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Replace EGR cooler > < Radiator, Replace

Astra H

Radiator, Replace (Z 20 LEL, Z 20 LER)

  Remove

1.   Open bonnet
2.   Disconnect battery
•   Detach ground connection from ground terminal
– Slacken nut
3.   Remove radiator grille (2)
•   Remove 4x body-bound rivets (1)
•   Unclip from front panelling from above
– Unclip 5x clips
Object Number: 3446256 Size: DEFAULT


4.   Secure radiator to upper brackets (1)
•   Insert 2x suitable tools
Object Number: 3446257 Size: DEFAULT


5.   Raise vehicle by half its height
6.   Detach front panelling (3)
•   Remove 5x body-bound rivets (2)
•   Unclip 4x clips (1)
Object Number: 3446633 Size: DEFAULT


7.   Place collecting basin underneath.
8.   Detach high-pressure headlamp cleaning system hose from reservoir (2)
•   Undo quick-release fitting (1)
Note:   Escaping fluid
Object Number: 3446632 Size: DEFAULT


9.   Remove front panelling
•   Second man
Note:   Push front panelling upwards at side and pull out of bracket
•   Detach front panelling from bracket
– Unclip 4x clips (1)
•   Unclip outside temperature sensor
Object Number: 3446634 Size: DEFAULT


10.   Raise vehicle by half its height
11.   Place collecting basin underneath.
12.   Drain coolant
•   Open drain bolt on radiator (1)
•   Collect coolant
•   Close drain bolt
Object Number: 3446550 Size: DEFAULT


13.   Detach fan wiring harness from fan housing
•   Disconnect wiring harness plug (1)
•   Undo cable tie
Object Number: 3446246 Size: DEFAULT


14.   Remove bracket, right side of radiator (2)
•   Unscrew 2x bolts
15.   Remove bracket, left side of radiator (1)
•   Unscrew 2x bolts
Object Number: 3446501 Size: DEFAULT


16.   Lower vehicle by its full height
17.   Remove charge pressure sensor (1)
•   Unscrew bolt
18.   Detach charge air hose from intercooler
•   Release clamp (2)
19.   Detach turbocharger coolant return hose from radiator
•   Release clamp (3)
•   Unclip from bracket
Object Number: 3446163 Size: DEFAULT


20.   Detach charge air cooler from condenser
Note:   Coolant module is shown removed to give a clearer illustration
•   Unscrew bolt (2), unscrew nut (1)
Note:   Tilt intercooler forward in lower bracket
Object Number: 3446624 Size: DEFAULT


21.   Detach fan from radiator
Note:   Coolant module is shown removed to give a clearer illustration
•   Unscrew 2x bolts (1)
•   Remove fan from vehicle in direction of arrow
Object Number: 3446507 Size: DEFAULT


22.   Detach upper radiator hose from radiator
•   Release clamp (1)
Object Number: 3446162 Size: DEFAULT


23.   Detach lower radiator hose from radiator
•   Release clamp (1)
Object Number: 3446502 Size: DEFAULT


24.   Raise vehicle by half its height
25.   Detach air conditioning wiring harness from radiator
•   Undo cable tie (1)
Object Number: 3446625 Size: DEFAULT


26.   Detach charge air hose (1) from radiator
•   Detach clamp
– Unscrew bolt (1)
Object Number: 3446626 Size: DEFAULT


27.   Detach condenser from radiator
Note:   Condenser is shown removed to give a clearer illustration
•   Unscrew 3x bolts (1)
Object Number: 3446627 Size: DEFAULT


28.   Suspend condenser with intercooler from closure plate
29.   Remove 2x radiator retainers from bracket
30.   Carefully remove radiator from below
Note:   Avoid damaging the radiator fins

  Install

31.   Install radiator from below
•   Insert 2x radiator retainers in bracket
32.   Install 2x radiator retainers in bracket
33.   Detach condenser with intercooler from closure plate
34.   Attach condenser to radiator
Important:   Insert bolt with screw locking compound
•   Tighten 3x bolt 5 Nm
35.   Attach charge air hose to radiator
•   Attach clamp
– Tighten bolt
36.   Attach air conditioning wiring harness to radiator
•   Connect cable ties
37.   Lower vehicle by half its height
38.   Attach lower radiator hose to radiator
•   Fasten clamp
39.   Attach upper radiator hose to radiator
•   Fasten clamp
40.   Install fan housing
•   Clip coolant hose into bracket
41.   Attach fan housing to radiator
•   Screw in 2x bolts
42.   Attach intercooler to condenser
Important:   Insert bolt with screw locking compound
•   Tighten 2x bolt 5 Nm
43.   Attach coolant return hose from turbocharger to radiator
•   Fasten clamp
•   Mount in bracket
44.   Attach charge pressure sensor
•   Tighten bolt
45.   Fit charge air hose between charge air pipe and intercooler
•   Tighten 2x clamps
46.   Raise vehicle by its full height
47.   Install left radiator bracket
•   Tighten 2x bolt 15 Nm
48.   Install right radiator bracket
•   Tighten 2x bolt 15 Nm
49.   Attach fan wiring harness to fan housing
•   Connect cable ties
•   Fix wiring harness plug
50.   Lower vehicle by half its height
51.   Insert front panelling
•   Second man
Note:   Slide side front panelling into bracket
•   Attach front panelling to bracket
– Clip in 4x clips
•   Clip in outside temperature sensor
52.   Attach high-pressure headlamp cleaning hose to reservoir
•   Connect quick release fitting
53.   Fit front panelling
•   Install 5x body-bound rivets
•   Screw in 4x bolts
54.   Lower vehicle by half its height
55.   Remove 2x radiator retainers from bracket
56.   Install radiator grille
•   Clip into front panelling from below
– Clip in 5x clips
•   Install 4x body-bound rivets
57.   Connect battery
•   Attach ground connection to ground terminal
– Tighten nut
58.   Fill with coolant and correct coolant level
59.   Programme transient memory
60.   Close bonnet

Replace EGR cooler > < Radiator, Replace