Page 869 of 1007
HEATING AND VENTILATION
80-4REPAIRS
Switch - fan - front heater
$% 80.10.22
Remove
1.Remove front console.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.
2.Disconnect multiplug from switch.
3.Remove drive shaft from switch.4.Remove 2 screws securing switch to heater
controls.
5.Remove switch.
Refit
1.Fit switch to heater controls and secure with
screws.
2.Fit drive shaft to switch.
3.Connect multiplug to switch.
4.Fit front console.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.
Page 870 of 1007
HEATING AND VENTILATION
REPAIRS 80-5
Ventilator - face level - LH
$% 80.15.05
Remove
1.Protect fascia and carefully lever vent from
fascia.
2.Remove and discard seal.Refit
1.Fit new seal to vent.
2.Fit vent to fascia.
Page 871 of 1007
HEATING AND VENTILATION
80-6REPAIRS
Plenum - air intake
$% 80.15.62
Remove
1.Remove both wiper arms.
+ WIPERS AND WASHERS, REPAIRS,
Arm - wiper - each.
2.Remove 6 studs securing rear edge of air
intake moulding.
3.Remove air intake moulding and bonnet
sealing rubber.
NOTE: Do not carry out further dismantling if
component is removed for access only.
4.Remove bonnet sealing rubber from air intake
moulding.
5.Remove 4 clips securing air intake filter
retainers. Remove retainers and filters.Refit
1.Fit filters and retainers to air intake moulding
and secure with clips.
2.Fit bonnet sealing rubber to air intake moulding.
3.Fit air intake moulding and secure with studs.
4.Fit wiper arms.
+ WIPERS AND WASHERS, REPAIRS,
Arm - wiper - each.
Page 872 of 1007
HEATING AND VENTILATION
REPAIRS 80-7
Heater unit
$% 80.20.01
Remove
1.Drain cooling system.
+ COOLING SYSTEM - Td4,
ADJUSTMENTS, Coolant - drain and refill.
+ COOLING SYSTEM - K SERIES 1.8,
ADJUSTMENTS, Coolant - drain & refill.
+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
2.Release 2 clips securing heater hoses to heater
and disconnect hoses.
3.Remove fascia.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
4.Remove 2 bolts from console support bracket,
release 2 relays and remove bracket. Up to
03MY illustrated.5.Disconnect 4 multiplugs from heater controls.
Up to 04MY illustrated.
6.Disconnect multiplug from heater and release
diagnostic socket.
7. Models with A/C: Disconnect multiplug from
evaporator.
8.Remove bolt from duct of LH outer face level
vent and release duct from heater.
Page 873 of 1007
HEATING AND VENTILATION
80-8REPAIRS
9. NOTE: Models with passenger airbag,
remove carrier.Remove bolt from duct of RH
outer face level vent and release duct from
heater.
10.Release duct of RH demister vent.
11.Release duct of LH demister vent.
12.Release air inlet connector hose.
13.Release harness from 2 clips on heater.
14.Remove 2 nuts and 1 bolt securing heater to
body and remove heater.
NOTE: Do not carry out further dismantling if
component is removed for access only.15.Disconnect 2 multiplugs from heater controls.
16.Release air blend control cable from lever and
abutment.
17.Release air distribution cable from lever and
abutment.
18.Remove heater controls.
Page 874 of 1007

HEATING AND VENTILATION
REPAIRS 80-9
Refit
1.Position heater controls to replacement heater.
2.Connect air distribution cable to lever and
abutment.
3.Connect air blend cable to lever and abutment.
4.Connect multiplugs to heater controls.
5.Fit heater and secure with nuts and bolt.
6.Position harness and connect to clips on
heater.
7.Fit air inlet connector hose.
8.Fit RH demister vent duct to heater.
9. Models with passenger airbag, fit carrier.Fit
RH outer face level vent duct to heater and
secure to body with bolt.
10.Fit LH demister vent duct to heater.
11.Fit LH outer face level vent duct to heater and
secure to body with bolt.
12. Models with A/C: Connect multiplug to
evaporator.
13.Connect multiplug to heater and secure
diagnostic socket.
14.Connect multiplugs to heater controls.
15.Fit console support bracket and secure with
bolts.
16.Fit relays to console support bracket.
17.Fit fascia.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
18.Connect heater hoses and secure with clips.
19.Refill cooling system.
+ COOLING SYSTEM - Td4,
ADJUSTMENTS, Coolant - drain and refill.
+ COOLING SYSTEM - K SERIES 1.8,
ADJUSTMENTS, Coolant - drain & refill.
+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
Page 875 of 1007
HEATING AND VENTILATION
80-10REPAIRS
Element - positive temperature co-
efficient (PTC) heater - Td4 models
$% 80.20.05
Remove
1.Remove heater matrix.
+ HEATING AND VENTILATION,
REPAIRS, Matrix - heater.
2.Release PTC top and bottom retaining stud
bosses from locating holes.
3.Release PTC element harness grommet from
passenger side of heater unit.
4.Carefully remove element also guiding harness
through assemblyRefit
1.Carefully fit PTC element into heater
assembly, also guide harness through opposite
side.
2.Fit harness grommet.
3.Locate bottom stud bosses into locating holes,
then locate top bosses.
4.Fit heater matrix..
+ HEATING AND VENTILATION,
REPAIRS, Matrix - heater.
Page 876 of 1007
HEATING AND VENTILATION
REPAIRS 80-11
Harness - positive temperature co-
efficient (PTC) heater - Td4 models
$% 80.20.06
Remove
1.Disconnect battery earth lead.
2.Remove bolt securing PTC cable from positive
side of battery.
3.Remove ECM from 'E' box.
+ ENGINE MANAGEMENT SYSTEM -
EDC, REPAIRS, Engine control module
(ECM).
4.Disconnect multiplugs from gearbox ECU and
cooling fan sensor5.Release harness from cable ties and release
relays from inner casing.
6.Release and disconnect cooling fan and joint
harness multiplugs.
7.Release 3 harnesses and air duct rubber
sleeve's from housing.
8.Release clips and remove fuse box cover.
9.Remove nut securing ECM housing.
10.Release housing from retaining brackets and
remove.
M80 0557