Remove the coolant expansion tank and lay it to one side.
Remove the wiper arms as described in Operation No. 32 588 0.
Remove the cowl grille.
Disconnect the hose from the windscreen washer jet.
Undo the bulkhead extension.
Remove eight bolts.
Pull the bulkhead extension forwards.
NOTE:Plug the heater radiator and coolant pipes.
NOTE:Do not mix the hoses up when fitting them (mark them if necessary).
Remove the heater water valve (LHD vehicle shown).
Disconnect the plug from the heater water valve.
Disconnect the coolant hoses using Special Tool 24-003.
Installation
All Vehicles
Refit the components in the reverse order.
Vehicles built from 09/96 to 08/99
NOTE:Only carry out steps 2 to 5 if there is a regular knocking noise coming from the facia crash padding when the heater control is set to between Min and Max
Remove the factory plastic burr on the removed bulkhead extension.
Right-hand part of the bulkhead extension
Plastic burr
LHD vehicles only
NOTE:Prevent the coolant hose clamps from touching the bodywork.
Install a new coolant hose on the left-hand side.
RHD vehicles only
NOTE:The coolant hose must be routed below the connections on the heater regulating valve and around the refrigerant lines.
NOTE:Prevent the radiator hose clamps from touching the bodywork.
Install a new coolant hose on the left-hand side.
All vehicles.
Install new heater control valve insulation.
Install the remaining components in reverse order.