Home ReviewsRefund
Home/Saab/9-5/Saab 9-5 II (2010-2012)/Repair manual/Automatic HVAC System/Climate System: Removal & Installation
Contents Wiring diagrams Section: Automatic HVAC System All sections

Climate System: Removal & Installation Saab 9-5 II

Automatic HVAC System 66 illustrations ~2125 words

Removal Procedure

Note. Instrument Panel Outer Air Outlet Deflector-left side is a part of Instrument Panel Upper Trim Panel.

Remove the instrument panel upper trim panel. Refer to INSTRUMENT PANEL UPPER TRIM PANEL REPLACEMENT .

Installation Procedure

Install the instrument panel upper trim panel. Refer to INSTRUMENT PANEL UPPER TRIM PANEL REPLACEMENT .

Scheme 1

Scheme 1: Instrument Panel Outer Air Outlet Deflector Replacement - Right Side
Scheme 1: Instrument Panel Outer Air Outlet Deflector Replacement - Right Side
CalloutComponent Name
Preliminary Procedure Remove the instrument panel outer air outlet duct. Refer to INSTRUMENT PANEL OUTER AIR OUTLET DUCT REPLACEMENT .
1Instrument Panel Outer Air Outlet Deflector Fastener (Qty: 3) Refer to FASTENER CAUTION .
2Instrument Panel Outer Air Outlet Deflector

Scheme 2

Scheme 2: Instrument Panel Compartment Air and Radio Cooling Duct Replacement
Scheme 2: Instrument Panel Compartment Air and Radio Cooling Duct Replacement
CalloutComponent Name
Preliminary Procedure Remove the instrument panel compartment. Refer to GLOVE COMPARTMENT, REPLACEMENT . Remove the floor air outlet duct. Refer to FLOOR AIR OUTLET DUCT REPLACEMENT - LEFT SIDE . Loosen the carpet in the range of the front floor console and instrument panel.
1Instrument Panel Compartment Air and Radio Cooling Duct

Scheme 3

Scheme 3: Front Floor Console Front Air Duct Replacement (CJ4)
Scheme 3: Front Floor Console Front Air Duct Replacement (CJ4)
CalloutComponent Name
Preliminary Procedure Remove the front floor console. Refer to FRONT FLOOR CONSOLE REAR COVER REPLACEMENT .
1Front Floor Console Front Air Duct Fastener (Qty: 1) Refer to FASTENER CAUTION .
2Front Floor Console Front Air Duct

Scheme 4

Scheme 4: Front Floor Console Rear Air Duct Replacement (CJ4)
Scheme 4: Front Floor Console Rear Air Duct Replacement (CJ4)
CalloutComponent Name
Preliminary Procedure Remove the front floor console rear cover. Refer to FRONT FLOOR CONSOLE REAR COVER REPLACEMENT .
1Front Floor Console Rear Air Duct Fastener (Qty: 3) Refer to FASTENER CAUTION .
2Front Floor Console Rear Air Duct

Scheme 5

Scheme 5: Front Floor Console Rear Air Duct Replacement (CJ2)
Scheme 5: Front Floor Console Rear Air Duct Replacement (CJ2)
CalloutComponent Name
Preliminary Procedure Remove the front floor console. Refer to FRONT FLOOR CONSOLE REPLACEMENT Remove the front floor console rear cover. Refer to FRONT FLOOR CONSOLE REAR COVER REPLACEMENT .
1Front Floor Console Rear Air Duct Fastener (Qty: 3)
2Front Floor Console Rear Air Duct

Scheme 6

Scheme 6: Front Floor Console Rear Air Outlet Deflector Housing Replacement
Scheme 6: Front Floor Console Rear Air Outlet Deflector Housing Replacement
CalloutComponent Name
Preliminary Procedure Remove the front floor console rear cover. Refer to FRONT FLOOR CONSOLE REAR COVER REPLACEMENT .
1Front Floor Console Rear Air Outlet Deflector Housing Procedure Press the 4 clips to release the housing.

Scheme 7

Scheme 7: Instrument Panel Outer Air Outlet Duct Replacement
Scheme 7: Instrument Panel Outer Air Outlet Duct Replacement
CalloutComponent Name
Preliminary Procedure Remove the instrument panel. Refer to INSTRUMENT PANEL ASSEMBLY REPLACEMENT .
1Instrument Panel Outer Air Outlet Duct Fastener (Qty: 4) Refer to FASTENER CAUTION .
2Instrument Panel Outer Air Outlet Duct

Note. Instrument Panel Center Air Outlet Deflector is a part of Instrument Panel Upper Trim Panel.

Remove the instrument panel upper trim panel. Refer to INSTRUMENT PANEL UPPER TRIM PANEL REPLACEMENT .

