Heater Core Case: Service and Repair

REMOVAL

Heater/Evaporator Housing:

1. Disconnect battery cables and remove battery.
2. Discharge refrigerant system.
3. Remove center vent/control panel.
4. Remove instrument panel.

Heater/Evaporator Housing Coolant Hoses:

5. Clamp heater hoses A and B to prevent excess engine coolant loss.
- A = return to water pump.
- B = feed to cylinder head.
6. Loosen clamps and remove hoses from fittings.
7. Cap hoses.
8. Remove A/C refrigerant lines from evaporator.

Air Plenum Cover:

9. Remove right side air plenum cover
10. Remove outside temperature sensor B.
11. Remove mounting bolts A.
12. Remove air intake.

Heater/Evaporator Connections:

13. Remove nuts A on firewall.
14. Remove vacuum hose from two way valve.
15. Remove water drain hose from heater/evaporator housing.

Fuel Injection Control Unit:

16. Remove fuel injection control unit (see arrow).
17. Remove heater/evaporator housing.

INSTALLATION

1. Check Bowden cables on heater/evaporator assembly for kinks and ease of movement, replace cables as necessary.
2. Install heater/evaporator housing.
3. Install fuel injection control unit.
4. Install water drain hose from heater/evaporator housing.
5. Install vacuum hose from two way valve.

Heater/Evaporator Connections:

6. Install nuts A on firewall, be sure rubber grommet B seals properly.
7. Install air intake, be sure gasket around air intake seals correctly.

Air Plenum Cover:

8. Fasten mounting bolts A.
9. Install outside temperature sensor B.
10. Install right side air intake cover.

A/C Refrigerant Lines To Evaporator:

11. Install A/C refrigerant lines to evaporator, be sure there is no tension on lines during installation.
- Torque lines to 16 Nm (11.8 ft lb)

Heater/Evaporator Connections:

12. Install heater hoses A & B, be sure to remove caps/plugs in hoses.
- A = return to water pump.
- B = feed to cylinder head.
13. Install instrument panel.
14. Install center vent/control panel.
15. Recharge refrigerant system.
16. Install battery.
17. Fill engine coolant, run engine to operating temperature and check for leaks.