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Vauxhall Workshop Service and Repair Manuals

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Vacuum Unit Change-Over Valves, Remove and Install > < Heat Protection Sleeve, Remove and Install

Astra H

Replace EGR valve

  Remove

Important:   The EGR-valve is only to be replaced in the module with the EGR-port
1.   Open bonnet
2.   Raise vehicle by its full height
3.   Detach the lower engine cover and right engine splash guard
4.   Place collecting basin underneath.
5.   Drain coolant
•   Open drain bolt on radiator (1)
•   Collect coolant
•   Close drain bolt
Object Number: 3446550 Size: DEFAULT


6.   Lower vehicle by its full height
7.   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
Object Number: 2412632 Size: DEFAULT


8.   Remove air intake manifold (1)
•   Detach wiring harness
– Release 3x clip
•   Undo 2 clamps
•   Unscrew 2x bolts
Object Number: 2412653 Size: DEFAULT


9.   Remove charge air pipe (1)
•   Unscrew 6x bolts
Object Number: 3447355 Size: DEFAULT


10.   Remove battery
•   Detach earth connection (4) from battery
•   Detach positive connection (3) from battery
•   Remove bracket 1)
– Unscrew bolt (2)
Object Number: 3447347 Size: DEFAULT


11.   Remove battery support.
•   Remove pre-glow system control unit (4)
•   Remove wiring harness plug (3)
•   Detach coolant hose
– Unclip clip (5)
•   Detach wiring harness
– Detach 2x cable ties (1)
•   Unscrew 3x bolts (2)
Object Number: 3446570 Size: DEFAULT


12.   Remove throttle valve body (1)
•   Detach charge air hose (3)
– Release clamp
•   Release bracket, throttle valve body (4)
– Detach from throttle valve body
– Release on camshaft housing
•   Disconnect wiring harness plug (2).
•   Unscrew 4x bolts
Object Number: 2412684 Size: DEFAULT


13.   Remove rear right engine transport shackle (1)
•   Unscrew 2x bolts
Object Number: 2412687 Size: DEFAULT


14.   Disconnect wiring harness plug from EGR-actuator (1)
Object Number: 2412656 Size: DEFAULT


15.   Remove EGR-port (1)
•   Detach coolant hose
– Release clamp
•   Detach EGR cooler
– Unscrew 2x bolts
•   Unscrew 2x bolts
Note:   Note different bolt lengths
Object Number: 2412688 Size: DEFAULT


  Install

Important:   Seal ring (1) may not be displaced on installation
16.   Install EGR-port
•   Replace gasket
•   Tighten 2x bolt 24 Nm
Note:   Note different bolt lengths
•   Attach coolant hose
– Fasten clamp
•   Attach EGR cooler -
– Replace gasket
– Tighten 2x bolts 28.5 Nm
Object Number: 2412691 Size: DEFAULT


17.   Install rear right engine transport shackle
•   Tighten 2x bolts
18.   Install throttle valve connecting piece
•   Replace gasket
•   Tighten 4x bolt 9.8 Nm
•   Fix wiring harness plug
•   Attach throttle valve body bracket to throttle valve body
– Tighten bolt 24 Nm
•   Attach throttle valve body bracket to camshaft housing
– Tighten bolt 24 Nm
•   Attach charge air hose
– Fasten clamp 3.5 Nm
19.   Install battery holder
•   Tighten 3x bolts
•   Attach pre-glow system control device
•   Attach wiring harness plug
•   Clip in coolant hose
•   Attach wiring harness
– Connect 2x cable ties
20.   Install battery
•   Install bracket
– Tighten 1x bolt
•   Attach earth connection to battery
– Tighten nut
•   Attach positive connection to battery
– Tighten nut
21.   Fit charge air pipe
•   Replace 2x gaskets
•   Tighten 6x bolt 24 Nm
22.   Install air intake pipe.
•   Fasten 2x clamp 3.5 Nm
•   Tighten 2x bolts
•   Attach wiring harness
– Clip in 3x clips
23.   Install engine cover
•   Detach oil filler port closure cap
•   Refit engine cover
•   Attach oil filler port closure cap
24.   Raise vehicle by its full height
25.   Install lower engine cover and right engine splash guard
26.   Lower vehicle by its full height
27.   Top up coolant or ensure correct quantity is present.
28.   Program volatile memories
29.   Close bonnet

Vacuum Unit Change-Over Valves, Remove and Install > < Heat Protection Sleeve, Remove and Install