Install the instrument panel upper trim panel. Refer to INSTRUMENT PANEL UPPER TRIM PANEL REPLACEMENT .

Scheme 8

Scheme 8: Floor Air Outlet Duct Replacement - Left Side
Scheme 8: Floor Air Outlet Duct Replacement - Left Side
CalloutComponent Name
Preliminary Procedure Remove the I/P lower trim panel insulator. Refer to Refer to INSTRUMENT PANEL LOWER TRIM PANEL INSULATOR REPLACEMENT - DRIVER SIDE . Loosen the carpet in the range of the front floor console and instrument panel on the left side.
1Floor Air Outlet Duct Retainer
2Floor Air Outlet Duct

Scheme 9

Scheme 9: Floor Air Outlet Duct Replacement - Right Side
Scheme 9: Floor Air Outlet Duct Replacement - Right Side
CalloutComponent Name
Preliminary Procedure Remove the instrument panel compartment. Refer to GLOVE COMPARTMENT, REPLACEMENT .
1Floor Air Outlet Duct Fastener
2Floor Air Outlet Duct

Scheme 10

Scheme 10: Floor Rear Air Outlet Duct Replacement
Scheme 10: Floor Rear Air Outlet Duct Replacement
CalloutComponent Name
Preliminary Procedure Remove the front floor panel carpet. Refer to FRONT FLOOR PANEL CARPET REPLACEMENT .
1Floor Rear Air Outlet Duct Procedure Remove the floor rear air outlet duct from the retainer and the heater air conditioning evaporator and blower module. Disconnect and transfer any parts as needed.

Scheme 11

Scheme 11: Floor Rear Air Outlet Duct Replacement - Left Side (CJ4 With Temperature Sensor)
Scheme 11: Floor Rear Air Outlet Duct Replacement - Left Side (CJ4 With Temperature Sensor)
CalloutComponent Name
Preliminary Procedure Remove the front floor panel carpet. Refer to FRONT FLOOR PANEL CARPET REPLACEMENT .
1Floor Rear Air Outlet Duct Procedure If equipped with temperature sensor, disconnect the electrical connector. Remove the floor rear air outlet duct from the retainer and the heater air conditioning evaporator and blower module. Remove the floor rear air outlet duct from the vehicle. If replacing the floor rear air outlet duct, transfer all necessary components.

Scheme 12

Scheme 12: Heater and Air Conditioning Remote Control Replacement
Scheme 12: Heater and Air Conditioning Remote Control Replacement
CalloutComponent Name
Preliminary Procedure Remove the rear end trim finish panel replacement panel. Refer to RADIO REPLACEMENT .
1Heater and Air Conditioning Remote Control Procedure Release the locking tabs and remove the heater and air condition remote control. Disconnect the electrical connector. For programming and set up information, refer to CONTROL MODULE REFERENCES .

Scheme 13

Scheme 13: Removal Procedure
Scheme 13: Removal Procedure

Scheme 14

Scheme 14
Scheme 14
  1. Remove the front bumper fascia. Refer to «FRONT BUMPER FASCIA REPLACEMENT»(ref-653649-S28914650632014090100000)
  2. Remove the front wheelhouse front liner. Refer to «FRONT WHEELHOUSE FRONT LINER REPLACEMENT»(ref-653645-S26257017002014090100000) .
  3. NOTE: Use a suitable tool. Secure the engine coolant heater.
  4. Remove the engine coolant heater bracket fastener (1).
  5. Remove the engine coolant heater bracket fastener (2).

Scheme 15

Scheme 15: Installation Procedure
Scheme 15: Installation Procedure
  1. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Install the engine coolant heater bracket fastener (1) and tighten the fastener to 9 Nm (80 lb in).
  2. Install the engine coolant heater bracket fastener (2) and tighten the fastener to 100 Nm (74 lb ft).
  3. Release the engine coolant heater.
  4. Install the front wheelhouse front liner. Refer to «FRONT WHEELHOUSE FRONT LINER REPLACEMENT»(ref-653645-S26257017002014090100000) .
  5. Install the front bumper fascia. Refer to «FRONT BUMPER FASCIA REPLACEMENT»(ref-653649-S28914650632014090100000)

Scheme 16

Scheme 16: Removal Procedure
Scheme 16: Removal Procedure

Scheme 17

Scheme 17
Scheme 17
  1. Remove the front bumper fascia. Refer to «FRONT BUMPER FASCIA REPLACEMENT»(ref-653649-S28914650632014090100000)
  2. Remove the front wheelhouse front liner. Refer to «FRONT WHEELHOUSE FRONT LINER REPLACEMENT»(ref-653645-S26257017002014090100000) .
  3. Secure the engine coolant heater.
  4. Release the engine coolant heater exhaust muffler from the engine coolant heater exhaust muffler bracket. Refer to «ENGINE COOLANT HEATER EXHAUST MUFFLER REPLACEMENT»(ref-653641-S39274513792014090100000) .
  5. Release the heater water auxiliary pump bracket from the engine coolant heater bracket. Refer to «HEATER WATER AUXILIARY PUMP BRACKET REPLACEMENT»(ref-653641-S09545384562014090100000) .
  6. Remove the engine coolant heater bracket fastener (1).
  7. Remove the engine coolant heater bracket fastener (2).
  8. Remove the engine coolant heater bracket fastener (3).
  9. Remove the engine coolant heater bracket.

