Models to 1991 and Including

REPLACEMENT OF HEATER CONTROL VALVE, MODELS TO 1991 INCL.

A1



Clamp heater hoses

Open hood.

Clamp heater hoses with hose clamping tools. loosen expansion tank cap to relieve pressure in system.

A2
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
- bolts holding center console panel

A3
Remove valve and mounting bracket Remove/disconnect:

- control cable from valve.
- valve incl. capillary tube and bracket from heater housing (pull towards left).




- support (A) between body and heater.
- reinstall capillary tube rubber grommet (reseal tube hole with duct tape or butyl tape)

A4
Remove valve and control cable




Heater hoses in engine compartment must be clamped. Clamp hose (A) from heater by applying hose clamp tool beside valve in car.

Undo hose clamps (B) and remove valve (C) with hose. Disconnect cable (D) at control panel (E) and remove cable.

A5
Attach new cable to new valve

Insert:

- wire in hole in valve control arm.




Adjust position of cable in clip (A) so that valve opens fully and closes fully.

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




Bend mounting bracket (B), 900 to left. Route cable between heater housing and radio compartment, and through hole (C) in heater mounting bracket.

A6

Install new control cable

Attach:

- cable to control lever




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

A7
ASSEMBLY OF MOUNTING BRACKET, HOSE, VALVE, PLASTIC FOAM PACKING AND HOSE RETAINER

Install/connect:




- plastic foam packing (A) and hose retainer (B) in bracket with screw.
- hose from heater to valve. Tighten hose clamp.
- secure hose in retainer.
- close valve and remove hose clamping tool.

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

A8
Install mounting bracket and valve




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

Bend mounting bracket (C) back into position.

A9
Install new hose and refit support Install:




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

A10
Remove hose clamping tools

Remove:




clamping tools from heater hoses in engine compartment.

A11
Checking procedure

Check:

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

A12
Reinstall components

Remove:

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

Reinstall/reconnect:

- cover beside accelerator pedal
- carpet (refit).

bolts on center console panel

- center console side panels.
- soundproofing panels and knee bolster/support bar