Models From 1992 on

B

REPLACEMENT OF HEATER CONTROL VALVE, MODELS FROM 1992 ON

B1
Clamp heater hoses

- Open hood.




- Clamp heater hoses with hose clamping tools.
- Loosen expansion tank cap.

B2
Preparations for draining coolant inside car Remove/disconnect:

- soundproofing panel and knee bolster/support bar on left-hand side.
- center console side panel.
- carpet (fold back).




- cover beside accelerator pedal.

Place container under heater hose connection to collect coolant. Use clean rags to absorb any spillage.

Remove/disconnect:

- soundproofing and center console side panel on right side

B3
Release mounting bracket and valve




- Disconnect support (D) from mounting bracket (C) by loosening bolt (A) and removing bolt (B).
- Bend mounting bracket (C) 900 to left.
- Bend the two stops (E) downward and pull mounting bracket (F) and valve 30 mm to left.

B4
Disconnect control cable from valve Remove:




- clip (A) securing cable sleeve. Pull gently towards left sufficiently to free cable from valve control arm.

Caution:
Control arm is easily broken and must be treated with extreme care.

- valve, by clamping hose from heater with hose clamp tool and undoing hose clamps.


B5
Attach cable to new valve

Insert:
- wire in hole in valve control arm.




Adjust position of cable in clip (A) so that valve opens fully when control lever is set to maximum and closes fully when control lever is set to minimum.

Caution: Control arm is easily broken and must be treated with extreme care.

B6
Assembly of mounting bracket, hose, valve, plastic foam packing and hose retainer.

Install/connect:

- hose from heater to valve. Tighten hose clamp.




- secure hose in retainer (A).
- close valve and remove hose clamping tool.

Note:
Valve must be closed or coolant will leak from heater.

B7
Install mounting bracket and valve




Push bracket (A) into slot in heater and secure with clip (B).

Bend mounting bracket (C & D) back into position.

B8
Reinstall hose and refit support Install:




- new hose (A) between bulkhead connection branch and valve. Tighten clamp.
- support (B) between body and heater.

B10

Remove hose clamping tools

Remove:




clamping tools from heater hoses in engine compartment.

B11
Checking procedure

Check:

- coolant level and tighten expansion tank cap.
- operation of heater with engine running.
- inspect for leakage.
- top up coolant, if necessary.

B12

Reinstall components

Remove:

- container and rags from underneath heater hose connection in car.

Reinstall/reconnect:

- cover beside accelerator pedal
- carpet (refit)
- center console side panels
- soundproofing panels and knee bolster/support bar