Heating/ventilation components - removal and refitting

Cooling, heating and ventilation systems / Heating/ventilation components - removal and refitting

Heater unit (including blower motor and matrix)
1 Drain the cooling system with reference to Chapter 1.

2 Remove the sealing strip and cover from the plenum chamber at the rear of the engine compartment.

3 Pull the wiring block from the terminals on the heater (see illustration).

9.3 Disconnecting the heater wiring block

4 Note the locations of the hoses then loosen the clips and disconnect them (see illustration).

9.4 Disconnecting the heater hoses

5 Release the clip and disconnect the temperature control cable (see illustration).

9.5 Showing heater temperature control and cable

6 Prise out the clips, ease the heater from the fresh air box, and withdraw it from the bulkhead. Remove all traces of gasket and sealing compound (see illustrations).

9.6a Prise off the clips . . ,

9.6b . . . and withdraw the heater

9.6c The heater air box on the bulkhead (heater removed)

7 Refitting is a reversal of removal, but fit a new gasket and fill and bleed the cooling system with reference to Chapter 1. Make sure the hoses are fitted the correct way round - the direction of flow is indicated on the outlet elbow (see illustration).

9.7 The flow direction arrow on the upper heater outlet - beneath the outlet with temperature valve fitted

Heater blower motor
Note: The blower motor is fixed in the heater unit housing and cannot be obtained as a separate item.

8 Remove the heater unit as described previously.

9 Remove the matrix as described later in this sub-Section.

10 Remove the series resistor from the housing (see illustration). If necessary, separate the housing halves and remove the motor.

9.10 Series resistor and motor connections

11 Refitting is a reversal of removal, but fit a new gasket and fill and bleed the cooling system with reference to Chapter 1.

Heater matrix
12 Remove the heater unit as described previously.

13 Remove the cross-head screws and slide the m a t r i x f r o m t h e h o u s i n g ( s e e illustrations).

9.13a Matrix retaining screw locations in the heater body

9.13b Removing the heater matrix

9.13c Heater matrix and temperature control valve

14 Check the condition of the gasket between the matrix and the housing and renew if necessary.

15 Refitting is a reversal of removal but fit a new housing gasket and fill and bleed the cooling system with reference to Chapter 1.

Air distribution housing (passenger compartment)
16 Remove the heater unit as previously described.

17 Remove the facia (see Chapter 11).

18 Disconnect the air ducts from the housing.

19 Note the positions of the control cables then disconnect them.

20 Unscrew the mounting bolts and remove the air distribution housing from inside the car.

21 Refitting is a reversal of removal, but fit a new housing gasket and fill and bleed the cooling system with reference to Chapter 1. If necessary adjust the control cables as described in the following paragraphs.

Heater/ventilation control panel and cables
22 Remove the radio and ashtray insert as described in Chapter 12.

23 Where necessary, remove the switches for the seat heating, rear window heating and foglights as described in Chapter 12.

24 Unscrew the screws securing the heater control panel to the facia and withdraw it (see illustration).

9.24 Removing the heater control panel securing screws

25 Note the positions of the control cables on the air distribution housing then disconnect them. Withdraw the cables from the facia and if necessary disconnect them from the controls (see illustration).

9.25 Heater control panel and cable connections

26 Refitting is a reversal of removal, but adjust them as follows.

27 To adjust the regulator valve cable turn the temperature knob fully anticlockwise to the “cold” position, then remove the clip which secures the inner cable to the lever on the housing. With the outer cable securely clipped to the housing, move the lever to the “cold” position then refit the inner cable clip.

28 To adjust the distribution cable turn the knob fully anticlockwise and remove the outer cable clip from the housing. Move the housing lever to the “dash panel outlet” position and refit the outer cable clip.