How to Replace the Radiator Opel Astra G

Remove

1. 1. Open bonnet
2. 2. Disconnect battery
3. 3. Raise vehicle • Half height
4. 4. Remove front panelling • 4 bolts (2) and (4), 5 clips (1) and (3) • Remove external temperature sensor

5. 5. Place collecting basin underneath.
6. 6. Drain coolant • Open radiator drain plug • Collect coolant • Close drain plug
7. 7. Lower vehicle • Half height
8. 8. Detach upper radiator hose (3) • From radiator – 1 clip – 1 clip (2)
9. 9. Detach coolant hose (1) • Unclip coolant hose from fan housing – 2 clips

10. 10. Remove air intake manifold • see illustration of air duct, Z 16 XEP – From air cleaner housing to resonator
11. 11. Remove resonator • see illustration of air duct, Z 16 XEP • 2 fastening bolts • 2 clips
12. 12. Raise vehicle • Half height
13. 13. Remove condenser (1) • 2 fastening bolts (2) and (3) • Attach condenser to front panel

14. 14. Detach wiring harness for air conditioning • From compressor – 1 plug (5) • From coolant temperature sensor – 1 plug (3) – 1 cable tie • From air conditioning pressure switch – 1 plug (1) – 1 clip (2)
15. 15. Detach lower radiator hose (4) • From radiator – 1 clip

16. 16. Raise vehicle • Half height
17. 17. Detach cooling module wiring harness plug • Unlock rotary plug (1) anticlockwise (arrow), disconnect rotary plug • Detach wiring harness plug (2) from side member – unlock with screwdriver
18. 18. Remove earth cable (3) • From side member – 1 fastening nut

19. 19. Secure radiator • On upper brackets (1) and (2) with suitable tool

20. 20. Remove lower radiator bracket (1) • 2 off – 4 fastening bolts

Note. Note different radiator brackets

21. 21. Remove radiator • Remove fuses • Lower radiator down and out
22. 22. Empty radiator residue
23. 23. Detach fan housing (2) • 2 fastening bolts (1)

24. 24. Remove rubber bearings • From radiator – 2 off

Install

25. 25. Fit rubber bearings • To radiator – 2 off
26. 26. Attach fan housing • 2 fastening bolts
27. 27. Install radiator • Insert radiator in upper bracket and fix in place
28. 28. Fit lower radiator bracket • 2 off – 4 fastening bolts – Tightening torque 15 Nm

Note. Note different radiator brackets

29. 29. Release radiator
30. 30. Install ground cable • To side member – 1 fastening nut
31. 31. Attach cooling module wiring harness plug • Attach wiring harness plug to side member • 1 clip • Lock rotary plug clockwise
32. 32. Attach lower radiator hose • To radiator – 1 clip
33. 33. Attach wiring harness for air conditioning • To pressure switch, air conditioning – 1 plug – 1 clip • To coolant temperature sensor – 1 plug • To compressor – 1 plug
34. 34. Lower vehicle • Half height
35. 35. Fit condenser • Detach condenser from front plate • 2 fastening bolts
36. 36. Fit front panelling • Fit external temperature sensor • 4 bolts, 5 clips
37. 37. Lower vehicle • Half height
38. 38. Install resonator • 2 fastening bolts • 2 clips
39. 39. Install air intake pipe. • From air cleaner housing to resonator
40. 40. Attach coolant hose • Clip coolant hose to fan housing – 3 clips
41. 41. Attach upper radiator hose • To radiator – 1 clip – 1 clip
42. 42. Connect battery
43. 43. Top up coolant or ensure correct quantity is present.
44. 44. Programme transient memory
45. 45. Close bonnet