Housing Assembly HVAC: Service and Repair

Climate control unit





To Remove

1 Drain the coolant by detaching the coolant hoses coming from the heat exchanger on the engine and blowing with compressed air.
Place a vessel under the car to collect the coolant.
Cars with air conditioning:
Drain the refrigerant from the A/C system, see Heating and Air Conditioning, Service and Repair. "Draining and Filling of Refrigerant." Service and Repair

2 Remove the dashboard, see Body and Frame, Interior Trim. Interior Moulding / Trim





3 Remove all ground connections from the dashboard member.
4 Cut all the cable ties holding the wire harness to the dashboard member.
5 Remove the middle cable conduit, 2 nuts.





6 Remove the knee shield, loosen 2 nuts and remove 2 nuts.

NOTE: The passenger knee shield must also be removed on cars with US and CA specifications, see Restraint Systems, Air Bag Systems, "Service and Repair." Procedures





7 Remove the relay retainer, 3 bolts.





8 Unscrew the steering column, 4 bolts.
9 Remove the steering shaft in one piece, 1 through bolt and 1 bolt to the steering gear.

Important
Do not separate the steering column.





10 Remove the pedal bracket, 4 bolts.
11 Remove 2 braces supporting the center of the dashboard member, 2 bolts on each side.
12 Remove the stabilizer plate in the center mounting.
13 Unscrew the center mounting, 8 bolts.





14 Unscrew the outer mountings, 2 bolts on each side.
15 Remove the dashboard member.





16 Cars with automatic transmission:
Disconnect the automatic transmission control module and put it to one side.
17 Unplug 4 connectors from the passenger side of the climate housing.





18 Remove the pipe between the charge air cooler and the throttle body, 1 bolt.





19 Remove the charge air bypass valve's solenoid valve holder as follows:
^ Remove the cover.
^ Unscrew the connector from the holder and unplug the connector.
^ Unscrew the holder from the bulkhead and put it to one side.





20 Detach the 2 hoses to the heat exchanger at the bulkhead.
21 Detach the A/C pipes' PAD connection from the expansion valve, 1 bolt in center.





22 Remove the expansion valve, 2 bolts.





23 Remove the center console, see Body and Frame, Interior Trim. Interior Moulding / Trim

24 Remove the front seats, see Body and Frame, Seats. Seats

25 Fold away the floor mat and remove the air ducts under the front seats.





26 Detach the drain hoses on both sides of the climate housing.





27 Unscrew the 3 bolts holding the climate housing to the bulkhead. The bolts are accessible from the engine bay.
28 Lift up the rear of the climate housing and take it past the mounting by the gear selector.
29 Wipe up any spillage in the car.





To Fit

1 Lift in the climate housing towards the bulkhead past the mounting by the gear selector.
2 Connect the drain hoses on both sides of the climate housing.
3 Fold away the floor mat and fit the air ducts under the front seats.





4 Screw in place the climate housing to the bulkhead from the engine bay (3 bolts). Make sure the rubber seals are still mounted on the bolts.





5 Lubricate all new O-rings with synthetic vaseline. Fit the O-rings on the pipes from the evaporator.
6 Fit the expansion valve.





7 Lubricate new O-rings with synthetic vaseline. Fit the O-rings on the pipes to the expansion valve.
8 Fit the A/C pipes' PAD connection to the expansion valve, 1 bolt in center.
9 Connect the 2 hoses to the heat exchanger at the bulkhead.





10 Fit the solenoid valve and holder to the bulkhead as follows:
^ Plug in the connector to the charge air bypass valve's solenoid valve and screw it to the holder, 1 bolt.
^ Fit the holder and connector to the bulkhead, 2 bolts.
^ Fit the cover on the solenoid valve.





11 Fit the pipe from the charge air cooler to the throttle body, 1 bolt





12 Plug in the 4 connectors to the passenger side of the climate housing.

13 Cars with automatic transmission:
Put back the automatic transmission control module.
14 Fit the center console, see Body and Frame, Interior Trim. Interior Moulding / Trim

15 Fit the front seats, see Body and Frame, Seats. Seats





16 Put the dashboard member in place.

NOTE: Check that cables are correctly placed and not jammed.

17 Screw on the outer mountings, 2 bolts on each side.





18 Screw on the center mounting, 8 bolts.
19 Fit the stabilizer plate in the center mounting.
20 Fit the 2 braces holding the middle of the dashboard member, 2 bolts on each side.
21 Fit the pedal bracket, 4 bolts.





22 Fit the steering column in one piece.
23 Screw tight the steering column.





24 Fit the relay retainer, 3 bolts.





25 Fit the knee shield, 4 nuts.

NOTE: The passenger knee shield must also be fitted on cars with US and CA specifications, see Restraint Systems, Air Bag Systems, "Service and Repair." Procedures





26 Fit the center cable conduit, 2 nuts.
27 Put back all the ground connections.
28 Fix the cables with new cable ties.





29 Fit the dashboard, see Body and Frame, Interior Trim. Interior Moulding / Trim

30 Refill with coolant.
31 Bleed the system as follows:

Fill the system to MAX level and replace the pressure cap. Start the engine and warm it up by varying the engine speed until the radiator fan operates. Remove the pressure cap and top up the coolant to MAX level again.

Replace the pressure cap and let the engine run at varying speeds until the radiator fan has started a further three times. Stop the engine and refill to MAX level is necessary.

Important
If the car is equipped with A/C or ACC, the air conditioning must be disengaged. Otherwise the radiator fan can start to operate during bleeding.

32 Cars with air conditioning:
Vacuum the system and refill with refrigerant, see Heating and Air Conditioning, Service and Repair. "Draining and Filling of Refrigerant." Service and Repair