Removal and installation the air conditioning evaporator (Opel Astra G)

The air conditioning system is under constant high pressure. Never disconnect refrigeration lines or remove any system components without first discharging the system. Discharging the air conditioning system must be done by an experienced technician in a car service workshop. Always wear safety glasses when disconnecting refrigeration lines!

When replacing air conditioning system components, a certain amount of replacement refrigeration oil will be required to fill the volume of the new unit. Use only oil suitable for use in R-134a systems (read the container label carefully).

Removal

Astra Models

1. Discharge the air conditioning system in a specialized workshop.

2. On 1.6L SOHC petrol engines remove the intake air duct from the throttle body (see Chapter Power and exhaust systems).

3. At the rear of the engine compartment, remove the union bolt securing the refrigerant line to the thermostatically controlled expansion valve. Screw in the bolt and remove the valve. Remove the sealing element. Immediately tape or plug the holes to prevent dirt from entering the system.

When installing the valve, it is necessary to insert two guide rods - in order to prevent the risk of damaging the tube, car service specialists usually use the Opel KM-6012 device to press the connection into the valve.

4. Remove the glove box and lower instrument panel trim sections (see Chapter Body).

5. Remove the heater fan (see Removal and installation the heater fan drive motor).



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6. Remove the cabin filter (see Chapter Routine maintenance), then, if equipped, disconnect the electrical wiring from the glass heating sensor.



7. Unscrew the fastening screws and remove the evaporator cover - note that the cover is seated on a sealant, all traces of which must be carefully removed from the mating surfaces.

On some models, you will need to use a knife to remove the evaporator cover.

8. If equipped, remove the glass heating sensor - try to remember its installation position. Carefully remove the evaporator from the heater housing.

Zafira Models

Some models are also equipped with a rear evaporator, mounted behind the rear quarter panel.

1. Discharge the air conditioning system in a specialized workshop.

2. At the rear of the engine compartment, remove the union bolt securing the refrigerant line to the thermostatically controlled expansion valve. Screw in the bolt and remove the valve. Remove the sealing element. Immediately tape or plug the holes to prevent dirt from entering the system.

When installing the valve, it is necessary to insert two guide rods - in order to prevent the risk of damaging the tube, car service specialists usually use the Opel KM-6012 device to press the connection into the valve.

3. Unscrew the bolts securing the cabin filter cover and the evaporator, if equipped, disconnect the electrical wiring from the glass heating sensor.



4. Remove the filter.





5. If equipped, remove the glass heating sensor - try to remember its installation position. Carefully remove the evaporator from the heater housing.

Installation

Installation is performed in the reverse order of dismantling the components. The air conditioning system should be charged in a car service workshop, where specialists will also install the expansion valve.

To install the evaporator cover, you will need a special sealant - consult with specialists from an Opel service station.