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Charge Air Cooler Replacement - LDE, LLU, and LUJ with AT > < Radiator Replacement - LDE, LDD with MT

Astra J

Charge Air Cooler Replacement (Diesel, and LLU, LUJ with MT)

Removal Procedure

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .

           2543478


3. Remove the 2 right front bumper fascia support bolts (2).
4. Remove the right front bumper fascia support (1).

           2190228


5. Remove the 2 front intake air duct splash shield bolts (2).
6. Remove the front intake air duct splash shield (1).

           2190229


7. Remove the front intake air duct bolt (1).
8. Remove the front intake air duct (2).
9. Remove the front bumper fascia center support. Refer to Front Bumper Fascia Center Support Replacement .

           2543475


10. Remove the radiator air seal (1).
11. Remove the 2 radiator air baffle clips (2) and the radiator air baffles.

           2543477


12. Disconnect and unclip the A/C pressure sensor wiring harness (1).

           2191445


13. Remove the 2 protector fenders (2) from the charge air cooler (1).

           2543476


14. Disconnect the charge air cooler outlet air hose (2) and the charge air cooler inlet air hose (1) from the charge air cooler.

           2191501


15. Unclip the A/C condenser (3) from the charge air cooler (2) and secure it at the bumper impact bar.
16. Unclip the charge air cooler (2) from the radiator (1) and remove it from vehicle.

Installation Procedure


           2191501


1. Install the charge air cooler (2) and clip it to the radiator (1).
2. Clip the A/C condenser (3) to the charge air cooler (2).

           2543476


3. Connect the charge air cooler outlet air hose (2) and the charge air cooler inlet air hose (1) to the charge air cooler.

           2191445


4. Install the 2 protector fenders (2) to the charge air cooler (1).

           2543477


5. Connect and clip in the A/C pressure sensor wiring harness (1).

           2543475


6. Install the 2 radiator air baffles and the radiator air baffle clips (2).
7. Install the radiator air seal (1).
8. Install the front bumper fascia center support. Refer to Front Bumper Fascia Center Support Replacement .

           2190229


9. Install the front intake air duct (2).

Caution: Refer to Fastener Caution .
10. Install the front intake air duct bolt (1) and tighten.

           2190228


11. Install the front intake air duct splash shield (1).
12. Install the 2 front intake air duct splash shield bolts (2) and tighten.

           2543478


13. Install the right front bumper fascia support (1).
14. Install the 2 right front bumper fascia support bolts (2) and tighten.
15. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .
16. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .

Charge Air Cooler Replacement - LDE, LLU, and LUJ with AT > < Radiator Replacement - LDE, LDD with MT