Scheme 18

Scheme 18: Installation Procedure
Scheme 18: Installation Procedure
  1. Install the engine coolant heater bracket.
  2. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Install the engine coolant heater bracket fastener (1) and tighten the fastener to 9 Nm (80 lb in).
  3. Install the engine coolant heater bracket fastener (2) and tighten the fastener to 9 Nm (80 lb in).
  4. Install the engine coolant heater bracket fastener (3) and tighten the fastener to 20 Nm (15 lb ft).
  5. Install the heater water auxiliary pump bracket to the engine coolant heater bracket. Refer to «HEATER WATER AUXILIARY PUMP BRACKET REPLACEMENT»(ref-653641-S09545384562014090100000) .
  6. Install the engine coolant heater exhaust muffler to the engine coolant heater exhaust muffler bracket. Refer to «ENGINE COOLANT HEATER EXHAUST MUFFLER REPLACEMENT»(ref-653641-S39274513792014090100000) .
  7. Release the engine coolant heater.
  8. Install the front wheelhouse front liner. Refer to «FRONT WHEELHOUSE FRONT LINER REPLACEMENT»(ref-653645-S26257017002014090100000) .
  9. Install the front bumper fascia. Refer to «FRONT BUMPER FASCIA REPLACEMENT»(ref-653649-S28914650632014090100000)

Scheme 19

Scheme 19: Engine Coolant Heater Air Supply Hose Replacement
Scheme 19: Engine Coolant Heater Air Supply Hose Replacement
CalloutComponent Name
Preliminary Procedure Remove the front bumper fascia. Refer to FRONT BUMPER FASCIA REPLACEMENT
1Engine Coolant Heater Air Supply Hose Retainer Refer to FASTENER CAUTION . Tighten 3, 5 Nm (31 lb in)
2Engine Coolant Heater Air Supply Hose Retainer
3Engine Coolant Heater Air Supply Hose Procedure Bore a 2 mm hole in the deepest place.

Scheme 20

Scheme 20: Engine Coolant Heater Exhaust Muffler Bracket Replacement
Scheme 20: Engine Coolant Heater Exhaust Muffler Bracket Replacement
CalloutComponent Name
Preliminary Procedure Remove the engine coolant heater exhaust muffler. Refer to ENGINE COOLANT HEATER EXHAUST MUFFLER REPLACEMENT .
1Engine Coolant Heater Exhaust Muffler Bracket Fastener (Qty: 2) Refer to FASTENER CAUTION . Tighten 9 Nm (80 lb in)
2Engine Coolant Heater Exhaust Muffler Bracket

Scheme 21

Scheme 21: Removal Procedure
Scheme 21: Removal Procedure

Scheme 22

Scheme 22
Scheme 22
  1. Disconnect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-653644-S42080336692014090100000) .
  2. Remove the instrument panel compartment. Refer to «GLOVE COMPARTMENT, REPLACEMENT»(ref-653664-S00614269702014090100000) .
  3. Remove the both engine coolant heater control module fasteners (1).
  4. Disconnect the electrical connector (1) from the engine coolant control module (2).
  5. Remove the engine coolant control module.

Scheme 23

Scheme 23: Installation Procedure
Scheme 23: Installation Procedure
  1. Install the engine coolant control module to the instrument panel tie bar anchor plate.
  2. Connect the electrical connector (1) to the engine coolant control module (2).
  3. Install the instrument panel compartment. Refer to «GLOVE COMPARTMENT, REPLACEMENT»(ref-653664-S00614269702014090100000) .
  4. Connect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-653644-S42080336692014090100000) .

