Removing and Installing Heater/Air-Conditioning Unit
Removing and Installing the Heating/Air-Conditioning Unit
Removing Heating/Air-Conditioning Unit
CAUTION: Risk of injury and short-circuit: The ground lead for the battery - body must be disconnected before any work is carried out. Refer to, Work instructions after disconnecting the battery.
- Drain engine coolant.
- Removing trim strip for instrument panel.
- Remove cover under instrument panel.
- Remove instrument panel cover.
- Remove instrument panel.
- Remove wiper link.
- Remove refrigerant by suction.
- Remove cowl panel cover.
- Remove the evaporator capacitor line and evaporator compressor line on expansion valve and close the connections.
NOTE: Before the carrier for instrument panel can be removed, the heater/ A/C unit must be supported with a plastic or wooden board under the centre section and under the evaporator.
1. Support the heater/ A/C unit under the centre section -A- and under the evaporator -B- with a plastic or wooden board.
2. Unscrew both fastening screws on the left heat exchanger cover and unclip the cover.
3. Unscrew the fastening screw on the right heat exchanger cover and unclip the cover.
4. Pull the retaining clips -A- of the coolant supply line and return line downward.
5. Pull the interior carpet away from the coolant lines and put in a suitable collecting container.
NOTE: Line the driver's footwell with very absorbent material.
6. Slowly pull out the -B- lines from the heat exchanger and drain the coolant into the collecting container.
7. Unscrew both fastening screws -1- and -2- on the carrier.
8. Unscrew the fastening screw -3- on the carrier in the centre console area.
9. Pull out the carrier for the instrument panel from the passenger compartment.
10. Remove the electrical antenna leads on the heater/ A/C unit and set aside.
11. Unscrew both centre air guide fastening screws -4- for the back seat area and pull out the upper air guide toward the rear -A- and the lower one toward the front -B-.
12. Pull out centre air vents on the left -A- and right -B-
13. Turn the left and right temperature sensor -90°- and pull out of the heater/ A/C unit.
14. Pull the centre air vents for the footwell downwards from the heater/ A/C unit, lift it toward the rear, and pull it out of the air vents for the footwell.
15. Unlock the electrical central plug -A- -a-, lever apart the connector -B- lock with two screwdrivers and pull off.
16. The main line harness is secured to the heater/ A/C unit with a tie-wrap. Separate the tie wrap carefully with side cutters.
NOTE: Make sure not to damage the insulation of the main wiring harness.
17. The main wiring harness runs along the right A-pillar and is secured to the heater/ A/C unit in the fan area with a tie-wrap. Separate the tie wrap carefully with side cutters.
18. Detach the main wiring harness on the heating/air-conditioning unit.
19. Fasten the heater/ A/C unit on the left and right, pull backwards about 5 cm, and completely remove.
Installing Heating/Air-Conditioning Unit
NOTE:
- Before the heater/ A/C unit is installed again, the following points must be checked.
- Check the water drainage for any cracks, deformities and other damage.
- Check on the body for damage to both mounts (stars) for the heater/ A/C unit. The stars must be able to turn for installation.
- Both mounts for the stars on the heater/ A/C unit must not be damaged.
1. Position the plastic or wooden boards used for removing in the vehicle, position the heater/ A/C unit in the vehicle, have a second person ensure the position of the stars, twist them if necessary.
2. Slide and support the heater/ A/C unit on both mounts (stars).
WARNING: Risk of damage to the mounts (stars): The heating/air-conditioning unit must be supported.
3. Slide the water drainage through the opening on the body, making sure there is correct seating.
4. Engage the main wiring harness on the heater/ A/C unit.
5. Lay main wiring harness on the heater/ A/C unit and position on the heater/ A/C unit -A- and -B- each with a tie-wrap.
6. Insert the electrical central plugs -A- and -B- into the plug connections until they click into place.
7. Plug in the centre temperature sensor on the left and right into the heating/air-conditioning unit and turn -90°-.
8. Insert the centre air vents for the footwell into the air guides for the footwell and push onto the heater/ A/C unit.
9. Connect centre air vents on the left -A- and right -B-.
10. Slide in the lower centre air guide into the rear air guide -B- and press onto the heater/ A/C unit -A- and screw down with both fastening screws -4-. Refer to tightening torques.
11. Lay the antenna leads on the heater/ A/C unit.
12. Position the carrier for the instrument panel.
13. Position fastening screws -1- and -2-.
14. Tighten fastening screw -3-. Refer to tightening torques.
15. Screw down fastening screws -1- and -2-. Refer to tightening torques.
16. Remove the support for the heating/air-conditioning unit.
17. Insert the coolant supply line and return line -B- into the heat exchanger.
NOTE: Make sure that the O-rings are not damaged. If in doubt, replace them.
18. Push on the retaining clips -A- until the clips click into place.
- Install relay carrier. Install holder from relay carrier.
- Install vehicle electrical system control unit.
- Install control unit for Kessy or remove control unit for immobilizer.
- Top up engine coolant.
19. Check the heating system for leaks.
20. Clip left cover and secure with the fastening screws. Refer to tightening torques.
- Install the evaporator capacitor line and evaporator compressor line on the expansion valve.
- Install the instrument panel.
- Clip cover for instrument panel into place on left and right.
- Install glove compartment.
- Install cover under instrument panel on left and right.
- Install trim strip for instrument panel.
- Install cover under instrument panel.
- Install the instrument panel cover.
- Install cowl panel cover.
- Install wiper link.
- Fill refrigerant.
Tightening Torques
