Heater Core Case: Service and Repair

Heater/Air Distributor Case Assembly Removal and Installation

Heater/Air Distributor Case Assembly Removal

1. Disconnect the negative battery cable.
2. Remove the instrument panel carrier assembly. Refer to Instrument Panel Removal.
3. Drain the cooling system. Refer to Draining and Refilling the Cooling System.
4. Twist the vacuum hose connection and remove it from beside the heater hoses.
5. Compress the heater hose clamps at the fire wall and slide the clamps toward the engine.
6. Remove the two heater hoses from the core pipes at the fire wall.




7. Remove the screws that secure the to the fire wall on either side of the heater hoses.




8. Remove the screw from above the brake pipe on the engine compartment side of the fire wall.
9. Have an assistant support the from inside the vehicle.
10. Remove the screws from the connecting block mount on the engine compartment side of the fire wall. That will start to drop.

CAUTION: To avoid damaging the heater core pipes, move the straight away from the vehicle until the pipes are free from their openings in the fire wall.




11. Remove the heater/air distributor case assembly.

Heater/Air Distributor Case Assembly Installation

1. Position the heater/air distributor case assembly in the vehicle.

CAUTION: To avoid damaging the vehicle, make sure the heater core pipes do not contact the fire wall opening.

2. Slowly raise the heater/air distributor case assembly into position against the fire wall and hold it there while the screws are installed and tightened from the engine side of the fire wall.




3. Install the heater/air distributor case assembly screws at the connecting block mount on the engine compartment side of the fire wall.

Tighten:
Tighten the heater/air distributor case assembly screws to 8 N.m (71 lb.in).

4. Align and install the heater/air distributor case assembly screw above the fuel filter.

Tighten:
Tighten the heater/air distributor case assembly screw to 8 N.m (71 lb.in).




5. Replace the fuel filter into its mounting clamp.
6. Install the heater/air distributor case assembly screws on either side of the heater core pipes.

Tighten:
Tighten the heater/air distributor case assembly screws to 8 N.m (71 lb.in).

7. Install the two heater hoses.
8. Slide the heater hose clamps into position.




9. Install the vacuum hose.
10. Install the instrument panel carrier assembly. Refer to Instrument Panel Installation.
11. Fill the cooling system. Refer to Draining and Refilling the Cooling System.
12. Connect the negative battery cable.




13. Operate the controls to verify that the heating and ventilation systems function properly.