Air Conditioning System Temperature Sensor Replacement Opel Agila B

Warning: Observe safety regulations before commencing any work on the airbag system – see “Safety Regulations – Restraint Systems”

Remove

1. 1. Drain refrigerant – see operation ”Refrigerant Drain and Refill”
2. 2. Disconnect battery negative lead • Release nut
3. 3. Remove cap from radiator
4. 4. Raise vehicle

Important. Observe the relevant environmental regulations when disposing of used coolant.

5. 5. Drain cooling system • Place collecting container below • Open radiator drain plug (1) • Allow coolant to drain into collecting container • Close radiator drain plug • Remove collecting container

6. 6. Lower vehicle
7. 7. Remove coolant expansion tank (1) from battery tray • Disconnect overflow hose from radiator – Release clip • Install 2x new blanking plug • Slide off

8. 8. Remove cap from coolant expansion tank

Important. Observe the relevant environmental regulations when disposing of used coolant.

9. 9. Drain any fluid from coolant expansion tank • Clean inside of coolant expansion tank; flush it well with clean water and drain
10. 10. Remove 2x wiper arm (2) from vehicle • Remove 2x cap • Remove 2x nut
11. 11. Remove cowl panel grille (1) • Remove 5x clip, then release 14x clip, 3x locator

12. 12. Partially release 2x weatherstrip from door aperture • Pull off
13. 13. Remove 2x lower inner trim panel (2) from A pillar • Release 6x clip, 12x locator
14. 14. Remove 2x upper inner trim panel (1) from A pillar • Remove 2x bolt • Release 6x clip, 6x locator

15. 15. Slide and tilt 2x seat assembly backward
16. 16. Remove 2x A-pillar lower inner trim panel from footwell • Release 8x clip
17. 17. Remove glove compartment (1) from instrument panel • Open glove compartment • Press 2x side panel inwards, then release from 2x locator (2)

18. 18. Remove lower trim panel (1) from instrument panel • Release 10x clip

19. 19. Release front section of centre console from vehicle • Remove 2x clip (1)
20. 20. Slide and tilt 2x seat forward
21. 21. Remove centre console from vehicle • Remove 2x clip (2) from rear of centre console • Disconnect 2x harness connector from 2x heater mat switch • Release harness for 2x heater mat switch from centre console – Release clip

22. 22. Slide and tilt 2x seat backward
23. 23. Remove lower trim strip (1) from upper trim strip and lower centre instrument trim panel • Prise off to release 6x clip, 3x locator
24. 24. Remove selector lever trim cover (2) from lower centre instrument trim panel • Prise off to release 6x clip, 2x locator
25. 25. Remove upper trim strip (3) from instrument panel and lower centre instrument trim panel • Open upper storage compartment • Release upper trim strip from upper storage compartment – Remove clip • Remove 2x screw • Prise off to release 10x clip

26. 26. Remove lower centre instrument trim panel from vehicle • Remove 4x screw (1), 4x clip (2) • Release lower centre instrument trim panel from 2x side bracket and selector lever bracket • Release 9x locator

27. 27. Remove 2x side bracket (1) from instrument panel carrier and gearshift lever bracket • Remove 8x bolt (2), then release locator

28. 28. Release bonnet handle from instrument panel • Release 2x clip and slide off
29. 29. Remove 2x canopy from steering column • Remove 3x screw • Remove ignition key • Release lower canopy from upper canopy – Release 7x clip
30. 30. Disconnect airbag harness connector (yellow) from airbag contact unit • Slide lock rearward

Note. Illustration shows steering wheel removed for clarity.

31. 31. Disconnect radio switch harness connector (2) from airbag contact unit
32. 32. Disconnect harness connector (1) from steering angle sensor
33. 33. Disconnect harness connector from turn signal multifunction switch
34. 34. Disconnect harness connector from windshield wiper switch
35. 35. Disconnect harness connector from immobilizer control module
36. 36. Disconnect 2x harness connector from ignition switch
37. 37. Release instrument harness from steering column assembly • Release 3x clip

38. 38. Release key interlock cable (1) from ignition switch assembly • Turn ignition switch to "ACC" position • Release clip and slide out, using suitable tool • Turn ignition switch to "LOCK" position

