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Vauxhall Workshop Service and Repair Manuals

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Radiator, Replace > < Engine cooling (Z22YH & not air conditioning)

Astra H

Replace radiator (without air conditioning)

  Remove

1.   Open bonnet
2.   Disconnect battery
•   Detach earth connection from negative terminal
– Slacken nut
3.   Raise vehicle by its full height
4.   Drain coolant
•   Place collecting pan underneath.
•   Attach suitable hose to drain connection (2)
•   Open coolant drain screw (1)
– Drain coolant
•   Close coolant drain screw
Object Number: 3446245 Size: DEFAULT


5.   Disconnect cooling module wiring harness plug (1)
Object Number: 3446246 Size: DEFAULT


6.   Lower vehicle by its full height
7.   Detach upper radiator hose (1) from radiator
•   Release clamp
8.   Detach lower radiator hose (2) from thermostat housing
•   Release clamp
Object Number: 3446254 Size: DEFAULT


9.   Detach coolant hose (1) for coolant expansion tank from radiator
•   Release clamp
10.   Detach lower radiator hose (2) from coolant expansion tank
•   Release clamp
•   Unclip 2x hoses
Object Number: 3446255 Size: DEFAULT


11.   Remove radiator grille
•   Remove 4x body-bound rivets (1)
•   Unclip radiator grille (2) upwards from front panelling
Object Number: 3446256 Size: DEFAULT


12.   Raise vehicle by half its height
13.   Undo front panelling (1)
•   Remove 5x body-bound rivets (3)
•   Unscrew 4x bolts (4)
14.   Remove front panelling
Note:   Second man
•   Push front panelling upwards in direction of arrow and pull out of bracket
•   Remove front panelling
– Unclip 4x clips (2)
•   Unclip outside temperature sensor
Object Number: 3446563 Size: DEFAULT


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


16.   Raise vehicle by half its height
17.   Detach lower radiator bracket (1) from front axle body
Note:   Check installation position
•   Unscrew 4x bolts
Object Number: 2398369 Size: DEFAULT


18.   Lower radiator down and out
•   Remove 2x fuses from bracket
19.   Detach attached parts from radiator
Note:   These operations must only be performed if the component is being replaced
•   Detach lower coolant hose (1) from radiator
– Release clamp
•   Detach fan housing from radiator
– Unscrew 2x bolts (2)
•   Detach 2x rubber bearing (3) from radiator
Object Number: 3446258 Size: DEFAULT


  Install

20.   Fit attaching parts to new radiator
•   Attach 2x rubber bearings
•   Attach fan housing
– Insert into bracket
– Tighten 2x bolts
•   Attach lower coolant hose
– Fasten clamp
21.   Insert radiator from above
•   Insert 2x fuses in bracket
22.   Attach lower radiator bracket to front axle body
Note:   Check installation position
•   Tighten 4x bolts
23.   Take fuses out of upper radiator brackets
24.   Attach wiring harness plug for cooling module
25.   Lower vehicle by half its height
26.   Fit front panelling
•   Attach outside temperature sensor
•   Position front panelling and engage at the sides
Note:   Second man
•   Install 5x body-bound rivets
•   Tighten 4x bolts
27.   Lower vehicle by half its height
28.   Install radiator grille
•   Clip into front panelling from below
•   Install 4x body-bound rivets
29.   Attach lower radiator hose
•   Attach lower radiator hose to thermostat housing
– Fasten clamp
•   Attach lower radiator hose to coolant expansion tank
– Fasten clamp
30.   Attach upper radiator hose to radiator
•   Fasten clamp
31.   Attach expansion tank coolant hose to radiator
•   Fasten clamp
•   Clip in 2x
32.   Fill with coolant and correct coolant level
33.   Connect battery
•   Attach earth connection to negative terminal
– Tighten nut
34.   Program volatile memories
35.   Close bonnet

Radiator, Replace > < Engine cooling (Z22YH & not air conditioning)