Engine Cooling System: Removal & Installation Saturn Astra I

Removal Procedure

1. Remove the battery. Refer to «Battery Replacement»(ref-302301-S27012632912008102100000) .
2. Place the drain pan below the surge tank.
3. Remove the surge tank. Unclip the coolant hoses. Detach the coolant hoses (1).

Installation Procedure

1. Install the surge tank. Attach the coolant hoses.
2. Install the battery. Refer to «Battery Replacement»(ref-302301-S27012632912008102100000) .
3. Fill the cooling system. Refer to «Cooling System Draining and Filling»(ref-302344-S34056996812008102100000) .

Scheme 3

Scheme 4

Scheme 5

1. Open the hood.
2. Disconnect the battery. Disconnect the ground connection from the ground terminal. Loosen the nut.
3. Raise the vehicle by its full height.
4. Place a drain pan underneath.
5. Drain the coolant. Place a drain pan underneath. Install a suitable hose to the drain connection (2). Open the coolant drain screw (1). Drain the coolant. Close the coolant drain screw.
6. Lower the vehicle by its full height.
7. Remove the coolant pipe (1) between the thermostat housing and the oil filter adapter. Remove the 2 bolts (2). Draw out of the oil filter housing.

1. Clean the sealing surface. Oil filter housing Thermostat housing
2. Install the thermostat housing coolant pipe to the oil filter adapter. Use 2 new gaskets. Push into the oil filter housing. Tighten: Tighten the 2 bolts to 8 N.m (70 lb in).
3. Connect the battery. Connect the ground connection to the ground terminal. Tighten: Tighten the nut to 5 N.m (44 lb in).
4. Fill and bleed the cooling system. Refer to «Cooling System Draining and Filling»(ref-302344-S34056996812008102100000) .
5. For programming procedures, refer to «Control Module References»(ref-302291-S24032387652008102100000) .
6. Close the hood.

1. Remove the oil filter adapter. Refer to «Oil Filter Adapter Replacement»(ref-302346-S37784863372008102100000) .
2. Remove the heat exchanger (1) from the oil filter adapter. Remove the 6 bolts (2).

1. Clean the sealing surface.
2. Install the heat exchanger to the oil filter adapter. Use a NEW gasket. Tighten: Tighten the 6 bolts to 2.5 N.m (22 lb in).
3. Install the oil filter adapter. Refer to «Oil Filter Adapter Replacement»(ref-302346-S37784863372008102100000) .

1. Open the hood.
2. Disconnect the battery. Remove the negative connection from the ground terminal. Loosen the nut.
3. Raise the vehicle by its full height.
4. Remove the compressor wiring harness from the fan housing. Disconnect the cable tie.
5. Lower the vehicle by its full height.
6. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-302298-S24403051502008102100000) .
7. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Inlet Duct Replacement»(ref-302298-S09162314662008102100000) .
8. Remove the upper radiator hose (1) from the fan housing. Remove 2x from the bracket (2).
9. Disconnect the coolant hose (1) from the bracket (2).
10. Disconnect the cooling module wiring harness plug (1).
11. Remove the fan housing.
12. Remove the 2 bolts (1).
13. Pull the 2 brackets (2) upward out of the radiator.
14. Lift the fan housing up and off.
15. Remove the fan motor out of the fan housing.
16. Disconnect the wiring harness plug (1).
17. Remove the bolt (2).
18. Disconnect the wiring harness (arrows).
19. Remove the 3 bolts (3).

1. Install the fan motor in the fan housing. Tighten: Tighten the 3 bolts to 3 N.m (26 lb in). Install the wiring harness plug. Install the bolt. Connect the 2 wiring harnesses.
2. Install the fan housing to the radiator. Tighten: Tighten the 2 bolts to 5 N.m (44 lb in).
3. Connect the cooling module wiring harness plug.
4. Install the 3 coolant hoses.
5. Install the air cleaner outlet resonator. Refer to «Air Cleaner Inlet Duct Replacement»(ref-302298-S09162314662008102100000) .
6. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-302298-S24403051502008102100000) .
7. Raise the vehicle by its full height.
8. Install the compressor wiring harness to the fan housing. Connect the cable ties.
9. Lower the vehicle by its full height.
10. Connect the battery. Install the negative connection to the ground terminal. Tighten: Tighten the nut to 5 N.m (44 lb in).
11. For reprogramming procedures, refer to «Control Module References»(ref-302291-S24032387652008102100000) .
12. Close the hood.