39. 39. Remove cover (1) from intermediate shaft coupling • Release 2x clip

40. 40. Remove intermediate shaft from steering gear • Turn steering gear for access to coupling bolt, then apply match marks • Remove 2x bolt (1, 2)

41. 41. Remove steering column assembly from vehicle • Remove 4x nut (1)

42. 42. Release earth lead from lower A pillar, right side • Remove bolt (1)

43. 43. Disconnect 5x harness connector from body control module (BCM) and junction block assembly
44. 44. Disconnect harness connector from heater fan motor
45. 45. Release harness for heater fan motor from HVAC module assembly • Release from clip
46. 46. Disconnect antenna lead (roof) (2) from antenna lead (Instrument panel)
47. 47. Release earth lead from lower A pillar, left side • Remove bolt (1)

48. 48. Disconnect 3x body harness connector (1) from 3x instrument panel harness connector • Release 2x lock

49. 49. Disconnect harness connector from recirculation flap servo motor
50. 50. Release 2x heater control cable (1) from HVAC module assembly • Release from 2x clip

51. 51. Disconnect harness connector (1) from heater fan motor resistor
52. 52. Disconnect harness connector (2) from air conditioning temperature sensor
53. 53. Release instrument harness from HVAC module assembly • Release instrument harness from clip • Release 2x clip – Prise off

54. 54. Disconnect drain hose from HVAC module assembly • Pull off
55. 55. Release selector lever cable (1) from selector lever assembly • Release ball joint • Release clip, then slide off
56. 56. Release key interlock cable (3) from selector lever assembly • Release ball joint • Release clip, then slide off
57. 57. Disconnect harness connector (2) from selector lever lock solenoid, selector lever position switch and illumination lamp harness connector

58. 58. Remove selector lever assembly from selector lever bracket • Remove 4x nut (1)

59. 59. Release instrument panel assembly from vehicle • Remove 2x clip (1) • Remove 4x bolt (2)
60. 60. Remove instrument panel assembly from vehicle • Release 5x locator from bulkhead panel

Note. 2x technician are required.

61. 61. Disconnect 2x heater hose (2) from heater core • Release 2x clip • Install 4x new blanking plug
62. 62. Disconnect 2x refrigerant pipe assembly (1) from evaporator • Remove bolt • Remove 2x O ring • Install 4x new blanking plug

63. 63. Remove HVAC module assembly from bulkhead panel • Remove 4x nut • Release HVAC module assembly from 2x locator
64. 64. Transfer HVAC module assembly to work bench
65. 65. Remove air inlet housing assembly (1) from HVAC module assembly • Remove 3x screw • Prise off

66. 66. Remove footwell air duct (1) from HVAC module assembly, left side • Remove 3x screw • Release 3x locator

Note. The air conditioning temperature sensor is released from the HVAC module assembly, when one of the screws is removed.

67. 67. Remove footwell air duct (2) from HVAC module assembly, right side • Remove 3x screw • Release 3x locator

68. 68. Remove heater core (2) from HVAC module assembly • Remove cover (1) – Remove 2x screw • Release clip

69. 69. Remove water drain pipe (1) from heater fan motor and HVAC module assembly • Pull off
70. 70. Remove heater fan motor from HVAC module assembly • Remove 3x screw (2) • Release clip

71. 71. Remove blanking cover (1) from HVAC module assembly • Remove 2x screw • Release sealant using suitable tool

72. 72. Release air conditioning temperature sensor from HVAC module assembly • Release harness connector (1) for air conditioning temperature sensor from holder – Slide out • Release sensor wire from clip (2)

73. 73. Separate 2x evaporator housing • Remove 20x screw • Prise apart to release sealant and 13x locator • Release excess wire for air conditioning temperature sensor – Remove clip – Remove clip
74. 74. Disconnect air conditioning temperature sensor (1) from evaporator
75. 75. Remove air conditioning temperature sensor from evaporator housing • Remove connector block from air conditioning temperature sensor – Pull off • Remove rubber grommet (2) from evaporator housing • Withdraw air conditioning temperature sensor through aperture in evaporator housing
76. 76. Clean mating surfaces of 2x evaporator housing (cleaning both surfaces)

