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Climate control unit

Climate control unit

Removing


1. Drain the coolant by detaching the coolant hoses coming from the heat exchanger on the engine and blowing with compressed air.

Place a container under the car to collect the coolant.

Cars with A/C:

Drain the refrigerant from the A/C system. See Draining and filling of refrigerant .

2. Remove the centre console. See Centre console .

3. Remove the front seats. See Front seat .

4. Fold away the floor mat and remove the air ducts under the front seats.


5. Remove the dashboard. See Dashboard .


6. Remove all ground connections from the dashboard member.


7. Cut all cable ties holding the wiring harness to the panel member.

8. Remove the middle cable conduit, 2 nuts.

9. Remove the knee shield, loosen 2 nuts and remove 2 nuts.


Note

The passenger knee shield must also be removed on US and CA specification cars. See group 8, Airbag (SRS) , ”Adjustment and replacement”.


10. Remove the relay holder, 3 bolts.


11. Loosen the steering column, 4 screws.


12. Remove the steering column in one piece, 1 through bolt and 1 bolt to the steering gear.

Important

Do not separate the steering column.


13. Remove the pedal bracket, 4 bolts.


14. Remove 2 braces supporting the centre of the dashboard member, 2 bolts on each side.

15. Remove the stabilizer plate in the centre mounting.

16. Unscrew the centre mounting, 8 bolts.

17. Unscrew the outer mountings, 2 bolts on each side.


18. Remove the dashboard member.

19. Cars with automatic transmission:


Disconnect the automatic transmission control module and put it to one side.

20. Unplug 4 connectors from the passenger side of the heating and ventilation unit.

21. Remove pipe from charge air cooler to throttle body.


22. Remove the charge air bypass valve solenoid valve holder as follows:


- Remove the cover.

- Unscrew the connector from the holder and unplug the connector.

- Unscrew the holder from the bulkhead and put it to one side.

23. Loosen the two hoses from the heat exchanger to the bulkhead.


24. Detach the A/C pipes PAD connection from the expansion valve, 1 bolt in centre.

25. Remove the expansion valve, 2 bolts.


26. Disconnect the drain hoses on both sides of the heating and ventilation unit.


27. Remove the three screws that hold the heating and ventilation unit on the bulkhead. The screws are accessible from the engine bay.


28. Lift up the rear of the heating and ventilation unit and move it past the mounting by the gear selector housing.

29. Wipe up any spillage in the car.


Fitting


1. Fit the sound insulation on the new climate control unit. Lift in the heating and ventilation unit towards the bulkhead past the mounting by the gear lever.


2. Connect the drain hoses on both sides of the heating and ventilation unit.

3. Fold away the floor mat and fit the air ducts under the front seats.

4. Fit the three screws, in the engine bay, that hold the heating and ventilation unit on the bulkhead.


Make sure the rubber seals are still mounted on the bolts.

5. Replace and lubricate the O-rings with synthetic vaseline. Fit the O-rings on the pipe from the evaporator.

6. Fit the expansion valve, 2 bolts.


7. Replace and lubricate the O-rings with synthetic vaseline. Fit the O-rings on the pipes to the expansion valve.

8. Fit the A/C pipes PAD connection to the expansion valve, 1 bolt in centre.


9. Connect the 2 hoses to the heat exchanger at the bulkhead.

10. Fit the solenoid valve and holder to the bulkhead as follows:


- Plug in the connector to the charge air bypass valve solenoid valve and screw it to the holder, 1 bolt.

- Fit the holder and connector to the bulkhead, 2 bolts.

- Fit the cover on the solenoid valve.

11. Fit the pipe from the charge air cooler to the throttle body.


12. Connect the connectors to the heating and ventilation unit on the passenger side.


13. Cars with automatic transmission:

Put back the automatic transmission control module.

14. Put the dashboard member in place.


Note

Check that cables are correctly placed and not pinched.


15. Screw on the outer mountings, 2 bolts on each side.

16. Screw on the centre mounting, 8 bolts.


17. Fit the stabilizer plate in the centre mounting.

18. Fit the two stays that hold the panel member at the middle, 2 screws on each side.

19. Fit the pedal bracket, 4 bolts.

20. Fit the complete steering column.


21. Fit and tighten screws for the steering column.

22. Fit the relay holder, 3 bolts.


23. Fit the knee shield, 4 nuts.


Note

On US and CA specification cars, the knee shield must also be fitted on the passenger side. See group 8, Airbag (SRS) , ”Adjustment/replacement”.


24. Fit the centre cable conduit, 2 nuts.


25. Refit all the ground connections.

26. Refit the cable ties holding the cables in place.

27. Fit the dashboard. See Dashboard .


28. Fit the centre console. See Centre console .

29. Fit the front seats. See Front seat .

30. Refill with coolant.

31. Bleed the system as follows:

Fill the system to MAX level. Fit the pressure cap, start the engine and run at varying engine speeds, until the cooling fan starts. Remove the pressure cap and top up to MAX level.

Fit the pressure cap and let the engine run with varying engine speeds until the cooling fan has started another three times. Turn off the engine and top up to MAX level if needed.

Important

If the car is equipped with A/C or ACC, the air conditioning must be disengaged. Otherwise the radiator fan can start to operate during bleeding.


32. Cars with A/C:

Evacuate the A/C system and refill with refrigerant. See Draining and filling of refrigerant .