Opel Astra H Heater Mix Flap (Mischklappe ) repair adapter (2004-2010)

How to diagnose a failed heater flap:

There is no hot air blowing from the HVAC in the Astra,

First checked the coolant in the engine, if there is none, you might have a bigger problem.

 Check if the the mix flap solenoid is working by turning on the ignition, but not the engine (nor blower or radio, it has to be quiet), and listen if you can hear the servo motor for the flap adjustment when turning the heat from hot to cold to hot ect. -if you don't hear it check the fuses associated with the HVAC. It is located on the middle console next to the drivers seat (left hand drive car) (see picture)

If all above are ok, remove the stepper motor and inspect the key way, if you can rotate it 360deg, then its broken.

How to fix:

Using a drill, (or dremel) dirll/cut around the flap-keyway to be able to remove it. (see pictures).

Print the STL laying down (you need suports, and no, dont print it standing up, it will be too weak). Tested in ASA for a week without fail, ABS and PET-G might work too, PLA will probably fail.

Turn on car, and set heating to the coldest.-this will set the servo to the coldest position.

Insert the 3d-printed-repair-fork, small fork leg pointing up.

Re install servo

Tested on a 2004 Opel Astra 1.7 CDTI - Rumours say this should work on other Opel/Vauxhall cars as well.