vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Cylinder head and attaching parts, check and measure - Survey > < Replace metal pipe exhaust gas recirculation, centre

Astra H

Replace metal pipe exhaust gas recirculation, lower

  Remove

1.   Open bonnet
2.   Disconnect battery
3.   Remove engine cover
•   Unscrew 2x bolts
•   Unscrew oil filler cap
•   Remove engine cover
•   Screw on oil filler cap
4.   Remove air cleaner housing
5.   Raise vehicle
6.   Drain coolant
Warning:   Only open the coolant compensation tank when the engine has cooled down.
•   Unscrew closure cap of coolant expansion tank
•   Place collecting basin underneath.
•   Open drain bolt (arrow)
Object Number: 2404562 Size: DEFAULT


7.   Lower vehicle
8.   Detach vacuum line
•   Unscrew 2x bolts (arrows)
•   Detach 2x hoses
Object Number: 2408150 Size: DEFAULT


9.   Remove charge air pipe (1)
•   Undo 2 clamps
Object Number: 2408585 Size: DEFAULT


10.   Remove engine vent hose
•   Release clamp (1)
Object Number: 3446023 Size: DEFAULT


11.   Remove air intake manifold (1)
•   Unscrew bolt
•   Release clamp
12.   Detach upper coolant hose
•   Release clamp
13.   Detach upper oil dipstick guide tube
•   Unscrew bolt (arrow)
14.   Remove connecting hose from charge air pipe to throttle valve module
•   Undo 2 clamps
15.   Detach cover
•   Unscrew 3 bolts
16.   Detach coolant pipe assembly (2)
•   Unscrew 5x bolts, nuts
•   Undo 4x clamps
Object Number: 2408599 Size: DEFAULT


17.   Remove exhaust gas recirculation metal pipe, lower (1)
•   Unscrew 2x bolts
•   Release clamp
– Unscrew bolt
Object Number: 3446025 Size: DEFAULT


  Install

18.   Install exhaust gas recirculation metal pipe, lower
•   Replace 2x seals
•   2x bolt 25 Nm
•   Tighten clamp
19.   Raise vehicle
20.   Close coolant drain screw
21.   Lower vehicle
22.   Install coolant pipe assembly
•   Tighten 5x bolts, nuts
•   Attach 4x clamps
23.   Fit cover
•   3x bolt 9 Nm
24.   Attach upper coolant hose
•   Fasten clamp
25.   Fasten top of oil dipstick guide tube
•   Bolt 9 Nm
26.   Install connecting hose from charge air pipe to throttle valve module
•   2x clamp 3.5 Nm
27.   Attach air intake pipe to turbocharger
Important:   Follow specified installation order
•   Put seal on turbocharger port
•   Fit air intake manifold pipe
– Tighten clamp 3.5 Nm
•   Tighten bolt 9 Nm
28.   Attach engine vent hose
•   Fasten clamp
29.   Install charge air pipe
•   2x clamp 3.5 Nm
30.   Attach vacuum line
•   2x bolt 9 Nm
•   Connect 2x hoses
31.   Install air cleaner housing LUREF_1.gif
32.   Attach engine cover
•   Unscrew oil filler cap
•   Position engine cover
•   Screw on oil filler cap
•   2x bolt 9 Nm
33.   Top up coolant
•   Observe specified coolant quantity LUREF_1.gif
34.   Connect battery
35.   Program volatile memories
36.   Close bonnet

Cylinder head and attaching parts, check and measure - Survey > < Replace metal pipe exhaust gas recirculation, centre