Vauxhall Workshop Service and Repair Manuals

 

Intercooler, Remove and Install (X 20 DTH with Air Conditioning)     Remove, Disconnect    Remove thermal insulation jacket (1) from battery.   Detach front relay frame (2) from battery retaining plate.   Unbolt battery retaining plate and remove battery.   Unclip coolant hose (3) and remove positive distribution unit (4) from battery support (5).   Remove fastening bolts (arrows) and remove battery support (5) from front frame.

 

Remove, Disconnect    Unbolt both brackets (1) for radiator on air deflector panel.   Disconnect wiring harness (2) from fan motor thermoswitch and place to one side together with front relay frame.   Disconnect wiring harness plug (3) for auxiliary fan and multiplug (5) (twist lock).   Unbolt ground cable (4) from body.

 

Remove, Disconnect    Release hose clamps (arrows) and remove upper charge air hose (1).   Unbolt power steering pump fluid reservoir (2) from air cleaner housing and place to one side.   Remove lower engine compartment cover.   Remove radiator grille and front panelling - see operation "Front Panelling, Remove and Install" in group "A".   Disconnect wiring harness plug (3) from both air conditioning pressure switches.   Disconnect wiring harness plug (4) from compressor.

 

Remove, Disconnect    Remove fastening bolts (1) from fan housing.   Carefully push radiator forwards into the nose of the vehicle and remove fan housing upwards together with fan motor.   Release hose clamp (arrow) and detach lower charge air hose (2) from intercooler.

 

Remove, Disconnect    Unclip power steering cooling coil (1) from brackets (2) on auxiliary fan housing.   Release fastening bolts (arrows) and remove receiver-dryer (3) from radiator.

 

Remove, Disconnect    Remove fastening bolts (arrows) and carefully remove auxiliary fan housing downwards.   Attach condenser to front member.     Important!    Do not bend refrigerant line (1).

 

Remove, Disconnect    Lift radiator out of lower fastening.   Unscrew fastening bolts (1) from intercooler. Fold intercooler away to the side and push to the rear out of lower guide on radiator (see enlargement). Carefully remove intercooler upwards.

  Install, Connect   

Attach intercooler to radiator.  

Carefully insert radiator complete with intercooler into lower fastenings.  

Carefully insert auxiliary fan housing from below and attach to radiator together with condenser.  

Bolt receiver-dryer onto radiator.  

Clip power steering coolant coil in auxiliary fan housing bracket.  

Notice: 

Before assembling components of the intake system (hoses, connections, etc.), they must be cleaned of any possible contamination (grease, oil, etc.). When tightening the hose clamps, be sure to observe exactly the tightening torque of 3.5 Nm / 2.6 lbf. ft.  

  Important!   

It is only ensured that the intake system is free of leaks, thus ensuring operational safety of the engine, if the hose clamps are tightened correctly to the prescribed tightening torque.  

  Install, Connect   

Attach lower charge air hose to intercooler - groove in lower charge air hose and lug on connector must align.  

Carefully insert air cleaner housing from above and fasten radiator.  

Connect wiring harness plug to compressor.  

Connect wiring harness plugs to both air conditioning pressure switches.  

Attach radiator grille and front panelling - see operation "Front Panelling, Remove and Install" in group "A".  

Install lower engine compartment cover.  

Install power steering pump fluid reservoir to fan housing.  

 

Install, Connect    Install upper charge air hose - groove in upper charge air hose and lug on connector must align (see illus.).   Bolt ground cable to body.   Connect wiring harness plug for auxiliary fan and multiplug with twist lock.   Fasten radiator with both brackets to air deflector plate.   Fasten battery support to front frame.   Clip on coolant hose and connect positive distribution unit to battery support.   Install battery retaining plate and battery.   Attach front relay frame to battery retaining plate.   Attach thermal insulation jacket to battery.