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Radiator Surge Tank Replacement > < Radiator and Charge Air Cooler Bracket Repair

Astra J

Engine Coolant Thermostat Replacement (1.3L Diesel LSF)

Special Tools

BO-38185   Hose Clamp Pliers

For equivalent regional tools, refer to Special Tools .

Removal Procedure

Warning: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result.

Note:  The thermostat cannot be removed by the thermostat housing.

1. Drain the coolant. Refer to Cooling System Draining and Filling .

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2. Remove the electronic control modul (1) from the battery tray.

Note:  Use a small scewdriver to unclip the retainer clip (black arrow) and pull the electronic control modul out.

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3. Remove the coolant air bleed hose clamp (3) from the thermostat housing (1) using the BO-38185   pliers .
4. Remove the coolant air bleed hose (2).
5. Remove the radiator inlet hose clamp (7) from the thermostat housing (1) using the BO-38185   pliers .
6. Remove the radiator inlet hose (6).
7. Remove the turbocharger bypass hose clamp (4) from the thermostat housing (1) using the BO-38185   pliers .
8. Remove the turbocharger bypass hose (5) from the thermostat housing (1).

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9. Disconnect the coolant temperature sensor wiring harness plug (1).
10. Remove the 2 bolts (3).
11. Remove the thermostat housing (2).
12. Remove the thermostat housing sealring.

Installation Procedure

1. Install a NEW thermostat housing sealring.

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2. Install the thermostat housing (2).

Caution: Refer to Fastener Caution .
3. Install the 2 bolts (3) and tighten to 25 N·m (18 lb ft) .
4. Connect the coolant temperature sensor wiring harness plug (1).

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5. Install the turbocharger bypass hose (5) to the thermostat housing (1).
6. Install the turbocharger bypass hose clamp (4) to the thermostat housing (1) using the BO-38185   pliers .
7. Install the radiator inlet hose (6).
8. Install the radiator inlet hose clamp (7) to the thermostat housing (1) using the BO-38185   pliers .
9. Install the coolant air bleed hose (2).
10. Install the coolant air bleed hose clamp (3) to the thermostat housing (1) using the BO-38185   pliers .

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11. Install the electronic control modul (1) to the battery tray.

Note:  Ensure that the retainer clip (black arrow) is engage.
12. Fill the coolant system. Refer to Cooling System Draining and Filling

Radiator Surge Tank Replacement > < Radiator and Charge Air Cooler Bracket Repair