Scheme 24

Scheme 24: Removal Procedure
Scheme 24: Removal Procedure

Scheme 25

Scheme 25
Scheme 25
  1. Remove the front bumper fascia. Refer to «FRONT BUMPER FASCIA REPLACEMENT»(ref-653649-S28914650632014090100000)
  2. Release the engine coolant heater exhaust pipe. Refer to «ENGINE COOLANT HEATER EXHAUST PIPE REPLACEMENT (UNIT/SILENCER)»(ref-653641-S26651739302014090100000) or «ENGINE COOLANT HEATER EXHAUST PIPE REPLACEMENT (PIPE WITH ENDCAP)»(ref-653641-S31028169692014090100000) .
  3. Release the engine coolant heater air supply hose. Refer to «ENGINE COOLANT HEATER AIR SUPPLY HOSE REPLACEMENT»(ref-653641-S23760280712014090100000) .
  4. Release the engine coolant inlet hose. Close the inlet hose (1) with a suitable tool (2).
  5. Release the engine coolant outlet hose. Close the outlet hose (3) with a suitable tool (4).
  6. Disconnect the electrical connector and remove the retainer.
  7. Release the fuel feed pipe (1) from the engine coolant heater (2). Open the retainer with a suitable tool.
  8. Release the heater water auxiliary pump bracket from the engine coolant haeter bracket - big. Refer to «HEATER WATER AUXILIARY PUMP BRACKET REPLACEMENT»(ref-653641-S09545384562014090100000) .
  9. Remove the engine coolant heater bracket - small. Refer to «ENGINE COOLANT HEATER BRACKET REPLACEMENT (FRONT)»(ref-653641-S35753000352014090100000) or «ENGINE COOLANT HEATER BRACKET REPLACEMENT (REAR)»(ref-653641-S21222157022014090100000) .
  10. Remove the engine coolant heater from the engine coolant heater bracket - big. Refer to «ENGINE COOLANT HEATER REPLACEMENT»(ref-653641-S17405749972014090100000) .
  11. Remove heater water auxuliary pump from the engine coolant heater. Refer to «HEATER WATER AUXILIARY PUMP REPLACEMENT»(ref-653641-S38092563692014090100000) .

Scheme 26

Scheme 26: Installation Procedure
Scheme 26: Installation Procedure

Scheme 27

Scheme 27
Scheme 27

Scheme 28

Scheme 28
Scheme 28
  1. Install heater water auxuliary pump to the engine coolant heater. Refer to «HEATER WATER AUXILIARY PUMP REPLACEMENT»(ref-653641-S38092563692014090100000) .
  2. Install the engine coolant heater to the engine coolant heater bracket - big. Refer to «ENGINE COOLANT HEATER REPLACEMENT»(ref-653641-S17405749972014090100000) .
  3. Install the engine coolant heater bracket - small. Refer to «ENGINE COOLANT HEATER BRACKET REPLACEMENT (FRONT)»(ref-653641-S35753000352014090100000) or «ENGINE COOLANT HEATER BRACKET REPLACEMENT (REAR)»(ref-653641-S21222157022014090100000) .
  4. Install the heater water auxiliary pump bracket to the engine coolant haeter bracket - big. Refer to «HEATER WATER AUXILIARY PUMP BRACKET REPLACEMENT»(ref-653641-S09545384562014090100000) .
  5. Install the fuel feed pipe (1) to the engine coolant heater (2).
  6. Disconnect the electrical connector.
  7. Install the park heater coolant inlet hose (1) to park heater recirculation pump (2).
  8. NOTE: Do not put the finger into the connecting piece. Bleeding the cooling system into the following steps and install the park heater outlet hose. Lock the connection pieces from the output connection with a suitable finger. Open the clip from the inlet side of the heating. Open carefully the output connection of the heating. If coolant liquid withdraws, put the outlet hose from the outlet connection on the connection piece.
  9. Install the engine coolant heater air supply hose. Refer to «ENGINE COOLANT HEATER AIR SUPPLY HOSE REPLACEMENT»(ref-653641-S23760280712014090100000) .
  10. Install the engine coolant heater exhaust pipe. Refer to «ENGINE COOLANT HEATER EXHAUST PIPE REPLACEMENT (UNIT/SILENCER)»(ref-653641-S26651739302014090100000) or «ENGINE COOLANT HEATER EXHAUST PIPE REPLACEMENT (PIPE WITH ENDCAP)»(ref-653641-S31028169692014090100000) .
  11. Install the front bumper fascia. Refer to «FRONT BUMPER FASCIA REPLACEMENT»(ref-653649-S28914650632014090100000)

Scheme 29

Scheme 29: Removal Procedure
Scheme 29: Removal Procedure

Scheme 30

Scheme 30
Scheme 30
  1. Remove the engine coolant heater housing. Refer to «ENGINE COOLANT HEATER COVER REPLACEMENT (HOUSING)»(ref-653641-S00223518682014090100000) or «ENGINE COOLANT HEATER COVER REPLACEMENT (HOUSING COVER)»(ref-653641-S26074759232014090100000) .
  2. Remove the 4 fasteners (1) from the engine coolant heater control (2).
  3. Disconnect with caution the electrical connector (1) from the engine coolant heater control (2).

