Astra climate control unit — checking and replacement (Opel Zafira A)

The need to perform this operation must be determined during the inspection of the technical condition of the air conditioning system (see "Air conditioning system - technical condition check").

To complete the work you will need a multimeter.

Checking and replacing the control unit

1. Prepare the car for work (see "Preparing the car for maintenance and repair").

2. Remove the mat from the storage shelf for small items located on the center console.

3. Using a slotted screwdriver, press the lower fasteners, lifting them up.



4. Similarly, press the upper fasteners.

5. Remove the shelf for small items.



6. Remove the hazard warning switch (see "Hazard warning light switch - checking and replacing").



7. Remove the cigarette lighter cover and open the ashtray lid (see "Cigarette lighter - adjustment and replacement of the socket, replacement of the backlight lamp").

8. Using a TORX T20 key, unscrew the lower screws of the center console trim panel.



9. Remove the car radio and its mounting frame (see "Car radio - removal and installation").

10. Using a TORX T20 key, unscrew the two side screws of the center console trim panel.



11. Using a slotted screwdriver, disconnect the fasteners of the climate control unit: the upper right...



...and the left upper mount.





12. Similarly, we disconnect the lower fasteners of the air conditioning control unit.



13. Slightly push the climate control unit inward.



14. Remove the center console trim panel together with the information display.

15. Using a slotted screwdriver, pry up and disconnect the wiring harness connector of the hazard warning light switch.





16. Lower the locking device of the information display wiring harness connector and remove the connector.



17. Remove the center console trim panel.



18. Press the side fasteners of the electric fan wiring harness connector and remove the connector from the climate control unit.



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19. Remove the second wiring harness connector.



20. Remove the holder of the drive cable of the damper that regulates the temperature of the incoming air.



21. Disconnect the cable.



22. Remove the holder and disconnect the upper air flow distribution flap drive cable.



23. Similarly, disconnect the holder of the lower air distribution flap drive cable.





24. Remove the cable.



25. Remove the climate control unit.

Note: To replace the backlight bulbs, turn the bulb holder counterclockwise and remove the bulb together with the holder.

26. Using a multimeter in ohmmeter mode, check the closure of contacts when switching the electric fan speeds. The closure of contacts when switching on different speeds of the electric fan should occur in the following order:

• 1st speed - 1 and 2;
• 2nd speed - 1 and 3;
• 3rd speed - 1 and 4;
• 4th speed - 1 and 5.

If any contacts do not close, replace the air conditioning control unit.

Checking and replacing the air conditioning drive cables

1. Remove the lower trim of the instrument panel (see "Throttle Pedal Replacement").

2. Make sure that the air flow distribution flap drive cable is in good working order and correctly connected.

3. If necessary, disconnect the cable mount by pulling the holder upwards.



4. Remove the ball tip from the rod and remove the cable.



5. Using a slotted screwdriver, turn the clamps of the lower trim of the instrument panel.





6. Remove the trim.



7. Make sure that the air temperature control flap drive cable is in good working order and correctly connected.

8. If necessary, use a 5.5 mm wrench to loosen the cable mounting bolt.



9. Remove the ball tip from the rod and remove the cable.



10. Install the parts in reverse order.