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Charge Air Cooler Replacement - Diesel, and LLU, LUJ with MT > < Radiator Replacement - Diesel, and LLU, LUJ with MT

Astra J

Radiator Replacement (LDE, LDD 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 .
3. Drain the cooling system. Refer to Cooling System Draining and Filling .

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

           2190228


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

           2190229


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

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

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12. Remove the 2 protector fenders (2) from the charge air cooler (1).
13. Disconnect the radiator outlet hose and the radiator inlet hose from the radiator. Refer to Radiator Outlet Hose Replacement and Radiator Inlet Hose Replacement .
14. Unclip the engine coolant fan shroud from the radiator.

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15. Remove the 2 radiator upper bracket bolts (1) and the 2 radiator upper brackets (2).

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16. Remove the radiator (1) from the 2 lower brackets (2).
17. Use care and rotate the radiator in order to gain more access for the removal.
18. Use care and lift the radiator up and away from the vehicle.

Installation Procedure


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Note:  Handle the radiator with care.
1. Use care and install the radiator (1).
2. Use care and rotate the radiator in order to get more access for the installation.
3. Install the radiator (1) to the 2 lower brackets (2).

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4. Install the 2 radiator upper brackets (2).

Caution: Refer to Fastener Caution .
5. Install the 2 radiator upper bracket bolts (1) and tighten to 22 N·m (16 lb ft) .
6. Clip the engine coolant fan shroud to the radiator.
7. Connect the radiator outlet hose and the radiator inlet hose to the radiator. Refer to Radiator Outlet Hose Replacement and Radiator Inlet Hose Replacement .

           2191445


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

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9. Connect and clip in the A/C pressure sensor wiring harness (1).
10. Install the front bumper fascia center support. Refer to Front Bumper Fascia Center Support Replacement .

           2190229


11. Install the front intake air duct (2).
12. Install the front intake air duct bolt (1) and tighten.

           2190228


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

           2543478


15. Install the right front bumper fascia support (1).
16. Install the 2 right front bumper fascia support bolts (2) and tighten.
17. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .
18. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
19. Fill and bleed the cooling system. Refer to Cooling System Draining and Filling .

Charge Air Cooler Replacement - Diesel, and LLU, LUJ with MT > < Radiator Replacement - Diesel, and LLU, LUJ with MT