Replace Exhaust Gas Recirculation Valve Opel Corsa D

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, pay strict attention to cleanliness as even the smallest particle of dirt may lead to malfunctions in engine operation or the fuel system. Seal opened fuel connections with suitable closure plugs 1) . Closure plugs are intended for single use.

Remove

1. 1. Open bonnet
2. 2. Raise vehicle by its full height
3. 3. Place collecting pan underneath.
4. 4. Drain coolant • Open drain bolt on radiator (1) • Collect coolant • Close drain bolt

5. 5. Lower vehicle by its full height
6. 6. Detach bulkhead closing part
7. 7. Detach engine cover
8. 8. Separate wiring harness plug, exhaust gas recirculation valve
9. 9. Detach charge air pipe (1) from intake manifold • Unscrew 3x bolts (2) • Detach from bracket (3) – Unscrew bolt

10. 10. Remove throttle valve housing (1) • Remove vacuum pipe (2) from solenoid valve • Unscrew 3 bolts

Note. Applies to vehicles with Z13 DTH engine.

11. 11. Remove brake force amplifier vacuum line (1) • Disconnect quick-release fitting
12. 12. Disconnect vacuum line (2)

13. 13. Detach 2x coolant hose heating (1) from coolant pipe • Undo 2 clamps

14. 14. Remove coolant hose (1) from thermostat housing • Release clamp • Detach from bracket

15. 15. Detach wiring harness bracket (1) • Unscrew bolt (2)

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

17. 17. Detach exhaust gas recirculation valve (1) from exhaust gas recirculation cooler (2) • Remove coolant hose, thermostat housing, from exhaust gas recirculation valve – Release clamp • Detach coolant hose - exhaust gas recirculation cooler at the coolant pipe – Undo 2 clamps • Unscrew 3 bolts • Detach coolant pipe from exhaust gas recirculation valve – Unscrew bolt

Install

18. 18. Clean sealing surface
19. 19. Attach exhaust gas recirculation valve to exhaust gas recirculation cooler • Attach coolant pipe to exhaust gas recirculation valve – Tighten bolt • Insert new gasket • Tighten 3x bolts 25 Nm • Attach coolant hose - exhaust gas recirculation cooler at the coolant pipe – Attach 2x clamps • Attach coolant hose, thermostat housing, to exhaust gas recirculation valve – Fasten clamp
20. 20. Install exhaust gas recirculation valve • Use new gasket • Tighten 2x bolt 22 Nm
21. 21. Attach exhaust gas recirculation valve to cylinder block • Tighten bolt 22 Nm
22. 22. Install wiring harness bracket • Tighten bolt 25 Nm
23. 23. Attach exhaust gas recirculation pipe to intake manifold • Tighten clamp
24. 24. Attach coolant hose to thermostat housing. • Fasten clamp • Install in bracket
25. 25. Attach 2x coolant hose heating to coolant pipe • Attach 2x clamps
26. 26. Attach throttle valve housing • Tighten 3x bolt 8 Nm • Attach vacuum pipe to solenoid valve

Note. Applies to vehicles with Z13 DTH engine.

27. 27. Attach charge air pipe to intake manifold • Replace gasket • Tighten 3x bolts • Attach to bracket – Tighten bolt
28. 28. Attach vacuum line brake servo • Connect quick release fitting
29. 29. Connect EGR valve wiring harness plug
30. 30. Install engine cover
31. 31. Install bulkhead closing part
32. 32. Top up coolant or ensure correct quantity is present.
33. 33. Close bonnet

1

) ; protective caps are available in the parts catalogue