Heater Core: Service and Repair

Heater Core

Service Repair No - 80.20.29

Removal

WARNING:
^ Persons working on the supplemental restraint system (SRS) must be fully trained and have been issued with the safety guidelines.
^ Allow a period of 10 minutes to elapse after disconnecting the battery before undertaking any work on the SRS.
^ The SRS electrical connectors are unique.DO NOT force, or attempt to connect electrical connectors to the wrong sockets.
^ The correct procedures must always be used when working on SRS components.
^ It is imperative that before any work is undertaken on the SRS system, the appropriate information is read thoroughly.
^ Always disconnect both battery cables before beginning work on the SRS system.Disconnect the ground cable first.Never reverse connect the battery.
^ Take extra care when handling SRS components.

1. Set the footwell duct air outlet to closed.
2. Make the air bag supplemental restraint system (SRS) safe.
3. Disconnect the battery ground cable.
4. Remove the heater and evaporator core housing.
5. Reposition the heater and evaporator core housing for access.
6. Remove the left-hand footwell duct.
^ Remove the 2 screws.





7. Remove the left-hand air intake duct.
^ Remove the 4 screws.





8. Remove the gasket from the heater core inlet and outlet pipes.





9. Remove the heater core, inlet and outlet pipes.
^ Remove the 2 screws.
^ Remove and discard the 3 O-ring seals.

CAUTION: Always plug any open connections to prevent contamination.





10. Remove the thermostatic expansion valve cover.
^ Release the wiring harness from the 2 tangs.
^ Remove the 4 screws.





11. Remove the right-hand footwell duct.
^ Remove the 4 screws.
^ Remove the clip.





12. Disconnect the floor duct actuator motor electrical connector.
13. Release the evaporator temperature sensor from the heater and evaporator core housing.
14. Remove the heater and evaporator core housing lower cover.
^ Remove the 7 screws.
^ Remove the 4 clips.





15. Remove the heater core.

Installation
1. Install the heater core.
2. Install the heater and evaporator core housing lower cover.
^ Install the screws.
^ Install the clips.
3. Install the evaporator temperature sensor to the heater and evaporator core housing.
4. Connect the floor duct actuator motor electrical connector.
5. Install the right-hand footwell duct.
^ Install the screws.
^ Install the clip.
6. Install the thermostatic expansion valve cover.
^ Install the screws.
^ Secure the wiring harness to the tangs.
7. Install the heater core, inlet and outlet pipes.
^ Clean the component mating faces.
^ Lubricate and install the new O-rings
^ Tighten the screws to 10 Nm (7 ft. lbs.).
8. Install the gasket to the heater core inlet and outlet pipes.
9. Install the left-hand air intake duct.
^ Install the screws.
10. Install the left-hand footwell duct.
^ Install the screws.
11. Reposition the heater and evaporator core housing for access.
12. Install the heater and evaporator core housing.
13. Connect the battery ground cable.