With A/C

CAUTION: Always disconnect the battery ground (GND) strap before working on the electrical system.

NOTE: Before disconnecting battery, obtain radio code for radios with antitheft coding.

Evaporator/Heater Housing Assembly





Note: A/C system must be discharged before removing components marked with an asterisk (*)

1 Heater, A/C fuse (S 23)
2 A/C relay (J 32)
3 Seal *
4 Heater core *
- install seals around perimeter of heater core so there are no gaps
- if heater core does not lock into place during installation, fasten to heater box using screws through the tabs on top of the heater core.
- after removing heater core, drain entire cooling system and refill with new coolant.
5 Connecting duct
- with seal
6 Evaporator housing *
- with evaporator
7 Air intake *
- with fresh air/recirculating flap
8 Fresh Air Blower Series Resistance (N 24)
9 Fresh air/recirculating flap vacuum servo *
10 Fresh air blower switch (E 9)
11 A/C switch (E 35) with A/C indicator light (K 84)
12 Vacuum hose *
- vacuum hose layout, refer to Heating and Air Conditioning, Vacuum and Vapor Hose Diagrams. Vacuum and Vapor Hose Diagrams
13 Fresh air blower (V 2)
14 A/C evaporator temperature switch (E 33)
- prevents evaporator from icing up
- switch opens (compressor OFF): below -2°C (28°F)
- located behind cover -15-
- insert sensor tube of temperature switch into evaporator 330 mm (13.0 in.)
15 Evaporator housing cover
- to remove: first remove instrument panel and footwell air outlets -30-
16 Retaining strap
- to remove: first remove instrument panel and footwell air outlets -30-
17 Right air duct
18 Air distribution duct
- to remove: first remove center console, instrument panel bracket, A/C (ventilation) control head -29-, center vent -20- and shelf below glove compartment
19 Instrument panel
20 Center vent
21 Left vent
22 Rear footwell air duct
- to remove: first remove center console, instrument panel bracket, pedal cover -32-, footwell air outlet -30-, front seats and carpeting
23 Seal
24 Left air duct
25 Trim plate for A/C (ventilation) control head
26 A/C cut-off control module (J 314)
- only on vehicles equipped with ECO-diesel engine (Canada only)
- located behind center console
- relay housing stamped with production control number 129
27 A/C clutch cut-off relay (J 246)
- only on vehicles equipped with automatic transmission
- located behind center console
- relay housing stamped with production control number 135
28 A/C time delay relay (J 70)
- only on vehicles equipped with 2.0L, 4-cylinder gas engine (code 9A)
- located behind center console
- relay housing stamped with production control number 35
29 A/C (ventilation) control head
- with A/C switch (E 35)
- removing/installing, refer to Heating and Air Conditioning, Control Assembly.
30 Footwell air outlets
- to remove: first remove center console, instrument panel bracket, and pedal cover -32-
31 Control cables
- to remove: first remove pedal cover -32- and footwell air outlets -30-
- installing/adjusting, refer to Air Door Cable. Service and Repair
32 Pedal cover
33 Central flap *
- in heater (air distribution) box -35-
34 Footwell/defroster flap *
- in heater (air distribution) box -35-
35 Heater (air distribution) box *
- with temperature flap
- with central flap
- with footwell/defroster flap
- do not disassemble further
36 Vacuum hose connection *

Removal

- Discharge AC system
- Disconnect the battery ground cable
- Remove instrument panel
- DIsconnect shift lock cable, if equipped
- Remove passenger side instrument panel support bracket
- Disconnect AC refrigerant hoses from the expansion valve.
Cover hose ends and expansion valve fittings to prevent debris from entering AC system
- Drain engine coolant completely
- Disconnect heater hoses from heater core
- Remove housing securing nuts on firewall in engine compartment
- Remove air distribution and evaporator housing with controls and cables attached.
Use care not to kink or bend cables
Use care to prevent spilling engine coolant in car interior

Installation Notes
- Replace gaskets between housing and body
- Do not bend or kink control cables
- Do not reuse old engine coolant