Heater fan (Delphi system)
1. Remove the glove box on the passenger side.
2. Remove the lower facing panel on the passenger side, remove the retainer and remove the air duct from the heater body (see photo).
3. Turn on the ignition and move the heater control levers to the recirculation position ("air recirculating"). Switch off the ignition and disconnect the dividing damper rod from the electric drive. Disconnect the wires from the drive (see photo). Loosen the bolts and remove the damper motor.
4. Disconnect the wires, unscrew the bolts and remove the fan (see photo).
Heater fan (Behr heating system)
5. Turn on the ignition and move the heater control levers to the recirculation position ("air recirculating"). Switch off the ignition and disconnect the dividing damper rod from the electric drive. Disconnect the connector from the drive.
Attention! The electric actuator supplied as spares is set to the recirculation position ("air recirculating").
6. Turn away 5 bolts, remove sealant from a flute of the case of a heater and remove the fan.
7. Apply sealant to the groove when installing the motor. Make sure the motor drive gear engages with the divider gear.
Heater control panel (Astra models with Delphi heating system)
8. Remove the ashtray and storage compartment (Chapter 11).
9. Remove the radio and radio bracket. On parts of cars, remove the navigation system module.
10. Pry off and remove the decorative overlay of the heater control panel.
11. Pry and remove panel switch buttons and vents, remove display (Chapter 12).
12. Set the handle of the heater thermostat to a vertical position and disconnect the cable, paying attention to its position along its route.
13. Disconnect the wires and other cables from the switches. Remove the panel.
14. After assembly, make sure that the mixing damper drive handle is securely fixed in the extreme positions (this indicates the correct adjustment of the cable)..
Heater control panel (Astra models with Behr heating system)
15. Remove the glove box (Chapter 11).
16. Remove the bottom trim panels on both sides.
17. Remove the heater air duct on the passenger side and the instrument panel.
18. Disconnect the cables from the upper and lower distribution flaps.
19. Get cables from brackets.
20. Remove the ashtray, remove the storage tray from the latches.
21. Remove the radio and radio bracket. On parts of cars, remove the navigation system module.
22. Pry and remove the decorative overlay of the heater control panel.
23. Disconnect the wires from the control panel.
24. Label and disconnect cables.
Heater control panel (model Zafira)
25. Remove the glove box (Chapter 11).
26. Remove the bottom trim panels on both sides.
27. Remove the ashtray.
28. The further procedure for removing the panel is illustrated in the photo.
Heater cover (only models without air conditioning)
Attention! On models with air conditioning, to remove the casing or heater core, it will be necessary to depressurize the refrigerant line. This procedure is performed in a car service.
29. Remove a forward facing of salon and the central section. On models with automatic transmission, also remove the transmission control unit.
30. Remove the air duct in the footwell and the airbag module on the passenger side.
31. Open the doors, unscrew the bolts and remove the steering cross member.
32. Drain the liquid from the cooling system.
33. Remove the windshield deflector panels.
34. Disconnect the hoses from the fittings of the heater radiator (hoses are fastened with quick couplings with a coupling and a ring).
35. Turn away bolts and remove casings of a junction box from a partition of a motor compartment.
36. Disconnect the wires from the fan and the divider damper drive. Disconnect the cables on the heater casing (see photo).
37. With an assistant, remove the heater cover and remove it from the passenger compartment.
38. Installation is carried out in the reverse order.
Heater radiator (only models without air conditioning)
39. Drain the liquid from the cooling system.
40. Disconnect the hoses from the fittings of the heater radiator (hoses are fastened with quick couplings with a coupling and a ring - see photo). Plug the fittings, or blow out the radiator with compressed air to remove the liquid.
41. Remove the central section of the forward panel of salon. Pull the air distribution box in the footwell towards you and remove (see photo). To remove the box on Zafira models, unscrew the bolts and remove the brackets.
42. On models with automatic transmission, remove the transmission control unit.
43. Remove 9 latches and remove the heater cover (see photo).
44. Get brackets and disconnect from a tube radiator. Remove the heater core (see photo).
45. Installation is carried out in the reverse order. Replace o-rings with silicone grease. When attaching hoses to the radiator with quick couplings, make sure the hoses are securely fastened (the green ring of the lock should turn freely).
Heater switch
46. Remove the heater control panel.
47. Move the thermostat knob to the warm air position. Move the distribution damper handle to the position of blowing the upper space (heads).
48. Pull up and remove the fan speed control knob. Bend the latches and remove the switch from the control panel.
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