Removing and Installing

CAUTION!
- Obtain security code for anti-theft radio.
- Note customer's pre-set radio stations.
- Move power seats to most rearward position.
- Switch off ignition and disconnect battery ground (GND) strap.

- Release pressure in coolant system by opening cap at coolant expansion tank.

WARNING!
- With hot engine cooling system is under pressure.
- Coolant expansion tank cap must be removed slowly.
- Dispose of used coolant properly. Check local regulations.
- Do not re-use used coolant.

- Clamp coolant hoses -A- and -B- with VAG3094 (or equivalent) and remove from heater core inlet/outlet.
- Place catch basin below heater core connection -A- and carefully blow coolant out of heater core with compressed air through connection -B-.
- Remove boot -C-.

CAUTION!
A/C refrigerant system must be discharged before removing heater/air conditioner assembly.

- Discharge refrigerant system.

- Remove bolt -A-.
- Remove refrigerant lines from evaporator and secure with tie wraps to prevent interference during installation.

- Plug evaporator openings using cap supplied with replacement evaporator -C-.
- Remove bulkhead grommet -D-.
- Remove glovebox.
- Remove driver side under-dash panel, center console and instrument panel outer skin.

- Remove instrument panel support -A-.
- Loosen instrument panel support -B- (the upper mounting bolt to the heater/air conditioning assembly can not be removed).
- Remove floor outlet. Refer to "Footwell Air Outlets, Removing and Installing" Service and Repair

- Remove bolts -A-.
- Disconnect all electrical connections from instrument panel harness to heater/air conditioner assembly.

- Remove bolts -A-.
- Remove heater/air conditioner assembly towards passenger side.
- Install in reverse order of removal.

NOTE:
- Replace all damaged heater/air conditioner assembly seals.
- Replace all removed cable tie wraps in the same location.
- Always replace evaporator inlet/outlet O-rings.
- Ensure refrigerant lines fit into evaporator without binding.