Installing Heater/Air-Conditioning Unit

Information 

Before the heater/air-conditioning unit is installed again, the following points must be checked:

• Check the water drain hose for any cracks, deformities and other damage. 
  Fig 1: Identifying Water Drainage Hose

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• Check both supports (stars) for the heater/air-conditioning unit on the body for damage. The stars must be able to turn for installation. 
  Fig 2: Identifying Heater/Air-Conditioning Unit Mounts (Stars)

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• Both supports for the stars on the heater/air-conditioning unit must not be damaged. 
  Fig 3: Identifying Supports For Stars On Heater/Air-Conditioning Unit

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1. Position the plastic or wooden boards used for removal in the vehicle. Position the heater/air-conditioning unit in the vehicle. Get a second person to check the position of the stars - twist them if necessary.
   WARNING: Risk of damage to the mounts (stars)!

   → The heater/air-conditioning unit must be supported

2. Slide the heater/air-conditioning unit onto both mounts (stars) and support it.
3. Push the water drainage hose onto the air-conditioning unit and make sure it is seated correctly.
   Fig 4: Pushing Water Drainage Hose Onto Air-Conditioning Unit

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4. Engage the main wiring harness on the heater/air-conditioning unit.
   Fig 5: Engaging Main Wiring Harness On Heater/Air-Conditioning Unit

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5. Lay the main wiring harness on the heater/air-conditioning unit and position it on the heater/air-conditioning unit -A-  and -B-  using one tie-wrap each.
   Fig 6: Laying Main Wiring Harness On Heater/Air-Conditioning Unit

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6. Insert the electric central connectors -A-  and -B-  into the plug connections until they click into place.
   Fig 7: Inserting Central Connectors

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7. Plug the centre temperature sensor on the left and right into the heater/air-conditioning unit and turn -90°-  .
   Fig 8: Installing Temperature Sensor

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8. Insert the centre air vents for the footwell into the air guides for the footwell and push onto the heater/air-conditioning unit.
9. Connect the centre air vents on the left -A-  and right -B-  .
   Fig 9: Connecting Centre Air Vents On Left And Right

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10. Slide the lower centre air guide into the rear air guide -arrow B-  , press the upper centre air guide onto the heater/air-conditioning unit -arrow A-  , and screw down with the two fastening screws -4-  . → Tightening torque: 1 ft lbs.  .
    Fig 10: Sliding Lower Centre Air Guide Into Rear Air Guide

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11. Position the carrier for the instrument panel. → Installing bracket for the dashboard
12. Tighten the fastening screws -1-  and -2-  . → Tightening torque: 7.5 ft lbs.. 
13. Remove the support for the heater/air-conditioning unit.

    Information 

    • Always replace O-rings. 
14. Insert the coolant supply line and return line -B-  into the heat exchanger.
    Fig 11: Inserting Coolant Lines Into Heat Exchanger

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15. Push on the retaining clips -A-  until the clips click into place.
16. Top up engine coolant. → Draining coolant .
17. Check the heating system for leaks.
18. Clip in left cover and secure with the fastening screws. → Tightening torque: 1 ft lbs.. 
    Fig 12: Securing Left Cover

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19. Clip in wiring harness on the left heat exchanger cover.
20. Install the condenser-evaporator line and the compressor-evaporator line on the expansion valve. Installing expansion valve