Install

77. 77. Install new air conditioning temperature sensor to evaporator housing • Position air conditioning temperature sensor through aperture in evaporator housing • Install rubber grommet (2) to evaporator housing • Install connector block to air conditioning temperature sensor – Push on
78. 78. Connect air conditioning temperature sensor (1) to evaporator

79. 79. Secure 2x evaporator housing together • Apply suitable sealant to evaporator housing • Secure 13x locator • Install 20x screw • Coil up excess wire for air conditioning temperature sensor, then install clip • Clean off excess sealant
80. 80. Secure air conditioning temperature sensor to HVAC module assembly • Secure harness connector (1) for air conditioning temperature sensor to holder – Slide in • Secure sensor wire to clip (2)

81. 81. Clean mating surfaces of blanking cover and HVAC module assembly (cleaning both surfaces)
82. 82. Install blanking cover (1) to HVAC module assembly • Apply suitable sealant to blanking cover • Install 2x screw • Clean off excess sealant

83. 83. Install heater fan motor to HVAC module assembly • Secure clip • Install 3x screw (2)
84. 84. Install water drain pipe (1) to heater fan motor and HVAC module assembly • Push on

85. 85. Install heater core (2) to HVAC module assembly • Install cover (1) – Secure clip • Install 2x screw

86. 86. Install footwell air duct (2) to HVAC module assembly, right side • Secure 3x locator • Install 3x screw
87. 87. Install footwell air duct (1) to HVAC module assembly, left side • Secure 3x locator • Install 3x screw

Note. The air conditioning temperature sensor is also secured to the HVAC module assembly, with one of the screws.

88. 88. Install air inlet housing assembly (1) to HVAC module assembly • Push on to secure clip • Install 3x screw

89. 89. Transfer HVAC module assembly to vehicle
90. 90. Install HVAC module assembly to bulkhead panel • Secure HVAC module assembly to 2x locator • Install 4x nut 6 Nm
91. 91. Connect 2x refrigerant pipe assembly (1) to evaporator • Remove 4x blanking plug • Apply lubricant to 2x new O ring • Install 2x O ring • Install bolt 11 Nm
92. 92. Connect 2x heater hose (2) to heater core • Remove 4x blanking plug • Secure 2x clip

93. 93. Install instrument panel assembly to vehicle • Secure 5x locator to bulkhead panel

Note. 2x technician are required.

94. 94. Secure instrument panel assembly to vehicle • Install 4x bolt (2) 23 Nm • Install 2x clip (1)

95. 95. Install selector lever assembly to selector lever bracket • Install 4x nut (1)

96. 96. Connect harness connector (2) to selector lever lock solenoid, selector lever position switch and illumination lamp harness connector
97. 97. Secure key interlock cable (3) to selector lever assembly • Slide on to secure clip • Secure ball joint
98. 98. Secure selector lever cable (1) to selector lever assembly • Slide on to secure clip • Secure ball joint

99. 99. Connect drain hose to HVAC module assembly • Push on
100. 100. Secure instrument harness to HVAC module assembly • Secure 2x clip – Push on • Secure instrument harness to clip
101. 101. Connect harness connector (2) to air conditioning temperature sensor
102. 102. Connect harness connector (1) to heater fan motor resistor

103. 103. Secure 2x heater control cable (1) to HVAC module assembly • Secure to 2x clip

104. 104. Connect harness connector to recirculation flap servo motor
105. 105. Connect 3x body harness connector (1) to 3x instrument panel harness connector • Secure 2x lock

106. 106. Secure earth lead to lower A pillar, left side • Install bolt (1)
107. 107. Connect antenna lead (roof) (2) to antenna lead (Instrument panel)

108. 108. Secure harness for heater fan motor to HVAC module assembly • Secure to clip
109. 109. Connect harness connector to heater fan motor
110. 110. Connect 5x harness connector to body control module (BCM) and junction block assembly
111. 111. Secure earth lead to lower A pillar, right side • Install bolt (1)

112. 112. Install steering column assembly to vehicle • Install 4x nut (1) 14 Nm

113. 113. Install intermediate shaft to steering gear • Locate shaft to upper spline and lower coupling • Install bolt (2) 25 Nm • Secure bolt (1) 25 Nm

Note. Align match marks and turn steering gear as required for bolt access.

