How to Replace the Radiator Opel Astra H

Remove

1. 1. Open bonnet
2. 2. Disconnect battery • Detach earth connection from earth terminal – Slacken nut
3. 3. Remove front panelling
4. 4. Secure radiator to upper brackets (1) • Insert 2x suitable tools

5. 5. Place collecting basin underneath.
6. 6. Drain coolant • Open drain bolt on radiator (1) • Collect coolant • Close drain bolt

7. 7. Detach fan wiring harness from fan housing • Disconnect wiring harness plug (1) • Undo cable tie

8. 8. Remove bracket, right side of radiator (2) • Unscrew 2x bolts
9. 9. Remove bracket, left side of radiator (1) • Unscrew 2x bolts

10. 10. Lower vehicle by its full height
11. 11. Remove charge pressure sensor (1) • Unscrew bolt
12. 12. Detach charge air hose from intercooler • Release clamp (2)
13. 13. Detach turbocharger coolant return hose from radiator • Release clamp (3) • Unclip from bracket

14. 14. Detach charge air cooler from condenser • Unscrew bolt (2), unscrew nut (1)

Note. Coolant module is shown removed to give a clearer illustration

Note. Tilt intercooler forward in lower bracket

15. 15. Detach fan from radiator • Unscrew 2x bolts (1) • Remove fan from vehicle in direction of arrow

Note. Coolant module is shown removed to give a clearer illustration

16. 16. Detach upper radiator hose from radiator • Release clamp (1)

17. 17. Detach lower radiator hose from radiator • Release clamp (1)

18. 18. Raise vehicle by half its height
19. 19. Detach air conditioning wiring harness from radiator • Undo cable tie (1)

20. 20. Detach charge air hose (1) from radiator • Detach clamp – Unscrew bolt (1)

21. 21. Detach condenser from radiator • Unscrew 3x bolts (1)

Note. Condenser is shown removed to give a clearer illustration

22. 22. Suspend condenser with intercooler from closure plate
23. 23. Remove 2x radiator retainers from bracket
24. 24. Carefully remove radiator from below

Note. Avoid damaging the radiator fins

Install

25. 25. Install radiator from below • Insert 2x radiator retainers in bracket
26. 26. Install 2x radiator retainers in bracket
27. 27. Detach condenser with intercooler from closure plate
28. 28. Attach condenser to radiator • Tighten 3x bolts
29. 29. Attach charge air hose to radiator • Attach clamp – Tighten bolt
30. 30. Attach air conditioning wiring harness to radiator • Connect cable ties
31. 31. Lower vehicle by half its height
32. 32. Attach lower radiator hose to radiator • Fasten clamp
33. 33. Attach upper radiator hose to radiator • Fasten clamp
34. 34. Install fan housing • Clip coolant hose into bracket
35. 35. Attach fan housing to radiator • Screw in 2x bolts
36. 36. Attach intercooler to condenser • Tighten 2x bolt 5 Nm

Important. Insert bolt with screw locking compound

37. 37. Attach coolant return hose from turbocharger to radiator • Fasten clamp • Mount in bracket
38. 38. Attach charge pressure sensor • Tighten bolt
39. 39. Fit charge air hose between charge air pipe and intercooler • Tighten 2x clamps
40. 40. Raise vehicle by its full height
41. 41. Install left radiator bracket • Tighten 2x bolt 15 Nm
42. 42. Install right radiator bracket • Tighten 2x bolt 15 Nm
43. 43. Attach fan wiring harness to fan housing • Connect cable ties • Fix wiring harness plug
44. 44. Fit front panelling
45. 45. Lower vehicle by half its height
46. 46. Remove 2x radiator retainers from bracket
47. 47. Connect battery • Attach ground connection to ground terminal – Tighten nut
48. 48. Fill with coolant and correct coolant level
49. 49. Programme transient memory
50. 50. Close bonnet