Installing Heating/Fresh Air Unit

Information 

Do not remove the stoppers for the air-conditioning lines until just before installing the expansion valve.

Check foam parts for signs of damage. If in doubt, replace them.

1. Insert heater/air-conditioning unit in the vehicle over the passenger's side.
   Fig 1: Placing Heater/Air-Conditioning Unit In Vehicle

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2. Lift heater/air-conditioning unit over the centre console and position under dashboard bracket.
   Fig 2: Positioning Heater/Air-Conditioning Unit

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3. Position holder for the B+ line on the heater/air-conditioning unit and tighten with the fastening screw -7-  . → Tightening torque: 1.7 Nm (1.5 ftlb.) 
   Fig 3: Tightening Holder For B + Lead

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4. Lay electric line from vehicle wire harness to heater/air-conditioning unit wire harness and fix with a tie-wrap.
   Fig 4: Identifying Fastening Electric Line

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5. Connect upper electric plug connection at heater/air-conditioning unit until it is felt to engage.
   Fig 5: Connecting Upper Electrical Plug Connection

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6. Connect upper electric plug connection at heater/air-conditioning unit until it is felt to engage.
   Fig 6: Connecting Lower Electrical Plug Connection

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7. Check water drain hose for damage; if drain hose shows no sign of damage, connect hose to the drain on heater/air-conditioning unit and fix with the clamp -C-  .
   Fig 7: Fixing Water Drain Hose

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8. Push heater/air-conditioning unit into position under right side of dashboard bracket in the direction of firewall.
   Fig 8: Positioning Heater/Air-Conditioning Unit

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9. Guide holder -B-  for the heater/air-conditioning unit over the dashboard bracket, push through the mounting of the heater/air-conditioning unit and turn through 90°.
   Fig 9: Positioning Holder For Heater/Air-Conditioning Unit

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10. Fix holder for heater/air-conditioning unit with cotter pin -A-  .
    Fig 10: Removing Holder For Heater/Air-Conditioning Unit

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11. Push dashboard bracket forwards while lifting the heater/air-conditioning unit and taking care that no electric lines get trapped.
    Fig 11: Pushing Dashboard Bracket Forwards

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12. Screw down dashboard bracket with the two fastening screws -5-  . → Tightening torque: 23 Nm (17 ftlb.) 
    Fig 12: Securing Dashboard Bracket

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13. Clip in the plastic holders for the electric main wire harness to the dashboard bracket.
    Fig 13: Clipping In Plastic Holders

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14. Secure dashboard bracket with the fastening screw -4-  . → Tightening torque: 9.7 Nm (7.0 ftlb.) 
    Fig 14: Securing Dashboard Bracket

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15. Screw down holder of heater/air-conditioning unit with the fastening screw -3-  . → Tightening torque: 3.5 Nm (2.5 ftlb.) 
    Fig 15: Securing Holder For Heater/Air-Conditioning Unit

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16. Slide the fastening bolts of the heater/air-conditioning unit through the firewall lid and tighten with the three fastening nuts -6-  . → Tightening torque: 9.7 Nm (7.0 ftlb.) 
    Fig 16: Securing Heater/Air-Conditioning Unit To Firewall

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    Information 

    Do not remove the stoppers for the air-conditioning lines until just before installing the expansion valve.

    Check foam parts for signs of damage. If in doubt, replace them.

17. Install expansion valve and tighten with the two fastening screws -2-  , replace sealing rings for refrigerant lines and wet them with refrigerant. → Installing expansion valve → Tightening torque: 9 Nm (6.5 ftlb.) 
    Fig 17: Installing Expansion Valve

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18. Replace sealing rings for refrigerant lines and wet with refrigerant. Position refrigerant line and tighten with fastening screw -1-  . → M8: 14 Nm (10.5 ftlb.) 
    Fig 18: Locating Refrigerant Lines Nut

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