Insert Drill Bit Through Holes Provided On Radiator Brackets; Condenser Right-Hand Upper Retaining Bolt; Undo Two Bolts Each Side; Remove Radiator Mounting Brackets, Noting Their Orientation - Opel Zafira B MPV 2006 Owners Workshop Manual

3.10 Insert a drill bit (arrowed) or similar,
through the holes provided on the radiator
mounting brackets (shown with radiator
removed)
bolts securing the right-hand side of the
condenser to the radiator (see illustrations).
Similarly undo the upper and lower bolts
securing the left-hand side of the condenser
to the radiator.
12 Undo the two bolts each side securing
the radiator left-hand and right-hand
mounting brackets to the subframe. Remove
the brackets, noting their orientation (see
illustrations).
13 Remove the drill bits, or similar tools used
to retain the radiator in position and carefully
lower the radiator out from under the car.
Inspection
14 If the radiator has been removed due
to suspected blockage, reverse-flush it as
described in Chapter 1A.
15 Clean dirt and debris from the radiator
fins, using an airline (in which case, wear eye
protection) or a soft brush.
Caution: Be careful, as the fins are easily
damaged, and are sharp.
16 If necessary, a radiator specialist can
perform a 'flow test' on the radiator, to
establish whether an internal blockage exists.
17 A leaking radiator must be referred to a
specialist for permanent repair. Do not attempt
to weld or solder a leaking radiator.
18 In an emergency, minor leaks from the
radiator can be cured by using a suitable
radiator sealant (in accordance with its
manufacturer's instructions) with the radiator
fitted in the vehicle.
19 Inspect the radiator mounting rubbers,
and renew them if necessary.
3.12a Undo the two bolts (arrowed) each
side •.•
Cooling, heating and air conditioning systems 3•3
3.11 a Condenser right-hand upper
retaining bolt (arrowed) •••
Refitting
20 Refitting is a reversal of removal, bearing
in mind the following points.
a) Ensure that all hoses are correctly
reconnected, and their retaining clips
securely tightened.
b) On completion, refill the cooling system
as described in Chapter 1 A.
c) On models with automatic transmission,
, check and if necessary top-up the
automatic transmission fluid level with
reference to the 'Transmission fluid
- draining and refilling' procedures
contained in Chapter 78.
Diesel engine models
Removal
21 Remove the battery and battery tray as
described in Chapter SA.
22 Where fitted, remove the plastic cover
from the top of the engine.
23 On models with automatic transmission,
remove the air cleaner assembly and intake
ducts as described in Chapter 48.
24 Apply the handbrake, then jack up the
front of the vehicle and support it on axle
stands (see Jacking and vehicle support).
25 Remove the front bumper as described in
Chapter 11.
26 Drain the cooling system as described in
Chapter 18.
27 Disconnect the cooling fan wiring harness
connector from the base of the fan housing.
Free the wiring harness from the cable ties.
28 On models with air conditioning, open the
retaining clip and detach the air conditioning
3.12b ••• and remove the radiator
mounting brackets, noting their orientation
3.11 b ••• and right-hand lower retaining
bolt (arrowed)
refrigerant pipe from the right-hand side of
the radiator. Release the air conditioning
compressor wiring harness from the retaining
clip.
29 Where applicable, release the two vacuum
hoses from the clips on the right-hand side of
the radiator.
30 Release the clamp and disconnect the
bottom hose from the radiator.
31 Retain the radiator in position by inserting
a drill bit or similar, through the holes provided
on each of the radiator upper mounting
brackets (see illustration 3.10).
32 Undo the two bolts each side securing
the radiator left-hand and right-hand
mounting brackets to the subframe. Remove
the brackets, noting their orientation (see
illustrations 3.12a and 3.12b}.
33 Release the clamps and disconnect the
top hose and expansion tank hose from the
right-hand side of the radiator.
34 Release the retaining clip and disconnect
the turbocharger charge air hose from the
charge air pipe.
35 Undo the bolt each side securing the
fan housing to the top of the radiator (see
illustrations). Unclip the charge air pipe,
lift the fan housing up and out of the lower
mounting brackets and move it to one side.
36 On models with automatic transmission,
detach the protective ring (where fitted) over the
fluid cooler pipe unions at the radiator. Using
a small screwdriver, release the quick-release
fitting retaining lugs and disconnect the fitting
from the radiator. Suitably cover the open
unions after disconnection.
3.35a Undo the fan housing right-hand
mounting bolt (arrowed) •..