Removal
Remove the instrument panel (see here).
Drain the coolant (see here).
For vehicles equipped with an air conditioning system, the refrigerant must be discharged from the air conditioning system in accordance with the operating instructions for the service equipment.
Unscrew the two bolts 1, Figure 13-1, of the lower fastening of the amplifier 2 of the instrument panel cross member to the base of the body (replaceable head 13, ratchet).
Figure 13-1 - Lower instrument panel cross member reinforcement mount: 1 - Instrument panel cross member reinforcement mounting bolt; 2 - Instrument panel cross member reinforcement
Unscrew the two nuts 1, Figure 13-2, of the upper mount of the amplifier 2 of the instrument panel cross member. Disconnect connector 3 of the wiring harness and remove amplifier 2 (replaceable head 13, ratchet).
Figure 13-2 - Upper instrument panel cross member reinforcement mount: 1 - Instrument panel cross member reinforcement mounting nut; 2 - Instrument panel cross member reinforcement; 3 - wiring harness block
Compress and move the two clamps 4, Figure 13-3 (clamp puller type 10614 "Stahlwille").
Remove the heater supply hoses 2 and outlet hoses 1 from the heater radiator pipes 3.
Figure 13-3 - Fastening the heating system hoses: 1 - heater outlet hose; 2 - heater supply hose; 3 - heater radiator pipes; 4 - clamp
Loosen the two screws 2, Figure 13-4, securing the air distribution unit 1 to the cross member 3 (torx T20 replaceable head, ratchet).
Figure 13-4 - Fastening the air distribution unit to the instrument panel crossmember: 1 - air distribution unit; 2 - screw for fastening the block to the crossbar; 3 - instrument panel crossbar
Loosen screw 4, Figure 13-5, securing the left front air duct and remove the air duct, similarly remove the right air duct (torx T20 replaceable head, extension, ratchet).
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Unscrew two screws 2 fastening crossbar 1 on the instrument panel on the right and left, move the crossbar away (replaceable head 13, ratchet).
Figure 13-5 - Fastening the instrument panel crossbar and left front air duct: 1 - instrument panel crossbar; 2 - crossbar mounting screw; 3 - front air duct; 4 - air duct mounting screw
For vehicles equipped with an air conditioning system: from the engine compartment, unscrew the two bolts 1, Figure 13-6, securing the pipelines to the evaporator, disconnect the connections and install technological plugs on the pipelines and the evaporator unit (replacement head 10, extension, ratchet).
Figure 13-6 - Fastening the evaporator pipes: 1 - bolt for fastening pipeline fittings; 2 - air conditioning system pipelines
Disconnect the wiring harness connectors from the fan and additional resistor.
Remove the heater unit assembly with the heating, air conditioning and ventilation control unit.
Installation
Installation is carried out in the reverse order of removal, while:
- for vehicles equipped with an air conditioning system: remove the plugs from the pipes and the evaporator unit, install new sealing rings on the pipes. Apply compressor oil to the sealing rings;
- perform a vacuum degassing of the air conditioning system and load the system with refrigerant, in accordance with the operating instructions for the service equipment.
Check the functionality of the heating, air conditioning and ventilation system.
Disassembly
Remove the heating, air conditioning and ventilation control unit by disconnecting the damper drive rods from the heater unit.
Remove the foam seals 2, Figure 13-7.
Unscrew two screws 3 and remove the pipe bracket 1 (torx T20 replaceable head, extension, ratchet).
Unscrew screw 4 and remove the inlet 7 and outlet 8 pipes of the heater radiator 6 (torx T20 replaceable head, extension, ratchet).
Unscrew two screws 5, press three clamps, remove radiator 6 from the heater housing and drain the remaining coolant (torx T20 replaceable head, ratchet).
Figure 13-7 - Heater unit: 1 - branch pipe bracket; 2 - foam seals; 3 - screw for fastening the bracket of the pipes; 4 - screw for fastening pipes; 5 - radiator mounting screw; 6 - radiator; 7 - supply pipe; 8 - outlet pipe
Unscrew six screws 1, Figure 13-8, and separate the heater unit into two parts.
Figure 13-8 - Heater unit: 1 - heater block screws
Remove evaporator 1, Figure 13-9, from the heater unit.
Figure 13-9 - Air conditioning system evaporator: 1 - air conditioning system evaporator
Assembly
Assemble the heater unit in the reverse order, while doing the following:
- install new foam seals;
- install new sealing rings on the heating system pipes.