Replace Engine Oil Cooler / Heat Exchanger Opel Astra H

Remove

1. 1. Disconnect battery and remove
2. 2. Detach battery support from body
3. 3. Remove oil drain bolt

Note. Collect engine oil

4. 4. Install oil drain bolt with new seal ring 10 Nm
5. 5. Remove inlet manifold
6. 6. Disconnect wiring harness plugs for knock sensor (1), ignition module (5), mixture regulating oxygen sensor (3), and ignition coil capacitor (2) and expose.
7. 7. Detach wiring harness plug bracket (4) from coolant flange

8. 8. Detach auxiliary coolant pump coolant hose (1) from coolant flange (4) and lay aside
9. 9. Remove lower coolant hose from heat exchanger
10. 10. Detach coolant expansion tank coolant hose (3) and heater core (2) from heat exchanger and lay aside

11. 11. Detach coolant hose (3) from thermostat housing
12. 12. Detach coolant hose (4) from coolant pump housing
13. 13. Detach heat exchanger oil lines (2) from heat exchanger

Note. Place collecting basin underneath.

14. 14. Detach heat exchanger fastening bolts (1) from heat exchanger
15. 15. Remove heat exchanger

Install

16. 16. Insert heat exchanger and attach to cylinder block with fastening bolts 20 Nm .
17. 17. Attach oil lines to heat exchanger with new seal rings 30 Nm
18. 18. Attach coolant hose to coolant pump housing
19. 19. Attach thermostat housing coolant hose to thermostat housing
20. 20. Attach coolant expansion tank coolant hose and heater core to heat exchanger
21. 21. Attach lower coolant hose to heat exchanger
22. 22. Attach auxiliary coolant pump coolant hose to coolant flange
23. 23. Attach wiring harness plug bracket to coolant flange 8 Nm
24. 24. Connect wiring harness plugs for knock sensor, ignition module, mixture regulating oxygen sensor, and ignition coil capacitor and route wiring harnesses
25. 25. Install intake manifold
26. 26. Attach battery support to body 15 Nm
27. 27. Install and connect battery
28. 28. Fill with oil up to "MAX" mark on oil dipstick
29. 29. Always use antifreeze 19 40 650 / 9194431 (red) and ensure that the concentration is 50% water and 50% antifreeze. The antifreeze does not just protect the entire cooling system from freezing, but also protects all coolant-flushed parts from rust-corrosion/calcium deposits. It is therefore important to add antifreeze, even in tropical countries.
30. 30. The water quality also plays an important role in addition to the mix ratio. Water of drinkable quality usually meets these requirements. The quality of purified sea water is inadequate!
31. 31. Damage may also be caused to the engine if unauthorised anti-freeze agent is used!
32. 32. If radiator, cylinder head or cylinder head gasket have been replaced the old coolant must not be re-used.

Important. Vehicles with air conditioning: switch air conditioning off and set to ECO mode with ECC

33. 33. Open cooling system Warning: Cooling system is under pressure • Unscrew coolant expansion tank cover
34. 34. Fill with coolant up to lower venting line (1) at coolant expansion tank
35. 35. Seal off cooling system • Screw in coolant expansion tank cover
36. 36. Start engine and allow to warm up • Allow engine to warm up at idling speed of up to 2500 rpm until first radiator fan setting switches on
37. 37. Vent cooling system • Allow engine to run for approximately 2 minutes at 2000 to 2500 rpm

Note. The air in the cooling system is removed via the venting lines

38. 38. Switch engine off and allow to cool
39. 39. Check coolant level and also top up coolant to "COLD" mark