Without A/C

CAUTION: Always disconnect the battery ground (GND) strap before working on the electrical system.

NOTE: Before disconnecting battery, obtain radio code for radios with antitheft coding.

Heater Housing Assembly





1 Plenum chamber cover
2 Dust and pollen filter
3 Hex screw with shank M6x22
- 5 Nm (44 in lb)
4 Gasket
5 Series resistor for fresh air blower with thermal fuse -N24-
6 Fresh air blower -V2-
7 Footwell vent
- Replacing: Remove shelf on drivers and passengers side, center console, instrument panel bracket and pedal cluster cover.
8 Air duct right
9 Air distribution
- Replacing center vent, heating and fresh air controls: remove shelf on passenger side, loosen instrument panel and lift.
10 Air vent, right
11 Grille
12 Center vent
13 Control panel trim
14 Grilles
15 Instrument panel trim
16 Grille
17 Air vent left
18 Rear duct
- Replacing: Remove console, instrument panel bracket, pedal cluster cover, footwell outlet.
19 Rear duct seal
- Replacing: Remove console, instrument panel bracket, pedal cluster cover, footwell outlet.
20 Instrument panel
21 Air duct left
22 Fresh air and heated air controls
23 Pedal cluster cover
24 Cables
- Replacing: First remove pedal cluster cover and foot well outlet.
25 Intermediate duct
- With gasket
- Replacing; remove instrument panel first
26 Air distribution housing
- With temperature flap
- With center flap
- With footwell/defrost flap
- Do not disassemble further
- Replacing: Remove instrument panel and heating items -22- to -28-
27 Heat exchanger
- Replacing: Remove instrument panel and heating items -22- to -28-
- After heat exchanger replacement, install fresh coolant
28 Air duct with main shut- off flap
- Replacing: Remove instrument panel and heating items -22- to -28-
29 Hex nut M6
- 5 Nm (44 in lb)

Removing and Installing:

- Disconnect the battery ground cable
- Remove instrument panel
- DIsconnect shift lock cable, if equipped
- Remove passenger side instrument panel support bracket
- Drain engine coolant completely
- Disconnect heater hoses from heater core
- Remove housing securing nuts on firewall in engine compartment
- Remove air distribution housing with controls and cables attached.
Use care not to kink or bend cables
Use care to prevent spilling engine coolant in car interior

Installation Notes
- Pre-assemble hex nuts on engine bulkhead.
- Tighten hex nut with shank, in plenum chamber.
- Tighten engine bulkhead Hex nuts.
- Replace gaskets between housing and body
- Do not bend or kink control cables
- Do not reuse old engine coolant