With Air Conditioning

Disconnect Tool, Spring Lock Coupling:

Special Tool

Removal

CAUTION: Disconnect the battery ground cable.

1. Remove the radio/cassette player and CD player (if fitted).
2. Perform The Refrigerant Discharging and Recovery Procedure.

Note: Observe the "Health and Safety Rules".

3. Drain the cooling system.
4. Remove the instrument panel. For additional information, refer to: Dashboard/Instrument Panel. Service and Repair
2G5. Detach the coolant hoses from the heat exchanger take-off connection.






6. Disconnect the refrigerant lines from the evaporator using special tool 412-081 (pressure pipe shown from below).






7. Remove the cross vehicle beam.
- Remove the cap.
- Remove the bolt behind the cap.






8. Remove the cross vehicle beam (continued).
1. Unclip and remove the ventilation hoses.
2. Remove the screws.
3. Detach the wiring harnesses from the cross vehicle beam (one shown).






9. Remove the cross vehicle beam (continued).
1. Unclip and remove the ventilation hoses.
2. Remove the screws.
3. Detach the central junction box from the cross vehicle beam.
- Unclip the wiring harnesses.






10. Remove the cross vehicle beam (continued).
1. Remove the ventilation hose.
2. Detach the wiring harnesses from the cross vehicle beam.
3. Remove the cross vehicle beam bracket (right-hand side shown).
- Remove the cross vehicle beam.






11. Remove the rear footwell ventilation hoses.






12. Unclip the wiring harnesses from the heater housing (two shown).






13. Remove the heater housing.
- Remove the nut.






14. Remove the heater housing (continued).
- Remove the nut.






15. Remove the heater housing (continued).
- Remove the nut in the engine compartment.






16. Remove the heater housing (continued).
- Remove the nut in the engine compartment.

Installation
1. Refit the components in reverse order.
2. Evacuate and refill the air conditioning system.

Note: Renew the O-rings and lubricate with refrigerant oil.

3. Fit the instrument panel.
4. Refill the cooling system with coolant.
5. Check the operation of the heating and air conditioning system (where fitted).