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Thread: egr exploded diagram

  1. #1
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    Default egr exploded diagram

    Hi, has anyone got an exploded diagram of a egr set up or a picture of an egr cooler for a 1.9 cdti 120 as i tried to change my coolant thermostat last weekend but had to give up as i couldn't get the egr cooler off - i couldn't find the 2 bolts that hold it on down the back of the engine., the cooler has to come off as one of it's brackets covers one of the bolts that holds the thermostat housing on. this has to be the stupidest design i've ever come across to date on this engine (& there are many).

    Many thanks.

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    Hi, I think it may depend on the engine you have. I have a Z19dt and the removal of the EGR is pretty starightforward. Two torx bolts (or Hex Key) on the bottom and two on the side, then the three bolts holding the EGR to the engine, watch out for the metal gaskets where the torx bolts are they can be used again or cost £1 from the dealers. If you have the Z19dth, let me know and I will type in exactly what it says in the manual.

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    Regular Member barney490's Avatar
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    John1, if you look at the cooler face on, there is the nut that holds the cooler to the thermostat on your left. look where the right hand hose fits to the cooler and behind the cooler at that point there is a vertical bracket with two bolts, that fasten to the rear of the block. They hold the cooler on. It's an absoloutely stupid place to put a thermostat and i have heard that some people with the 120's also remove the vac pump, to make access to the thermostat easier. Three bolts and two hoses are all that hold the vac pump on, easy to remove.

    you will also have to remove the two bolts that hold the cooler pipe to the egr, to allow sufficient movement. You dont have to unbolt from the exhaust manifold.
    Last edited by barney490; 17th September 2010 at 14:33.

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    thanks for your help, stupid thing is that i removed one of the bolts at the back which i could see but couldn't work out or see what else held the thing onto the engine block, then i gave up completely & put everything back together. can't believe i was one bolt away from getting the b***dy thing off. I'll take the ERG off next time as it could do with another clean anyway.

    Cheers

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    Full Member wright879's Avatar
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    Vehicle : Vectra Estate

    Trim : Life

    Engine : CDTI 120

    Year : 2005

    Wink Thermostat removal

    Don't know if it helps but when I replaced my thermostat last weekend I took the clamps off either end of the exhaust gas cooler, nut off the thermostat end and levered the cooler to one side - it was a bit of a struggle but I got the thermostat changed. The main pain was getting the cooler clamps back on - kept dropping bits

    My handbook says you should remove the battery tray and vacuum pump but I only read that once I'd finished to see why I'd struggled - it's a man thing according to my OH!

    Has anyone removed their undertray and left it off? Got to make it easier to do lots of jobs

    Steve
    Last edited by wright879; 19th September 2010 at 10:03. Reason: Added a bit

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    thanks for the advise Steve, i managed to get it done today what a complete pig of a job. my undertray has been off for a few weeks now but i intend to put it back on when the weather gets bad to help stop spray into the engine compartment, but i need to change a tie rod first. your right you cant even change the oil & unless you have car lift.

    Cheers.

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    Regular Member barney490's Avatar
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    The 120 thermostat is a right pig of a job due to that cooler. Just a word of advice to anybody who split the egr cooler to get access, make sure the gaskets in the cooler dont get lost and the clamps are done up TIGHT!!!! I had the dealers change my stat and they left the back clamp loose. I could smell exhaust fumes in the car, thought it was something else, till the smoke poured from under the bonnet. It was comming from that joint. The round gaskets in there cant be bought and it's a complete cooler.

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    i'm glad i took the ERG off, i didn't fully clean it down as it wasn't to dirty cos i stripped it a while ago, however i did take the 90deg pipe off that connects it to the intake manifold & the hole into the manifold was virtually blocked solid with crap, cleaned it out & car seems i little more responsive now.

    so for anyone who's planning to clean thier EGR is's advisable to remove this pipe & have a check.

  9. #9
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    Vehicle : Vectra Estate

    Trim : Life

    Engine : CDTI 120

    Year : 2005

    rolleyes

    Mmmmmm, I don't remember seeing any gaskets at the cooler clamp joints - maybe I'll take a peek at the weekend and make sure it's not leaking. I was thinking of blanking the whole lot off at the exhaust manifold and getting rid of the cooler and EGR anyway so maybe I'll do it sooner than later if it's leaking ( ready for my DPF removal plans

    Steve

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    i just checked on EPC and found a gasket, part number 93179089 listed for the cooler joints on Zafira 1.9 DTH, i guess they would fit Veccy also. They look slightly dished to fit the shape of the cooler joint.

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