Remove the heater unit

WARNING: This page is about a different car, the 2004 Volvo S40, 2003 Volvo S40, 2002 Volvo S40, 2001 Volvo S40, and 2000 Volvo S40. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Heater Unit Screws

Courtesy of VOLVO CARS OF NORTH AMERICA.

Disconnect all connectors.

Remove the power unit

Cars with AC:

Disconnect the AC-pipe in the engine compartment from the support.

Loosen the screws and the nut from the power unit and pull it backwards as far as possible

Remove the top part of the housing.

Disconnect the connector for the floor heater (1x bracket)

Press down the pipes and remove the bottom part.

Remove the four attaching nuts.

Pull loose the housing, press down the floor heater and remove the housing.

Disconnect the control rod on the valve side.

Remove the bracket and all clips around it.

Carefully pull apart the parts.

Replace damaged parts, if needed.

NOTE: Do not remove the damper motors when adjusting.

Replace the refrigerant temp sensor, see Replace the Refrigerant Temperature Sensor .

Replace the heat exchanger, see Install the whole heater unit .

Check the seals (also on dampers).

Install the control mechanism last.

Install in the reverse order.

Check the damper motors' setting, see Replace the Air Distribution Damper Motor or Adjust the Temperature Damper Motor .