114. 114. Install cover (1) to intermediate shaft coupling • Secure 2x clip

115. 115. Secure key interlock cable (1) to ignition switch assembly • Turn ignition switch to "ACC" position • Slide in to secure clip • Turn ignition switch to "LOCK" position

116. 116. Secure instrument harness to steering column assembly • Release 3x clip

Note. Illustration shows steering wheel removed for clarity.

117. 117. Connect 2x harness connector to ignition switch
118. 118. Connect harness connector to immobilizer control module
119. 119. Connect harness connector to windshield wiper switch
120. 120. Connect harness connector to turn signal multifunction switch
121. 121. Connect harness connector (1) to steering angle sensor
122. 122. Connect radio switch harness connector (2) to airbag contact unit
123. 123. Connect airbag harness connector (yellow) to airbag contact unit

124. 124. Install 2x canopy to steering column • Secure lower canopy to upper canopy – Secure 7x clip • Install ignition key • Install 3x screw
125. 125. Secure bonnet handle to instrument panel • Slide on to secure 2x clip
126. 126. Install 2x side bracket (1) to instrument panel carrier and gearshift lever bracket • Secure locator, then install 8x bolt (2) 23 Nm

127. 127. Install lower centre instrument trim panel to vehicle • Secure lower centre instrument trim panel to 2x side bracket and selector lever bracket – Secure 9x locator • Install 4x clip (2), 4x screw (1)

128. 128. Install upper trim strip (3) to instrument panel and lower centre instrument trim panel • Push on to secure 10x clip • Install 2x screw • Secure upper trim strip to upper storage compartment – Install clip • Close upper storage compartment
129. 129. Install selector lever trim cover (2) to lower centre instrument trim panel • Push on to secure 2x locator, 6x clip
130. 130. Install lower trim strip (1) to upper trim strip and lower centre instrument trim panel • Push on to secure 3x locator, 6x clip
131. 131. Slide and tilt 2x seat forward

132. 132. Install centre console to vehicle • Connect 2x harness connector to 2x heater mat switch • Secure harness for 2x heater mat switch to centre console – Secure clip • Install 2x clip (2) to rear of centre console
133. 133. Slide and tilt 2x seat rearward
134. 134. Secure front section of centre console to vehicle • Install 2x clip (1)

135. 135. Install lower trim panel (1) to instrument panel • Secure 10x clip

136. 136. Install glove compartment (1) to instrument panel • Push into 2x locator (2) • Press 2x side panel inwards, then secure to instrument panel • Close glove compartment

137. 137. Install 2x A-pillar lower inner trim panel to footwell • Secure 8x clip
138. 138. Slide and tilt seat assembly to original position
139. 139. Install 2x upper inner trim panel (1) to A pillar • Secure 6x locator, 6x clip • Install 2x bolt
140. 140. Install 2x lower inner trim panel (2) to A pillar • Secure 12x locator, 6x clip

141. 141. Secure 2x weatherstrip to door aperture • Push on
142. 142. Install cowl panel grille (1) to vehicle • Secure 3x locator, 14x clip, then install 5x clip
143. 143. Install 2x wiper arm (2) to vehicle • Adjust and align wiper arm • Install 2x nut 18 Nm • Install 2x cap

144. 144. Install coolant expansion tank (1) to battery tray • Slide on • Remove 2x blanking plug • Connect overflow hose to radiator – Secure clip

Important. Only use coolant approved by the manufacturer and ensure a concentration of 50% water and 50% anti-freeze.

145. 145. Fill coolant expansion tank with new coolant fluid up to maximum level mark
146. 146. Install cap to coolant expansion tank
147. 147. Fill radiator with new coolant fluid up to bottom of radiator filler neck
148. 148. Install cap to radiator
149. 149. Connect battery negative lead • Secure nut 11 Nm
150. 150. Program all volatile memories – see operation “Program Volatile Memories”
151. 151. Start engine and allow it to run at idle speed until thermostat opens

Note. Cooling system bleeds itself automatically during the warm-up phase.

152. 152. Switch off engine
153. 153. Check and correct coolant fluid level
154. 154. Refill refrigerant – see operation ”Refrigerant Drain and Refill”