Procedure

1 Remove the glovebox, lower section of the panel, floor console and center console. See WIS Body, Interior equipment, Glovebox and Center console.

2 Remove the knee shields on the driver's and passenger sides. See WIS Body, Airbag (SRS), Driver knee shields, Passenger knee shields.





3 Cut off the cable tie and remove the air ducts for the rear seat Remove the cable harness for the alarm from the center air duct.





4 Remove the front floor air ducts.

5 If the car is equipped with an Audio system with extra amplifiers, remove the amplifier located on the passenger side of the center console.

6 Remove both left and right dash supports. Place these off to the side after removing only one self-anchoring cable tie on the left side upper support.

7 Remove the clips and loosen the screws holding the rear cover of the air distribution drum.

8 Cars with MCC:

Remove the control shaft for the air distribution drum if is has not already been removed. Go to step 11.





9 Cars with ACC:

Remove the stepper motor for the air distribution drum and remove the mixed air temperature sensor.





10 Remove the stepper motor for the temperature valve.





11 Slide the radio out at least 2". Remove the cover by pressing the heating and ventilation unit with your hand and lifting the cover as high as possible. Pull the cover rearward. Pull it out through the passenger side when it loosens.





12 Use your finger on the shaft to keep the drum from turning. Make sure the shaft is taped so that it still can be moved but does not fall off.





13 Open the cover of the heat exchanger.

14 If the shaft comes loose and the fork link of the shaft comes loose from the cam disc, they must be refitted according to the following instructions.

a Make sure the shaft is taped so that it still can be moved but does not fall off. See illustration.





b Rotate the right drum so that the straight part in the guide pin track in the shaft coupling points to eleven o'clock.

c Set the center damper so that it is 3 cm from the lower edge, even with the lower edge of the little right-hand hole.

d Check that the two openings of the cam disc are straight against the left-hand outlet.





e Insert the fork link in the left-hand outlet with the toothed end pointing up and to the right.

f First press down the left fork link and then the right-hand one.

g When the fork link is inserted over the toothed shaft, the center damper will move up until fully open.

h Carefully refit the fork link to the floor damper. Carefully close the floor damper. If this cannot be done, the fork link must be taken out again. Begin. again from point 15a until the damper can be closed.

j Check the function by turning the shaft coupling so that the drums and dampers work.

15 Turn the linkage of the temperature damper so that the rear side surfaces are moved away from the end-stop.

Note
Do not remove the old grease from the walls of the heating and ventilation unit.

If an attempt is made to remove the old grease, do not use any solvents: use a clean, dry rag only.





16 Apply grease with the brush, passing it through in the opening over the heater core. Apply grease to the surfaces that the rubber seal of the temperature damper rubs against both sides of the housing.

17 Close the cover of the heater core.

18 Rotate the air distribution drums to a position in which the three rear outlets are partially or completely open.

19 Turn the linkage of the temperature damper so that the front side surfaces are away from the endstop.





20 Apply grease with the brush, inserting it in the center opening for rear outlet Apply grease to the surfaces that the rubber seal of the temperature damper rubs against in the heating and ventilation unit (right and left-hand sides).

21 Move the temperature damper forward and backward so that the grease can spread itself over the slide faces.

22 Close the air distribution drum's center opening for rear outlet.

Important
Be careful when the air distribution drum is being turned. Components in the heating and ventilation unit's mechanism can come loose.





23 Apply plenty of grease to all visible parts of the drum and make sure that grease comes between the heating and ventilation unit and the drum. Rotate the drum and apply grease until it reaches its end position.





24 Then continue with the air distribution damper drum on the drive's side. Set it to the end position and apply plenty of grease to all visible parts of the drum, making sure that grease comes between the housing and the drum. Rotate the drum and apply grease until it reaches the other end position. Do the same to the drum on the passenger side.





25 Remove the bevel gear shaft, grease it and refit it according to the following instructions:

a Rotate the drive link to the full clockwise end stop, then rotate slightly back until the tab lines up with the slot.

b The bevel gear shaft in the heating and ventilation unit should be in a position that has a missing tooth (a wider tooth opening) to the left.

c Install the shaft so that its wide tooth fits into the corresponding wide tooth opening to the left in the bevel gear. The guide lug of the shaft should stand straight up. Then turn the shaft slightly clockwise.





26 Rotate the drums so that the rear air duct dampers are closed and remove the tape holding the shaft in place.





27 Lubricate the hole in the cover for the shaft and fit the cover of the air distribution drum. Insert it from the passenger side and press upward so that the catches fasten in the upper edge. Check that the seven catches sit securely in the upper edge.

28 Pull the cover down and carefully lift the shaft coupling of the control shaft(stepping motor so that it fits into the hole.





29 Press the heating and ventilation unit down with your hand and press it into the track. Ask an assistant to check that the cover is in place in the bottom edge of the track. Check that the drum moves freely.





30 Fit the clips and screw the screws into place. Do not over-tighten the screws as this may distort the drum. If binding is noted, back off the screws by 1'2 turn.





31 Fit the air ducts.

32 Use a cable tie to fasten the cable harness around the air ducts.

33 Refit the supports on the driver's and passenger sides. Begin by lifting the screw and nut in the upper mounting and then the two screws in the lower mountings.

34 Cars without ACC:

If the cable for the temperature valve has become slow, it should be replaced with a cable marked with yellow. If the cable is already marked with yellow, it does not need to be replaced. See WIS Body, Manual Climate Control, MCC Control Cable.

35 Fit the air distribution shaft and check that the dampers work.





36 Cars with ACC:

Fit the stepping motor for the air distribution damper and mixed air temperature sensor.





37 Fit the stepping motor for the temperature valve.

38 Fit the knee shields on the drive's and passenger sides. See WIS Body, Airbag (SRS), Driver knee shields, Passenger knee shields.

39 Fit the glovebox, lower section of the panel, floor console and center console. See WIS Body, Interior equipment, Glovebox and center console. Refit radio.

40 Check that the heat. ventilation and electrical functions of the center console work.