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Exhaust Gas Recirculation Pipe, Replace (X 12 XE, Z 12 XE to MY 2003, Z 14 XEP) > < Attaching Parts - Cylinder Head, Remove and install

Astra G

EGR Valve, Replace (X 12 XE, Z 12 XE up to MY 2003, Z 14 XEP)

  Remove

1.   Open bonnet
2.   Disconnect earth cable from battery
•   Slacken nuts
3.   Raise vehicle
4.   Place collecting basin underneath.
5.   Drain coolant
•   Place collecting basin underneath.
•   Put a suitable hose on the drain port (2)
•   Open coolant drain bolt (1)
– Drain coolant
•   Close coolant drain bolt
Object Number: 3446245 Size: DEFAULT


6.   Lower vehicle
7.   Detach positive terminal from positive pole
•   Slacken nuts
8.   Remove battery
•   Unscrew bolt (1)
– Remove retaining plate (2)
•   Remove battery
Object Number: 3446124 Size: DEFAULT


9.   Remove battery support (2)
•   Unscrew 3x bolt (1)
•   Detach wiring harness
– Release cable ties
Object Number: 3446125 Size: DEFAULT


10.   Disconnect wiring harness plug for ignition module (1)
11.   Disconnect wiring harness plug for EGR-valve (2)
12.   Remove engine transport shackle (3)
•   Unscrew bolt (4)
Object Number: 3446269 Size: DEFAULT


13.   Disconnect wiring harness plug for mixture control oxygen sensor (1).
14.   Detach wiring harness bracket (2)
•   Unscrew 2x bolt
Object Number: 3446268 Size: DEFAULT


15.   Disconnect wiring harness (1) from engine control unit.
•   Unlatch fuse (2)
Object Number: 3446271 Size: DEFAULT


16.   Detach coolant hose (3) from EGR-valve
•   Release clamp
17.   Detach exhaust gas recirculation pipe (1) from EGR-valve
•   Unscrew 2x bolt (2)
18.   Remove EGR valve (4)
•   Unscrew 4x bolt
Object Number: 3446270 Size: DEFAULT


  Install

19.   Clean sealing surfaces.
20.   Install AGR valve
•   Use new seals
•   Tighten 4x bolt 8 Nm
21.   Attach exhaust gas recirculation valve to EGR-valve
•   Tighten 2x bolt 8 Nm
22.   Connect wiring harness plug for engine control unit
•   Lock retainer
23.   Attach coolant hose to EGR-valve
•   Fasten clamp
24.   Install wiring harness bracket
•   Tighten 2x bolt 60 Nm
25.   Fit engine transport shackle
•   Tighten bolt 20 Nm
26.   Connect wiring harness plug for mixture control oxygen sensor.
•   Clip into bracket
27.   Connect wiring harness plug, exhaust gas recirculation valve
28.   Connect wiring harness plug, ignition module
29.   Install battery holder
•   Tighten 3x bolt
•   Detach wiring harness from battery support
– Fasten cable tie
30.   Install battery
•   Install battery bracket
– Tighten bolt
•   Connect positive terminal to positive pole
– Tighten nut
31.   Top up coolant or ensure correct quantity is present.
32.   Programme volatile memories
33.   Close bonnet
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Exhaust Gas Recirculation Pipe, Replace (X 12 XE, Z 12 XE to MY 2003, Z 14 XEP) > < Attaching Parts - Cylinder Head, Remove and install