Scheme 31

Scheme 31: Installation Procedure
Scheme 31: Installation Procedure

Scheme 32

Scheme 32
Scheme 32
  1. Connect the electrical connector (1) to the engine coolant heater control unit (2).
  2. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Install the 4 fasteners (1) to the engine coolant heater control (2).
  3. Install the engine coolant heater housing. Refer to «ENGINE COOLANT HEATER COVER REPLACEMENT (HOUSING)»(ref-653641-S00223518682014090100000) or «ENGINE COOLANT HEATER COVER REPLACEMENT (HOUSING COVER)»(ref-653641-S26074759232014090100000) .

Scheme 33

Scheme 33: Engine Coolant Heater Control Replacement (Receiver Control Module)
Scheme 33: Engine Coolant Heater Control Replacement (Receiver Control Module)
CalloutComponent Name
Preliminary Procedure Remove the engine coolant heater control module. Refer to ENGINE COOLANT HEATER CONTROL MODULE REPLACEMENT .
1Engine Coolant Heater Receiver Control Module Fastener (Qty: 2) Procedure Disconnect the antenna. Disconnect the electrical connector.
2Engine Coolant Heater Control (Receiver Control Module)

Scheme 34

Scheme 34: Engine Coolant Heater Combustion Chamber Replacement
Scheme 34: Engine Coolant Heater Combustion Chamber Replacement
CalloutComponent Name
Preliminary Procedure Remove the engine coolant heater combustion fan. Refer to ENGINE COOLANT HEATER COMBUSTION FAN REPLACEMENT .
1Engine Coolant Heater Combustion Chamber Gasket
2Park Heater Glow Plug Adapter Filter Gasket
3Engine Coolant Heater Combustion Chamber

Scheme 35

Scheme 35: Heater Core Replacement (RHD)
Scheme 35: Heater Core Replacement (RHD)
CalloutComponent Name
Preliminary Procedure Remove the heater inlet hose from the heater core tube. Refer to HEATER INLET HOSE REPLACEMENT (LAU/A28NER) or HEATER INLET HOSE REPLACEMENT (LHU/A20NFT) . Remove the heater outlet hose from the heater core tube. Refer to HEATER OUTLET HOSE REPLACEMENT (LAU/A28NER) or HEATER OUTLET HOSE REPLACEMENT (LHU/A20NFT) . Remove the instrument panel compartment. Refer to GLOVE COMPARTMENT, REPLACEMENT . Remove the floor air outlet duct. Refer to FLOOR AIR OUTLET DUCT REPLACEMENT - RIGHT SIDE .
1Heater Core Tube Clamp (Qty: 2) Procedure Loosen the carpet in the range of the heater core.
2Heater Core Tube Assembly NOTE: Coolant may still be in the heater core, collect coolant or blow out heater core with compressed air.
3Heater Core Tube Seal (Qty: 2)
4Heater Core Bracket Fastener
5Heating Element Procedure Pull out the heater core.
NOTE
Coolant may still be in the heater core, collect coolant or blow out heater core with compressed air.

Scheme 36

Scheme 36: Heater Core Replacement (LHD)
Scheme 36: Heater Core Replacement (LHD)
CalloutComponent Name
Preliminary Procedure Remove the heater inlet hose from the heater core tube. Refer to HEATER INLET HOSE REPLACEMENT (LAU/A28NER) or HEATER INLET HOSE REPLACEMENT (LHU/A20NFT) . Remove the heater outlet hose from the heater core tube. Refer to HEATER OUTLET HOSE REPLACEMENT (LAU/A28NER) or HEATER OUTLET HOSE REPLACEMENT (LHU/A20NFT) . Remove the floor air outlet duct - left side. Refer to FLOOR AIR OUTLET DUCT REPLACEMENT - LEFT SIDE .
1Heater Core Tube Clamp (Qty: 2) Procedure Loosen the carpet in the range of the heater core.
2Heater Core Tube Assembly NOTE: Coolant may still be in the heater core, collect coolant or blow out heater core with compressed air.
3Heater Core Tube Seal (Qty: 2)
4Heater Core Bracket Fastener
5Heating Element Procedure Pull out the heater core.
NOTE
Coolant may still be in the heater core, collect coolant or blow out heater core with compressed air.

Scheme 37

Scheme 37: Engine Coolant Heater Fuel Pump Bracket Replacement (Rubber)
Scheme 37: Engine Coolant Heater Fuel Pump Bracket Replacement (Rubber)
CalloutComponent Name
Preliminary Procedure Raise the vehicle by its full height. Refer to LIFTING AND JACKING THE VEHICLE . Remove the Engine Coolant Heater Fuel Pump. Refer to ENGINE COOLANT HEATER FUEL PUMP REPLACEMENT .
1Engine Coolant Heater Fuel Pump Bracket Fastener
2Engine Coolant Heater Fuel Pump Bracket - Rubber

