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[Solved] - ASTRA G Blower Issue: Strange Air Flap Function, Open-Closed Circuit & Fix Solutions

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  • #1 17175731
    elektronikq
    Level 25  
    Posts: 3325
    Help: 70
    Rate: 612
    Today when disassembled the glove box, I saw that the air flap works like this:

    link
    does it have anything to do with the open closed circuit? The indicator light in this closed circuit lights up when pressed.
    How can you fix this?
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  • Helpful post
    #2 17193689
    mlbta
    Level 9  
    Posts: 3
    Help: 1
    Rate: 3
    I had the same thing. I just fixed it today. I also searched various forums and websites to see how to fix it. And actually the tips work. If the LED on the button is on, the internal circuit is on, if it is off, the air is coming in from outside. In my case, whether the internal circuit was on or off, the flap was still flying. It was even so with the ignition on and the zero speed of the air supply. Some write about a decaying engine, others about the side clips holding the flap, and so it was in my case, or rather the broken left side of the upper part of the flap (such a white tube). I unscrewed the storage, then 3 screws (left side) holding the motor and the motor can be removed from the white handle, then the screws holding the housing with the blower - under the flap grille, then the screws holding the grille with the flap, then after moving the pit outside there is a grille mounted on the 4 star bolts, and under it in the middle one bolt holding the grill with the flap and from the inside you can remove the entire grill with the flap. After removing the grille with a flap, the flap is held on two such white handles on the sides. From the motor side, the strip into which the handle enters was cracked and therefore the flap was jumping. Gently with the forceps you have to pull out these white handles, turn the flap backwards to the front (180 degrees, as some write) insert the side handles and fold everything. It is a bit muddy, not enough space to unscrew the screws, but it was worth it, because it has been repaired and works, it hasn't been flying anymore, and I was ready to leave it permanently in the external circulation position and lock it.



    - ASTRA G Blower Issue: Strange Air Flap Function, Open-Closed Circuit & Fix Solutions - ASTRA G Blower Issue: Strange Air Flap Function, Open-Closed Circuit & Fix Solutions - ASTRA G Blower Issue: Strange Air Flap Function, Open-Closed Circuit & Fix Solutions


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  • #3 17366967
    elektronikq
    Level 25  
    Posts: 3325
    Help: 70
    Rate: 612
    Did you give a system to lower the current? I blocked the flap but I want to do it as the producer has commanded.

    Added after 3 [minutes]:

    Did you give a system to lower the current? I blocked the flap but I want to do it as the producer has commanded.
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  • #4 17479845
    andysb
    Level 9  
    Posts: 8
    Help: 2
    Rate: 30
    Can you buy such a system?
  • #5 17479991
    elektronikq
    Level 25  
    Posts: 3325
    Help: 70
    Rate: 612
    To lower the current?
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  • #6 17480023
    andysb
    Level 9  
    Posts: 8
    Help: 2
    Rate: 30
    Yes, a system for lowering the current. My flap has had a malfunction twice. This time it torn the flap off the shaft. Replacing the flap or repair will not help for a long time. This roller turning motor is too strong.
  • #7 17480547
    elektronikq
    Level 25  
    Posts: 3325
    Help: 70
    Rate: 612
    I will test with the converter reducing the voltage. Lower voltage lower current. You just have to check if it manages to open and close. So adjust before putting on the clipboard.
  • #8 17480740
    lopr_pol
    Level 32  
    Posts: 1691
    Help: 161
    Rate: 476
    The same problem is in Astra H, you give a 5-8 Ohm resistor about 0.5-1W and it's ok and it doesn't break the drive.
  • #9 17482228
    andysb
    Level 9  
    Posts: 8
    Help: 2
    Rate: 30
    I don't know much about electronics, so I will ask for exact directions and I will do it with this resistor. Should it be plugged into one cable (e.g. the one with higher potential) supplying the motor just before the motor to reduce the flowing current? Does it matter which cable? Thank you.

    If the power supply to this motor is on a separate fuse, could you replace the fuse with a larger resistance (resistor) to get the same effect as after plugging in an additional resistor?
  • #10 17482396
    elektronikq
    Level 25  
    Posts: 3325
    Help: 70
    Rate: 612
    It depends on what current is consumed by this motor. Then you could choose a resistor. If the current is relatively large, the resistor may not withstand.
  • #11 17537704
    elektronikq
    Level 25  
    Posts: 3325
    Help: 70
    Rate: 612
    Here is such a short guide
    Attachments:
    • Astra G - obieg wewnętrzny.txt (1.23 KB) You must be logged in to download this attachment.
  • #12 17538145
    elektronikq
    Level 25  
    Posts: 3325
    Help: 70
    Rate: 612
    Same as above.
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Topic summary

