Replace Coolant Pump Opel Astra H

Spezialwerkzeugliste:

KM-J-43651

Remove

1. 1. Open bonnet
2. 2. Disconnect battery • Detach earth cable
3. 3. Remove air cleaner housing (4) • If present: unclip bonnet contact switch (1) • Unscrew bolt (2) • Unclip tank vent line (3) • Release and disconnect wiring harness plug of hot film mass air flow meter (7) – Unclip wiring harness (6) from bracket • Detach intake pipe – Loosen clamp (5)

4. 4. Remove engine cover.

5. 5. Remove exhaust manifold heat shield, air cleaner housing • Detach engine transport shackle (2) – Unscrew nut (1) • Unscrew 3x stud bolt (3)
6. 6. Raise vehicle by its full height
7. 7. Remove lower engine compartment cover (2) • Unscrew 4x bolts (1) • Remove 2x body-bound rivets (3)

8. 8. Place collecting basin underneath.
9. 9. Unscrew coolant pump coolant drain bolt (arrow)
10. 10. Lower vehicle by its full height
11. 11. Drain coolant • Unscrew closure cap of coolant expansion tank

Note. Opening the coolant compensation tank accelerates coolant drainage

12. 12. Detach wiring harness plug for coolant temperature sensor (1) • Unclip wiring harness (2)
13. 13. Detach coolant hose (3) • From thermostat housing

14. 14. Detach 2x heating hose • From radiator
15. 15. Remove thermostat housing • Unscrew stud bolt (3) • Unscrew 2x bolts (1)

Note. Pull thermostat housing with coolant pipe (2) out of coolant pump

16. 16. Raise vehicle by its full height
17. 17. Close coolant drain screw
18. 18. Detach coolant pump service cover • Unscrew 4x bolts (1)

19. 19. Fix coolant pump sprocket • Use KM-J-43651 (1) – Tighten 3x bolt (3) (4), there is space to further rotate KM-J-43651 clockwise • Screw in 2x bolt (2) • Rotate KM-J-43651 on fastening bolt (6) clockwise in order to eliminate any clearance in timing chain drive • Tighten 2x bolt (5) and (7) while keeping bolt (6) under tension

Note. Note that in the long holes

Important. The following process must definitely be implemented. Failure to comply with this instruction may lead to overtensioning of the timing chain and hence lead to noise and damage to components.

20. 20. Undo coolant pump sprocket • Unscrew 3x bolts (3)

21. 21. Undo coolant pump • Unscrew 2x bolts (1)

22. 22. Remove coolant pump • Unscrew 2x bolts (1) – Unscrew lower bolt – Lower vehicle by its full height – Unscrew upper bolt

Note. Lower bolt cannot be removed.

23. 23. Clean sealing surfaces.

Install

24. 24. Insert coolant pump For this reason, the position of the drive flange of the old coolant pump must be transferred to the drive flange of the new coolant pump. • Replace gasket

Note. To ensure problem-free assembly, the sprocket holes must be flush with the threaded holes in the drive flange of the new coolant pump.

Note. Coat gasket lightly with silicone grease (white).

25. 25. Attach coolant pump • Tighten 3x bolt 23 Nm

Note. 2x bolt on back side and lower bolt on timing side

26. 26. Lower vehicle by its full height
27. 27. Fasten upper coolant pump on timing side • Tighten upper bolt 23 Nm
28. 28. Raise vehicle by its full height
29. 29. Fasten coolant pump sprocket • Tighten 3x bolt 8 Nm
30. 30. Detach KM-J-43651
31. 31. Attach coolant pump • Tighten 3x bolt 23 Nm
32. 32. Attach coolant pump service cover • Replace gasket • Tighten 4x bolts 7 Nm
33. 33. Install lower engine compartment cover • Tighten 4x bolts • Install 2x body-bound rivets
34. 34. Lower vehicle by its full height
35. 35. Install coolant pipe • Replace 2x coolant pipe seal ring • Insert coolant pipe – In thermostat housing

Note. Coat gasket lightly with silicone grease (white)

Note. Sprue on coolant pipe engages in recess on thermostat housing

36. 36. Install thermostat housing • Replace gasket • Tighten 2x bolt 9 Nm • Tighten stud bolt 9 Nm

Note. Coat gasket lightly with silicone grease (white)

37. 37. Attach 2x heater hose • On radiator, thermostat housing
38. 38. Attach coolant hose • To thermostat housing
39. 39. Connect wiring harness plug for coolant temperature sensor • Attach wiring harness
40. 40. Attach exhaust manifold heat shield • Tighten 2 stud bolts 23 Nm • Tighten bolt • Install wiring harness bracket – Tighten nut – Tighten bolt • Connect 2x wiring harness plug, oxygen sensor

Note. Insert engine transport shackle

41. 41. Install air cleaner housing • Install intake pipe – Tighten clamp • Attach wiring harness • Connect wiring harness plug of hot film mass air flow meter • Attach engine vent hose
42. 42. Attach engine cover
43. 43. Top up coolant • Observe specified coolant quantity

Note. Fill and bleed cooling system

44. 44. Connect battery
45. 45. Close bonnet
46. 46. Program volatile memories