Heater/Evaporator Box Removal and Installation

Heater Box and Evaporator Housing, Removing and Installing

CAUTION: Before disconnecting the battery, determine the correct Coding for the anti-theft radio.






- Disconnect battery Ground strap.
- Discharge A/C refrigerant system.
- Remove instrument panel and center console. Refer to Body and Frame/Interior Trim/Dash Board/Service and Repair Service and Repair

- Relieve cooling system pressure at coolant reservoir cap.

WARNING: The cooling system is pressurized when the engine is warm. Wear gloves and other appropriate protection, and slowly and carefully release system pressure, if necessary before performing repairs.

- Clamp coolant hoses using clamp Snap-On YA 2850 or equivalent.






- Remove heater hoses -A- and -B-.
- Arrow -A-: Hose outlet from heater core to water pump
- Arrow -B-: Hose inlet to heater core from cylinder head
- Plug all open hose connections to prevent dirt contamination

NOTE: When adding or refilling coolant, loosen vent screw -C- to bleed air from cooling system. Close vent screw when coolant flows from vent.






- Disconnect refrigerant lines from evaporator and plug all open line connections. Refer to Heating and Air Conditioning, Hose/Line HVAC, Service and Repair Service and Repair
- Remove right-side plenum tray.
- Remove grill from fresh air intake duct.
- Remove outside (ambient) temperature sensor -B- (where applicable).
- Remove two mounting screws (arrows -A-).
- Remove fresh air intake duct.

NOTE: When installing fresh air intake duct, make sure seal is installed correctly.






- Remove two nuts -A- from bulkhead.
- Disconnect vacuum hose from two-way valve.
- Disconnect evaporator water drain hose.

NOTE: When installing heater box and evaporator housing assembly, make sure grommet -B- is installed correctly and seals properly against bulkhead and heater core tubes.






- Remove control module -A- in direction of arrow.
- Remove heater box and evaporator housing assembly.

NOTE: Before installing heater box and evaporator housing assembly on vehicles equipped with manual A/C, check for ease of movement of bowden cables. Replace any damaged or binding cables.

- Install heater box and evaporator housing assembly in reverse order of removal.