Heater/Cooler Assembly

Removal
1. Disconnect battery ground cable.
2. Recover refrigerant from air conditioning system.
3. Drain radiator coolant only.
4. Remove instrument panel.







5. From under the hood: Disconnect air conditioning pipes at the evaporator.
1. Remove bolts.
2. Discard O-rings.
3. Install suitable blanking plugs.







6. Disconnect heater hoses from heater matrix pipes.
1. Release spring band clips and disconnect heater hoses.
2. Install suitable blanking plugs.







7. From inside the vehicle: remove brace.
- Remove steering column upper mounting bracket/brace to firewall securing bolt.
- Remove brace to firewall securing bolt (where fitted).
- Remove brace to transmission tunnel securing bolts.
- Remove brace.







8. Remove LH fan motor duct.
- Remove screws.
- Remove duct.







9. Remove RH fan motor duct.
- Remove screws.
- Remove duct.







10. Disconnect heater/cooler unit electrical connector.







11. Disconnect air conditioning control module electrical connectors.







12. Disconnect condensate drain tubes from heater/cooler assembly.







13. Remove fixing securing evaporator pipe support bracket to firewall.







14. Remove heater/cooler assembly fixings.
1. Remove lower fixing nut.
2. Remove upper fixing nuts.







15. Remove heater/cooler unit from vehicle.
- Manoeuvre matrix heater pipe stubs through firewall grommet into vehicle.
- Remove unit.

Installation







1. Install heater/cooler unit into vehicle.
- Guide matrix heater pipe stubs through firewall grommet.
- Position heater/cooler unit against firewall.







2. Install heater/cooler assembly fixings.
- Install upper fixing nuts.
- Install lower fixing nut.







3. Install fixing securing evaporator pipe support bracket to firewall.







4. Connect condensate drain tubes to heater/cooler unit.







5. Reconnect air conditioning control module electrical connectors.







6. Connect heater/cooler unit electrical connector.







7. Install LH fan motor duct.
- Reposition and install duct.
- Install screws.







8. Install RH fan motor duct.
- Reposition and install duct.
- Install screws.







9. Install brace.
- Reposition and align brace to heater/cooler unit.
- Install brace to transmission tunnel securing bolts.
- Install brace to bulkhead securing bolt (where fitted).
- Install steering column upper mounting bracket/brace to firewall securing bolt.
10. Under hood: reconnect heater hoses to heater matrix pipes.
- Remove blanking plugs.
- Reconnect heater hoses and reposition spring band clips.







11. Reconnect air conditioning pipes at the evaporator.
- Remove blanking plugs.
- Install fully seat and lubricate new O-rings.
- Install bolts.
12. Install instrument panel.
13. Recharge air conditioning system.
14. Re-fill cooling system.
15. Reconnect battery ground cable.