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Vauxhall Workshop Service and Repair Manuals

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Camshaft Housing, Replace > < Replace EGR cooler

Astra H

Replace turbocharger

  Remove

1.   Open bonnet
2.   Disconnect battery
•   Detach earth connection from earth terminal
– Slacken nut
Warning:   The cooling system is pressurised. Open the closure cap carefully
3.   Unscrew coolant expansion tank closure cap
4.   Remove engine cover
5.   Remove air intake manifold (1)
•   Undo 2 clamps
Object Number: 10680323 Size: DEFAULT


6.   Remove oil dipstick
7.   Release oil dipstick guide tube (2)
•   Unscrew bolt (1)
Object Number: 10678239 Size: DEFAULT


8.   Remove charge air pipe (3)
•   Detach camshaft vent hose (1) from charge air pipe
– Release clamp
•   Unclip hose for wastegate unit of exhaust gas recirculation cooler bypass valve (2)
•   Unscrew bolt
•   Release clamp
Object Number: 10678240 Size: DEFAULT


9.   Detach charge air hose (1) from charge air pipe.
•   Release clamp
Object Number: 10680294 Size: DEFAULT


10.   Raise vehicle by its full height
11.   Remove lower engine compartment cover and/or right-hand engine splash guard
12.   Place collecting basin underneath.
13.   Drain engine oil
14.   Place collecting basin underneath.
15.   Drain coolant
16.   Detach pre-catalytic converter temperature sensor (1)
•   Unscrew temperature sensor
Object Number: 10678244 Size: DEFAULT


17.   Detach charge air pipe (1) from turbocharger
•   Unscrew 2x bolts
•   Remove gasket
•   Remove pipe with hose
Object Number: 10680324 Size: DEFAULT


18.   Detach temperature sensor (2) of rear exhaust pipe
•   Unscrew temperature sensor
19.   Remove oxygen sensor (1)
•   Unscrew oxygen sensor
Object Number: 10678228 Size: DEFAULT


20.   Detach temperature sensor (1) from particle filter
Object Number: 10678229 Size: DEFAULT


21.   Detach pressure connection for differential pressure sensor (1)
•   Unscrew pressure connection
Object Number: 10678230 Size: DEFAULT


Important:   Protect the exhaust pipe from uncontrolled sagging as deflection as little as 5-10 degrees from the prescribed installation position could damage the flex pipe housed within it
22.   Suspend front exhaust pipe
•   2 mechanics required
•   Unhook 2x damper rings
•   Unscrew 2x nuts
•   Detach front exhaust pipe from catalytic converter
– Unscrew 3x nut
– Remove gasket
•   Set exhaust system aside and suspend
23.   Remove oil dipstick guide tube (1)
•   Unscrew 2x bolts (2)
Object Number: 10678241 Size: DEFAULT


24.   Remove ribbed V-belt
Note:   Mark direction of rotation
•   Apply tension to ribbed V-belt tensioner via bolt (1) in the direction of the arrow
•   Fix ribbed V-belt tensioner at bore (2) with KM-6130
•   Remove ribbed-V-belt
Object Number: 3447354 Size: DEFAULT


25.   Detach catalytic converter support (1) from catalytic converter
•   Unscrew 2x bolts (2)
Object Number: 10678245 Size: DEFAULT


26.   Pull off vacuum hose for turbocharger wastegate unit (1)
Object Number: 10679182 Size: DEFAULT


27.   Detach hose between turbocharger and cylinder block (1) from cylinder block
•   Release clamp
Object Number: 10678251 Size: DEFAULT


28.   Lower vehicle by its full height
29.   Remove compressor (1)
•   Disconnect wiring harness connector.
•   Unscrew 3x bolts (2)
•   Suspend compressor
Object Number: 10678252 Size: DEFAULT


