Replace Exhaust Gas Recirculation Cooler Opel Vectra C

Remove

1. 1. Open bonnet
2. 2. Disconnect battery.
3. 3. Detach upper engine cover
4. 4. Drain coolant Warning: Only open coolant compensation tank once engine has cooled down • Unscrew coolant compensation tank closure cap • Place collecting basin underneath. • Open drain bolt (arrow)

5. 5. Detach metal EGR pipe (2) • Unscrew 4x bolt (1) • Remove 2x gasket

Note. Note installation position.

6. 6. Detach connection hose (3) • Release 2x clamp
7. 7. Detach throttle valve module (1) • Unscrew 3x bolt (2) • Disconnect wiring harness plug • Remove gasket.

8. 8. Remove exhaust gas recirculation metal pipe (1) • Unscrew 2x bolt (2) • Remove loose seal from clamp (arrow)

9. 9. Detach coolant hose • Release clamp
10. 10. Disconnect 2x wiring harness plug • Coolant temperature sensor, pressure sensor
11. 11. Remove coolant pipe • Unscrew bolt, nut
12. 12. Detach 2x coolant line • On the starter – Unscrew 2x bolt
13. 13. Detach 2x coolant hose • Release 2x clamp
14. 14. Detach vacuum reservoir (1) with retaining plate • Unscrew 3 bolts (arrows)

Note. If fitted

15. 15. Detach crankcase vent hose • Release clamp
16. 16. Remove cooler, exhaust gas recirculation (1) • Unscrew bolt, nut (arrows) • Release clamp

Install

17. 17. Cleaning work
18. 18. Install cooler, exhaust recirculation • Tighten bolt 25 Nm , tighten nut 9 Nm • Tighten clamp
19. 19. Attach crankcase vent hose • Fasten clamp
20. 20. Attach vacuum reservoir with retaining plate • Tighten 3x bolt

Note. If fitted

21. 21. Attach 2x coolant hose • Secure 2x clamp
22. 22. Attach 2x coolant line • On the starter – Tighten 2x bolt
23. 23. Fit coolant pipe. • Tighten bolt, nut
24. 24. Connect 2x wiring harness plug • Coolant temperature sensor, pressure sensor
25. 25. Attach coolant hose. • Fasten clamp
26. 26. Install exhaust gas recirculation metal pipe • Remove gasket. • Tighten 2x bolt 25 Nm • Tighten clamp
27. 27. Install throttle valve module • Replace gasket • Connect wiring harness plug • Tighten 3x bolt
28. 28. Attach metal EGR pipe • Replace 2x gasket • Tighten 4x bolt 25 Nm

Note. Note installation position.

29. 29. Attach connection hose • Tighten 2x clamp 3,5 Nm
30. 30. Top up coolant • Observe specified coolant quantity

Note. Top up and bleed cooling system – see operation "Cooling System, Top up and Bleed".

31. 31. Attach upper engine cover
32. 32. Connect battery.
33. 33. Program volatile memories
34. 34. Close bonnet