Housing Assembly HVAC: Service and Repair
Climate control unit complete, removal and installation
Special tools:
115 8957, 999 5385,999 5472, 999 5838
Before starting work on climate control unit
CAUTION! Follow the safety precautions for work on air conditioning (A/C) systems according to Safety instructions when handling refrigerant Technician Safety Information
NOTE! Read the sections covering slow and quick leaks first, according to General Repair Information Service and Repair
NOTE! Always plug pipes and couplings when working on the climate control system.
Removing climate control unit complete
Operations in engine compartment
- First read section Before starting work on the climate control system
- Disconnect battery lead.
- Clamp the hoses. Use lock grip pliers 115 8957.
- Disconnect the heater hoses from heat exchanger by pressing in the hose connection, pressing in the catch and pulling out the hose
- Plug the pipe for the heater exchanger.
- Remove cover plate and rubber seal for lead-in.
- Remove windshield wiper, refer to Wiper and Washer Systems - Wiper Arm - Service and Repair - Procedures Service and Repair
- Remove gutter, refer to Wiper and Washer Systems - Wiper Motor - Service and Repair - Procedures Service and Repair
- Remove pollen filter if installed.
- Remove holder.
Additional operations in engine compartment for cars with air conditioning (A/C):
- remove the screw holding the pipe connector and the receiver/drier bracket (to facilitate disconnecting pipes from the evaporator)
- Remove the pipes from the evaporator using special tool 999 5838 and 999 5472 and plug the pipes.
- Remove the cover plate and rubber seal for lead-in.
Operations in passenger compartment
- Remove the ECC control module according to Service and Repair
- Remove the MCC control module according to Service and Repair
- Remove dashboard, refer to Boday and Frame - Dash Board - Service and Repair - Procedures Service and Repair
- Right-hand drive car:
- disconnect control module box fresh air intake hose
- Remove floor carpet mountings.
- Remove the cable tie straps to expose the passenger side floor duct pipe.
- Disconnect the floor duct pipes for floor ducts from the climate control unit.
- Also remove the RTI (road traffic information) or amplifier bracket if installed.
- Remove the RTI member with its mounting on the cowl side on the passenger side
- Remove knee bolster if applicable
- Remove the nut, remove the screw and fold back the bracket on the passenger side.
- Disconnect the drain hose from the floor.
- Remove the vacuum regulator for the cruise control.
- Remove the cable duct from its mounting on the blower fan motor.
- Remove and disconnect the connector.
- Remove the cable harness from bracket (was relay base).
- Remove the cable harness from tie straps on the air distribution housing.
- Remove the climate control screws.
- Remove climate control system.
Installing climate control assembly
Work in the passenger compartment
- Install climate control system.
- Install the climate control unit screws.
- Install the cruise control vacuum regulator
- Install drain hose to floor.
- Install knee bolster, if necessary.
- Install the RTI (road traffic information) member with its mounting on the cowl side on passenger side.
- Install the RTI or amplifier bracket.
- Fold forward the bracket on the passenger side and screw into place.
- Install the floor duct pipes.
- Install the cable tie straps so that the passenger side floor duct is exposed.
- Install floor carpet mountings.
- Connect and install the climate control unit connector.
- Install the cable harness with tie straps on the air distribution housing.
- Install the cable harness on the bracket (was relay base).
- Right-hand drive car:
- install fresh air intake on the control module box.
- Install the dashboard, refer to Boday and Frame - Dash Board - Service and Repair - Procedures Service and Repair
- Install center console
- Install the electronic climate control (ECC) module Service and Repair
- Install the manual climate control (MCC) module Service and Repair
Work in the engine compartment
- Install cover plate and rubber seal for heat exchanger lead-in.
- Install the heater pipes on the heat exchanger.
- Top up the coolant.
- Install the holder.
- Install the pollen filter.
- Install the gutter, refer to Wiper and Washer Systems - Wiper Motor - Service and Repair - Procedures Service and Repair
- Install windshield wiper, refer to Wiper and Washer Systems - Wiper Arm - Service and Repair - Procedures Service and Repair
- Connect the battery lead.
Additional for cars with air conditioning (A/C):
- install the cover plate and rubber seal for the evaporator lead-in.
- install the evaporator pipes
NOTE! Use new O-rings.
- install the screw holding the pipe connector and receiver/drier bracket
- fill system with refrigerant and check for leaks Service and Repair
- Carry out self-adjustment of the damper motors when the work is finished.