Removal and installation the cooling system radiator (Opel Astra H)

Warning: Any maintenance or repair work on the cooling system must be carried out on a cold engine! See also warnings at the beginning Section 2.

1. The operation for removing the radiator on models with the Z16XEP engine is taken as a basis. For other engines, only additional operations or features of this procedure are required.

Z16XEP Engine (without air conditioning)

Removal

1. Disconnect the battery (see Chapter 5).

2. Drain the coolant (see Section 3).

3. Disconnect the electrical connector on the radiator and lower the vehicle.

4. Loosen the clamp on the left radiator hose and slide it back. Separate the hose from the radiator and release it from the holder (see accompanying illustration).



5. After loosening the fastening clamp and sliding it back (see accompanying illustration), remove the right radiator hose from the thermostat housing and disconnect the coolant temperature sensor wiring connector.





6. Remove the decorative radiator grille (see Chapter 11).

7. Remove the bumper cover (see Chapter 11).

8. Secure the radiator with a suitable tool or wire to the upper holders (see accompanying illustration).



9. Mark the installation position of the lower radiator holders with a marker, unscrew the 4 mounting bolts and remove the radiator holders from the front suspension (see accompanying illustration).



10. Remove the clips from the upper holders and remove the radiator together with the fan.



11. If necessary, remove the fan shroud from the radiator.

Examination

12. After removal from the vehicle, the radiator can be checked for signs of leaks, damage and violations of the internal permeability of the heat exchanger.

13. Insect and vegetation debris can be removed from the space between the heat exchanger plates by blowing them out with compressed air (don't forget to wear safety glasses!), or cleaning with a soft brush. Try not to bend the thin heat exchanger plates or cut your fingers on them. If necessary, the radiator can be flushed before installation by spraying water from a garden hose (see Section 5).

14. Check the condition of the radiator rubber mounts; if necessary, replace any faulty components.

15. Small leaks can be sealed with a suitable sealant (follow the product manufacturer's instructions). Any more complex repairs should be carried out only in a specialized workshop using the necessary equipment.

Installation

16. If the radiator is being replaced, reinstall all the attachments from the old radiator onto the new radiator and install the fan shroud.

The source is on the online website OPELBOOK

15. Secure the radiator to the upper supports using a suitable tool and, observing the markings, install the lower holders on the subframe.

16. Further installation is carried out in the reverse order of dismantling the components.

Features of the Z14XEP engine (without air conditioning)

17. Disconnect the connecting hose from the radiator that goes to the expansion tank.

Features of Z20LE(L/R/H) engines

Note: The description applies to Z20LEL and Z20LER engines. The radiator removal operations for the Z20LEH engine have some differences.

18. Unscrew the boost air pressure sensor (see accompanying illustration) and disconnect the air duct from the cooler.



19. Disconnect the turbocharger cooling return hose from the radiator (see illustration 7.18) and remove it from the holder.

20 Remove the mounting bolt and nut and separate the intercooler from the condenser (see accompanying illustration). Tilt the cooler forward in the lower holders and remove it.

Note: For better visibility, the cooling module is shown removed in the illustration.

21. For the 220LEH engine, additionally disconnect the hose from the radiator that goes to the expansion tank.



22. Unscrew the radiator mounting bolts and pull it upward.

Note: For the Z20LEH engine, additionally disconnect the fan shroud from the intercooler.

23. Loosen the clamp and disconnect the upper hose from the radiator (see accompanying illustration).



24. Raise the car on a lift and place it on stands.

25. Mark the installation position of the air conditioner wiring harness fasteners and cut them, disconnect the wiring harness from the radiator.

26. Loosen the mounting bolt, remove the clamp and remove the intake air duct (see accompanying illustration) from the cooler.



27. Unscrew the mounting bolts (see accompanying illustration) and remove the capacitor from the radiator.





28. Secure the condenser and intercooler to the front panel using wire.

29. Carefully remove the radiator from the holders and pull it out downwards.

30. Installation is carried out in reverse order.

Features of the Z22YH engine (without air conditioning)

31. Remove the air cleaner (see Chapter 4).

32. Remove the right engine lifting eye.

33. Remove the battery and battery tray (see Chapter 5).

34. Disconnect the upper coolant hose from the cylinder head.

35. Disconnect the connecting hose from the radiator that goes to the expansion tank.

Z17DT(L/H) Engines

36. The procedure for removing the radiator is the same as for the Z16XEP engine. In this case, it is necessary to carry out preparatory work as when removing the fan (see Section 6).

Z19DTH Engine

See Section 6.