Heater Core Replacement - RHD

REMOVAL

WARNING:
- ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
- DO NOT OPEN THE RADIATOR DRAIN-COCK OR DISCONNECT COOLANT HOSES WHEN THE SYSTEM IS HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT CAN OCCUR.

1. Disconnect the negative battery cable.
2. Drain the cooling system.
3. Evacuate the refrigerant system.
4. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, Instrument Panel Assembly

Fig.17 Expansion Valve Position And Orientation:

5. Remove the refrigerant line retaining bolt from the expansion valve. Remove the refrigerant lines from the expansion valve.
6. Disconnect the electrical connector from the bottom of the expansion valve.
7. Remove the expansion valve retaining bolts and remove the valve from the vehicle.

Fig.18 Heater Core Coolant Supply Lines:

8. Remove the heater core coolant supply hoses from the heater core.
9. Working from inside the engine compartment, remove the A/C-Heater housing retaining fasteners from the bulkhead.
10. Remove the A/C-Heater housing drain tube. Remove the spring clip and pull the hose from the housing nipple.
11. Working from inside the vehicle, remove the defroster duct from the A/C-Heater housing and body attachment point.
12. Remove the A/C-Heater housing retaining bolts.
13. Disconnect the electrical connectors from the A/C-Heater housing.
14. Remove the A/C-Heater housing from the vehicle and place the assembly on a bench.
15. Remove the heater core cover from the housing assembly.
16. Remove the heater core coolant lines from the heater core.

Fig.19 Heater A/C Housing:

17. Remove the screws necessary to disassemble the A/C-Heater housing assembly.
18. Remove the heater core from the A/C-Heater housing.

INSTALLATION

Fig.20 Heater A/C Housing:

1. Install the heater core in the A/C-Heater housing.
2. Reassemble the A/C-Heater housing.
3. Install the housing in the vehicle and install the retaining bolts. Torque the bolts to 20 Nm (177 in. lbs.).
4. Connect the electrical connectors on the A/C- Heater housing.
5. Install the defroster duct on the A/C-Heater housing and secure at the body attachment point.
6. Install the A/C-Heater housing drain tube and retaining clip.
7. Install the A/C-Heater housing retaining fasteners. Torque the fasteners to 20 Nm (177 in. lbs.).

Fig.21 Heater Core Coolant Supply Lines:

8. Install the heater core coolant supply hoses on the heater core.
9. Install the expansion valve, gasket and retaining bolts. Torque the bolts to 11 Nm (97 in. lbs.).

Fig.22 Expansion Valve Position And Orientation:

10. Connect the electrical connector on the bottom of the expansion valve.

CAUTION: Be certain the refrigerant line sealing O-rings are well lubricated and free of tears.

11. Install the refrigerant lines and retaining bolt. Torque the bolt to 23 Nm (203 in. lbs.).
12. Install the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, Instrument Panel Assembly

13. Evacuate the refrigerant system.
14. Charge the refrigerant system.
15. Fill the cooling system .
16. Connect the negative battery cable.