How to Remove and Install the Coolant Pipe Opel Astra H

Remove

1. 1. Remove turbocharger
2. 2. Remove battery • Detach positive terminal (3) from positive pole – Slacken nut • Remove bracket 1) – Unscrew bolt (2)

3. 3. Remove battery support. • Unclip control unit of pre-heating system (4) • Unclip coolant hose bracket (5) • Detach wiring harness – Unclip 2x from battery support (1) • Unclip wiring harness plug (3) • Unscrew 3x bolts (2)

4. 4. Detach coolant hose between thermostat housing and radiator (1) from thermostat housing • Release clamp

5. 5. Detach heat exchanger coolant return hose from coolant pipe (1) • Release clamp

6. 6. Remove coolant return pipe (1) • Unscrew bolt, nut (arrows)

7. 7. Remove coolant pipe (1) • Detach coolant pipe from cylinder block – Unscrew bolt (2) • Detach coolant pipe from thermostat housing – Unscrew bolt • Draw coolant pipe out of coolant flange in direction of arrow • Unclip vacuum hose • Detach coolant hose between coolant pipe and thermostat housing flange (3) from coolant pipe – Release clamp

Install

8. 8. Install coolant pipe • Attach coolant hose between coolant pipe and thermostat housing flange to coolant pipe – Fasten clamp • Clip in vacuum hose • Insert coolant pipe into coolant flange – Replace sealing ring • Attach coolant pipe to cylinder block – Tighten bolt 95 Nm • Attach coolant pipe to thermostat housing – Tighten bolt 24 Nm
9. 9. Install coolant return pipe • Tighten bolt 51 Nm • Tighten nuts 24 Nm
10. 10. Attach heat exchanger coolant return hose to coolant pipe • Fasten clamp
11. 11. Attach coolant hose between thermostat housing and radiator to thermostat housing • Fasten clamp
12. 12. Install battery holder • Tighten 3x bolts • Clip in wiring harness plug • Attach wiring harness – Clip 2x to battery support • Clip in bracket for coolant hose • Clip in control unit of pre-heating system
13. 13. Install battery • Install bracket – Tighten bolt • Attach positive connection to positive terminal – Tighten nut
14. 14. Install turbocharger