When the engine is hot, the cooling fan may activate at any time - exercise extreme caution!
Examination
The electric fan is powered by the battery. The electric circuit of the fan includes a protective fuse, ignition switch and relay (see Chapter On-board electrical equipment). The fan operation is controlled by an electronic control unit based on data from the coolant temperature sensor. The control unit is located on the left under the front spoiler, behind the front bumper.
1. To check the proper functioning of the fan, start the engine and warm it up at idle speed to normal operating temperature. The fan should start before the needle of the engine temperature gauge on the vehicle instrument panel approaches the overheating sector of the dial. If the fan does not start, check the proper functioning of the power supply voltage on the corresponding fan wire and relay (see Chapter On-board electrical equipment). Power failure may occur as a result of a blown fuse, a faulty ignition switch, a faulty relay, or damaged wiring. It is also possible that the fan drive motor is faulty.
Removal
Petrol models
Astra models without air conditioning
1. Disconnect the negative battery cable (see Chapter Engine electrical equipment) and move it away from the pole terminal.
2. Disconnect the fan wiring connector and release the wiring harness from the intermediate clips.
(Original source on the website: www.OPELBOOK.ru)
3. Remove the upper bolts securing the fan to the radiator.
1 - Upper mounting bolts
2 - Lower supports
4. Carefully lift the engine compartment.
5. Move the fan to the workbench, remove the mounting screw, disconnect the contact connector and remove the pre-resistor from the frame.
6. Loosen the fastening screws (1) and remove the drive motor and impeller from the fan assembly frame.
7. If necessary, loosen the screws (2) and separate the impeller from the motor.
Zafira models without air conditioning
1. Remove the front bumper (see Chapter Body).
2. Disconnect the electrical wiring from the fan and release it from the intermediate fasteners.
3. Remove the side bolts and, lowering the fan assembly, carefully remove it from the engine compartment.
4. Transfer the fan to a workbench, release the clamps and remove the diffuser, unscrew the three mounting bolts and remove the impeller. Unscrew the mounting screw, disconnect the contact connector and remove the pre-resistor from the frame. If necessary, loosen the fasteners and remove the electric motor.
Astra models with air conditioning
1. Remove the battery with the support bracket.
2. Remove the air cleaner assembly with the air duct (see Chapter Power and exhaust systems).
3. Remove the front bumper (see Chapter Body).
4. Drain the cooling system (see Chapter Routine maintenance).
5. Disconnect the wiring for the fan, pressure sensor and A/C compressor. Also disconnect the rear connector from the cooling system control module, located on the left under the front spoiler. Loosen the mounting nut and disconnect the ground bus from the splash guard.
6. Disconnect the upper and lower hoses from the radiator.
7. Remove the upper bolts securing the fan to the radiator.
1 - Upper mounting bolts
2 - Lower supports
8. Carefully lift the fan assembly out of the lower supports and remove it from the engine compartment.
9. Move the fan to the workbench, remove the mounting screw, disconnect the contact connector and remove the pre-resistor from the frame.
10. Loosen the fastening screws (1) and remove the drive motor and impeller from the fan assembly frame.
5. If necessary, loosen the screws (2) and separate the impeller from the motor.
Zafira models with air conditioning
1. Remove the air cleaner assembly with the air duct (see Chapter Power and exhaust systems). Disconnect the electrical wiring from the air mass meter (see Chapter Power and exhaust systems).
2. Loosen the mounting clamp and disconnect the crankcase ventilation hose from the timing cover.
3. After unscrewing the bolts and releasing the clamps, remove the air resonator from the front panel.
4. Remove the front bumper (see Chapter Body).
5. Disconnect the electrical wiring from the fan and release it from the intermediate fasteners.
2. Unscrew the mounting bolts and remove the fan assembly from the engine compartment.
1 - Upper mounting bolts
2 - Lower supports
3. Transfer the fan to a workbench, remove the protective grille if so equipped, unscrew the mounting screws and remove the fan assembly. Disconnect the contact connector and remove the pre-resistor from the frame.
4. If necessary, loosen the screws (2) and separate the impeller from the motor.
Diesel models
Models with 1.7L engines
1. Remove the battery with the support bracket.
2. Remove the front bumper (see Chapter Body).
3. Loosen the mounting clamps and disconnect the intake air duct and intake air blower hose from the intercooler.
4. Loosen the clamp and disconnect the remaining part of the intake air duct from the intercooler. Move the air duct to the side and tie it to the body elements.
5. Set the parking brake, jack up the vehicle and place it on supports. If so equipped, remove the crankcase guard.
6. On models equipped with air conditioning, disconnect the A/C wiring connector located near the horn on the right side of the front spoiler. Also disconnect the pressure sensor wiring connector there.
7. Disconnect the multi-pin connector of the cooling system control module on the left side of the spoiler. Disconnect the ground bus from the body element.
8. If necessary, disconnect the wiring of the additional fan located below in front of the radiator.
9. Loosen the mounting bolts (1) and, lifting it, carefully remove the fan assembly from the radiator and remove it from the engine compartment.
10. On models equipped with an additional electric fan, remove the front panels, resonator, disconnect the wiring, lower the additional fan assembly and remove it from under the vehicle.
11. Transfer the fan to a workbench, remove the protective grille if so equipped, unscrew the mounting screws and remove the fan assembly. Disconnect the contact connector and remove the pre-resistor from the frame.
12. If necessary, loosen the screws (2) and separate the impeller from the motor.
Models with 2.0L engines
1. Remove the radiator assembly with the fan (see Removal and installation the cooling system radiator).
2. Release the latches and remove the fan cover from the radiator.
3. Disconnect the fan wiring connector.
4. Unscrew the mounting bolts and remove the fan.
5. Unscrew the mounting bolts and remove the impeller.
6. On models equipped with an additional fan, remove the front bumper (see Chapter Body), then disconnect the wiring and release the connector mounting bolt. Loosen the mounting nuts and lower the fan down. Disconnect the grille and remove the pre-resistor.
Installation
All models
Installation is carried out in the reverse order of dismantling the components.
After completing the installation, fill the cooling system with fresh mixture (see Chapter Routine maintenance) and check it for signs of developing leaks.
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