Replace Radiator (Without 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. Lower vehicle by half its height
13. 13. Detach right coolant hose (1) from radiator • Release clamp

14. 14. Detach 2x vacuum lines (1) from radiator • Unclip from bracket (2)

15. 15. Detach wiring harness of auxiliary fan motor (1) • Disconnect wiring harness connector. • Unfasten 3x cable ties

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

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

18. 18. Lower vehicle by half its 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 intercooler • Release clamp

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

25. 25. Detach coolant hose (2) from fan housing • Release from clip (2)

26. 26. Raise vehicle by half its height
27. 27. Remove cooling module • Remove 2x fuses from bracket

Install

28. 28. Modify attaching parts • Charge air pipe • Fan housing • Auxiliary fan housing • Charge air pipe • Charge air pipe bracket • Vacuum line brackets • Radiator holder rubbers • 6x locking nuts
29. 29. Install cooling module • Insert 2x fuses in bracket
30. 30. Install lower radiator bracket • Tighten 4x bolt 15 Nm
31. 31. Attach 2x vacuum lines from radiator • Clip into bracket
32. 32. Attach right coolant hose to radiator • Fasten clamp
33. 33. Attach wiring harness of auxiliary fan motor • Fix wiring harness plug • Attach 3 cable ties
34. 34. Remove 2x retainers from upper radiator bracket
35. 35. Raise vehicle by half its height
36. 36. Attach wiring harness of fan motor • Attach cable ties • Fix wiring harness plug
37. 37. Install lower engine cover and right engine splash guard
38. 38. Lower vehicle by half its height
39. 39. Insert front panelling • Clip in outside temperature sensor • Insert front panelling – Clip in 4x clips

Note. Second mechanic

40. 40. Fit front panelling • Install 5x body-bound rivets • Tighten 4x bolts
41. 41. Lower vehicle by half its height
42. 42. Clip coolant hose into fan housing
43. 43. Attach charge air hose to charge air pipe • Fasten clamp 3.5 Nm
44. 44. Attach charge air hose to intercooler • Fasten clamp 3.5 Nm
45. 45. Attach left coolant hose to radiator • Fasten clamp • Clip into bracket
46. 46. Attach expansion tank coolant hose to radiator • Fasten clamp
47. 47. Install control unit - pre-heating system • Clip to battery support
48. 48. Install battery • Install bracket – Tighten bolt • Attach positive connection to positive terminal – Tighten nut
49. 49. Connect battery • Attach ground connection to ground terminal – Tighten nut
50. 50. Install radiator grille • Clip into front panelling – Clip in 6x clip • Install 4x body-bound rivets
51. 51. Top up coolant or ensure correct quantity is present.
52. 52. Program volatile memories
53. 53. Close bonnet