vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Radiator, Replace > < Replace radiator (Z 10 XE, Z 10 XEP, with air conditioning, LHD)

Corsa C

J 600500 Radiator, Replace (Y 17 DT, with AC, RHD)

1. Open bonnet

2. Drain air conditioning

  • Note! Drain air conditioning – see operation "Drain air conditioning" in group "D"

Caution!

On vehicles from model year 04 with ESP - the steering angle sensor loses its basic adjustment each time the battery is disconnected. It must be recalibrated.

3. Disconnect battery

  • Detach ground cable

4. Remove air cleaner housing (1)

  • Remove wiring harness plug for hot film mass air flow meter (3)
    • Release in direction of arrow
  • Remove air intake hose (4)
    • Loosen clamp (5)
  • Remove bolt (2)
 Object Number: 2411064 Size: DEFAULT

5. Release upper front panelling

  • Remove 3 bolts (1)
 Object Number: 2410625 Size: DEFAULT

6. Raise vehicle

7. Release lower front panelling

  • Disconnect wiring harness plug
  • Remove 3 clips (2)
  • Remove 4 bolts (1)
  • Remove 2 nuts (3)
 Object Number: 2410626 Size: DEFAULT

8. Detach front panelling

  • Note! 2. mechanic

9. Raise vehicle

10. Remove ribbed V-belt cover

  • Remove 3 bolts (1)
  • Remove clip (arrow).
 Object Number: 2410600 Size: DEFAULT

11. Remove ribbed V-belt

  • Tension ribbed V-belt tensioner in direction of arrow
    • With KM-913-A
  • Note! Mark running direction
 Object Number: 2411073 Size: DEFAULT

12. Remove lower charge air pipe (1)

  • From centre charge air pipe (2), intercooler
    • Release 2 clamps
  • Remove from guide
 Object Number: 2411130 Size: DEFAULT

13. Remove lower AC line (2)

  • Unclip wiring harness
  • Disconnect pressure switch wiring harness plug (1)
  • Remove bolt (3)
  • Set line to one side
 Object Number: 2411195 Size: DEFAULT

14. Remove charge air hose

  • From intercooler

15. Detach fan housing

  • Unscrew right bolt (3)
  • Disconnect compressor wiring harness plug (1)
  • Release lower coolant hose (2)
 Object Number: 2404423 Size: DEFAULT

16. Release lower radiator bracket

  • Remove rear 2 bolts
  • Release 2 front bolts
 Object Number: 2411134 Size: DEFAULT

17. Lower vehicle

18. Drain coolant

  • Place collecting basin underneath.
  • Open drain bolt
 Object Number: 2411059 Size: DEFAULT

19. Unclip air duct (2)

  • Caution! Carefully pull upward (danger of breakage)
 Object Number: 2411197 Size: DEFAULT

20. Remove auxiliary fan

  • Detach wiring harness plug (1)

21. Lower vehicle

22. Remove overflow hose (1)

  • From radiator

23. Detach upper coolant hose (2)

  • From radiator
 Object Number: 2411132 Size: DEFAULT

24. Detach fan housing

  • Unscrew left bolt

25. Detach ribbed V-belt guide roller

  • Remove bolt

26. Disconnect lower radiator hose

  • From radiator

27. Raise vehicle

28. Remove radiator

  • Note! 2. mechanic
  • Detach fan housing
  • Remove radiator downwards carefully
    • Note! Swing lower radiator bracket aside

29. Detach AC radiator

  • Remove 2 bolts (1)

30. Remove intercooler

  • Loosen 2 fastening clamps (2)
 Object Number: 2404424 Size: DEFAULT

31. Transfer attaching parts

  • Intercooler bracket rubber mounts

32. Attach intercooler

  • Fasten 2 fastening clamps

33. Attach AC radiator

  • Tighten 2 bolts

34. Install radiator

  • Note! 2. mechanic
  • Close coolant drain bolt
  • Insert radiator
    • In lower radiator bracket

35. Install auxiliary fan

  • Connect wiring harness plug.

36. Carefully clip in air duct

37. Tighten lower radiator bracket

  • Note! Observe fan housing positioning
  • Tighten bolts (15 Nm / 11 lbf. ft.)

38. Lower vehicle

39. Attach fan housing

  • Tighten 2 bolts (5 Nm / 3.7 lbf. ft.)
  • Clip in lower coolant hose

40. Connect upper radiator hose

41. Attach overflow hose

42. Connect lower radiator hose

43. Attach ribbed V-belt guide roller

  • Tighten bolt (38.2 Nm / 28.2 lbf. ft.)

44. Raise vehicle

45. Attach charge air hose

  • To charge air cooler

46. Install lower charge air pipe

47. Attach lower AC line

  • Renew seal rings
  • Tighten bolt (20 Nm / 15 lbf. ft.)
  • Connect pressure switch wiring harness plug
  • Clip on wiring harness.

48. Install ribbed V-belt

  • Note! Observe running direction and installation position
  • Release ribbed V-belt tensioner

49. Attach ribbed V-belt cover

  • Screw in bolts
  • Install clip

50. Lower vehicle

51. Position front panelling

  • Note! 2. mechanic

52. Fasten lower front panelling

  • Install clips
  • Tighten bolts
  • Tighten nuts
  • Connect wiring harness plug.

53. Lower vehicle

54. Fasten upper front panelling

  • Tighten bolts

55. Install air cleaner housing

  • Tighten bolt
  • Fasten air intake hose.
    • Tighten clamp (3.5 Nm / 2.6 lbf. ft.)
  • Connect wiring harness plug to hot film mass air flow meter

56. Connect battery

57. Calibrate steering angle sensor

  • Switch on ignition

Note:   Rotate the steering wheel one time from its right-hand to its left-hand stop.

58. Top up coolant

  • Note! Top up and bleed cooling system – see operation "Top up and bleed cooling system"
  • Observe specified coolant quantity

59. Program volatile memories

60. Charge air conditioning

  • Note! Charge air conditioning – see operation "Evacuate and charge air conditioning" in group "D".

61. Close bonnet
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Radiator, Replace > < Replace radiator (Z 10 XE, Z 10 XEP, with air conditioning, LHD)