Housing Assembly HVAC: Service and Repair

Climate units

Note! The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Preparatory work

Draining the air conditioning (A/C) system

Warning! Follow the safety instructions for work on air conditioning systems.

Read the instructions for slow and fast leaks according to: AC-system, oil, refilling AC-System, Oil, Refilling.

Caution! Always use new O-rings lubricated with compressor oil.

Note! Plug the pipes and connections when working on the climate control system.

Drain the refrigerant from the AC-system according to: Refrigerant, draining Refrigerant, Draining.

Draining coolant and removing components




Remove the expansion tank cap.
Raise the vehicle.
Remove the shield under the vehicle. It is secured with 7 clips. See the illustration.
Install a hose on the nipple at the radiator.
Feed the hose down to a container.
Open the nipple. Drain off the engine coolant.




Remove the dashboard. See: Dashboard Dashboard.

Removal

Removing the climate control unit





Remove:
- the 2 screws and remove the right-hand half of the lead-in. See the illustration
- the section that holds the heat exchanger and evaporator pipes apart.




Lift up both air conditioning (A/C) hoses from their mountings below the right-hand spring strut turret.
Remove the 1 screw securing the air conditioning (A/C) pipes to the evaporator. See the illustration.
Pull the pipes off from the evaporator connection.
Separate the pipes to the hear exchanger as follows:
For cars with split pipes, -2005 (LHD) see: Heat exchanger, L.H.D Service and Repair
For cars with complete pipes, -2006 (LHD) see: Heat exchanger, L.H.D Service and Repair
For cars with split pipes, -2005 (RHD) see: Heat exchanger, L.H.D Service and Repair.
For cars with complete pipes, -2006 (RHD) see: Heat exchanger, L.H.D Service and Repair





Remove:
- the drainage hose from the lower connection on the right-hand side under the heat exchanger housing
- the climate control unit.

Installation

Note! For tightening torques, see: Tightening torque, B5254T7 [1][2]Body and Frame.

Installing the climate control unit

Install:
- the climate control unit
- the drainage hose from the heat exchanger housing
Install the pipes to the heat exchanger as follows:
For cars with split pipes, -2005 (LHD) see: Heat exchanger, L.H.D Service and Repair
For cars with complete pipes, -2006 (LHD) see: Heat exchanger, L.H.D Service and Repair
For cars with split pipes, -2005 (RHD) see: Heat exchanger, L.H.D Service and Repair.
For cars with complete pipes, -2006 (RHD) see: Heat exchanger, L.H.D Service and Repair

Install:
- the 1 M8 screw securing the air conditioning (A/C) pipes to the evaporator in the engine compartment. Tighten
- both the air conditioning (A/C) hoses in their mountings below the right-hand spring strut turret
- the spacer that holds the heat exchanger and evaporator pipes apart
- the 2 screws and the right-hand half of the lead-in. Tighten
- the dashboard. Do not install the glove compartment. See: Dashboard Dashboard
- the drain nipple on the radiator.
Fill with coolant and warm up the engine until the thermostat opens. Top up if necessary.
Check that the pipe coupling does not leak.

Finishing

Accumulator replacement with function check and leak detection
Replace accumulator according to: Accumulator Service and Repair.
Vacuum pump the air conditioning (A/C) system. See: Vacuum pumping Vacuum Pumping.
Fill the AC-system with refrigerant according to: Refrigerant, filling Refrigerant, Filling.
Leak trace the air conditioning (A/C) system. See: Leak detection, tracer agent Leak Detection, Tracer Agent or.

Installing components





Install:
- the glove compartment. See Glove compartment Glove Compartment
- the shield under the vehicle using the 7 clips. See the illustration.