Electric Cooling Fan; Coolant Temperature Sensor; Undo Bolt Securing Fan Motor Resistor To Housing; Undo Three Bolts And Remove Motor From The Housing - Opel Zafira B MPV 2006 Owners Workshop Manual

Warning: If the engine is hot, the
cooling fan may start up at any
• time. Take extra precautions when
working in the vicinity of the fan.
Removal
1.6 and 1.8 litre petrol models
1 Disconnect the battery negative terminal
(refer to Disconnecting the battery in the
Reference Chapter).
2 On 1.8 litre models, remove the air cleaner
assembly as described in Chapter 4A. Detach
the air cleaner intake from the duct on the
bonnet crossmember. Undo the two retaining
bolts, slide the intake duct sideways and
remove it from the crossmember.
3 Release the clips and detach the radiator
hoses from the fan housing brackets.
4 Disconnect the cooling fan wiring harness
connector from the base of the fan housing.
Free the wiring harness from the cable ties.
5 Undo the bolt each side securing the fan
housing to the top of the radiator. Lift the fan
housing up and out of the lower mounting
brackets and remove the fan housing from the
car.
6 To remove the fan motor, undo the three
bolts and lift off the fan.
7 Undo the bolt securing the fan motor
resistor to the housing, then undo the three
bolts and remove the motor from the housing
(see illustrations).
2.2 litre petrol models
8 Remove the battery and battery tray as
described in Chapter 5A.
9 Disconnect the cooling fan wiring harness
connector from the base of the fan housing.
Free the wiring harness from the cable ties.
10 Unscrew the retaining bolt and release the
engine wiring harness support bracket. Move
the harness to one side.
11 Undo the bolt each side securing the fan
housing to the top of the radiator. Lift the fan
housing up and out of the lower mounting
brackets and remove the fan housing from the
car.
12 To remove the fan motor, undo the three
bolts and lift off the fan.
13 Undo the bolt securing the fan motor
resistor to the housing, then undo the three
bolts and remove the motor from the housing
(see illustrations 5.7a and 5.7b).
Diesel models
14 Remove the radiator as described in
Section 3, then lift the fan housing out of the
engine compartment.
15 To remove the fan motor, undo the three
bolts and lift off the fan.
16 Undo the bolt securing the fan motor
resistor to the housing, then undo the three
bolts and remove the motor from the housing
(see illustrations 5.7a and 5.7b).
Cooling, heating and air conditioning systems 3•5
5.7a Undo the bolt (arrowed) securing the
fan motor resistor to the housing •••
Refitting
17 Refitting is a reversal of removal.
Testing
1 Testing of the coolant temperature sensor
must be entrusted to a Vauxhall/Opel dealer,
who will have the necessary specialist
diagnostic equipment.
Removal
2 Partially drain the cooling system with
reference to Chapter 1 A or 1 B, as applicable.
Alternatively, it is possible to change the
sensor quickly with minimal loss of coolant by
first releasing any pressure from the cooling
system. With the engine cold, temporarily
remove the expansion tank cap.
3 Where fitted, remove the plastic cover over
the top of the engine.
1.6 litre petrol models
4 The coolant temperature sensor is located
in the thermostat housing at the left-hand end
of the cylinder head.
5 Remove the battery and battery tray as
described in Chapter 5A.
6 Disconnect the wiring from the temperature
sensor, then unscrew and remove it from the
thermostat housing. If the cooling system has
not been drained, either insert the new sensor
6.8 Coolant temperature sensor location
(arrowed) - 1.8 litre petrol engine models
5. 7b ••• then undo the three bolts
(arrowed) and remove the motor from the
housing
or fit a blanking plug to prevent further loss of
coolant.
1.8 litre petrol models
7 The coolant temperature sensor is located
in the thermostat housing at the left-hand end
of the cylinder head.
8 Disconnect the wiring from the temperature
sensor, then unlock the retaining clamp and
remove it from the thermostat housing (see
illustration). If the cooling system has not
been drained, either insert the new sensor or
fit a blanking plug to prevent further loss of
coolant.
2.2 litre petrol models
9 The coolant temperature sensor is located
in the thermostat housing at the left-hand end
of the cylinder head.
10 Disconnect the wiring from the temperature
sensor, then unscrew and remove it from the
thermostat housing. If the cooling system has
not been drained, either insert the new sensor
or fit a blanking plug to prevent further loss of
coolant.
Diesel models
11 The coolant temperature sensor is located
in the thermostat housing at the left-hand end
of the cylinder head (see illustration).
12 Slacken the two retaining clips and
disconnect the upper charge air hose from
the throttle housing, and intercooler left-hand
charge air pipe.
13 Disconnect the wiring from the temperature
sensor, then unscrew and remove it from the
thermostat housing. If the cooling system has
6.11 Coolant temperature sensor location
(arrowed) - diesel engine models