Scheme 38

Scheme 38: Engine Coolant Heater Fuel Pump Bracket Replacement (Metal)
Scheme 38: Engine Coolant Heater Fuel Pump Bracket Replacement (Metal)
CalloutComponent Name
Preliminary Procedure Raise the vehicle by its full height. Refer to LIFTING AND JACKING THE VEHICLE . Remove the Engine Coolant Heater Fuel Pump. Refer to ENGINE COOLANT HEATER FUEL PUMP REPLACEMENT .
1Engine Coolant Heater Fuel Pump Bracket Fastener (Qty: 2)
2Engine Coolant Heater Fuel Pump Fastener
3Engine Coolant Heater Fuel Pump Bracket - Rubber
4Engine Coolant Heater Fuel Pump Bracket - Metal

Scheme 39

Scheme 39: Engine Coolant Heater Fuel Pump Replacement
Scheme 39: Engine Coolant Heater Fuel Pump Replacement
CalloutComponent Name
Preliminary Procedure Raise the vehicle by its full height. Refer to LIFTING AND JACKING THE VEHICLE .
1Engine Coolant Heater Fuel Pump Bracket WARNING: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. WARNING: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. Procedure Disconnect the electrical connector. Release the fuel feed front pipe.
2Engine Coolant Heater Fuel Pump
WARNING
Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.
WARNING
Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete.

Scheme 40

Scheme 40: Heater Water Auxiliary Pump Bracket Replacement
Scheme 40: Heater Water Auxiliary Pump Bracket Replacement
CalloutComponent Name
Preliminary Procedure Remove the front bumper fascia. Refer to FRONT BUMPER FASCIA REPLACEMENT
1Heater Water Auxiliary Pump Bracket Fastener Procedure Disconnect the electrical connector.
2Heater Water Auxiliary Pump Bracket

Scheme 41

Scheme 41: Engine Coolant Heater Exhaust Muffler Replacement
Scheme 41: Engine Coolant Heater Exhaust Muffler Replacement
CalloutComponent Name
1Engine Coolant Heater Exhaust Muffler Retainer (Qty: 2)
2Engine Coolant Heater Exhaust Muffler Fastener
3Engine Coolant Heater Exhaust Muffler

Scheme 42

Scheme 42: Engine Coolant Heater Exhaust Pipe Replacement (Unit/Silencer)
Scheme 42: Engine Coolant Heater Exhaust Pipe Replacement (Unit/Silencer)
CalloutComponent Name
Preliminary Procedure Remove the right front wheelhouse front liner. Refer to FRONT WHEELHOUSE FRONT LINER REPLACEMENT .
1Engine Coolant Heater Exhaust Pipe Retainer (Qty: 2)
2Engine Coolant Heater Exhaust Pipe Procedure Measure the old pipe. Transfer measure to the new pipe and cut it.

Scheme 43

Scheme 43: Engine Coolant Heater Exhaust Pipe Replacement (Pipe with Endcap)
Scheme 43: Engine Coolant Heater Exhaust Pipe Replacement (Pipe with Endcap)
CalloutComponent Name
Preliminary Procedure Remove the right front wheelhouse front liner. Refer to FRONT WHEELHOUSE FRONT LINER REPLACEMENT .
1Engine Coolant Heater Exhaust Pipe Retainer
2Engine Coolant Heater Exhaust Pipe Procedure Measure the old pipe. Transfer measure to the new pipe and cut it.

Scheme 44

Scheme 44: Removal Procedure
Scheme 44: Removal Procedure

Scheme 45

Scheme 45
Scheme 45
  1. Remove the front bumper fascia. Refer to «FRONT BUMPER FASCIA REPLACEMENT»(ref-653649-S28914650632014090100000)
  2. Release the engine coolant inlet hose. Close the inlet hose (1) with a suitable tool (2).
  3. Release the engine coolant outlet hose. Close the outlet hose (3) with a suitable tool (4).
  4. Disconnect the electrical connector (1) from the heater water auxiliary pump (4).
  5. Release the heater water auxiliary hose retainer (2).
  6. Release the heater water auxiliary hose (3) from the heater water auxiliary pump (4).
  7. Remove the heater water auxiliary pump (4) from the heater water auxiliary pump bracket (5).

Scheme 46

Scheme 46: Installation Procedure
Scheme 46: Installation Procedure

Scheme 47

Scheme 47
Scheme 47

Scheme 48

Scheme 48
Scheme 48
  1. Install the heater water auxiliary pump (1) to the heater water auxiliary pump bracket (2).
  2. Install the heater water auxiliary hose (3) to the heater water auxiliary pump (1).
  3. Install the heater water auxiliary hose retainer (4).
  4. Connect the electrical connector (5) to the heater water auxiliary pump (1).
  5. Install the engine coolant inlet hose (1) to heater water auxiliary pump (2).
  6. NOTE: Do not put the finger into the connecting piece. Bleeding the cooling system into the following steps. 6.1. Lock the connection pieces from the output connection with a suitable finger. 6.2. Open the clip from the inlet side of the heating. 6.3. Open carefully the output connection of the heating. 6.4. If coolant liquid withdraws, put the outlet hose from the outlet connection on the connection piece.
  7. Install the engine coolant outlet hose.
  8. Install the front bumper fascia. Refer to «FRONT BUMPER FASCIA REPLACEMENT»(ref-653649-S28914650632014090100000)
  9. Check the engine coolant fluid.