30.   Remove compressor bracket (1)
•   Unscrew 3x bolts (2)
Object Number: 10678253 Size: DEFAULT


31.   Remove heat shield for cylinder 1 and 2 exhaust manifold (1)
•   Unscrew 3x bolts (2)
Object Number: 10678254 Size: DEFAULT


32.   Detach clamp for coolant hose between coolant pipe and exhaust gas recirculation cooler (1)
•   Push onto pipe of exhaust gas recirculation cooler
Object Number: 10678248 Size: DEFAULT


33.   Remove exhaust gas recirculation cooler (5)
•   Detach pipe (2) from exhaust gas recirculation valve
– Unscrew 2x bolts
– Remove gasket
•   Detach pipe (4) from thermostat housing
– Unscrew bolt
•   Detach retaining plate of exhaust gas recirculation cooler from cylinder head
– Unscrew 2x bolts (1 and 3)
•   Detach bypass valve from exhaust manifold
– Unscrew 2x bolts (6)
– Remove gasket
•   Detach coolant hose between coolant pipe and exhaust gas recirculation cooler
Object Number: 10678255 Size: DEFAULT


34.   Remove heat shield for cylinders 3 and 4 exhaust manifold (2)
•   Unscrew 2x bolts (1)
Object Number: 10678256 Size: DEFAULT


35.   Detach oil feed line from turbocharger (1)
•   Unscrew bolt (2)
– Remove 2x seal ring
Object Number: 10678250 Size: DEFAULT


36.   Detach coolant hose (2) from coolant flange
•   Release clamp
37.   Detach 2x coolant hoses (1) and (3) from coolant return pipe
•   Undo 2 clamps
Object Number: 10680325 Size: DEFAULT


38.   Remove exhaust manifold with turbocharger (1)
•   Unscrew 2x bolts
•   Unscrew 7x nuts
•   Remove 2x gaskets
Object Number: 10678257 Size: DEFAULT


39.   Detach turbocharger (1) from exhaust manifold
•   Unscrew 3x nuts (arrows)
•   Remove gasket
Object Number: 10679183 Size: DEFAULT


40.   Detach catalytic converter heat shield (2)
•   Release 3x bolts (1)
Object Number: 10678246 Size: DEFAULT


41.   Detach catalytic converter (1) from turbocharger
•   Unscrew 3 bolts
•   Remove gasket
Object Number: 10678249 Size: DEFAULT


42.   Detach hose between turbocharger and cylinder block (1) from turbocharger
•   Release clamp
Object Number: 10678251 Size: DEFAULT


  Install

43.   Attach hose between turbocharger and cylinder block to turbocharger
•   Fasten clamp
44.   Attach catalytic converter to turbocharger
•   Replace gasket
•   Tighten 3x bolts
45.   Attach catalytic converter heat shield
•   Tighten 3x bolt 5 Nm
46.   Attach turbocharger to exhaust manifold
Note:   Fill 0.4 ml clean engine oil into the aperture of the oil feed line
•   Replace gasket
•   Tighten 3x new nuts with MKM-6600-305 in conjunction with KM-6600-12
– 1st tightening 24 Nm
– 2nd tightening 48 Nm
47.   Install exhaust manifold with turbocharger
Note:   Note correct tightening sequence (1-2-3-4-5-1-2-3-6-7-8-9)
•   Replace 2x gaskets
•   Tighten 2x new bolts 69 Nm
•   Tighten 7x new nuts 69 Nm
Object Number: 10678258 Size: DEFAULT


