Opel Insignia - Loss of coolant/EGR radiator | HELLA

Opel

Insignia

Model year: 2008 - 2013

Engine: 2.0 CDTI

Loss of coolant/EGR radiator

The above vehicles may experience a slow coolant loss due to a defective exhaust gas recirculation (EGR) radiator housing.

In case of coolant loss, the AGR radiator housing (Figure 1) should be examined closely. A crack is sufficient to allow a small amount of coolant to leak out. Due to its installation position, the AGR radiator is difficult to get to. To replace the component, proceed as follows:

• Remove the top engine cover and underride protection (engine) You can now see the area surrounding the AGR radiator (Figure 2)

• Remove the mountings for the charge air pipe and the wiring harness and disconnect the wiring harness connector (Figure 3) Unscrew the connector receptacle bracket from the AGR radiator housing

• Clear cables, brackets and hoses out of the way and fix them in place to allow access to the AGR radiator housing

• Mark the vacuum hoses above and below the housing, then remove them

• Unscrew the oil dipstick pipe bracket (Figure 4, Item A) and carefully move it to one side

• Remove the 5 screws (Figure 4) that hold the housing in place
• Remove the housing with the AGR radiator inside it
• Perform a visual inspection on the AGR radiator

• Mount a new gasket from the AGR radiator housing repair kit on the "engine block" (Figure 5) In order to prevent the gasket from falling off, a suitable sealant can be used as a mounting aid
• Insert the AGR radiator with the new gasket into the housing
• Mount the AGR radiator together with the housing
• Mount the vacuum hoses, brackets and connectors
• Refill coolant
• Bleed the cooling system and check for leaks
• Mount the engine cover/underride protection

Figure 1

Figure 2

Figure 3

Figure 4