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Engine Cooling|Description and Operation > < Charge Air Cooler Replacement - Diesel, and LLU, LUJ with MT

Astra J

Charge Air Cooler Replacement (LDE, LLU, and LUJ with AT)

Removal Procedure


Note:  Although the 1.6 L (LDE) engine is natural aspirated, it is equipped with a charge air cooler in order to support the automatic transmission fluid cooler. The charge air cooler was added supplementary to the CRFM package.

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .

           2543478


3. Remove the 2 right front bumper fascia support bolts (2).
4. Remove the right front bumper fascia support (1).

           2190228


5. Remove the 2 front intake air duct splash shield bolts (2).
6. Remove the front intake air duct splash shield (1).

           2190229


7. Remove the front intake air duct bolt (1).
8. Remove the front intake air duct (2).
9. Remove the front bumper fascia center support. Refer to Front Bumper Fascia Center Support Replacement .

           2543475


10. Remove the radiator air seal (1).
11. Remove the 2 radiator air baffle clips (2) and the radiator air baffles.

           2543477


12. Disconnect and unclip the AC pressure sensor wiring harness (1).

           2191445


13. Remove the 2 protector fenders (2) from the charge air cooler (1).

           2543476



Note:  This step is not necessary for the 1.6 L (LDE) engine.
14. Disconnect the charge air cooler outlet air hose (2) and the charge air cooler inlet air hose (1) from the charge air cooler.

           2373204


15. Remove the transmission fluid auxiliary cooler bolt (3).
16. Unclip the transmission fluid cooler pipes (2) from the charge air cooler.
17. Unclip the transmission fluid cooler (1) from the charge air cooler and lay aside.

           2191501


18. Unclip the AC condenser (3) from the charge air cooler (2) and secure it at the bumper impact bar.
19. Unclip the charge air cooler (2) from the radiator (1) and remove it from vehicle.

Installation Procedure


           2191501


1. Install the charge air cooler (2) and clip it to the radiator (1).
2. Clip the AC condenser (3) to the charge air cooler (2).

           2373204


3. Clip the transmission fluid cooler (1) to the charge air cooler.
4. Clip the transmission fluid cooler pipes (2) to the charge air cooler.

Caution: Refer to Fastener Caution .
5. Install the transmission fluid auxiliary cooler bolt (3) and tighten.

           2543476



Note:  This step is not necessary for the 1.6 L (LDE) engine.
6. Connect the charge air cooler outlet air hose (2) and the charge air cooler inlet air hose (1) to the charge air cooler.

           2191445


7. Install the 2 protector fenders (2) to the charge air cooler (1).

           2543477


8. Connect and clip in the AC pressure sensor wiring harness (1).

           2543475


9. Install the 2 radiator air baffles and the radiator air baffle clips (2).
10. Install the radiator air seal (1).
11. Install the front bumper fascia center support. Refer to Front Bumper Fascia Center Support Replacement .

           2190229


12. Install the front intake air duct (2).
13. Install the front intake air duct bolt (1) and tighten.

           2190228


14. Install the front intake air duct splash shield (1).
15. Install the 2 front intake air duct splash shield bolts (2) and tighten.

           2543478


16. Install the right front bumper fascia support (1).
17. Install the 2 right front bumper fascia support bolts (2) and tighten.
18. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .
19. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .

Engine Cooling|Description and Operation > < Charge Air Cooler Replacement - Diesel, and LLU, LUJ with MT