Removal and installation the main heater body (Opel Astra G)

On models equipped with air conditioning, it is necessary to first discharge the air conditioning system in a specialized auto repair shop.

Control cables connected to the heater body (execution A)



1. Mixing flap drive cable retainer.

2. Valve timing cable retainer (air supply to the lower level).

3. Valve timing cable retainer (air supply to the upper level).

Control cables connected to the heater body (execution B)



1. Valve timing cable retainer (air supply to the upper level).

2. Mixing flap drive cable retainer.

Removal

1. Remove the center console and instrument panel (see Chapter Body).

2. Disconnect the air supply hose to the rear footwells from the main heater body - prepare a rag to collect the coolant flowing out of the heater heat exchanger.



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3. Remove the passenger airbag (see Chapter On-board electrical equipment).

4. Open both front doors, remove the TORX head bolts and remove the steering crossmember from the engine compartment bulkhead.

5. On equipped with K/V models set the parking brake, jack up the front of the vehicle and place it on supports, if equipped, remove the crankcase guard. Remove the rear engine mount (see Chapter Engine).





6. Unscrew the two mounting bolts and remove the condensate drainage unit from the floor panel.

Dismantling the drainage unit is possible without first removing the support, but this makes the work significantly more difficult.

7. Drain the cooling system (see Chapter Routine maintenance).

8. Remove the plastic insert from the windshield, unscrew the mounting bolts and remove the lower cover panel.

9. In the engine compartment, disconnect the heater hoses from the heat exchanger pipes - mark the hoses first to ensure that they are connected correctly during assembly.

Branded hoses are equipped with quick-connect connectors.

10. On equipped with K/V models unscrew the union bolt of the refrigeration pipe connector on the expansion valve.

11. Remove the air distributor housings from the top of the engine compartment bulkhead.

12. On equipped with K/V models disconnect the electrical wiring from the coolant shut-off valve.



13. In the passenger compartment, disconnect the electrical wiring from the servomotor of the circulation flap and from the electric motor of the heater fan. Disconnect the control cables from the heater housing (shown Distribution flap drive cable retainer (air supply to the upper level), execution B) (see also illustrations Control cables connected to the heater body (execution A) and Control cables connected to the heater body (execution B)).





14. With the help of an assistant, free the main heater housing from the engine compartment bulkhead and remove it from the passenger compartment.

Installation

Installation is carried out in the reverse order of dismantling the components.

Finally, fill the cooling system (see Chapter Routine maintenance). If equipped, take the vehicle to a specialist workshop to have the air conditioning system recharged. When installing the steering crossmember, make sure the upper guides are installed in their proper places before tightening the bolts.