Housing Assembly HVAC: Service and Repair
Removing and installing climate control unit assembly
Special tools:
115 8957 HOSE PLIERS 115 8957 Hose Pliers
999 5385 KEY 999 5385 Key
999 5472 KEY 5/8" 999 5472 Key 5/8"
Before starting work on the climate control system
Caution! Follow the safety instructions for work on air conditioning (A/C) systems. See Refrigerant, safety regulations Refrigerant, Safety Regulations.
Note! First read the instructions covering slow and fast leaks.
Note! Always plug pipes and connectors when working on the climate control system.
Removing climate control assembly
Work in the engine compartment
- First read section Before starting work on the climate control system
- Disconnect the battery lead
- Clamp the hoses. Use lock grip pliers 115 8957 HOSE PLIERS 115 8957 Hose Pliers
- Disconnect the heater hoses from the heat exchanger by pressing in the hose connector, pressing together the catch and pulling out the hose
- Plug the pipes for the heat exchanger
- Remove cover plate and rubber seal for lead-in.
- Remove the windshield wiper. See Lighting, instrumentation and other electrical equipment
- Remove the gutter. See Interior, exterior
- Also remove the pollen filter
- Remove the holder.
Additional work in the engine compartment on 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 pipe from the evaporator using special tool 999 5385 KEY 999 5385 Key and 999 5472 KEY 5/8" 999 5472 Key 5/8" and plug the pipe
- Remove cover plate and rubber seal for lead-in.
Work in the passenger compartment
- Remove the electronic climate control module. See Replacing ECC control module Removal and Replacement
- Remove the manual climate control module. See Replacing or adjusting control cables / mechanical rear section and control panel / front section (Manual climate control / STANDARD) Service and Repair
- Remove the dashboard. See Interior, exterior Dashboard Dashboard. Remove the center console. See Interior, exterior Center console Center Console
- 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 from the climate control unit
- Also remove the RTI (road traffic information) or amplifier bracket
- Remove the RTI (road traffic information) member with its mounting on the cowl side on the passenger side
- Remove the 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 the bracket (was relay base)
- Remove the cable harness from tie straps on the air distribution housing
- Remove the climate control unit screws
- Remove the climate control system.
Installing climate control assembly
Work in the passenger compartment
- Install the climate control system
- Install the climate control unit screws
- Install cruise control vacuum regulator
- Install the drain hose on the floor
- Install the knee bolster if necessary
- Install the RTI (road traffic information) member with its mounting on the cowl side on the passenger side
- Install the RTI (road traffic information) 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 pipe is exposed
- Install the 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 the fresh air intake hose on the control module box.
- Install the dashboard. See Interior, exterior Dashboard Dashboard. Install the center console. See Interior, exterior Center console Center Console
- Install the electronic climate control (ECC) control module. See Replacing ECC control module Removal and Replacement
- Install the manual climate control (MCC) control module. See Replacing or adjusting control cables / mechanical rear section and control panel / front section (Manual climate control / STANDARD) Service and Repair.
Work in the engine compartment
- Install the cover plate and rubber seal for the 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. See Interior, exterior
- Install the windshield wiper. See Lighting, instrumentation and other electrical equipment
- Connect the battery lead
Additional work on cars with air conditioning (A/C):
- install the cover plate and rubber seal for evaporator lead-in
- install the evaporator pipes
Note! Use new O-rings.
- install the screw holding the pipe connector and receiver / drier bracket
- fill the system with refrigerant. See Refrigerant, overview Refrigerant, Overview and Emptying/vacuum pumping/filling with refrigerant Emptying/Vacuum Pumping/Filling With Refrigerant. Check for leaks.
- Carry out self-adjustment of motors when the work is finished.