Contents: Removal ⇩ Installation ⇩
Removal
1. Evacuate the air conditioning system. For more information, refer to Refrigerant Recovery, Evacuation, and Charging of the Air Conditioning (A/C) System (82.30.02)
2.
CAUTION: Never work on a vehicle supported solely by a jack. Always support the vehicle securely.
Raise the vehicle and place it on supports.
3. Drain the coolant from the cooling system. For more information, refer to Draining/Filling Coolant and Bleeding the Cooling System (10/26/01)
4. Remove the driver's seat. For more information, refer to Front Seat (78.10.44/99)
5. Remove the upper section of the instrument panel. For more information, refer to Upper Section of the Instrument Panel (76.46.04)
6. Disconnect the 3 ground wires from the lower part of the front body pillar on the driver's side. Unscrew the 2 nuts.
7. Disconnect the 5 electrical connectors at the bottom of the A-pillar on the driver's side.
8. Disconnect the 3 ground wires from the lower part of the front body pillar on the passenger side. Unscrew the 2 nuts.
9. Disconnect the heater motor electrical connector.
10. Disconnect the 5 electrical connectors at the bottom of the front pillar on the passenger side.
11. Disconnect the 2 central junction block (CJB) electrical connectors.
12. Disconnect the 2 electrical connectors from the center control panel reinforcement.
13.
CAUTION: Cover the fiber optic connections to prevent dust from entering them.; avoid bending fiber optic cables with a radius less than 30 mm.
Disconnect the fiber optic cables from the control panel center reinforcement (if equipped). Disconnect the electrical connector.
14. Install the central air ducts of the heater body.
15. Disconnect the intermediate steering column shaft from the steering column.
- Mark the installation position.
- Unscrew the special bolt and discard the nut.
16. Disconnect the heater housing from the control panel bracket. Remove the 7 Torgx head screws.
17. Remove the mixing chamber panel. For more information, refer to Accumulating Chamber (80.15.62)
18. Remove the Torx head bolt securing the control panel bracket to the bulkhead.
19. Remove the instrument panel with assistance. Remove the 6 Torgx head bolts.
20. Disconnect both hoses from the EGR coolant bypass pipe. (exhaust gas recirculation). Release the 2 clamps.
21. Remove the EGR coolant bypass pipe.
- Remove 2 bolts.
- Release the 2 clamps.
22.
CAUTION: Before disconnecting or disassembling parts, clean the area around mating surfaces and connections. To avoid contamination of the system, plug all open connections.
Disconnect the 2 heater hoses from the bulkhead. Release the 2 clamps.
23. Disconnect the 2 air conditioning pipes from the body. Unscrew the nut.
24.
CAUTION: Immediately plug all refrigerant lines to prevent dirt and moisture from entering.
Disconnect the 2 air conditioner pipes from the bulkhead.
- Remove the bolt.
- Remove and discard the O-rings.
25. Remove 2 transition panels. Unscrew 4 nuts.
26. Disconnect the two drain tubes from the heater body.
27. Remove the driver's side lower air duct. Remove the 2 Torx head screws.
28. Remove the lower air duct on the passenger side. Remove the 2 Torx head screws.
(The article was copied from the website: lrman.ru)
29. From the driver's side: Remove the Torx head bolt securing the heater housing to the bulkhead.
30. From the passenger side: Remove the Torx head bolt securing the heater housing to the bulkhead.
31. Remove the heater housing.
32. Disconnect the evaporator radiator temperature sensor electrical connector.
33. Release the heater radiator housing.
- Remove 2 screws.
- Remove 8 clamps.
34. Remove the evaporator radiator. Disconnect the temperature sensor.
Installation
1. Install the evaporator radiator. Secure the temperature sensor.
2. Secure the heater radiator housing.
- Install the clamps.
- Tighten the screws.
4. Install the heater housing.
5. From the passenger side: screw in the Torx head bolt securing the heater housing to the bulkhead (tightening torque 6 Nm).
6. From the driver's side: screw in the Torx head bolt securing the heater housing to the bulkhead (tightening torque 6 Nm).
7. Install the lower air ducts. Tighten the Torx head screws.
8. Connect the drain tubes to the heater body.
9. Install the transition panels. Tighten the nuts. (tightening torque 6 Nm).
10. Secure the air conditioner pipes to the bulkhead.
- Clean the parts.
- Install new O-rings.
- Tighten the bolt (tightening torque 6 Nm).
12. Secure the heater hoses to the bulkhead.
13. Install the EGR coolant bypass pipe. Tighten the bolts. (tightening torque 10 Nm).
- Engage the clamps.
- Connect the hoses and secure them with clamps.
15. Install the instrument panel mounting bracket to the bulkhead and secure it with a Torx head bolt. (tightening torque 25 Nm).
16. Install the mixing chamber panel. For more information, refer to Accumulating Chamber (80.15.62)
17. Secure the heater housing. Tighten the screws.
18. Attach the intermediate shaft of the steering column. Screw in the special bolt and tighten the new nut. (tightening torque 22 Nm).
19. Install the central air ducts of the heater housing.
20. Connect the fiber optic cables to the control panel center reinforcement.
21. Connect the electrical connectors to the central reinforcement of the control panel.
22. Connect the CJB electrical connectors.
23. Connect the heater motor electrical connector.
24. Connect the electrical connectors at the bottom of the front pillar on the passenger side.
25. Connect the ground wires to the lower part of the front body pillar on the passenger side. Tighten the nuts. (tightening torque 10 Nm).
26. Connect the electrical connectors at the bottom of the A-pillar on the driver's side.
27. Connect the ground wires to the lower part of the front body pillar on the driver's side. Tighten the nuts. (tightening torque 10 Nm).
28. Install the upper instrument panel section. For more information, refer to Upper Instrument Panel Section (76.46.04)
29. Install the front seat. For more information, refer to Front Seat (78.10.44/99)
30. Charge the air conditioning system. For more information, refer to Refrigerant Recovery, Evacuation, and Charging of the Air Conditioning (A/C) System (82.30.02)
31. Fill the cooling system. For more information, refer to Draining/Filling Coolant and Bleeding the Cooling System (10/26/01)
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