~572 words

Remove

Important. The EGR-valve is only to be replaced in the module with the EGR-port

  1. 1. Open bonnet
  2. 2. Raise vehicle by its full height
  3. 3. Detach the lower engine cover and right engine splash guard
  4. 4. Place collecting basin underneath.
  5. 5. Drain coolant • Open drain bolt on radiator (1) • Collect coolant • Close drain bolt
  1. 6. Lower vehicle by its full height
  2. 7. Remove engine cover (2) • Detach oil filler port closure cap (1) • Pull off engine cover • Attach oil filler port closure cap

Note. Rubber retainers (3) must remain on engine cover

  1. 8. Remove air intake manifold (1) • Detach wiring harness – Release 3x clip • Undo 2 clamps • Unscrew 2x bolts
  1. 9. Remove charge air pipe (1) • Unscrew 6x bolts
  1. 10. Remove battery • Detach earth connection (4) from battery • Detach positive connection (3) from battery • Remove bracket 1) – Unscrew bolt (2)
  1. 11. Remove battery support. • Remove pre-glow 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)
  1. 12. Remove throttle valve body (1) • Detach charge air hose (3) – Release clamp • Release bracket, throttle valve body (4) – Detach from throttle valve body – Release on camshaft housing • Disconnect wiring harness plug (2). • Unscrew 4x bolts
  1. 13. Remove rear right engine transport shackle (1) • Unscrew 2x bolts
  1. 14. Disconnect wiring harness plug from EGR-actuator (1)
  1. 15. Remove EGR-port (1) • Detach coolant hose – Release clamp • Detach EGR cooler – Unscrew 2x bolts • Unscrew 2x bolts

Note. Note different bolt lengths

Install

Important. Seal ring (1) may not be displaced on installation

  1. 16. Install EGR-port • Replace gasket • Tighten 2x bolt 24 Nm • Attach coolant hose – Fasten clamp • Attach EGR cooler - – Replace gasket – Tighten 2x bolts 28.5 Nm

Note. Note different bolt lengths

  1. 17. Install rear right engine transport shackle • Tighten 2x bolts
  2. 18. Install throttle valve connecting piece • Replace gasket • Tighten 4x bolt 9.8 Nm • Fix wiring harness plug • Attach throttle valve body bracket to throttle valve body – Tighten bolt 24 Nm • Attach throttle valve body bracket to camshaft housing – Tighten bolt 24 Nm • Attach charge air hose – Fasten clamp 3.5 Nm
  3. 19. Install battery holder • Tighten 3x bolts • Attach pre-glow system control device • Attach wiring harness plug • Clip in coolant hose • Attach wiring harness – Connect 2x cable ties
  4. 20. Install battery • Install bracket – Tighten 1x bolt • Attach earth connection to battery – Tighten nut • Attach positive connection to battery – Tighten nut
  5. 21. Fit charge air pipe • Replace 2x gaskets • Tighten 6x bolt 24 Nm
  6. 22. Install air intake pipe. • Fasten 2x clamp 3.5 Nm • Tighten 2x bolts • Attach wiring harness – Clip in 3x clips
  7. 23. Install engine cover • Detach oil filler port closure cap • Refit engine cover • Attach oil filler port closure cap
  8. 24. Raise vehicle by its full height
  9. 25. Install lower engine cover and right engine splash guard
  10. 26. Lower vehicle by its full height
  11. 27. Top up coolant or ensure correct quantity is present.
  12. 28. Program volatile memories
  13. 29. Close bonnet

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