Heater and A/C Unit - Removing and Installing

CAUTION!
Before beginning repairs on the electrical system:
- Obtain the anti-theft radio security code
- Switch off all electrical consumers
- Switch ignition off and remove ignition key
- Disconnect negative (-) battery terminal
- When disconnecting and reconnecting battery terminals, observe all applicable Notes and torque specifications, as well as instructions on performing OBD program and electrical system function checks.

Notes
- Observe all A/C refrigerant system safety measures.
- Service refrigerant system using Kent More ACR 4 or equivalent.
- During servicing, all couplings, fittings and related fasteners must be torqued to specifications.

Removing
- Discharge refrigerant system. Service and Repair
- Drain engine coolant. Service and Repair
- Remove instrument panel. Service and Repair



- Remove coolant hoses at heater core.
- Note Installation orientation of coolant hoses -A- (inlet and outlet) in engine compartment.
- Clamp off both coolant hoses to heater core using 3094 hose clamps (or equivalent).
- Release both coolant hose clamps using suitable pliers and pull hoses off from heater core inlet and outlet.
- Seal off inlet and outlet at heater core to prevent coolant from escaping.



- Remove refrigerant lines at evaporator.
- Remove screw -3- (15 Nm).
- Gently rock flange with refrigerant lines -2- up and down until they release from evaporator.
CAUTION! Immediately plug open connections on A/C components and lines to prevent dirt and moisture contamination
- Always replace both O-rings -1-.



- Remove Heating and NC unit mounting screws -2- (12 Nm) and -3- (3.5 Nm).



- Remove footwell vent assembly -6-.



- Remove support -5-.
- Disconnect all electrical connections and wiring harness tie straps at heating and NC unit.



- Carefully pull out and remove complete housing -1- from vehicle.



- Loosen instrument panel cross member -4- if necessary.

Installing
Install in reverse order of removal, noting the following:
- Inspect all heating and A/C unit housing seals for damage and replace if necessary before installation.
- Ensure all electrical harness tie straps are replaced and installed in their original locations.
- Replace both evaporator inlet/outlet 0-rings.
- Ensure refrigerant pipes are reinstalled stress free.
- Ensure evaporator water drain and drain valve are installed and function properly.