Heater And A/C Unit, Removing And Installing: Removing
-- Switch off the ignition.
-- Discharge the refrigerant circuit. Refer to Refrigerant Circuit or Working with A/C Service Station (1 Of 2) / Working with A/C Service Station (2 Of 2) .
-- Remove the plenum chamber cover. Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .
The cooling system is under pressure when the engine is warm. There is a risk of scalding from hot steam and coolant.
Scalding the skin and other parts of the body is possible.
- Wear safety gloves.
- Wear protective eyewear.
- Reduce the pressure by covering the coolant expansion tank cap with a cloth and carefully opening it.
-- Carefully open the coolant expansion tank cap -A- (do not completely remove).
TIP
- There are different versions of the coolant expansion tank and in different layouts in the plenum chamber and in the engine compartment. Refer to COOLANT, DRAINING AND FILLING .
-- Mark the layout of the coolant hoses on the connections to the heat exchanger -A- (supply to the heat exchanger in the heater and A/C unit) and -B- (engine return).
-- Clamp the coolant hoses -A- and -B- with hose clamps -C-.
-- Cover the area beneath connections for coolant hoses -A- and -B-, for example with absorbent paper.
-- Place a small container under the connections for coolant hoses -A- and -B- (to the heater core).
-- Remove the coolant hoses -A- and -B- from the connections to the heater and A/C unit heater core.
-- Insert one section each of hose -A- and -B- on to both connections to heater core.
-- Place the container -B- under the other end of the hose -C-.
-- Using a compressed air gun -D-, carefully blow the coolant out of the heater core (against the normal flow direction of the coolant) using the hose -A- into a container -B-.
Danger or frostbite due to refrigerant coming out under pressure.
Frostbite on the skin and other parts of the body is possible.
- Wear safety gloves.
- Wear protective eyewear.
- Evacuate or drain refrigerant and open the refrigerant circuit immediately.
- If more than 10 minutes elapse after extracting or draining the refrigerant and the refrigerant circuit was not opened, extract or drain the refrigerant again. Pressure develops in the refrigerant circuit due to evaporation.
-- Remove both refrigerant lines -B and C- from the front expansion valve -D-.
-- Loosen the grommet with the support ring -D- from the plenum chamber rear wall toward the passenger compartment (it is removed and installed with the heater and A/C unit).
-- Remove the instrument panel crossmember. Refer to Instrument Panel Crossmember .
-- Vehicles with a "High" A/C system, remove the rear air duct.
-- Remove the air ducts from the rear footwell vent, but do not remove completely.
On a vehicle with an Auxiliary Heater Heating Element -Z35-
-- Release the locking mechanism -B- on the connector -A- to the Auxiliary Heater Heating Element -Z35- and release the connector -A-.
All
-- Remove both condensation water drains -A- from the connections -B- on the heater and A/C unit.
TIP
- The "A/C system" wiring harness is removed with the heater and A/C unit.
-- Cover the floor covering in the area of the center tunnel with a sturdy mat.
-- Free up the wiring harness -F-.
-- Remove the grommet -E- for the coolant pipes to the heat exchanger and grommet -D- for the expansion valve from the openings in the rear wall of the plenum chamber and carefully detach the heater and A/C unit -C- (so that no components are damaged by any still attached connections) slightly from the vehicle and remove it in the direction of the front passenger footwell.