1. Raise the vehicle.
2. Remove the fascia. Refer to «Front Bumper Fascia Replacement»(ref-302288-S30625941892008102100000) .
3. Remove the auxiliary fan (1). Disconnect the cable ties. Unclip the relays. Disconnect the wiring harness connector. Detach the wiring harness. Unclip the clips. Remove the nuts. Pull the auxiliary fan from the bracket and remove from below.

1. Install the auxiliary fan. Insert the auxiliary fan housing into the bracket Tighten: Tighten the nuts to 5 N.m (44 lb in). Attach the wiring harness. Clip in the clips. Fix the wiring harness plug. Clip in the relays. Attach the cable ties.
2. Install the front fascia. Refer to «Front Bumper Fascia Replacement»(ref-302288-S30625941892008102100000) .
3. Lower the vehicle.

1. Disconnect the battery.
2. Disconnect the negative cable.
3. Disconnect the positive cable.
4. Remove the battery holder (1). Remove the bolt.
5. Remove the battery.
6. Remove the surge tank from the bracket. Remove the tank in the direction of travel (arrow) from the bracket.
7. Disconnect the wiring harness plug.
8. Remove the coolant level indicator. Disconnect the lug (1).

1. Insert the coolant level indicator. Connect the lug.
2. Connect the wiring harness plug.
3. Insert the surge tank into the bracket.
4. Insert the battery.
5. Install the battery holder. Tighten: Tighten the bolt to 15 N.m (11 lb ft).
6. Connect the battery. Connect the positive cable. Connect the negative cable.
7. For reprogramming procedures, refer to «Control Module References»(ref-302291-S24032387652008102100000) .

Engine Coolant Thermostat Housing Replacement

Special Tools

1. MK-6340 Locking Tool. See «Special Tools»(ref-302344-S04730840612008102100000) .
2. MK-6628 Locking Tool. See «Special Tools»(ref-302344-S04730840612008102100000) .

1. Remove the camshaft sensor of exhaust camshaft. Disconnect the wiring harness connector. Remove the bolt.
2. Remove the camshaft sensor of intake camshaft. Disconnect the wiring harness connector. Remove the bolt.
3. Remove the camshaft adjustment valve, exhaust camshaft. Disconnect the wiring harness connector. Disconnect the wiring harness from the cylinder head. Remove the bolt.
4. Remove the camshaft adjustment valve, intake camshaft. Disconnect the wiring harness connector. Remove the bolt.
5. Remove the closure bolt, exhaust camshaft adjuster.
6. Remove the intake camshaft closure bolt.
7. Install the MK-6340 . See «Special Tools»(ref-302344-S04730840612008102100000) .
8. Slacken the exhaust camshaft adjuster. Counterhold at the camshaft hexagon.
9. Detach the exhaust camshaft adjuster. Remove the bolt.
10. Slacken the intake camshaft adjuster. Counterhold at the camshaft hexagon.
11. Detach the intake camshaft adjuster. Remove the bolt.
12. Remove the rear toothed belt cover. Unclip the wiring trough cover. Remove the 4 bolts.
13. Remove the thermostat housing. Remove the 4 bolts.