✨ The discussion revolves around a blower issue in the ASTRA G vehicle, specifically concerning the air flap's operation in relation to an open-closed circuit. Users report that the air flap malfunctions regardless of the circuit's status, with some identifying broken components as the cause. Solutions proposed include using a resistor to lower the current supplied to the motor, which has been effective in similar cases. Users share experiences with replacing or repairing the flap and suggest testing with a voltage converter to ensure proper operation. Detailed guidance on implementing a resistor to manage current flow is also requested and provided.
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FAQ

TL;DR: For Astra G/H owners, recirc flaps “fly” from cracked pivots or over‑torque; a 5–8 Ω, 0.5–1 W series resistor helps. “...and it's ok and it doesn't break the drive.” Fix by rotating the flap 180° or limiting voltage. [Elektroda, lopr_pol, post #17480740]

Why it matters: This restores OEM airflow control, prevents repeat breakage, and keeps cabin air quality under control.

Quick Facts

What does the Astra G recirculation LED actually mean?

The LED shows recirculation status. LED on means internal air recirculation. LED off means outside air intake. This simple check helps diagnosis. Expert note: "If the LED on the button is on, the internal circuit is on." [Elektroda, mlbta, post #17193689]

Why does my air flap keep “flying” even with the fan at zero?

A cracked side pivot lets the flap jump freely. Users report it happening with ignition on and zero fan speed. The broken left “white tube” is common. "The flap was still flying." Inspect before replacing the motor. [Elektroda, mlbta, post #17193689]

How do I fix a broken recirculation flap without new parts?

Try the mechanical flip-and-reseat method to reuse good plastic.
  1. Remove glovebox; undo the motor’s 3 left-side screws and lift it off.
  2. Remove the grille (4 Torx bolts plus one center bolt) and extract flap.
  3. Pull out the white side pins, rotate the flap 180°, reinsert pins, reassemble.
This stops jumping when the opposite pivot is intact. [Elektroda, mlbta, post #17193689]

Can a resistor prevent the actuator from breaking the flap?

Yes. Owners add a series resistor to soften the drive. Reported working values are 5–8 Ω at 0.5–1 W. One expert wrote, "it’s ok and it doesn't break the drive." Mount it securely and test operation. [Elektroda, lopr_pol, post #17480740]

Where exactly should I wire the resistor?

Install the resistor in series on one actuator motor lead. Place it close to the motor harness. Polarity does not matter for a series resistor. Secure it to avoid heat near plastics. Verify smooth opening and closing afterward. [Elektroda, lopr_pol, post #17480740]

Can I replace the actuator fuse with a higher-resistance part?

No. Keep the factory fuse for protection. Limit torque with a proper series resistor sized for motor current. "If the current is relatively large, the resistor may not withstand." Choose power rating accordingly and avoid overheating. [Elektroda, elektronikq, post #17482396]

My motor tore the flap off the shaft. What should I do?

Repair or replace the flap and address actuator torque. Without torque limiting, failures return. Consider adding a series resistor or voltage reduction. As one owner said, "This roller turning motor is too strong." Reduce stress and recheck travel. [Elektroda, andysb, post #17480023]

Is a voltage-lowering converter better than a resistor?

It is a valid option. A DC‑DC converter lets you tune voltage precisely. "Lower voltage lower current." Adjust until it opens and closes reliably. Test before refitting the glovebox to save time. [Elektroda, elektronikq, post #17480547]

Is blocking the flap in fresh‑air position a safe workaround?

It works as a temporary measure, but you lose recirculation. The thread author blocked it, then sought an OEM‑style fix later. Plan a mechanical repair and torque limiting. [Elektroda, elektronikq, post #17366967]

How many fasteners are involved during disassembly?

Expect small but numerous fasteners. The motor uses three left‑side screws. The grille sits on four Torx bolts plus a center bolt. The flap holds on two white side pins. Keep hardware organized to speed reassembly. [Elektroda, mlbta, post #17193689]

What tools will I need for this repair?

Use Torx/star bits, Phillips screwdrivers, and small forceps or pliers. A flashlight helps in the tight space. Space is tight around screws, so patience helps. Refer to the linked images for orientation. [Elektroda, mlbta, post #17193689]

How should I test before reassembling the glovebox?

Power the ignition and toggle the recirculation button. Watch the flap for full, stable travel. If you reduced voltage, fine‑tune it until it opens and closes reliably. Do this before refitting trim to avoid repeat work. [Elektroda, elektronikq, post #17480547]

Is this issue also seen on Astra H?

Yes. Owners report the same recirculation flap stress on Astra H. A 5–8 Ω, 0.5–1 W series resistor reduces breakage risk. The approach protects the drive during end stops. [Elektroda, lopr_pol, post #17480740]

Where can I see photos or a video of the fix?

See user‑posted photos and a short YouTube clip in the thread. They show the flap, white side pins, motor location, and movement. Use them to confirm parts and orientation before you begin. [Elektroda, mlbta, post #17193689]
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