Replacing the cooling system radiator

Due to the layout of the Opel Astra J car, it is possible to remove the radiator of the cooling system from the engine compartment only downwards and only with the electric fan previously removed.

You will need: end head «at 13», sliding pliers or pliers, flat blade screwdriver.



1. Drain the liquid from the cooling system (see Coolant replacement).



2. Remove the cooling fan (see Removal and installation of the electric fan of the radiator of the engine cooling system, complete with casing).



3. Remove the crankcase protection (see Removal and installation of mudguards and engine crankcase protection).




4. Remove the front bumper (see Removal and installation of a forward bumper).



5. Loosen and slide the hose clamp on the radiator outlet pipe..



6.... and disconnect the hose from the branch pipe of the left radiator tank.



7. Pry with a screwdriver..




8.... and lock the spring retainer of the radiator inlet hose in the upper position.



9. Disconnect a hose from a branch pipe of a radiator.



10. Without depressurizing the air conditioning system, wring out the clamps of the air conditioner condenser and disconnect it from the grooves of the cooling system radiator.

Note. Hang the condenser, for example, on a wire, as shown in the photo to item 10.

11. Turn out two bolts of fastening of the top supports of a radiator …



12.... and remove the supports.

Note. If the rubber pads on the mounts are severely compressed, hardened, or torn, replace them.

13. Remove a radiator of system of cooling down.




14. Rinse the outside of the radiator with a jet of water and dry. If cracks appear on the plastic tanks of the radiator, replace the radiator.

15. Check the tightness of the radiator, for which plug the radiator pipes, supply air to it at a pressure of 0.1 MPa (1 kgf/cm²) and immerse in a container of water for at least 30 seconds. Leakage of the radiator is determined by the outgoing air bubbles. If the radiator does not fit into the container as a whole, check it sequentially from all sides.

16. Establish a radiator and all removed details in sequence, return to removal.

Note. In order to further eliminate the possibility of leakage of coolant, before installing the hoses, lubricate the radiator pipes with a thin layer of silicone sealant.

17. Fill in coolant and remove air pockets from the cooling system (see Coolant replacement).