Heater Core: Service and Repair
REMOVE1. Remove the heater assembly. Service and Repair
Heating/Cooling Unit:
2. Remove the left duct to footwell outlet.
3. Mark the position of vent control rod, for reassembly. Disconnect by carefully prying open the plastic clip.
4. Remove the ten spring clips, three circlips and the two screws that secure the halves of the heater casing together. Ensure all fasteners and foam gaskets are removed.
5. Remove the pad from around the two coolant hose connections.
Flap Positioning:
6. Position the flap (A) as shown, pry and slide its lower edge through the gap between motor housing and outer case. While separating each half of the heater casing.
7. Note for reassembly the location of the air flap pivots.
8. Slide out the separate panel.
9. Remove the heater core complete with the sponge packing.
REFIT
1. Fit the heater core into the left half of the casing. Slide in the separate panel (8) up to the coolant hose connections.
2. Mark a white spot on the end of each air flap pivot to be reassembled into the heater casing.
3. Offer the heater casing halves together. Ensure the flap (A) is positioned to reverse instruction 6.
4. Point the remaining air flap pivots in the direction of their location.
5. Locate and slot into the left casing the heater control panel assembly. Examine closely to ensure that both fasteners engage and slide into their housing.
6. Slowly and firmly push the casing halves together checking that all components are aligning. Any solid resistance felt suggests a component is not locating correctly. Rectify and continue until the casing halves are together.
7. Refit all of the fasteners that hold the heater casing halves together.
8. Connect the rod to the vent control lever to its marked position.
9. Check all controls operate and air flaps seal against the heater casing.
10. Renew the pad around the two coolant hose connections.
11. Refit the left duct to footwell outlet.
12. Renew the foam gaskets.
13. Refit the heater assembly.