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Turbocharger Coolant Return Pipe Replacement - 1.6L LLU > < Engine Coolant Fan Replacement - 2.0L Diesel LBS and LBX

Astra J

Engine Coolant Thermostat Housing Replacement (1.6L LLU)

Removal Procedure

1. Open the hood.
2. Raise the vehicle by its full height. Refer to Lifting and Jacking the Vehicle .
3. Place collecting basin underneath.
4. Drain the cooling system. Refer to Cooling System Draining and Filling .
5. Lower the vehicle by its full height.
6. Remove the charge air cooler outlet air hose. Refer to Charge Air Cooler Outlet Air Hose Replacement .

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7. Loosen the radiator inlet hose clamp (4).
8. Remove the radiator inlet hose (3) from the engine coolant thermostat (5).
9. Unclip the ECM wiring harness guide from the cylinder head cover.
10. Remove the throttle body. Refer to Throttle Body Assembly Replacement .

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11. Release the quick connect fitting (3). Refer to Plastic Collar Quick Connect Fitting Service .
12. Remove the turbocharger coolant return hose (1) from the engine coolant thermostat housing (4).
13. Remove the heater inlet and outlet hose from the engine coolant thermostat housing. Refer to Heater Inlet and Outlet Hose Replacement .
14. Remove the thermostat housing bracket nut.
15. Remove the thermostat housing bracket.
16. Disconnect wiring harness plug engine coolant thermostat.

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

Note:  Pull the engine oil cooler pipe out of the engine oil cooler.
19. Remove the engine oil cooler pipe (5).
20. Remove the engine oil cooler pipe seals (4, 7).
21. Remove the 4 engine coolant thermostat housing bolts (3).
22. Remove the thermostat housing (2).
23. Remove the thermostat housing seal (8).
24. Remove coolant temperature sensor.

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. Connect the engine coolant temperature sensor connector (1).
10. Connect wiring harness plug engine coolant thermostat.
11. Install the engine coolant thermostat housing bracket.
12. Install the engine coolant thermostat housing bracket nut and tighten to 6 N·m (53 lb in). .
13. Install the heater inlet and outlet hose to the engine coolant thermostat housing. Refer to Heater Inlet and Outlet Hose Replacement .

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14. Install the turbocharger coolant return hose (1) to the engine coolant thermostat housing (4).
15. Install the quick connect fitting (3). Refer to Plastic Collar Quick Connect Fitting Service .
16. Install the throttle body. Refer to Throttle Body Assembly Replacement .
17. Clip in the ECM wiring harness guide to the cylinder head cover.

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18. Install the radiator inlet hose (3) to the engine coolant thermostat (5).
19. Install the radiator inlet hose clamp (4).
20. Install the charge air cooler outlet air hose. Refer to Charge Air Cooler Outlet Air Hose Replacement .
21. Fill the cooling system. Refer to Cooling System Draining and Filling .
22. Close the hood.

Turbocharger Coolant Return Pipe Replacement - 1.6L LLU > < Engine Coolant Fan Replacement - 2.0L Diesel LBS and LBX