Replace Radiator (With Air Conditioning) Opel Astra H

Remove

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

4. 4. Raise vehicle by half its height
5. 5. Detach front panelling (1) • Remove 5x body-bound rivets (3) • Unscrew 4x bolts (4)
6. 6. Remove front panelling • Push front panelling upwards in direction of arrow and pull out of bracket • Remove front panelling – Unclip 4x clips (2) • Detach outside temperature sensor – Unclip 1x clip

Note. Use a second person

7. 7. Raise vehicle by half its height
8. 8. Detach the lower engine cover and right engine splash guard
9. 9. Place collecting basin underneath.
10. 10. Drain coolant • Open drain bolt on radiator (1) • Collect coolant • Close drain bolt

11. 11. Detach wiring harness from radiator • Detach wiring harness plug (1) from fan motor • Detach 2x cable ties

12. 12. Detach refrigerant line (1) from radiator • Open clip (4)
13. 13. Detach compressor wiring harness (2) from radiator • Undo clip
14. 14. Detach right coolant hose (3) from radiator • Release clamp
15. 15. Detach 2x vacuum lines (5) from radiator • Unclip from bracket

16. 16. Secure radiator at upper radiator brackets (1) • Insert 2x suitable tools

17. 17. Remove lower radiator bracket (1) • Unscrew 4x bolts

Note. Note: brackets are not the same

18. 18. Lower vehicle by its full height
19. 19. Remove battery • Detach positive terminal (3) from positive pole – Slacken nut • Remove bracket 1) – Unscrew bolt (2)

20. 20. Remove control unit, pre-heating system (1) • Pull pre-heating system control unit out of bracket in direction of arrow • Disconnect wiring harness connector.

21. 21. Detach expansion tank coolant hose (2) from radiator • Release clamp
22. 22. Detach left coolant hose (1) from radiator • Release clamp

23. 23. Detach charge air hose (1) from charge air pipe. • Release clamp

24. 24. Detach fan housing from radiator • Unscrew 2x bolts (2) • Unclip charge air pipe (1)

25. 25. Raise vehicle by half its height

26. 26. Suspend condenser from top of front panel
27. 27. Detach condenser with auxiliary fan and intercooler from radiator • Unscrew 5x bolts (1 to 3) and (5) • Pull intercooler from bracket (4)
28. 28. Remove radiator • Remove 2x fuses from bracket

Install

29. 29. Modify attaching parts • Charge air pipe bracket • Vacuum line brackets • Radiator holder rubbers • 6x locking nuts
30. 30. Install radiator • Insert 2x fuses in bracket
31. 31. Attach condenser with auxiliary fan and intercooler to radiator • Insert condenser into bracket • Tighten 5x bolt 5 Nm

Important. Insert bolt with thread locking compound

32. 32. Detach condenser from top of front plate
33. 33. Raise vehicle by half its height
34. 34. Attach 2x vacuum lines from radiator • Clip into bracket
35. 35. Attach right coolant hose to radiator • Fasten clamp
36. 36. Attach compressor wiring harness to radiator • Attach clip
37. 37. Install lower radiator bracket • Screw in 4x bolts 15 Nm

Note. Note: brackets are not the same

38. 38. Remove 2x retainers from upper radiator bracket
39. 39. Attach refrigerant line to radiator • Close clip
40. 40. Attach wiring harness to radiator • Attach 2x cable ties • Fix wiring harness plug
41. 41. Install lower engine cover and right engine splash guard
42. 42. Lower vehicle by half its height
43. 43. Insert front panelling • Clip in outside temperature sensor • Insert front panelling – Clip in 4x clips

Note. Use a second person

44. 44. Fit front panelling • Install 5x body-bound rivets • Tighten 4x bolts
45. 45. Lower vehicle by half its height
46. 46. Attach fan housing to radiator • Insert into bracket • Tighten 2x bolts • Clip in charge air pipe
47. 47. Attach charge air hose to charge air pipe • Fasten clamp
48. 48. Attach left coolant hose to radiator • Fasten clamp
49. 49. Attach expansion tank coolant hose to radiator • Fasten clamp
50. 50. Install control unit - pre-heating system • Fix wiring harness plug • Clip to battery support
51. 51. Install battery • Install bracket – Tighten bolt • Attach positive connection to positive terminal – Tighten nut
52. 52. Connect battery • Attach ground connection to ground terminal – Tighten nut
53. 53. Install radiator grille • Clip into front panelling – Clip in 5x clips • Install 4x body-bound rivets
54. 54. Top up coolant or ensure correct quantity is present.
55. 55. Program volatile memories
56. 56. Close bonnet