Without A/C

Special tool

Clamp pliers for heating cables 108 589 013 700


Removal
1 Push back both front seats and cover.
2 Remove foot mats in legroom front left and right.
3 Remove instrument panel
4 Remove center console
5 Drain coolant.
6 Remove ABS control unit.







7 Release three hose straps (36) and detach heating hoses.







8 Unscrew screws on air ducts (see arrow) on the left and right for rear compartment heating and remove air ducts on transmission tunnel and front floor.







9 Disconnect 12-pole coupling from electronic switching unit (9).







10 Disconnect 5-pole coupling (see arrow) from temperature selector (2 and 3) as well as couplings from air flow and air distribution switches (4 and 24).












11 Detach vacuum lines at air flow switch (4).







12 Unscrew bolts (37) from brace (38).












13 Loosen cable straps (see arrow) on blower housing.







14 Loosen cable straps (see arrow) for main cable harness on heater unit.
15 Detach air duct for fresh air nozzle, left and right on heater unit.







16 Disconnect 2-pole coupler from temperature sensors (6 and 7).







17 Unscrew bolt (39) for electric cables at cable connector.







18 Separate electrical plug connection (see arrow) on heater unit and unclip coupling piece from securing bracket (40).







19 Unscrew bolts (41) on lower angle bracket.







20 Unscrew nut (42) from angle bracket on blower housing.







21 Unscrew nut (43) on upper right angle bracket of firewall.







22 Unscrew bolt (44) on upper left angle bracket of heater unit.
23 Pull heater unit backward so that the heating pipes disengage from the firewall.
24 Lift out heater unit over passenger legroom, holding the heating pipes upward to prevent coolant flowing out.

Installation







25 Mount heater unit on transmission tunnel from front passenger side.
26 Push heater unit against firewall, inserting heating pipes through firewall.
27 Secure heater unit to firewall with upper left angle bracket and bolt (44).







28 Screw heater unit onto firewall with upper right angle bracket and nuts (42 and 43).







29 Install lower angle bracket with bolts (41).







30 Connect electric plug (see arrow) and clip into securing bracket (40).
31 Install electric cables to cable connector.







32 Connect 2-pole couplings to temperature sensors (6 and 7).
33 Connect air duct for fresh air nozzle right and left to heater unit.







34 Lay main cable harness at heater unit and secure with cable straps (see arrow).







35 Lay electric cables at blower housing and secure with cable straps (see arrow).







36 Install brace (38) with bolts (37).







37 Connect vacuum lines to air flow switch (4).







38 Connect 5-pole coupling to temperature selector left and right and couplings to air flow and air distribution switches (4 and 24).







39 Connect 12-pole coupling to electronic switching unit (9).







40 Install air ducts left and right for rear compartment heating.
41 Install heating hoses.
42 Install ABS control unit.
43 Fill in coolant and check cooling system for leaks.
44 Install center console
45 Install instrument panel
46 Lay foot mats in legroom front left and right.
47 Check function of automatic heating system.