Air Conditioning System; Air Conditioning System Components; Air Conditioning Service Ports; Compressor - Opel Zafira B MPV 2006 Owners Workshop Manual

3•10 Cooling, heating and air conditioning systems
10.6 Air conditioning system
high-pressure service port (arrowed) •••
37 Undo the two bolts securing the conden-
sation drain tube to the engine compartment
bulkhead.
38 Remove the complete facia assembly
and the facia crossmember as described in
Chapter ii.
39 Release the retaining clips and remove
the air distribution ducts in the vicinity of the
centre console.
40 Working in the windscreen cowl panel
aperture and around the engine compartment
bulkhead, undo the eight bolts securing the
air distribution housing to the bulkhead.
41 Carefully withdraw the air distribution
housing from the bulkhead. Note: Keep the
matrix unions uppermost
as
the housing
is
removed, to prevent coolant spillage. Mop-up
any spilt coolant immediately, and wipe the
affected area with a damp cloth to prevent
staining.
Refitting
42 Refitting is the reverse of removal. On
completion, refill the cooling system as
described in Chapter 1A or i 8. On models with
air conditioning, have the system evacuated,
charged and leak-tested by the specialist who
discharged it.
General information
1 Air conditioning is standard on top of the
range models, and optional on certain other
":odels. It enables the temperature of incoming
air to be lowered, and also dehumidifies the
air, which makes for rapid demisting and
increased comfort.
2 The cooling side of the system works in
the same way as a domestic refrigerator.
Refrigerant gas is drawn into a belt-driven
compressor, and passes into a condenser
mounted in front of the radiator, where it
loses heat and becomes liquid. The liquid
passes through an expansion valve to an
evaporator, where it changes from liquid under
high pressure to gas under low pressure.
This change is accompanied by a drop in
temperature, which cools the evaporator. The
10.7 ... and low-pressure service port
(arrowed)
refrigerant returns to the compressor, and the
cycle begins again.
3 Air blown through the evaporator passes
to the heater assembly, where it is mixed
with hot air blown through the heater matrix,
to achieve the desired temperature in the
passenger compartment.
4 The heating side of the system works
in the same way as on models without air
conditioning (see Section 8).
5 The operation of the system is controlled
electronically. Any problems with the system
should be referred to a Vauxhall/Opel dealer
or an air conditioning specialist.
Air conditioning service ports
Note: The air conditioning service port
location varies slightly according to model.
The following
is a
general description of
service port location.
6 The high-pressure service port is the larger
of the two service port connections and is
located in front of the radiator. Remove the
radiator grille as described in Chapter i 1 for
access (see illustration).
7 The low-pressure service port is located
at the rear right-hand side of the engine
compartment (see illustration).
Precautions
8 It is necessary to observe special
precautions whenever dealing with any part of
the system, its associated components, and
any items which necessitate disconnection of
the system.
4.
Warning: The refrigeration circuit
~ contains a liquid refrigerant.
This refrigerant is potentially
dangerous, and should only be handled by
qualified persons. If it is splashed onto the
skin, it can cause frostbite. It is not itself
poisonous, but in the presence of a naked
flame it forms a poisonous gas; inhalation
of the vapour through a lighted cigarette
could prove fatal. Uncontrolled discharging
of the refrigerant is dangerous, and
potentially damaging to the environment.
Do not disconnect any part of the system
unless it has been discharged by a
Vauxhall!Opel dealer or an air conditioning
specialist.
Caution: Do not operate the air
conditioning system if it is known to be
short of refrigerant, as this may damage
the compressor.
Air conditioning
system components -
removal r$1ttln~
Warning: The air conditioning
system is under high pressure. Do
not loosen any fittings or remove
any components until after the system
has been discharged. Air conditioning
refrigerant should be properly discharged
into an approved type of container at a
dealer service department or an automotive
air conditioning repair facility capable of
handling R134a refrigerant. Cap or plug the
pipe lines as soon as they are disconnected
to prevent the entry of moisture. Always
wear eye protection when disconnecting
air conditioning system fittings.
Note: This Section refers to the components
of the air conditioning system itself - refer to
Sections 8 and 9 for details of components
common to the heating/ventilation system.
Compressor
Removal
1 Have the refrigerant discharged at a dealer
service department or an automotive air
conditioning repair facility.
2
Disconnect the battery negative terminal
(refer to Disconnecting the battery in the
Reference Chapter).
3 Firmly apply the handbrake, then jack up
the front of the car and support it securely on
axle stands (see Jacking and vehicle support).
4 Remove the auxiliary drivebelt as described
in Chapter 1 A or i B.
5 With the system discharged, undo the
retaining bolt(s) and disconnect the refrigerant
pipes from the compressor. Discard the 0-ring
seals - new ones must be used when refitting.
Suitably cap the open fittings immediately to
keep moisture and contamination out of the
system.
6 Disconnect the compressor wiring
connector.
7
Unbolt the compressor from the cylinder
block/crankcase/sump, then withdraw the
compressor from the vehicle.
Refitting
8 Refit the compressor in the reverse order of
removal; renew all seals disturbed.
9 If you are installing a new compressor, refer
to the compressor manufacturer's instructions
for adding refrigerant oil to the system.
10 Have the system evacuated, charged and
leak-tested by the specialist that discharged
it.
11 After installing a new compressor, always
observe the following running-in procedure:
1) Open all instrument panel air outlet flaps.
2) Start vehicle engine and stabilise idle
speed for approximately 5 seconds.
3) Switch fan to maximum speed.