Replace Radiator (With Air Conditioning, At) Opel Astra H

Remove

1. 1. Open bonnet
2. 2. Disconnect battery • Detach ground connection from ground terminal – Undo nut
3. 3. Detach radiator grille (2) • Detach 4x body-bound rivets (1) • Release 6x lugs from front panelling

4. 4. Detach fan from radiator • Unscrew 2x bolts (1) • Remove 2x fans from bracket (2)

Note. Fan is shown in removed state to provide a better overview

5. 5. Raise vehicle by half its height
6. 6. Detach front panelling (3) • Remove 5x body-bound rivets (2) • Unscrew 4x bolts (1)

7. 7. Place collecting basin underneath.
8. 8. Detach high-pressure headlamp cleaning system hose from reservoir (2) • Undo quick-release fitting (1)

Note. Escaping fluid

9. 9. Remove front panelling • Second man • Detach front panelling from bracket – Unclip 4x clips (1) • Unclip outside temperature sensor

Note. Push front panelling upwards at side and pull out of bracket

10. 10. Secure radiator at right and left using suitable wire bars (1) • Insert 2x wire bars

11. 11. Raise vehicle by half its height
12. 12. Place collecting basin underneath.
13. 13. Drain coolant • Open drain bolt on radiator (1) • Collect coolant • Close drain bolt

14. 14. Disconnect wiring harness from left side of radiator • Undo cable tie (1)

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

17. 17. Place collecting basin underneath.
18. 18. Detach lower radiator hose (2) from radiator (4) • Release clamp (1)
19. 19. Detach lower oil line from radiator • Unscrew bolt (3)

20. 20. Detach wiring harness from right side of radiator (2) • Unclip cable tie (3) from bracket (1)

21. 21. Lower vehicle by its full height
22. 22. Detach expansion tank coolant hose (1) from radiator (3) • Release clamp (2)

23. 23. Detach upper oil line (1) from radiator • Unscrew bolt (2)

24. 24. Detach upper radiator hose (1) from radiator • Release clamp (2)

25. 25. Raise vehicle by half its height
26. 26. Detach condenser from radiator • Suspend condenser from top at front using suitable strap • Unscrew 4x bolts (1)

27. 27. Lower radiator down and out • Remove 2x retainers from radiator bracket
28. 28. Radiator, Replace • Transfer 6x plate nuts • Transfer 2x rubber bearings

Install

29. 29. Insert radiator from below • Install 2x retainers in radiator bracket
30. 30. Attach condenser to radiator • Tighten 4x bolts • Unhook evaporator from front at top
31. 31. Lower vehicle by half its height
32. 32. Attach top radiator hose to radiator • Fasten clamp
33. 33. Attach upper oil line to radiator • Tighten bolt with new seals
34. 34. Attach expansion tank coolant hose to radiator • Fasten clamp
35. 35. Raise vehicle by its full height
36. 36. Attach wiring harness to right side of radiator
37. 37. Attach lower oil line to radiator • Tighten bolt with new seals
38. 38. Attach lower radiator hose to radiator • Fasten clamp
39. 39. Install left radiator bracket • Tighten 2x bolt 15 Nm
40. 40. Install right radiator bracket • Tighten 2x bolt 15 Nm
41. 41. Attach wiring harness to left side of radiator
42. 42. Lower vehicle by half its height
43. 43. Insert front panelling • Second man • Attach front panelling to bracket – Clip in 4x clips • Clip in outside temperature sensor

Note. Slide front panelling into bracket from side

44. 44. Attach high-pressure headlamp cleaning hose to reservoir • Connect quick-release fitting
45. 45. Fit front panelling • Install 5x body-bound rivets • Screw in 4x bolts
46. 46. Lower vehicle by half its height
47. 47. Remove 2x radiator retainers from bracket • Remove 2x retainers
48. 48. Attach fan to radiator • Install 2x fans in bracket • Tighten 2x bolts
49. 49. Install radiator grille • Clip into front panelling – Clip in 5x clips • Install 4x body-bound rivets
50. 50. Connect battery • Attach ground connection to ground terminal
51. 51. Fill and bleed cooling system
52. 52. Check and correct transmission fluid AT
53. 53. Programme transient memory
54. 54. Close bonnet