Scheme 49

Scheme 49: Engine Coolant Heater Cover Replacement (Housing)
Scheme 49: Engine Coolant Heater Cover Replacement (Housing)
CalloutComponent Name
Preliminary Procedure Remove the front bumper fascia. Refer to FRONT BUMPER FASCIA REPLACEMENT Release the fuel feed front pipe.
1Engine Coolant Heater Cover Housing Fastener (Qty: 4)
2Engine Coolant Heater Cover

Scheme 50

Scheme 50: Engine Coolant Heater Cover Replacement (Housing Cover)
Scheme 50: Engine Coolant Heater Cover Replacement (Housing Cover)
CalloutComponent Name
Preliminary Procedure Remove the engine coolant heater control. Refer to ENGINE COOLANT HEATER CONTROL REPLACEMENT (UNIT) or ENGINE COOLANT HEATER CONTROL REPLACEMENT (RECEIVER CONTROL MODULE) .
1Engine Coolant Heater Cover Replacement

Scheme 51

Scheme 51: Removal Procedure
Scheme 51: Removal Procedure

Scheme 52

Scheme 52
Scheme 52
  1. Remove the engine coolant heater cover. Refer to «ENGINE COOLANT HEATER COVER REPLACEMENT (HOUSING)»(ref-653641-S00223518682014090100000) or «ENGINE COOLANT HEATER COVER REPLACEMENT (HOUSING COVER)»(ref-653641-S26074759232014090100000) .
  2. NOTE: When removing the glow plug, note cable assignment in wiring harness plug of add on heater control. Remove the glow plug cable pin (1) from the engine coolant wiring harness connector (2) with a suitable tool (3).
  3. Remove the glow plug (1) from the glow plug shell (2).

Scheme 53

Scheme 53: Installation Procedure
Scheme 53: Installation Procedure

Scheme 54

Scheme 54
Scheme 54
  1. Install the glow plug (1) to the park heater glow plug shell (2).
  2. NOTE: When installing the glow plug. Install the glow plug cable pin (1) to the engine coolant wiring harness connector (2).
  3. Install the engine coolant heater cover. Refer to «ENGINE COOLANT HEATER COVER REPLACEMENT (HOUSING)»(ref-653641-S00223518682014090100000) or «ENGINE COOLANT HEATER COVER REPLACEMENT (HOUSING COVER)»(ref-653641-S26074759232014090100000) .

Scheme 55

Scheme 55: Removal Procedure
Scheme 55: Removal Procedure

Scheme 56

Scheme 56
Scheme 56
  1. Drain the cooling system. Refer to «COOLING SYSTEM DRAINING AND FILLING (LAU/A28NER)»(ref-653648-S06131525382014090100000) or «COOLING SYSTEM DRAINING AND FILLING (LHU/A20NFT)»(ref-653648-S39426541432014090100000) .
  2. Remove the engine coolant heater. Refer to «ENGINE COOLANT HEATER REPLACEMENT»(ref-653641-S17405749972014090100000) .
  3. Remove the engine coolant heater cover. Refer to «ENGINE COOLANT HEATER COVER REPLACEMENT (HOUSING)»(ref-653641-S00223518682014090100000) or «ENGINE COOLANT HEATER COVER REPLACEMENT (HOUSING COVER)»(ref-653641-S26074759232014090100000) .
  4. Release the engine coolant heater combustion chamber temperature sensor from the engine coolant heater. Refer to «ENGINE COOLANT HEATER REPLACEMENT»(ref-653641-S17405749972014090100000) .
  5. NOTE: When removing the engine coolant heater combustion fan, note cable assignment in wiring harness plug of add-on heater control. Remove the engine coolant heater combustion fan cable connector pin (1) from the engine coolant heater wiring harness connector (2) with a suitable tool (3).
  6. Remove the 3 engine coolant heater combustion fan fasteners (1) and the engine coolant heater combustion fan (2).

