Heater Core 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. For vehicles with air conditioning, drain refrigerant • 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) (if installed) 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) (if installed) 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, right side • Remove 3x screw • Release 3x locator

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

Install

26. 26. Install insulation to new heater core • Slide on
27. 27. Install heater core (2) to air distribution housing • Install cover (1) – Secure clip • Install 2x screw

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

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

30. 30. Transfer air distribution housing to vehicle
31. 31. Install air distribution housing to bulkhead panel • Secure air distribution housing to 2x locator • Install 4x nut 6 Nm
32. 32. For gasoline engine, connect 2x refrigerant pipe assembly (1) (if installed) to evaporator • Remove 4x blanking plug • Apply lubricant to 2x new O ring • Install 2x O ring • Install bolt 11 Nm
33. 33. For gasoline engine, connect 2x heater hose (2) to heater core • Remove 4x blanking plug • Secure 2x clip

34. 34. For diesel engine, raise vehicle
35. 35. For diesel engine, connect 2x refrigerant pipe assembly (2) (if installed) to evaporator • Remove 4x blanking plug • Apply lubricant to 2x new O ring • Install 2x O ring • Install bolt 11 Nm
36. 36. For diesel engine, connect 2x heater hose (1) to heater core • Remove 4x blanking plug • Secure 2x clip
37. 37. Lower vehicle

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

41. 41. 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.

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

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

49. 49. Switch off engine
50. 50. Check and correct coolant fluid level
51. 51. For vehicles with air conditioning, refill refrigerant – see operation ”Refrigerant Drain and Refill”