Heater System

Heater/Air Distributor Case Assembly

Removal Procedure




1. Disconnect the negative battery cable.
2. Remove the instrument panel carrier assembly. Refer to Instrumentation/Driver Information.
3. Drain the cooling system. Refer to Engine Cooling.
4. Turn the vacuum hose and pull the hose off.




5. Compress the heater hose clamps at the bulkhead and slide the clamps toward the engine.
6. Remove the two heater hoses from the core lines at the bulkhead.
7. Remove the screws that secure the heater/air distributor case assembly to the bulkhead on either side of the heater core pipes.




8. Remove the heater/air distributor case screw located above the fuel filter on the engine compartment side of the bulkhead.




9. Have an assistant support the heater/air distributor case from inside the vehicle.

NOTE: Handle the case carefully to avoid damage to the mechanical door operating linkage.

10. Remove the screws from the connecting block opening mount on the engine compartment side of the bulkhead on the right-hand side of the vehicle. The case assembly will start to drop.
11. Pull the heater/air distributor case straight away from the bulkhead to free the alignment pegs from their openings in the bulkhead.
12. Remove the heater/air distributor case assembly from the vehicle.

Installation Procedure




1. Position the heater/air distributor case in the vehicle.

NOTE: Avoid damaging the heater core tubes by making sure they do not contact the bulkhead opening.

2. Slowly raise the heater/air distributor case into position.
- Insert the guide pegs through their holes in the bulkhead.
- Hold the case in position against the bulkhead while installing and tightening the screws on the engine side of the bulkhead.

3. Install the screws through the bulkhead from the engine compartment side.
- Install the two screws at the connecting block mount.
- Install the screw above the fuel filter.

Tighten
Tighten the heater/air distributor case assembly screws to 4 N.m (35 lb-in).




4. Install the two heater/air distributor case screws that flank the heater core pipes.

Tighten
Tighten the heater/air distributor case assembly screws to 4 N.m (35 lb-in).




5. Install the vacuum hose.
6. Install the two heater hoses.
7. Slide the heater hose clamps into position.

8. Install the instrument panel carrier assembly.
9. Fill the cooling system.
10. Connect the negative battery cable.

NOTE: If the vehicle is equipped with air conditioning, Heater/Air Distributor Case Assembly.

11. Operate the controls to verify the proper function of the heating and ventilating systems.