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Vauxhall Workshop Service and Repair Manuals

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Replace radiator (with air conditioning) > < Radiator, Replace (Z 20 LEL, Z 20 LER)

Astra H

Replace EGR cooler

  Remove

1.   Open bonnet
2.   Disconnect battery
•   Detach earth connection from earth terminal
– Slacken nut
3.   Raise vehicle by its full height
4.   Detach the lower engine cover and right engine splash guard
5.   Place collecting basin underneath.
6.   Drain coolant
•   Open drain bolt on radiator (1)
•   Collect coolant
•   Close drain bolt
Object Number: 3446550 Size: DEFAULT


7.   Lower vehicle by its full height
8.   Remove engine cover
9.   Remove charge air hose (1)
•   Undo 2 clamps
Object Number: 7360939 Size: DEFAULT


10.   Remove battery
•   Detach positive terminal (3) from positive pole
– Slacken nut
•   Remove bracket 1)
– Unscrew bolt (2)
Object Number: 7360933 Size: DEFAULT


11.   Remove coolant pipe (2)
•   Unclip 2x coolant hoses from bracket (4)
•   Remove from bracket (3)
– Unscrew 2x nuts
•   Remove from bracket (1)
– Unscrew nut
Object Number: 7361576 Size: DEFAULT


12.   Disconnect wiring harness plug (2) from coolant temperature sensor (1)
Object Number: 7361586 Size: DEFAULT


13.   Remove thermostat housing (1)
•   Detach 4x coolant hoses
– Undo 4x clamps
•   Unscrew 2x bolts (2)
Object Number: 7361587 Size: DEFAULT


14.   Remove charge air hose (1)
•   Undo 2 clamps
Object Number: 7360935 Size: DEFAULT


15.   Detach coolant hose (1) from coolant pipe
•   Release clamp
Object Number: 7361588 Size: DEFAULT


16.   Detach 3x coolant hoses
•   Detach coolant hose (1) from top coolant pipe
– Release clamp
•   Detach coolant hose (3) from bottom coolant pipe
– Release clamp
•   Detach coolant hose (2) from EGR cooler
– Release clamp
Object Number: 7361589 Size: DEFAULT


17.   Release EGR metal tube (1) from exhaust manifold
•   Detach from intake manifold
– Unscrew 2x bolts
•   Release at EGR cooler
– Release clamp
18.   Release EGR metal tube (3) from EGR valve
•   Detach from EGR valve
– Unscrew 2x bolts
•   Release at EGR cooler
– Release clamp
19.   Remove EGR cooler (2)
•   Unscrew 2x bolts
Object Number: 7361590 Size: DEFAULT


  Install

20.   Install EGR cooler
•   Tighten 2x bolt 25 Nm
21.   Attach EGR metal tube to exhaust manifold
•   Insert new gasket
•   Tighten 2x bolts
•   Tighten clamp
22.   Attach EGR metal tube to EGR valve
•   Insert new gasket
•   Tighten 2x bolts
•   Tighten clamp
23.   Attach 3x coolant hoses
•   Attach coolant hose to top coolant pipe
– Fasten clamp
•   Attach coolant hose to bottom coolant pipe
– Fasten clamp
•   Attach coolant hose to EGR cooler
– Fasten clamp
24.   Attach coolant hose to coolant pipe
•   Fasten clamp
25.   Fit turbocharger charge air hose to charge air pipe
•   Tighten 2x clamp 3.5 Nm
26.   Clean sealing surface
27.   Clean 2x threads
28.   Install thermostat housing
•   Insert new gasket
Note:   Coat gasket with special grease (white)
•   Tighten 2x bolts
•   Attach 4x coolant hoses
– Attach 4x clamps
29.   Connect coolant temperature sensor wiring harness plug
30.   Install coolant pipe
•   Tighten 3x nut 9 Nm
•   Clip 2x coolant hoses into bracket
31.   Fit intercooler charge air hose to throttle valve connection
•   Tighten 2x clamp 3.5 Nm
32.   Install engine cover
33.   Raise vehicle by its full height
34.   Install lower engine cover and right engine splash guard
35.   Lower vehicle by its full height
36.   Install battery
•   Install bracket
– Tighten bolt
•   Insert battery insulation
•   Attach positive connection to positive terminal
– Tighten nut
•   Attach positive cable to positive terminal
– Tighten bolt
37.   Connect battery
•   Attach ground connection to ground terminal
– Tighten nut
38.   Top up coolant or ensure correct quantity is present.
39.   Program volatile memories
40.   Close bonnet

Replace radiator (with air conditioning) > < Radiator, Replace (Z 20 LEL, Z 20 LER)