Removing
1. Remove the intake manifold. For more information refer to Intake Manifold (30.15.02)
2. Evacuate the air conditioning system. For more information, refer to Refrigerant Recovery, Vacuuming and Charging the Air Conditioning System (A/C) (82.30.02)
3.
WARNING: It is forbidden to carry out work on a vehicle supported only by a jack. Always place secure supports under the vehicle.
Raise and support the vehicle.
4. Drain the coolant from the cooling system. For more information, refer to Draining/Filling Coolant and Bleeding the Cooling System (26.10.01)
5. Remove the floor console. For more information refer to Floor Console (76.25.01)
6. Remove both doorway trim panels. For more information refer to Front Doorway Trim Panel (76.13.27)
7. Remove the decorative panel from the driver's side.
- Release the clamp.
- Remove two screws.
- Disconnect the electrical connector.
8. Remove the decorative panel from the passenger side.
- Release the clamp.
- Remove two screws.
- Disconnect the electrical connector.
9. Disconnect the door opening limiter from the A-pillar. Remove two Torx screws.
10.
NOTE: At this stage, the door is still secured with the appropriate fasteners.
Call an assistant and use the two of you to release and support the door assembly. Turn out two bolts.
11. Disconnect the electrical connector from the rack "A".
- Remove the sealing sleeve.
- Release carefully. and then slide the latch to insert it into the notches marked with arrows.
12. Remove the door.
- Remove the sealing sleeve.
- Release the electrical connector.
- Disconnect the electrical connector.
13. Remove the front seats. For more information refer to Front Seat (78.10.44/99)
14. Release the gearbox selector cable.
- Remove the clamp.
- Release the cable.
15. Remove the gear selector lever. Turn out four bolts.
16. Disconnect an intermediate shaft of a steering column from a steering column.
- Mark the installation position.
- Turn out the special bolt and discard the nut.
17. Disconnect the two drain lines from the heater body.
18. Take the central air ducts of the heater body to the side to gain access.
19. Turn out two Torx bolts from the central arm of the panel of devices.
20. Remove the central speaker grille from the instrument panel. Release four clamps.
21. Turn out a bolt of fastening of the top section of the panel of devices to a body.
22. Remove the collection chamber panel. For more information, refer to Storage Chamber (80.15.62)
23. Turn out a Torx bolt of fastening of an arm of the panel of devices to a partition.
24.
CAUTION: Before disconnecting or removing components, clean the area around the contact surfaces and connections. Plug all open connections to avoid contamination of the system.
Disconnect the two heater hoses from the bulkhead. Release two clamps.
25. Disconnect two pipelines of the conditioner from a body. Loosen the nut.
26.
CAUTION: Plug off all refrigerant lines immediately to prevent dirt and moisture from entering.
Disconnect the two air conditioning lines from the bulkhead.
- Turn out a bolt.
- Remove and discard o-rings.
27. Remove the two transition panels. Remove four nuts.
28. Disconnect the three ground wires from the bottom of the A-pillar on the driver's side. Remove two nuts.
29. Disconnect the five electrical connectors on the bottom of the A-pillar on the driver's side.
30. Disconnect the three ground wires from the bottom of the A-pillar on the passenger side. Remove two nuts.
31. Disconnect the five electrical connectors on the bottom of the A-pillar on the passenger side.
32. Disunite an electric socket of the electric motor of a heater.
33. Disconnect the two electrical connectors of the central electrical junction box (CJB).
34. Disconnect two electric sockets from the central strengthening of the panel of devices.
35. Disconnect fiber-optic cables from the central strengthening of the panel of devices. if the car is equipped with them. Disconnect the electrical connector.
36. From the driver's side: Remove the Torx bolt securing the heater housing to the bulkhead.
37. Passenger side: Remove the Torx bolt securing the heater housing to the bulkhead.
38. With assistance, remove the instrument panel. Remove the four Torx bolts.
Installation
1. With assistance, install the instrument panel. Tighten the Torx bolts to 25 Nm.
2. Passenger side: Screw in the Torx bolt securing the heater housing to the bulkhead and tighten to 6 Nm.
3. On the driver's side: Screw in the Torx bolt securing the heater housing to the bulkhead and tighten to 6 Nm.
4. Connect the fiber optic cables to the central reinforcement of the instrument panel.
5. Attach electric sockets to the central strengthening of the panel of devices.
6. Connect the electrical connectors of the central electrical box (CJB).
7. Dock an electric socket of the electric motor of a heater.
8. Connect the electrical connectors on the lower part of the A-pillar on the passenger side.
9. Connect the ground wires to the bottom of the front pillar on the passenger side. Tighten the nuts to 10 Nm.
10. Dock the electrical connectors on the bottom of the A-pillar on the driver's side.
11. Connect ground wires to the bottom of the A-pillar on the driver's side. Tighten the nuts to 10 Nm.
12. Install transition panels. Tighten the nuts to 10 Nm.
13. Fix the air conditioner piping to the bulkhead.
- Clear the elements.
- Install new o-rings.
- Tighten the bolt to 10 Nm.
15. Attach the heater hoses to the bulkhead.
16. Screw in the Torx bolt securing the instrument panel to the bulkhead and tighten to 25 Nm.
17. Install the collection chamber panel. For more information, refer to Storage Chamber (80.15.62)
18. Screw in the bolt securing the upper part of the instrument panel to the body and tighten to 10 Nm.
19. Install the speaker grille. Fasten with clips.
20. Screw in Torx bolts of the central bracket of the instrument panel and tighten to 25 Nm.
21. Install the central air ducts of the heater housing.
22. Connect the drain pipes to the heater body.
23. Attach an intermediate shaft of a steering column. Screw in the special bolt and tighten the new nut to 22 Nm.
24. Install the gear selector lever. Tighten the bolts to 10 Nm.
25. Connect a cable of the lever of the selector of a transmission. Install the clamp.
26. Install the front seats. For more information refer to Front Seat (78.10.44/99)
27. With assistance, install the door assembly.
- Connect the electrical connector.
- Fasten the electrical connector.
- Fasten the sealing sleeve.
- Tighten the bolts to 10 Nm.
29. Establish the decorative panel from outside the driver.
- Connect the electrical connector.
- Fasten the clamp.
- Tighten the screws.
- Install the interior lamp.
- Connect the electrical connector.
- Fasten the clamp.
32. Install the floor console. For more information refer to Floor Console (76.25.01)
33. Fill the cooling system. For more information, refer to Draining/Filling Coolant and Bleeding the Cooling System (26.10.01)
34. Prime the A/C system. For more information, refer to Refrigerant Recovery, Vacuuming and Charging the Air Conditioning System (A/C) (82.30.02)
35. Install the intake manifold. For more information refer to Intake Manifold (30.15.02)
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