How to Remove and Install the Intercooler Opel Zafira B

Remove

1. 1. Remove charge pressure sensor wiring harness plug (1) from charge pressure sensor (2) and remove charge pressure sensor from intercooler,
2. 2. Detach charge air hose (3) from intercooler and throttle body.
3. 3. Remove front panelling – see operation "Front Panelling, Remove and Install" in group "A".

Install

4. 4. Remove impact absorber (4) – see operation "Impact Absorber, Remove and Install" in group "A".
5. 5. Detach lower charge air hose (3) from intercooler.
6. 6. Unclip auxiliary fan motor wiring harness (2) from intercooler.
7. 7. Remove intercooler mounting bolts (1) from radiator and remove intercooler.

8. 8. Insert intercooler and attach to radiator – Tightening torque – 5 Nm / 3.7 lbf. ft ,
9. 9. Clip auxiliary fan motor wiring harness into intercooler.
10. 10. Attach lower charge air hose to intercooler – Tightening torque 3.5 Nm / 2.6 lbf. ft ,
11. 11. Install impact absorber – see operation "Impact Absorber, Remove and Install" in group "A".
12. 12. Install front panelling – see operation "Front Panelling, Remove and Install" in group "A".
13. 13. Attach charge air hose to intercooler and throttle body – Tightening torque 3.5 Nm / 2.6 lbf. ft ,
14. 14. Attach charge pressure sensor to intercooler and connect charge pressure sensor wiring harness plug to charge pressure sensor,