1. Attach the thermostat housing. Use a new gasket. Tighten: Tighten the 4 bolts to 8 N.m (70 lb in).
2. Clean the 4 thread, rear toothed belt cover.
3. Install the rear toothed belt cover. Coat the 4 bolts with locking compound (red). Tighten: Tighten the 4 new bolts to 6 N.m (53 lb in). Clip in the wiring trough cover.
4. Attach the intake camshaft adjuster. Install the bolt.
5. Attach the exhaust camshaft adjuster. Install the bolt.
6. Insert MK-6340 . See «Special Tools»(ref-302344-S04730840612008102100000) .
7. Insert MK-6628 into camshafts. See «Special Tools»(ref-302344-S04730840612008102100000) . Align camshafts using hexagon until MK-6628 can be inserted in both camshafts. See «Special Tools»(ref-302344-S04730840612008102100000) .
8. Tighten the exhaust camshaft adjuster. Counterhold at the camshaft hexagon. Tighten: Tighten the exhaust camshaft adjuster to 65 N.m (48 lb ft) plus 120 degrees plus 15 degrees.
9. Tighten the intake camshaft adjuster. Counterhold at the camshaft hexagon. Tighten: Tighten the intake camshaft adjuster to 65 N.m (48 lb ft) plus 120 degrees plus 15 degrees.
10. Tighten the exhaust camshaft adjuster closure bolt. Replace the seal ring. Tighten: Tighten the bolt to 30 N.m (22 lb ft).
11. Tighten the closure bolt, intake camshaft adjuster. Replace the seal ring. Tighten: Tighten the bolt to 30 N.m (22 lb ft).
12. Install the camshaft adjustment valve, exhaust camshaft. Tighten the bolt. Clip the wiring harness to the cylinder head. Connect the wiring harness plug.
13. Install the camshaft adjustment valve, intake camshaft. Tighten the bolt. Connect the wiring harness plug.
14. Install the camshaft sensor of exhaust camshaft. Tighten the bolt. Connect the wiring harness plug.
15. Install the camshaft sensor, intake camshaft. Tighten the bolt. Connect the wiring harness plug.

1. Open the hood.
2. Disconnect the battery. Remove the negative connection from the ground terminal. Loosen the nut.
3. Raise the vehicle by its full height.
4. Place a drain pan underneath.
5. Drain the coolant. Place a drain pan underneath. Install the suitable hose to the drain connection (2). Open the coolant drain screw (1). Drain the coolant. Close the coolant drain screw.
6. Lower the vehicle by its full height.
7. Remove the wiring harness bracket (1) from the thermostat housing. Remove the nut (2).
8. Disconnect the thermostat wiring harness plug (4).
9. Remove the upper radiator hose (5) from the coolant discharge port. Release the clamp.
10. Remove the thermostat housing (3). Remove the 4 bolts.

1. Clean the sealing surface.
2. Install the thermostat. Replace the gasket. Tighten: Tighten the 4 bolts to 8 N.m (70 lb in).
3. Install the upper radiator hose to the coolant discharge port. Fasten the clamp.
4. Install the wiring harness bracket to the thermostat housing. Tighten: Tighten the nut to 5 N.m (44 lb in).
5. Connect the thermostat wiring harness plug.
6. Fill and bleed the cooling system. Refer to «Cooling System Draining and Filling»(ref-302344-S34056996812008102100000) .
7. Connect the battery. Install the negative connection to the ground terminal. Tighten: Tighten the nut to 5 N.m (44 lb in).
8. For reprogramming procedures, refer to «Control Module References»(ref-302291-S24032387652008102100000) .
9. Close the hood.

1. Reposition the air bleed hose clamp at the surge tank using SA9111E . See «Special Tools»(ref-302344-S04730840612008102100000) .
2. Remove the air bleed hose from the surge tank.
3. Reposition the air bleed hose clamp at the engine using SA9111E . See «Special Tools»(ref-302344-S04730840612008102100000) .
4. Remove the heater hoses from the engine.

1. Install the air bleed hose to the surge tank.
2. Install the air bleed hose to the engine
3. Reposition the hose clamps to secure the hose using SA9111E . See «Special Tools»(ref-302344-S04730840612008102100000) .
4. Fill the cooling system. Refer to «Cooling System Draining and Filling»(ref-302344-S34056996812008102100000) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-302298-S24403051502008102100000) .
2. Remove the water pump strap disc (1). Remove the 3 bolts (2). Do not remove. Counterhold against the bolt of the torsional vibration damper.
3. Raise the vehicle by its full height.
4. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-302346-S09616944802008102100000) .
5. Drain the coolant. Place a drain pan underneath. Install the suitable hose to the drain connection (2). Open the coolant drain screw (1). Drain the coolant. Close the coolant drain screw.
6. Lower the vehicle by its full height.
7. Remove the water pump strap disc. Remove the 3 bolts.
8. Remove the water pump (2) from the pump module (1). Remove the 5 bolts. Remove the water pump.
9. Clean the sealing surfaces.
10. Clean the thread. Clean the 3 water pump threads.