Scheme 57

Scheme 57: Installation Procedure
Scheme 57: Installation Procedure

Scheme 58

Scheme 58
Scheme 58
  1. NOTE: Use NEW gasket. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Install the engine coolant heater combustion fan (1) and the 3 engine coolant heater combustion fan fasteners (2).
  2. Install the engine coolant heater combustion fan cable connector pin (1) to the engine coolant heater wiring harness connector (2).
  3. Install the engine coolant heater combustion chamber temperature sensor to the engine coolant heater. Refer to «ENGINE COOLANT HEATER REPLACEMENT»(ref-653641-S17405749972014090100000) .
  4. Install the engine coolant heater cover. Refer to «ENGINE COOLANT HEATER COVER REPLACEMENT (HOUSING)»(ref-653641-S00223518682014090100000) or «ENGINE COOLANT HEATER COVER REPLACEMENT (HOUSING COVER)»(ref-653641-S26074759232014090100000) .
  5. Install the engine coolant heater. Refer to «ENGINE COOLANT HEATER REPLACEMENT»(ref-653641-S17405749972014090100000) .
  6. Fill the cooling system. Refer to «COOLING SYSTEM DRAINING AND FILLING (LAU/A28NER)»(ref-653648-S06131525382014090100000) or «COOLING SYSTEM DRAINING AND FILLING (LHU/A20NFT)»(ref-653648-S39426541432014090100000) .

Scheme 59

Scheme 59: Removal Procedure
Scheme 59: Removal Procedure
  1. Remove the engine coolant heater. Refer to «ENGINE COOLANT HEATER REPLACEMENT»(ref-653641-S17405749972014090100000) .
  2. Remove the 4 heater coolant heater exchanger fasteners (1).
  3. Solve the heat exchanger housing cover (2).
  4. Release the enigne coolant inlet and outlet pipe (3).
  5. Remove the old gasket (4).

Scheme 60

Scheme 60: Installation Procedure
Scheme 60: Installation Procedure
  1. NOTE: Use NEW gasket. Install the NEW gasket (1).
  2. Install the enigne coolant inlet and outlet pipe (2).
  3. Install the heat exchanger housing cover (3).
  4. Install the 4 heater coolant heater exchanger fasteners (4).
  5. Install the engine coolant heater. Refer to «ENGINE COOLANT HEATER REPLACEMENT»(ref-653641-S17405749972014090100000) .

Scheme 61

Scheme 61: Glow Plug Shell Replacement
Scheme 61: Glow Plug Shell Replacement
CalloutComponent Name
Preliminary Procedure Remove the glow plug. Refer to GLOW PLUG REPLACEMENT . Remove the engine coolant heater combustion chamber temperature sensor. Refer to ENGINE COOLANT HEATER COMBUSTION CHAMBER TEMPERATURE SENSOR REPLACEMENT .
1Glow Plug Shell Filter
2Glow Plug Shell Filter Gasket
3Glow Plug Shell Gasket
4Glow Plug Shell

Scheme 62

Scheme 62: Removal Procedure
Scheme 62: Removal Procedure

Scheme 63

Scheme 63
Scheme 63
  1. Remove the engine coolant heater housing cover. Refer to «ENGINE COOLANT HEATER COVER REPLACEMENT (HOUSING)»(ref-653641-S00223518682014090100000) or «ENGINE COOLANT HEATER COVER REPLACEMENT (HOUSING COVER)»(ref-653641-S26074759232014090100000) .
  2. NOTE: When removing the engine coolant glow plug, note cable assignment in wiring harness plug of add-on heater control. Remove the engine coolant heater chamber temperature sensor cable connector pin (1) from the engine coolant wiring harness (2) with a suitable tool (3).
  3. Remove the engine coolant heater chamber temperature sensor (1) and the glow plug shell bracket (2).

Scheme 64

Scheme 64: Installation Procedure
Scheme 64: Installation Procedure

Scheme 65

Scheme 65
Scheme 65
  1. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Install the glow plug shell bracket (1) and the engine coolant heater chamber temperature sensor (2).
  2. Install the engine coolant heater chamber temperature sensor cable pin (1) to the engine coolant wiring harness (2).
  3. Install the engine coolant heater cover. Refer to «ENGINE COOLANT HEATER COVER REPLACEMENT (HOUSING)»(ref-653641-S00223518682014090100000) or «ENGINE COOLANT HEATER COVER REPLACEMENT (HOUSING COVER)»(ref-653641-S26074759232014090100000) .

Scheme 66

Scheme 66: Auxiliary Heater Core Replacement
Scheme 66: Auxiliary Heater Core Replacement
CalloutComponent Name
Preliminary Procedure Remove the instrument panel. Refer to INSTRUMENT PANEL ASSEMBLY REPLACEMENT .
1Auxiliary Heater Core Retainer Procedure Use a screw driver to release the snap feature and move the connector from the bracket. Disconnect the electrical connector.
2Auxiliary Heater Core Fastener (Qty: 2) Refer to FASTENER CAUTION .
3Auxiliary Heater Core Procedure Pull out the auxiliary heater core.

More articles — Climate System