Removing and Installing Heater/Air-Conditioning Unit

Removing And Installing Heater/Air-Conditioning Unit

Preliminary work
1. Drain engine coolant.
2. Remove the carrier for the instrument panel.
3. Remove the condenser-evaporator line and compressor-evaporator line at the expansion valve and close the connections.

Removing heater/air-conditioning unit

ATTENTION:
Risk of material damage
- Remove ignition key. Disconnect battery. Route or isolate the ground strap so that all contact with a ground carrier (e.g. body, seat frame) is avoided.







1. Support the heater/air-conditioning unit under the centre section -A- and under the evaporator -B- with a plastic or wooden board.







2. Unclip wiring harness on the left heat exchanger cover.







3. Unscrew both fastening screws on the left heat exchanger cover and unclip the cover.
4. Unscrew the fastening screw of the right heat exchanger cover and unclip the cover.







5. Pull the retaining clips -arrows A- off the coolant supply line and return line.







NOTE: Line the driver's footwell with very absorbent material.

6. Pull the interior carpet away from the coolant lines and place a suitable collecting container in position.







7. -arrows B- Slowly pull out the lines from the heat exchanger and drain the coolant into the collecting container.
8. Unscrew both centre air guide fastening screws -4- for the back seat area and pull out the upper air guide toward the rear -arrow A- and the lower one toward the front -arrow B-.







9. Pull out centre air vents on the left -A- and right -B-.







10. Turn the left and right temperature sensor 90 degrees and pull out of the heater/air-conditioning unit.







11. Pull the centre air vents for the footwell downwards from the heater/air-conditioning unit, lift it toward the rear, and pull it out of the air vents for the footwell.
12. Release the electric central connector -A- (-arrows a-), lever apart the connector lock -B- with two screwdrivers and pull off.







NOTE: Make sure not to damage the insulation of the main wiring harness.

13. The main wiring harness is secured to the heater/air-conditioning unit with tie-wraps. Separate the tie wraps carefully with side cutters.







14. The main wiring harness runs along the right A-pillar and is secured to the heater/air-conditioning unit in the fan area with a tie-wrap. Separate the tie wrap carefully with side cutters.







15. Disconnect the water drainage hose from the air-conditioning unit.







16. Detach the main wiring harness on the heater/air-conditioning unit.







17. Grasp the heater/air-conditioning unit on the left and right, pull backwards about 5 cm and remove completely.

Installing heater/air-conditioning unit

NOTE:
Before the heater/air-conditioning unit is installed again, the following points must be checked:
- Check the water drainage hose for any cracks, deformities and other damage.







- Check on the body for damage to both mounts (stars) for the heater/air-conditioning unit. The stars must be able to turn for installation.







- Both mounts for the stars on the heater/air-conditioning unit must not be damaged.







1. Position the plastic or wooden boards used for removal in the vehicle. Position the heater/air-conditioning unit in the vehicle. Get a second person to check the position of the stars - twist them if necessary.

WARNING:
Risk of damage to the mounts (stars).
- The heater/air-conditioning unit must be supported.

2. Slide the heater/air-conditioning unit onto both mounts (stars) and support it.
3. Push the water drainage hose onto the air-conditioning unit and make sure it is seated correctly.







4. Engage the main wiring harness on the heater/air-conditioning unit.







5. Lay the main wiring harness on the heater/air-conditioning unit and position it on the heater/air-conditioning unit -A- and -B- using one tie-wrap each.







6. Insert the electric central connectors -A- and -B- into the plug connections until they click into place.







7. Plug the centre temperature sensor on the left and right into the heater/air-conditioning unit and turn 90 degrees.







8. Insert the centre air vents for the footwell into the air guides for the footwell and push onto the heater/air-conditioning unit.
9. Connect the centre air vents on the left -A- and right -B-.







10. Slide the lower centre air guide into the rear air guide -arrow B-, press the upper centre air guide onto the heater/air-conditioning unit -arrow A-, and screw down with the two fastening screws -4-. Tightening torque: 1 ftlb.







11. Position the carrier for the instrument panel.
12. Tighten the fastening screws -1- and -2-. Tightening torque: 7.5 ftlb.
13. Remove the support for the heater/air-conditioning unit.

NOTE: Always replace O-rings.

14. Insert the coolant supply line and return line -B- into the heat exchanger.







15. Push on the retaining clips -A- until the clips click into place.
16. Top up engine coolant.
17. Check the heating system for leaks.







18. Clip in left cover and secure with the fastening screws. Tightening torque: 1 ftlb.
19. Clip in wiring harness on the left heat exchanger cover.
20. Install the condenser-evaporator line and the compressor evaporator line on the expansion valve.

Subsequent work
1. Install the carrier for the instrument panel.
2. Carry out work instruction after disconnecting the battery.