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Radiator Outlet Hose Replacement - 1.6L LDE, LGE, LLU, LXV, and 1.8L 2H0 > < Radiator Surge Tank Engine Hose Replacement - 2.0L Diesel LBS and LBX

Astra J

Engine Coolant Thermostat Housing Replacement (1.6L LDE, LXV, and 1.8L 2H0)

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Place collecting basin underneath.
3. Drain the cooling system. Refer to Cooling System Draining and Filling .
4. Lower the vehicle.

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5. Loosen the radiator inlet hose clamp (4).
6. Remove the radiator inlet hose (3) from the engine coolant thermostat (5).

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7. Remove the throttle body heater inlet hose (2) from the engine coolant thermostat (1).
8. Remove the heater inlet hose from the engine coolant thermostat housing. Refer to Heater Inlet Hose Replacement .
9. Remove the heater outlet hose from the engine coolant thermostat housing. Refer to Heater Outlet Hose Replacement .
10. Remove the thermostat housing bracket nut.
11. Remove the thermostat housing bracket.

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12. Disconnect the engine coolant temperature sensor connector (1).
13. Remove the 2 engine oil cooler pipe bolts (6).

Note:  Pull the engine oil cooler pipe out of the engine oil cooler.
14. Remove the engine oil cooler pipe (5).
15. Remove the engine oil cooler pipe seals (4, 7).
16. Remove the 4 engine coolant thermostat housing bolts (3).
17. Remove the thermostat housing (2).
18. Remove the thermostat housing seal (8).

Installation Procedure

1. Clean sealing surface.

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2. Install a NEW engine coolant thermostat housing seal (8).
3. Install the engine coolant thermostat housing (2).

Caution: Refer to Fastener Caution .

Note:  Screw in the 4 bolts until the engine coolant thermostat housing is in contact with the cylinder head.
4. Install the 4 engine coolant thermostat housing bolts (3) and tighten to 2 N·m (18 lb in) .

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Caution: Following the proper fastener tightening sequence and torque is essential. Failure to do so may fracture the thermostat housing.

5. Tighten the 4 engine coolant thermostat housing bolts to 8 N·m (71 lb in) in sequence (1–2–3–4).

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6. Install NEW engine oil cooler pipe seals (4, 7).

Note:  Push the engine oil cooler pipe into the engine oil cooler.
7. Install the engine oil cooler pipe (5).
8. Install the 2 engine oil cooler pipe bolts (6) and tighten to 8 N·m (71 lb in) .
9. Install the heater outlet hose to the engine coolant thermostat housing. Refer to Heater Outlet Hose Replacement .
10. Install the heater inlet hose to the engine coolant thermostat housing. Refer to Heater Inlet Hose Replacement .
11. Connect the engine coolant temperature sensor connector (1).
12. Install the engine coolant thermostat housing bracket.
13. Install the engine coolant thermostat housing bracket nut and tighten to 6 N·m (53 lb in) .

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14. Install the throttle body heater inlet hose (2) to the engine coolant thermostat housing (1).

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15. Install the radiator inlet hose (3) to the engine coolant thermostat (5).
16. Install the radiator inlet hose clamp (4).
17. Fill the cooling system. Refer to Cooling System Draining and Filling .

Radiator Outlet Hose Replacement - 1.6L LDE, LGE, LLU, LXV, and 1.8L 2H0 > < Radiator Surge Tank Engine Hose Replacement - 2.0L Diesel LBS and LBX