48.   Attach 2x coolant hoses to coolant return pipe
•   Attach 2x clamps
49.   Attach coolant hose to coolant flange
•   Fasten clamp
50.   Attach oil feed line to turbocharger
•   Replace 2x seal rings
– Tighten bolt 21 Nm
51.   Install heat shield for cylinders 3 and 4 exhaust manifold
•   Tighten 2x bolt 10 Nm
52.   Install EGR cooler
•   Connect coolant hose between coolant pipe and exhaust gas recirculation cooler
•   Attach bypass valve to exhaust manifold
– Replace gasket
– Tighten 2x bolts 29 Nm
•   Attach retaining plate of exhaust gas recirculation cooler to cylinder head
– Tighten 2x bolts 29 Nm
•   Attach pipe to thermostat housing.
– Replace sealing ring
– Tighten bolt 10 Nm
•   Attach pipe to exhaust gas recirculation valve
– Replace gasket
– Tighten 2x bolts 29 Nm
53.   Fasten clamp for coolant hose between coolant pipe and exhaust gas recirculation cooler
54.   Install heat shield for cylinders 1 and 2 exhaust manifold
•   Insert heat shield from the side
•   Tighten 3x bolt 10 Nm
55.   Install compressor bracket
•   Tighten 3x bolt 43 Nm
56.   Attach compressor
•   Suspend compressor
•   Tighten 3x bolt 25 Nm
•   Fix wiring harness plug
57.   Raise vehicle by its full height
58.   Attach hose between turbocharger and cylinder block to cylinder block
•   Fasten clamp
59.   Attach vacuum hose for turbocharger wastegate unit
60.   Attach catalytic converter support to catalytic converter
•   Tighten 2x bolt 25 Nm
61.   Clean 2x threads
Important:   Protect the exhaust pipe from uncontrolled sagging as deflection as little as 5-10 degrees from the prescribed installation position could damage the flex pipe housed within it
62.   Unhook front exhaust pipe
•   2 mechanics required
•   Attach 2x damper rings
•   Tighten 2x nuts
Note:   Insert with locking compound
•   Attach front exhaust pipe to catalytic converter
– Replace gasket
– Tighten 3x nuts
63.   Attach pressure connection for differential pressure sensor
•   Tighten pressure connection
64.   Attach temperature sensor to particle filter
•   Tighten temperature sensor
65.   Attach charge air pipe to turbocharger
•   Move charge air hose upwards
•   Replace gasket
•   Tighten 2x bolts
66.   Attach pre-catalytic converter temperature sensor
•   Tighten temperature sensor with MKM-6600-207 in conjunction with MKM-6600-2
67.   Attach oxygen sensor
•   Apply assembly paste
Note:   Select a suitable assembly paste from the replacement parts catalogue
•   Tighten oxygen sensor MKM-6600-211 in connection with MKM-6600-2
68.   Attach temperature sensor of rear exhaust pipe
•   Apply assembly paste
Note:   Select a suitable assembly paste from the replacement parts catalogue
•   Tighten temperature sensor with MKM-6600-207 in conjunction with MKM-6600-2
69.   Insert ribbed V-belt
Note:   Note running direction of ribbed V-belt
•   Position ribbed V-belt
– I. Ribbed V-belt without air conditioning
– II. Ribbed V-belt with air conditioning
•   Apply tension to ribbed V-belt tensioner via bolt (1) in the direction of the arrow
•   Take out fixing
•   Release ribbed V-belt tensioner
– Remove KM-6130
Object Number: 2415977 Size: DEFAULT


70.   Install dipstick guide tube
•   Replace seal ring
•   Tighten 2x bolt 10 Nm
71.   Install lower engine cover and right engine splash guard
72.   Lower vehicle by its full height
73.   Fit charge air pipe
•   Tighten clamp 3.5 Nm
•   Tighten bolt
•   Clip in hose for wastegate unit of exhaust gas recirculation cooler bypass valve
•   Attach camshaft vent hose to charge air pipe
– Fasten clamp
74.   Attach dipstick guide tube
•   Tighten bolt 10 Nm
75.   Insert oil dipstick
76.   Install air intake pipe.
•   Tighten 2x clamp 3.5 Nm
77.   Install engine cover
78.   Connect battery
•   Attach ground connection to ground terminal
– Tighten nut
79.   Program volatile memories
80.   Top up engine oil
81.   Fill and bleed cooling system LUREF_1.gif
82.   Close bonnet

Camshaft Housing, Replace > < Replace EGR cooler