1. Install the water pump. Use NEW bolts. Tighten: Tighten the 5 bolts to 8 N.m (70 lb in).
2. Install the water pump strap disc. Install the 3 bolts. Use NEW bolts.
3. Raise the vehicle.
4. Install the drive belt. Refer to «Drive Belt Replacement»(ref-302346-S09616944802008102100000) .
5. Lower the vehicle.
6. Install the water pump belt pulley. Tighten: Tighten the 3 bolts to 20 N.m (15 lb ft).
7. Fill and bleed the cooling system. Refer to «Cooling System Draining and Filling»(ref-302344-S34056996812008102100000) .
8. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-302298-S24403051502008102100000) .

1. Open the hood.
2. Disconnect the battery. Remove the ground connection from the ground terminal. Loosen the nut.
3. Raise the vehicle by its full height.
4. Place a drain pan underneath.
5. Drain the coolant. Place a drain pan underneath. Install the suitable hose to the drain connection (2). Open the coolant drain screw (1). Drain the coolant. Close the coolant drain screw.
6. Lower the vehicle by its full height.
7. Remove the positive cable from the positive clamp. Remove the bolt.
8. Remove the battery. Remove the positive connection from the positive terminal. Loosen the nut. Remove the bracket. Remove the bolt.
9. Remove the battery support (1). Disconnect the 2 coolant hoses (3). Remove the wiring harness (4) from the battery support. Remove the 2 cable ties. Remove the 3 bolts (2).
10. Remove the upper radiator hose from the coolant flange. Release the clamp.
11. Remove the coolant pipe (1) between the thermostat housing and the oil filter adapter. Remove the 2 bolts (2). Draw out of the oil filter adapter.
12. Disconnect the thermostat wiring harness plug (7).
13. Disconnect the wiring harness plug for the coolant temperature sensor (4).
14. Remove the wiring harness bracket (1). Remove the nut (2).
15. Remove the 2 coolant hoses (5). Remove the 2 clamps.
16. Remove the coolant supply line for preheating of the throttle valve module (3). Disconnect the quick-release fitting.
17. Remove the coolant pump manifold. Remove the 4 bolts (6).

1. Clean the sealing surface.
2. Install the coolant pump manifold. Use a NEW gasket. NOTE: Refer to «Fastener Notice»(ref-302287-S04735057762008102100000) . IMPORTANT: It is essential to comply with the specified tightening sequence - risk of fracture. Screw in the 4 bolts evenly until the coolant pump manifold is in contact with the cylinder head. Tighten: Tighten the 4 bolts (1, 2, 3 and 4) to 8 N.m (71 lb in). Install the coolant pipe between the thermostat housing and the oil filter adapter. Use 2 new gaskets. Push into the oil filter adapter. Tighten: Tighten the 2 bolts to 8 N.m (71 lb in).
3. Install the coolant supply line for the preheating of the throttle valve module. Connect the quick release fitting.
4. Install the 3 coolant hoses to the thermostat housing. Install the 3 clamps.
5. Install the wiring harness bracket to the thermostat housing. Tighten: Tighten the nut to 2.5 N.m (22 lb in).
6. Connect the coolant temperature sensor wiring harness plug.
7. Connect the thermostat wiring harness plug.
8. Install the battery holder. Tighten: Tighten the 3 bolts to 15 N.m (11 lb ft). Clip on the coolant hose bracket. Clip on the 2 wiring harnesses.
9. Install the battery. Install the battery bracket. Tighten: Tighten the bolt to 5 N.m (44 lb in). Install the positive connection to the positive terminal. Tighten: Tighten the nut to 5 N.m (44 lb in).
10. Install the positive cable to the positive terminal. Tighten: Tighten the bolt to 5 N.m (44 lb in).
11. Connect the battery. Install the ground connection to the ground terminal. Tighten: Tighten the nut to 5 N.m (44 lb in).
12. Fill and bleed the cooling system. Refer to «Cooling System Draining and Filling»(ref-302344-S34056996812008102100000) .
13. For reprogramming procedures, refer to «Control Module References»(ref-302291-S24032387652008102100000) .
14. Close the hood.

