Heater/Air Conditioner Assembly, Removing and Installing

Heater/air Conditioner Assembly, Removing And Installing (1997 >)

CAUTION:
- Obtain security code for anti-theft radio.
- Note customer's pre-set radio stations.
- Move power seats to most rearward position.
- Switch off ignition and disconnect battery ground (GND) strap.

- Release pressure in coolant system by opening cap at coolant expansion tank.

WARNING:
- With hot engine, cooling system is under pressure. Coolant expansion tank cap must be removed slowly.
- Dispose of used coolant properly.
- Check local regulations.
- Do not re-use used coolant.







- Clamp coolant hoses -A- and -B- with VAG3094 (or equivalent) and remove from heater core inlet/outlet.
- Place catch basin below heater core connection -A- and carefully blow coolant out of heater core with compressed air through connection -B-.
- Remove boot -C-.

CAUTION: A/C refrigerant system must be discharged before removing heater/air conditioner assembly.

- Discharge refrigerant system.







- Remove bolt -A-.
- Remove refrigerant lines from evaporator and secure with tie wraps to prevent interference during installation.

CAUTION: Immediately plug open connections on A/C components and lines to prevent dirt and moisture contamination.







- Plug evaporator openings using cap supplied with replacement evaporator -C-.
- Remove bulkhead grommet -D-.
- Remove glovebox.
- Remove driver side under-dash panel, center console and instrument panel outer skin.







- Remove instrument panel support -A-.
- Loosen instrument panel support -B- (the upper mounting bolt to the heater/ conditioning assembly can not be removed).
- Remove floor outlet.







- Remove bolts -A-.
- Disconnect all electrical connections from instrument panel harness to heater/air conditioner assembly.








- Remove bolts -A-.
- Remove heater/air conditioner assembly towards passenger side.
- Install in reverse order of removal.

Notes on installation:
- Replace all damaged heater/air conditioner assembly seals.
- Replace all removed cable tie wraps in the same location.
- Always replace evaporator inlet/outlet O-rings.
- Ensure refrigerant lines fit into evaporator without binding.
- Check evaporator line and heater core bulkhead grommets for correct fit.
- Check evaporator drain and evaporator drain valve for correct fit (1996; 1997 >).