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Replace exhaust gas recirculation valve > < Cylinder Head, Remove and Install

Astra H

Attach and detach attaching parts

  Remove

1.   Remove cylinder head
2.   Remove 4x injector
Note:   If injectors cannot be removed by hand use EN-46786 together with KM-328-B . Fit sealing plugs on the injectors after removal (arrows). 1)
•   Unscrew 4x nut
Object Number: 3446070 Size: DEFAULT


3.   Remove camshaft pulley
•   Unscrew bolt (2)
Important:   When counterholding, do not damage the camshaft sensor (arrow)
•   Counterhold at camshaft sprocket with EN-46787 (1) together with KM-956-1
Object Number: 3446020 Size: DEFAULT


4.   Detach vacuum pump (1)
•   Unscrew 3x bolts (2)
Object Number: 2408149 Size: DEFAULT


5.   Turn camshaft forwards approx. 45°
6.   Detach camshaft (2)
•   Unscrew 12x bolts (1)
Note:   Loosen bearing cover in stages, 1/2 - 1 turn from outside. Camshaft must detach itself evenly from bearing seat
•   Remove oil line
•   Remove 5x camshaft bearing covers
Note:   Observe correct assignment.
•   Remove camshaft seal
Object Number: 7360112 Size: DEFAULT


7.   Remove cup tappets
•   Remove 8 cup tappets (1)
Note:   Observe correct assignment
Object Number: 7360113 Size: DEFAULT


8.   Detach EGR cooler (1)
•   Detach pipe from EGR cooler
– Release clamp (2)
•   Unscrew 2x bolts
Object Number: 8125483 Size: DEFAULT


9.   Remove thermostat housing (1)
•   Detach coolant hose (2) from coolant pipe
– Release clamp
•   Unscrew 2x bolts
Object Number: 8125484 Size: DEFAULT


10.   Remove camshaft sensor (1)
•   Disconnect wiring harness connector.
•   Detach panelling
– Unscrew 2x bolts (2)
Object Number: 3446021 Size: DEFAULT


11.   Remove coolant pump (1)
•   Unscrew 2x bolts (2)
Object Number: 3446022 Size: DEFAULT


  Install

12.   Clean sealing surfaces.
•   Thermostat housing
•   EGR cooler
•   Coolant pump
13.   Clean 2x threads
14.   Install coolant pump
•   Replace seal
•   Tighten 2x new bolt 25 Nm
15.   Install camshaft sensor
•   Attach panelling
Note:   Insert bolt with locking compound (red). The maximum installation time including torque check is 10 minutes.
– Tighten 2x bolt 9 Nm
•   Fit wiring harness plug
16.   Attach thermostat housing
•   Replace seal
•   Tighten 2x bolt 25 Nm
•   Attach coolant hose to coolant pipe
– Fasten clamp
17.   Insstall EGR cooler
•   Replace seal
•   Tighten 2x bolt 25 Nm
•   Attach hose to EGR cooler
– Fasten clamp
18.   Install cup tappet
•   Insert 8 cup tappets
Note:   Observe correct assignment
19.   Install camshaft
•   Fit oil line
•   Fit 5x camshaft bearing covers
Important:   Observe correct assignment.
•   Insert bearing covers 1 and 5 with surface sealing compound (green)
•   Tighten 12x bolt 15 Nm
Note:   Tighten in stages, working in a spiral from the inside out
20.   Install crankshaft seal ring (1) with EN-46793 (2)
•   Drive seal ring in flush
Object Number: 7360115 Size: DEFAULT


21.   Clean sealing surface
22.   Install vacuum pump
•   Replace seal
•   Tighten 3x bolt 20 Nm
23.   Install camshaft sprocket
•   Tighten new bolt 120 Nm
Important:   When counterholding, do not damage the camshaft sensor
– Counterhold at camshaft sprocket with EN-46787 together with KM-956-1
24.   Cleaning work
Note:   Use EN-47632 to clean the injector seats. Insert EN-47632 with coarse fleece in the injector shaft and turn it to clean the injector seat. Finish by cleaning with fine fleece.
25.   Install 4x injector
•   Replace 4x seal rings
•   Tighten 4x nut 32 Nm
26.   Install cylinder head
1 ) Protective caps can be found in the Opel spare parts catalogue under catalogue no. 45 06 154 / part no. 9201697

Replace exhaust gas recirculation valve > < Cylinder Head, Remove and Install