Climate control unit

Climate control unit

To remove

1.	Cars with AC: Drain the AC system of refrigerant.

2.	Remove the dashboard. See Service Manual 8:2 Interior equipment .

3.	Cars with AC: Separate the AC hoses at the lead-through in the bulkhead wall.

4.	Fit hose clips on the hoses by the heater-box.

5.	Remove the hoses from the heater-box.

6.	Blow compressed air through one of the hoses to empty the heater box of coolant.

7.	Remove the draining hose.

8.	Remove the knee guard on the driver's side

9.	Snip the cable ties and remove the rear air ducts on the floor in front of the heater box.

10.	Remove the air ducts leading to the middle vent in the dashboard.

11.	Remove the air ducts leading to the dashboard's side vents.

12.	Remove the wiper arms.

13.	Remove the cover over the bulkhead.

14.	Remove the wiper unit.

15.	Remove the nuts and bolts retaining the dashboard cross-member.

16.	Remove the support by the climate control unit on the driver's side.

17.	Cars with an airbag on the passenger's side: Remove the knee guard on the passenger's side.

18.	Unplug the steering wheel pad and horn connectors.

19.	Remove the bolt securing the steering column to the steering gear.

20.	Remove the bolt securing the support on the steering column to the dashboard cross-member.

21.	Remove the two nuts securing the steering column to the dashboard cross-member and lift it out. Important Do not separate the steering column.

22.	Remove the four nuts securing the angular supports at the top of the pedal assembly.

23.	Fold out the angular supports.

24.	Fold out the dashboard cross-member.

25.	Remove the two screws securing the main fuse box to the dashboard cross-member.

26.	Remove the dashboard cross-member. Make a note of how the cables are run.

27.	Unplug the connectors on the climate control unit.

28.	Remove the fresh-air filter.

29.	Unplug the ventilation fan's connector.

30.	Remove the four screws securing the climate control unit by the ventilation fan.

31.	Remove the screw securing the climate control unit to the lower part of the bulkhead wall.

32.	Lift out the climate control unit.

To fit

1.	Position the climate control unit in place and tighten the four screws by the ventilation fan.

2.	Plug in the ventilation fan's connector.

3.	Refit the fresh-air filter.

4.	Tighten the screw securing the climate control unit to the lower part of the bulkhead wall.

5.	Cars with AC:

5.a.

Lubricate all new O-rings with synthetic vaseline and fit them on the AC hoses.

5.b.

Remove the plugs, fit the AC hoses and tighten the screw.

6.	Refit the coolant hoses to the pipes on the heater box and tighten the hose clips.

7.	Refit the draining hose and tighten the screws.

8.	Remove the upper part of the climate control unit.

9.	Position the wiring harness on the dashboard cross-member.

10.	Refit the main fuse box on the dashboard cross-member and tighten the screws.

11.	Refit the dashboard cross-member together with the angular supports.

12.	Refit the upper part of the climate control unit.

13.	Tighten the nuts and bolts securing the dashboard cross-member.

14.	Tighten the nuts securing the angular supports.

15.	Refit the steering column and insert the nuts holding the steering column to the dashboard cross-member.

16.	Tighten the screw securing the steering column to the steering gear.

17.	Insert the bolt securing the support on the steering column to the dashboard cross-member.

18.	Tighten the bolts securing the steering column to the dashboard cross-member.

19.	Tighten the bolt securing the support on the steering column to the dashboard cross-member.

20.	Plug in the steering wheel pad and horn connectors.

21.	Cars with an airbag on the passenger's side: Refit the knee guard on the passenger's side.

22.	Refit the support on the climate control unit on the driver's side.

23.	Refit the air ducts.

24.	Secure the cables with cable ties to the rear air ducts on the floor.

25.	Refit the knee guard on the driver's side.

26.	Refit the wiper unit.

27.	Refit the cover over the space between the bulkhead partitions.

28.	Refit the wiper arms.

29.	Refit the dashboard. See Service Manual 8:2 Interior equipment .

30.	Fill up with coolant.

31.

Bleed the system as follows (V6 engines only): Fill the system to the MAX level, refit the pressure cap, start the engine and warm it up, preferably at varying speeds, until the radiator fan starts. Remove the pressure cap and top up to MAX. Refit the pressure cap and run the engine at varying speeds until the radiator fan cuts in three more times. Switch off the engine and top up to the MAX level as necessary.

32.	Cars with AC: Fill up with refrigerant.