Replace EGR cooler (Cooling System)

Make

Vauxhall

Model

Astra H

Section

Cooling System › Repair Instructions › Replace EGR cooler

Engine and Engine AggregatesReplace EGR cooler

Replace EGR cooler   Remove 1.   Open bonnet 2.   Disconnect battery •   Detach earth connection from earth terminal 3.   Remove engine cover (2) •   Detach oil filler port closure cap (1) •   Pull off engine cover Note:   Rubber retainers (3) must remain on engine cover •   Attach oil filler port closure cap 4.   Remove air intake manifold (1) •   Detach wiring harness – Release 3x clip •   Undo 2 clamps •   Unscrew 2x bolts 5.   Raise vehicle by its full height 6.   Detach the lower engine cover and right engine splash guard 7.   Place collecting basin underneath. 8.   Drain coolant •   Open drain bolt on radiator (1) •   Collect coolant •   Close drain bolt 9.   Detach lower coolant hose (1) •   From cooler, exhaust gas recirculation – Release clamp 10.   Lower vehicle by its full height 11.   Remove bracket, oil dipstick guide tube (1) •   Unclip vacuum line – Unclip 2x clips •   Remove oil dipstick guide tube – Release clamp •   Detach bracket, oil dipstick guide tube, from camshaft housing – Unscrew 2x bolts 12.   Detach upper coolant hose (1) from EGR cooler •   Release clamp 13.   Remove EGR cooler - •   Detach from intake manifold – Unscrew 2x bolts (3) •   Detach from exhaust gas recirculation port – Unscrew 2x bolts (2) •   Detach from camshaft housing – Unscrew bolt (1) •   Remove 2x gasket   Install 14.   Install EGR cooler - •   Replace 2x gaskets •   Attach to exhaust manifold – Tighten 2x bolts 28.5 Nm •   Attach to exhaust gas recirculation port – Tighten 2x bolts 28.5 Nm •   Attach to camshaft housing – Tighten bolt 24 Nm 15.   Attach upper coolant hose to heat exchanger exhaust gas recirculation •   Fasten clamp 16.   Install bracket, oil dipstick guide tube •   Attach bracket, oil dipstick guide tube, to camshaft housing – Tighten 2x bolts •   Attach vacuum line – Clip in 2x clips •   Attach dipstick guide tube – Fasten clamp 17.   Raise vehicle 18.   Attach lower coolant hose to heat exchanger exhaust gas recirculation •   Fasten clamp 19.   Install lower engine cover and right engine splash guard 20.   Lower vehicle by its full height 21.   Install air intake pipe. •   Fasten 2x clamp 3.5 Nm •   Tighten 2x bolts •   Attach wiring harness – Clip in 3x clips 22.   Install engine cover •   Detach oil filler port closure cap •   Refit engine cover •   Attach oil filler port closure cap 23.   Connect battery •   Attach earth connection to earth terminal 24.   Top up coolant or ensure correct quantity is present. 25.   Program volatile memories 26.   Close bonnet

09 Engine