Evaporator Replacement Opel Agila B

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

Remove

1. 1. Disconnect battery negative lead • Release nut
2. 2. Drain air conditioning system • See operation ”Refrigerant Drain and Refill”
3. 3. For gasoline engine, remove cap from radiator
4. 4. For diesel engine, remove cap from coolant expansion tank
5. 5. Raise vehicle

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

6. 6. Drain cooling system • Place collecting container below • Open radiator drain plug • Allow coolant to drain into collecting container • Close radiator drain plug • Remove collecting container
7. 7. Lower Vehicle
8. 8. For gasoline engine, remove coolant expansion tank (1) from battery tray • Disconnect overflow hose from radiator – Release clip • Install 2x new blanking plug • Slide off

9. 9. For gasoline engine, remove cap from coolant expansion tank

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

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

13. 13. Remove instrument panel • See operation “Instrument Panel Padding Remove and Install”
14. 14. For gasoline engine, disconnect 2x heater hose (2) from heater core • Release 2x clip • Install 4x new blanking plug
15. 15. For gasoline engine, disconnect 2x refrigerant pipe assembly (1) from evaporator • Remove bolt • Remove 2x O ring • Install 4x new blanking plug

16. 16. For diesel engine, raise vehicle
17. 17. For diesel engine, disconnect 2x heater hose (1) from heater core • Release 2x clip • Install 4x new blanking plug
18. 18. For diesel engine, disconnect 2x refrigerant pipe assembly (2) from evaporator • Remove bolt • Remove 2x O ring • Install 4x new blanking plug

19. 19. Lower vehicle
20. 20. Remove air distribution housing from bulkhead panel • Remove 4x nut • Release air distribution housing from 2x locator
21. 21. Transfer air distribution housing to work bench
22. 22. Remove air inlet housing assembly (1) from air distribution housing • Remove 3x screw • Prise off

23. 23. Remove footwell air duct (1) from air distribution housing, left side • Remove 3x screw • Release 3x locator
24. 24. Remove footwell air duct (2) from air distribution housing, right side • Remove 3x screw • Release 3x locator

25. 25. Remove heater core (2) from air distribution housing • Remove cover (1) – Remove 2x screw • Release clip

26. 26. Remove water drain pipe (1) from heater fan motor and air distribution housing • Pull off
27. 27. Remove heater fan motor from air distribution housing • Remove 3x screw (2) • Release clip

28. 28. Remove blanking cover (1) from air distribution housing • Remove 2x screw • Release sealant using suitable tool

29. 29. For gasoline engine, release air conditioning temperature sensor from air distribution housing • Release harness connector (1) for air conditioning temperature sensor from holder – Slide out • Release sensor wire from clip (2)

30. 30. Separate 2x evaporator housing • Remove 20x screw • Prise apart to release sealant and 13x locator • For gasoline engine, release excess wire for air conditioning temperature sensor – Remove clip
31. 31. For gasoline engine, disconnect air conditioning temperature sensor from evaporator
32. 32. Remove evaporator (2) from evaporator housing • Remove insulator, then slide out evaporator
33. 33. Clean mating surfaces of 2x evaporator housing (cleaning both surfaces)
34. 34. Remove expansion valve (1) from evaporator • Remove 2x bolt • Install 2x new blanking plug
35. 35. Remove 2x refrigerant pipe assembly from evaporator • Remove 2x bolt (3) • Remove 4x O ring • Install 6x new blanking plug

Install

36. 36. Install 2x refrigerant pipe assembly to new evaporator (2) • Remove 6x blanking plug • Apply lubricant to 4x new O ring • Install 4x O ring • Install 2x bolt (3)
37. 37. Install expansion valve (1) to evaporator • Remove 2x blanking plug • Install 2x bolt 3.5 Nm
38. 38. Install evaporator to evaporator housing • Slide in evaporator, then install insulator

39. 39. For gasoline engine, measure and set mark on evaporator for air conditioning temperature sensor • Air conditioning temperature sensor (3) is fixed to 14th fin from pipe (2) fitting side • Air conditioning temperature sensor bracket (1) is fixed to 15th fin from pipe fitting side • Dimension Y = 30 ± 2 mm
40. 40. For gasoline engine, connect air conditioning temperature sensor to evaporator

41. 41. Secure 2x evaporator housing together • Apply suitable sealant to evaporator housing • Secure 13x locator • Install 20x screw • For gasoline engine, coil up excess wire for air conditioning temperature sensor, then install clip • Clean off excess sealant
42. 42. For gasoline engine, secure air conditioning temperature sensor to air distribution housing • Secure harness connector (1) for air conditioning temperature sensor to holder – Slide in • Secure sensor wire to clip (2)

43. 43. Clean mating surfaces of blanking cover and air distribution housing (cleaning both surfaces)
44. 44. Install blanking cover (1) to air distribution housing • Apply suitable sealant to blanking cover • Install 2x screw • Clean off excess sealant

45. 45. Install heater fan motor to air distribution housing • Secure clip • Install 3x screw (2)
46. 46. Install water drain pipe (1) to heater fan motor and air distribution housing • Push on

47. 47. Install heater core (2) to air distribution housing • Install cover (1) – Secure clip • Install 2x screw

48. 48. Install footwell air duct (2) to air distribution housing, right side • Secure 3x locator • Install 3x screw
49. 49. Install footwell air duct (1) to air distribution housing, left side • Secure 3x locator • Install 3x screw

Note. The air conditioning temperature sensor is also secured to the air distribution housing, with one of the screws.

50. 50. Install air inlet housing assembly (1) to air distribution housing • Push on to secure clip • Install 3x screw

51. 51. Transfer air distribution housing to vehicle
52. 52. Install air distribution housing to bulkhead panel • Secure air distribution housing to 2x locator • Install 4x nut 6 Nm
53. 53. For gasoline engine, 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
54. 54. For gasoline engine, connect 2x heater hose (2) to heater core • Remove 4x blanking plug • Secure 2x clip

55. 55. For diesel engine, raise vehicle
56. 56. For diesel engine, connect 2x refrigerant pipe assembly (2) to evaporator • Remove 4x blanking plug • Apply lubricant to 2x new O ring • Install 2x O ring • Install bolt 11 Nm
57. 57. For diesel engine, connect 2x heater hose (1) to heater core • Remove 4x blanking plug • Secure 2x clip
58. 58. Lower vehicle

59. 59. Install instrument panel • See operation “Instrument Panel Padding Remove and Install”
60. 60. Install cowl panel grille (1) to vehicle • Secure 3x locator, 14x clip, then install 5x clip
61. 61. Install 2x wiper arm (2) to vehicle • Adjust and align wiper arm • Install 2x nut 18 Nm • Install 2x cap

62. 62. For gasoline engine, 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.

63. 63. Fill coolant expansion tank with new coolant fluid up to maximum level mark
64. 64. Install cap to coolant expansion tank
65. 65. Fill radiator with new coolant fluid up to bottom of radiator filler neck
66. 66. For gasoline engine, install cap to radiator
67. 67. Connect battery negative lead • Secure nut 11 Nm
68. 68. Program all volatile memories – see operation “Program Volatile Memories”
69. 69. Start engine and allow it to run at idle speed until thermostat opens

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

70. 70. Switch off engine
71. 71. Check and correct coolant fluid level
72. 72. Refill refrigerant – see operation ”Refrigerant Drain and Refill”