Heater Core Case: Service and Repair

Heater Core and Evaporator Core Housing

Removal

All vehicles
1. Disconnect the battery ground cable.
2. Carry out the air conditioning recovery procedure.
3. Release the cooling system pressure.
- Remove the coolant expansion tank pressure cap.

CAUTION:
- The engine cooling system must be maintained with the correct concentration and type of anti-freeze solution to prevent corrosion and frost damage. Failure to follow this instruction may result in damage to the engine.
- Never remove the coolant pressure cap under any circumstances while the engine is operating. Failure to follow this instruction may result in damage to the engine.

4. Remove the cowl vent screen.







5. Remove the engine compartment support.







6. Remove the engine compartment support.







7. Remove the cabin filter cover and cabin filter.







8. Remove the cabin filter housing.
- Remove the cabin filter housing retaining nuts.
- Remove the cabin filter housing.







9. Remove the engine compartment panel.
- Remove the engine compartment panel retaining bolt.
- Remove the engine compartment panel.

Right-hand drive vehicles







1. Disconnect the bonnet cable.


All vehicles







1. Remove the engine compartment panel.
- Remove the engine compartment panel retaining clip.
- Remove the engine compartment panel.







2. Detach the heater hoses.
- Reposition the heater hose retaining clips.
- Detach the heater hoses.

NOTE: Cap the heater hoses to prevent coolant loss.







3. Disconnect the expansion valve manifold and tube assembly.
- Remove and discard the O-ring seals.

NOTE: Cap the air conditioning ports.

4. Remove the instrument panel.







5. Remove the floor console register duct.
1. Remove the retaining nut.
- Remove the floor console register duct.







6. Remove the floor console adaptor duct.
- Detach the floor console adaptor duct retaining tang.
- Remove the floor console adaptor duct.







7. Disconnect the AC module electrical connector.







8. Disconnect the heater motor electrical connector.







9. Remove the heater core and evaporator core housing retaining bolt.







10. Remove the heater core and evaporator core housing retaining bolt.







11. Remove the heater core and evaporator core housing.
1. Detach the rear footwell vent ducts.
- Remove the heater core and evaporator core housing retaining bolts.
- Remove the heater core and evaporator core housing.

CAUTION:
- Care should be taken when handling the heater core and evaporator core housing not to lift it by the heater core inlet or outlet pipes, actuator units or by the AC module. Failure to follow this instruction may result in damage to the heater core and evaporator core housing.
- Care should be taken when handling the heater core and evaporator core housing as coolant may leak out of the unit.

Installation







1. To install, reverse the removal procedure.
- Tighten to 7 Nm.







2. Tighten to 7 Nm.







3. Tighten to 7 Nm.







4. Tighten to 8 Nm.

NOTE: Fit new O-ring seals to expansion valve manifold and tube assembly.







5. Tighten to 25 Nm.







6. Tighten to 25 Nm.
7. Reconnect the battery ground cable.
8. Carry out coolant system filling and bleeding procedure.
9. Carry out the air conditioning system evacuation and charging procedure.