Astra J
Water Outlet Replacement (1.7L Diesel LPL and LPV)Removal Procedure
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| 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. |
| Caution: Use care when performing this procedure. Use of excessive force may damage the coolant thermostat. |
| 1. | Open the hood. |
| 2. | Unclip the engine control module bracket and hang the engine control module aside. Refer to Engine Control Module Replacement . |
| 3. | Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . |
| 4. | Drain the cooling system. Refer to Cooling System Draining and Filling . |
| 5. | Lower the vehicle. |
Note: Place a drain tray underneath. |
| 6. | Unclip the engine coolant air bleed hose retainer clip (1). |
| 7. | Remove the engine coolant air bleed hose (2) from the water outlet (4) and hang aside. |
| 8. | Loosen the radiator inlet hose clamp (5). |
| 9. | Remove the radiator inlet hose (6) and hang aside. |
| 10. | Remove the 2 water outlet bolts (3). |
| 11. | Remove the water outlet (4) from the engine coolant thermostat housing (1). |
| 12. | Remove and DISCARD the water outlet sealing (2). |
| 13. | Clean the sealing surface from old gasket material. |
Installation Procedure
| 1. | Install a NEW water outlet sealing (2). |
| 2. | Install the water outlet (4) to the engine coolant thermostat housing (1). |
Caution: Refer to Fastener Caution . |
| 3. | Install the 2 water outlet bolts (3) and tighten to 24 N·m (18 lb ft) . |
| 4. | Install and reposition the radiator inlet hose (6). |
| 5. | Tighten the radiator inlet hose clamp (5). |
| 6. | Install and reposition the engine coolant air bleed hose (2) to the water outlet (4). |
| 7. | Tighten the engine coolant air bleed hose clamp (3). |
| 8. | Clip in the engine coolant air bleed hose (2) to the retainer clip (1). |
| 9. | Fill the cooling system. Refer to Cooling System Draining and Filling . |
| 10. | Clip in the engine control module to the engine control module bracket. Refer to Engine Control Module Replacement . |
| 11. | Close the hood. |
