Heater Core: 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.

Heater/Evaporator Assembly:

18. Remove heater plenum chamber retaining clips.
19. Carefully pry the heater plenum chamber from the evaporator housing.
20. Remove the heater core.

Heater Core:

INSTALLATION
1. Seal gaskets A and B of heater core to housing, be sure to seal completely leaving no gaps.
2. Lock heater core in place. If it does not lock firmly, use self-tapping screws to secure.
3. Apply caulk type sealing material on mating surfaces of heater plenum chamber to evaporator housing.
4. Fasten heater plenum chamber to evaporator housing with clips.
5. Check Bowden cables on heater/evaporator assembly for kinks and ease of movement, replace cables as necessary.
6. Install heater/evaporator housing.
7. Install fuel injection control unit.
8. Install water drain hose from heater/evaporator housing.
9. Install vacuum hose from two way valve.

Heater/Evaporator Connections:

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

Air Plenum Cover:

12. Fasten mounting bolts A.
13. Install outside temperature sensor B.
14. Install right side air intake cover.

A/C Refrigerant Lines To Evaporator:

15. 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:

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