1. Open the hood.
2. Disconnect the battery. Disconnect the negative connection. Loosen the nut.
3. Remove the upper grille. Remove the 4 body-bound rivets (1). Remove from the front fascia from above. Remove the 6 clips.
4. Remove the front fascia at the top. Remove the 2 bolts (1). Remove the 2 body-bound rivets (2). Disconnect the wiring harness connector.
5. Raise the vehicle by half its height.
6. Remove the front fascia. Remove the 6 body-bound rivets (2). Remove the 4 bolts (1).
7. Raise the vehicle by half its height.
8. Drain the coolant. Place a drain pan underneath. Install the suitable hose to the drain connection (2). Open the coolant drain screw (1). Drain the coolant. Close the coolant drain screw.
9. Disconnect the cooling module wiring harness plug (1).
10. Remove the radiator wiring harness. Disconnect the wiring harness plug for the coolant temperature sensor (1). Disconnect the 3 wiring harnesses. Cut the cable tie on the fan housing.
11. Place a drain pan underneath.
12. Remove the 2 radiator hoses from the radiator. Remove 2 clamps.
13. Lower the vehicle by its full height.
14. Remove the coolant hose from the radiator. Release the clamp. Remove the coolant hose.
15. Remove the 2 coolant hoses. Remove the radiator hose (top) from the bracket. Remove the coolant hose from the fan housing.
16. For vehicles equipped with an automatic transmission: Remove the lower oil cooling line (2) with the connecting hose from the oil cooler. Remove the banjo bolt. Remove the upper oil cooling line (1) with the connecting hose from the oil cooler. Remove the banjo bolt.
17. Remove the fan housing from the radiator. Remove the 2 bolts (1). Pull the 2 brackets (2) upward out of the radiator.
18. Secure the radiator to the upper brackets (1). Insert 2 suitable tools.
19. Remove the condenser from the radiator. Secure the condenser to the upper front with the retaining straps (1). Remove the 4 bolts (2, 3).
20. Raise the vehicle by its full height.
21. Remove the lower radiator bracket (1) from the front axle body. Remove the 4 bolts.
22. Lower the radiator down and out. Remove the fuses from the upper holders. Push the condenser forward. IMPORTANT: These operations must only be performed if the component is being replaced. Remove the attached parts from the radiator.

1. Remove the 2 rubber bearings.
2. Pull away the 6 sheet metal nuts.
3. Remove the coolant temperature sensor.

1. Install the attaching parts to the radiator. Install the 2 rubber bushes. Push on the 6 sheet metal nuts. Install the coolant temperature sensor.
2. Insert the radiator from below. Secure to the upper radiator with a suitable tool.
3. Install the lower radiator bracket. Tighten: Tighten the 4 bolts to 15 N.m (11 lb ft).
4. Remove the fuses.
5. Lower the vehicle by half its height.
6. Install the condenser to the radiator. Tighten: Tighten the 4 bolts to 5 N.m (44 lb in).
7. Remove the retaining straps.
8. Lower the vehicle by half its height.
9. Install the fan housing. Insert in bracket at the bottom of the radiator. Tighten: Tighten the 2 bolts to 5 N.m (44 lb in). Install the 2 radiator hoses into the bracket. Install the NEW cable tie.
10. Install the expansion tank coolant hose to the radiator. Fasten the clamp. Install the coolant hose.
11. Raise the vehicle by its full height.
12. Install the lower oil cooling line with the connecting hose on the oil cooler. Use NEW seal rings. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
13. Install the upper oil cooling line with the connecting hose on the oil cooler. Use NEW seal rings. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
14. Install the 2 coolant hoses to the radiator. Install the 2 clamps.
15. Fasten the radiator wiring harness. Connect the coolant temperature sensor wiring harness plug. Install the 3 wiring harnesses. Fasten the wiring harness to the fan housing with the cable ties.
16. Connect the fan wiring harness plug.
17. Lower the vehicle by half its height.
18. Install the front fascia. Connect the 2 wiring harness plugs. Install the front fascia on the side.
19. Install the front paneling at bottom. Install the 6 body-bound rivets. Tighten: Tighten the 4 bolts to 2.5 N.m (22 lb in).
20. Lower the vehicle by half its height.
21. Install the fascia at top. Fasten the 2 body-bound rivets. Tighten: Tighten the 2 bolts to 2.5 N.m (22 lb in).
22. Install the radiator grille. Install the 6x. Install the 4 body-bound rivets.
23. Fill and bleed the cooling system. Refer to «Cooling System Draining and Filling»(ref-302344-S34056996812008102100000) .
24. Connect the battery. Connect the negative connection. Tighten: Tighten the nut to 5 N.m (44 lb in).
25. For reprogramming procedures, refer to «Control Module References»(ref-302291-S24032387652008102100000) .
26. Close the hood.