2With the engine cold, slowly unscrew the
expansion tank cap to release any remaining
pressure from the cooling system, then refit
the cap.
3Disconnect the wiring from the sender
terminal (see illustrations).
4Unscrew and remove the sender, and
temporarily plug the aperture.
Refitting
5Refitting is a reversal of removal, but smear
a little sealing compound on the sender unit
threads before fitting.
6On completion, check and if necessary top-
up the coolant level.
Removal
1Disconnect the battery negative lead.
2Remove the securing screws and unclip the
lower and upper steering column shrouds.
3Remove the four securing screws and
withdraw the instrument panel surround. Note
that the bottom right-hand screw is covered
by a plastic panel which must be prised out.
4Remove the passenger side lower facia
panel.
5Where necessary for improved access,
detach the two vent hoses from the left-hand
side of the heater, then detach the lower ends
of the two control cables from the heater by
removing the retaining screws (see
illustration).
6Unscrew the three securing screws, and
remove the heater control panel by sliding it
through the facia panel and withdrawing it
downwards. Disconnect the wiring from the
control panel illumination bulb.
7If necessary, the bulb can be removed with
its holder.
Refitting
8Refitting is a reversal of removal, bearing in
mind the following points.
9When reconnecting the wiring to the control
panel illumination bulb, wrap insulating tapearound the wiring loom over a length of
approximately 330.0 mm (13.0 in) starting
from the bulbholder. Route the loom, ensuring
that it is located in the two retaining clips,
bend it over and secure it to the bulbholder
with insulating tape as shown (see
illustration). This procedure will prevent the
wiring loom from chafing against the heater
control levers.
10When reconnecting the control cables to
the heater, move the control levers on the
control panel to the fully up position, then
attach the cables to the clips on the heater.
The cable ends should project from the clips
by between 0 and 4.0 mm (0 and 0.16 in). The
cables are adjusted automatically by moving
the control levers fully downwards. It is
possible that considerable resistance may
have to be overcome when moving the control
levers.
Removal
1Disconnect the battery negative lead.
2If the coolant is still hot, release the
pressure in the system by slowly unscrewing
the expansion tank cap. Place a thick rag over
the cap to prevent scalding as the pressure is
released.
3Note the location of the two heater hoseson the engine compartment bulkhead, then
disconnect and plug them (see illustration).
Alternatively, the hoses can be secured high
enough to prevent the coolant from draining.
4To prevent unnecessary spillage of coolant
when the heater unit is removed, blow into the
upper heater pipe until all the coolant has
been expelled through the lower pipe.
5Remove the two securing screws and
withdraw the heater pipe cover from the
bulkhead (see illustration). Recover the
gasket.
6Working inside the vehicle, remove the
passenger side lower facia panel.
7Disconnect the ends of the two control
cables from the heater by removing the two
retaining screws.
8Detach the five vent hoses from the heater.
9Unscrew the two mounting bolts, and move
the heater to the rear until the pipes are clear
of the bulkhead, then withdraw the heater to
the left. If necessary, remove the lower facia
bracket (see illustration).
Refitting
10Refitting is a reversal of removal, but
adjust the control cables by moving the levers
on the control panel to the top and then the
bottom stops. Considerable resistance may
be encountered when moving the levers
towards the bottom stops, which should be
overcome.
11On completion, top-up the coolant level.
18Heater unit - removal and
refitting
17Heater controls - removal and
refitting
Cooling, heating and air conditioning systems 3•9
3
18.3 Location of heater hoses on engine
compartment bulkhead18.9 Withdrawing the heater18.5 Heater pipe cover
17.9 Heater control panel illumination bulb
wiring loom correctly routed17.5 Heater control cable lower end fittings
(arrowed)
