Zafira climate control unit — check and replacement (Opel Zafira A)

The need to perform this work 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. Using a TORX T20 key, unscrew the cigarette lighter mounting screw.



3. Using a slotted screwdriver, remove the cigarette lighter assembly with the ashtray.



4. Disconnect the right connector of the cigarette lighter wiring harness by pulling it off the terminals.





5. Similarly, disconnect the left connector and remove the cigarette lighter.



6. Using a TORX T20 key, unscrew the two lower screws securing the air conditioning system.



7. Using a slotted screwdriver, disconnect the air conditioning control unit clamps and remove the unit by pulling it towards you.



8. Using a slotted screwdriver, remove the Traction Control switch (if installed).





9. Similarly, remove the hazard warning light switch.



10. Disconnect the wiring harness connector by pulling it upwards.



11. Disconnect the second block of the wiring harness by pressing the lock with a slotted screwdriver.



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





13. Disconnect the left fastening of the climate control unit panel.



14. Similarly, we disconnect the right mount.



15. Remove the panel.



16. Remove the retainer of the drive cable of the damper that regulates the temperature of the incoming air.





17. Disconnect the cable.

18. Compress the locking end of the cable holder and remove it from the bracket.



19. Disconnect the upper air flow distribution flap drive cable.



20. Similarly, remove the holder of the lower air flow distribution flap drive cable.



21. Disconnect the cable.





22. Remove the climate control unit.

23. 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.

24. If any contacts do not close, replace the electric fan control unit. To do this, first remove the electric fan speed switch by pulling it towards you.



25. Using a slotted screwdriver, press the fasteners of the electric fan control unit.





26. Remove the block.



27. Install the parts in reverse order.

Checking and replacing the air conditioning drive cables

1. Remove the glove box (see "Air conditioning filter model Zafira - replacement").

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



3. If necessary, use a slotted screwdriver to disconnect the cable.





4. Remove the cable mount by pressing the lock with a slotted screwdriver and remove the cable.



5. Similarly, we check and, if necessary, replace the upper air flow distribution flap drive cable.



6. Remove the lower trim of the instrument panel (see "Air conditioning filter model Zafira - replacement").

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



8. If necessary, use a slotted screwdriver to disconnect the cable.



9. Remove the cable mount by pressing the lock with a slotted screwdriver and remove the cable.



10. Install the parts in reverse order.