vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Radiator, Remove and Install (with Air Conditioning) > < Replace radiator (with air conditioning)

Astra H

Replace intercooler

  Remove

1.   Open bonnet
2.   Disconnect battery
•   Detach earth connection from earth terminal
– Slacken nut
3.   Detach radiator grille (2)
•   Detach 4x body-bound rivets (1)
•   Release 6x lugs from front panelling
Object Number: 3446548 Size: DEFAULT


4.   Raise vehicle by half its height
5.   Detach front panelling (1)
•   Remove 5x body-bound rivets (3)
•   Unscrew 4x bolts (4)
6.   Remove front panelling
Note:   Use a second person
•   Push front panelling upwards in direction of arrow and pull out of bracket
•   Remove front panelling
– Unclip 4x clips (2)
•   Detach outside temperature sensor
– Unclip 1x clip
Object Number: 3446563 Size: DEFAULT


7.   Raise vehicle by half its height
8.   Detach the lower engine cover and right engine splash guard
9.   Place collecting basin underneath.
10.   Drain coolant
•   Open drain bolt on radiator (1)
•   Collect coolant
•   Close drain bolt
Object Number: 3446550 Size: DEFAULT


11.   Detach wiring harness from radiator
•   Detach wiring harness plug (1) from fan motor
•   Detach 2x cable ties
Object Number: 3446561 Size: DEFAULT


12.   Detach refrigerant line (1) from radiator
•   Open clip (4)
13.   Detach compressor wiring harness (2) from radiator
•   Undo clip
14.   Detach right coolant hose (3) from radiator
•   Release clamp
15.   Detach 2x vacuum lines (5) from radiator
•   Unclip from bracket
Object Number: 8125293 Size: DEFAULT


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


17.   Remove lower radiator bracket (1)
Note:   Note: brackets are not the same
•   Unscrew 4x bolts
Object Number: 2415997 Size: DEFAULT


18.   Lower vehicle by its full height
19.   Remove battery
•   Detach positive terminal (3) from positive pole
– Slacken nut
•   Remove bracket 1)
– Unscrew bolt (2)
Object Number: 7360933 Size: DEFAULT


20.   Remove control unit, pre-heating system (1)
•   Pull pre-heating system control unit out of bracket in direction of arrow
•   Disconnect wiring harness connector.
Object Number: 3446554 Size: DEFAULT


21.   Detach expansion tank coolant hose (2) from radiator
•   Release clamp
22.   Detach left coolant hose (1) from radiator
•   Release clamp
Object Number: 7360934 Size: DEFAULT


23.   Detach charge air hose (1) from charge air pipe.
•   Release clamp
Object Number: 7360935 Size: DEFAULT


24.   Detach fan housing from radiator
•   Unscrew 2x bolts (2)
•   Unclip charge air pipe (1)
Object Number: 7360936 Size: DEFAULT


25.   Raise vehicle by half its height
Object Number: 7360937 Size: DEFAULT

26.   Suspend condenser from top of front panel
27.   Detach condenser with auxiliary fan and intercooler from radiator
•   Unscrew 5x bolts (1 to 3) and (5)
•   Pull intercooler from bracket (4)

28.   Remove radiator
•   Remove 2x fuses from bracket
29.   Detach charge air hose (1) from intercooler
•   Release clamp
Object Number: 7360939 Size: DEFAULT


30.   Detach charge air pipe (1) with connecting hose from intercooler
•   Release clamp
Object Number: 7360938 Size: DEFAULT


31.   Detach wiring harness from intercooler
•   Unclip from bracket (1)
Object Number: 7360940 Size: DEFAULT


32.   Detach charge air cooler from condenser
•   Detach from condenser
– Unscrew 3x bolts (1) and (2)
•   Remove intercooler from below
Object Number: 7360941 Size: DEFAULT


33.   Remove intercooler
•   Detach from top of front plate

  Install

34.   Replace intercooler
•   Suspend from top of front panel
35.   Attach intercooler to condenser
•   Attach to condenser
Important:   Insert bolt with thread locking compound
– Tighten 3x bolt 5 Nm
36.   Attach wiring harness to intercooler
•   Clip into bracket
37.   Attach charge air pipe to intercooler with connecting hose
•   Tighten clamp 3.5 Nm
Note:   Do not secure charge air pipe yet
38.   Attach charge air hose to intercooler
•   Tighten clamp 3.5 Nm
39.   Install radiator
•   Insert 2x fuses in bracket
40.   Attach condenser with auxiliary fan and intercooler to radiator
•   Insert condenser into bracket
Important:   Insert bolt with thread locking compound
•   Tighten 5x bolt 5 Nm
41.   Detach condenser from top of front plate
42.   Raise vehicle by half its height
43.   Attach 2x vacuum lines from radiator
•   Clip into bracket
44.   Attach right coolant hose to radiator
•   Fasten clamp
45.   Attach compressor wiring harness to radiator
•   Attach clip
46.   Install lower radiator bracket
Note:   Note: brackets are not the same
•   Screw in 4x bolts 15 Nm
47.   Remove 2x retainers from upper radiator bracket
48.   Attach refrigerant line to radiator
•   Close clip
49.   Attach wiring harness to radiator
•   Attach 2x cable ties
•   Fix wiring harness plug
50.   Install lower engine cover and right engine splash guard
51.   Lower vehicle by half its height
52.   Insert front panelling
Note:   Use a second person
•   Clip in outside temperature sensor
•   Insert front panelling
– Clip in 4x clips
53.   Fit front panelling
•   Install 5x body-bound rivets
•   Tighten 4x bolts
54.   Lower vehicle by half its height
55.   Attach fan housing to radiator
•   Insert into bracket
•   Tighten 2x bolts
•   Clip in charge air pipe
56.   Attach charge air hose to charge air pipe
•   Fasten clamp
57.   Attach left coolant hose to radiator
•   Fasten clamp
58.   Attach expansion tank coolant hose to radiator
•   Fasten clamp
59.   Install control unit - pre-heating system
•   Fix wiring harness plug
•   Clip to battery support
60.   Install battery
•   Install bracket
– Tighten bolt
•   Attach positive connection to positive terminal
– Tighten nut
61.   Connect battery
•   Attach ground connection to ground terminal
– Tighten nut
62.   Install radiator grille
•   Clip into front panelling
– Clip in 5x clips
•   Install 4x body-bound rivets
63.   Top up coolant or ensure correct quantity is present.
64.   Program volatile memories
65.   Close bonnet

Radiator, Remove and Install (with Air Conditioning) > < Replace radiator (with air conditioning)