Astra J
Radiator Replacement (LDE, LLU, and LUJ with AT)Removal Procedure
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| 1. | Disconnect 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 coolant fluid. Refer to Cooling System Draining and Filling . |
| 4. | Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . |
| 5. | Remove the radiator outlet hose from the radiator. Refer to Radiator Outlet Hose Replacement . |
| 6. | Remove the radiator inlet hose from the radiator. Refer to Radiator Inlet Hose Replacement . |
| 7. | Remove the charge air cooler inlet air hose from the charge air cooler. Refer to Charge Air Cooler Inlet Air Hose Replacement . |
| 8. | Remove the charge air cooler outlet air hose from the charge air cooler. Refer to Charge Air Cooler Outlet Air Hose Replacement . |
| 9. | Remove the transmission fluid auxiliary cooler pipe. Refer to Transmission Fluid Cooler Hose/Pipe Replacement . |
| 10. | Remove the transmission fluid cooler inlet pipe from the radiator. Refer to Transmission Fluid Cooler Inlet Pipe Replacement . |
| 11. | Remove the transmission fluid cooler outlet pipe from the transmission fluid auxiliary cooler. Refer to Transmission Fluid Cooler Outlet Pipe Replacement . |
| 12. | Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . |
| 13. | Remove the air conditioning evaporator hose (3) from the condenser. |
| 14. | Disconnect the air conditioning refrigerant pressure sensor wiring harness plug (2). |
| 15. | Disconnect the engine coolant temperature sensor wiring harness plug (1). |
| 16. | Lower the vehicle. |
| 17. | Remove the air conditioning compressor and condenser hose nut (1). |
| 18. | Remove the air conditioning compressor and condenser hose (2). |
| 19. | Unclip the engine coolant fan shroud from the radiator and hang it aside, using cable straps. |
| 20. | Secure the radiator assembly with 2 straps. |
| 21. | Remove the 4 radiator lower bracket bolts (1). |
| 22. | Remove the 2 lower radiator brackets (2). |
Note: A second technician is required. |
Note: Do not remove the engine cooling fan shroud (1). |
| 23. | Remove the radiator assembly (2). |
| 24. | Remove the transmission fluid auxiliary cooler pipe bolt (3). |
| 25. | Unclip the 2 transmission fluid cooler pipes (2) from the transmission fluid cooler pipe bracket. |
| 26. | Unclip the transmission fluid cooler (1) from the radiator. |
| 27. | Unclip the transmission fluid cooler pipe bracket from the radiator. |
| 28. | Unclip the charge air cooler along with the AC condenser from the radiator. |
Installation Procedure
| 1. | Clip the charge air cooler along with the AC condenser to the radiator. |
| 2. | Clip the transmission fluid cooler pipe bracket to the radiator. |
| 3. | Clip the transmission fluid cooler (1) to the radiator. |
| 4. | Clip the 2 transmission fluid cooler pipes (2) to the transmission fluid cooler pipe bracket. |
| 5. | Install the transmission fluid auxiliary cooler pipe bolt (3) and tighten. |
Note: A second technician is required. |
| 6. | Install the radiator assembly (2) and secure with 2 straps. |
| 7. | Install the 2 lower radiator brackets (2). |
Caution: Refer to Fastener Caution . |
| 8. | Install the 4 radiator lower bracket bolts (1) and tighten to 22 N·m (16 lb ft) . |
| 9. | Clip in the engine coolant fan shroud to the radiator. |
| 10. | Install the air conditioning compressor and condenser hose (2). Use a NEW seal ring. |
| Install the air conditioning compressor and condenser hose nut (1) and tighten to 19 N·m(14 lb ft) . |
| 11. | Raise the vehicle. |
| 12. | Install the air conditioning evaporator hose (3) to the condenser. Use a NEW seal ring. |
| 13. | Tighten the air conditioning evaporator hose nut to 19 N·m(14 lb ft) . |
| 14. | Connect the air conditioning refrigerant pressure sensor wiring harness plug (2). |
| 15. | Connect the engine coolant temperature sensor wiring harness plug (1). |
| 16. | Lower the vehicle. |
| 17. | Install the radiator inlet hose to the radiator. Refer to Radiator Inlet Hose Replacement . |
| 18. | Install the radiator outlet hose to the radiator. Refer to Radiator Outlet Hose Replacement . |
| 19. | Install the charge air cooler inlet air hose to the charge air cooler. Refer to Charge Air Cooler Inlet Air Hose Replacement . |
| 20. | Install the charge air cooler outlet air hose to the charge air cooler. Refer to Charge Air Cooler Outlet Air Hose Replacement . |
| 21. | Install the transmission fluid cooler inlet pipe to the radiator. Refer to Transmission Fluid Cooler Inlet Pipe Replacement . |
| 22. | Install the transmission fluid cooler outlet pipe to the transmission fluid auxiliary cooler. Refer to Transmission Fluid Cooler Outlet Pipe Replacement . |
| 23. | Install the transmission fluid auxiliary cooler pipe. Refer to Transmission Fluid Cooler Hose/Pipe Replacement . |
| 24. | Fill up the refrigerant. Refer to Refrigerant Recovery and Recharging . |
| 25. | Fill up coolant fluid. Refer to Cooling System Draining and Filling . |
| 26. | Install the front bumper fascia. Refer to Front Bumper Fascia Replacement . |
| 27. | Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection . |
