Overhaul

DISASSEMBLY
1. Remove the heater and ventilation housings from the vehicle.
2. Place the heater housing in the upright position on a work bench, making allowance for leakage of fluids.

Heater Housing:

3. Remove the gasket located at the evaporator and heater core tubes and the gasket that seals the ventilation housing to the heater housing.
4. Remove the 12 screws that secure the two housing halves together.
5. Remove the heater housing cover from the heater housing.
6. Remove the heater core from the heater housing.
7. Remove the wire harness.
8. Remove the three heater core tube retaining bolts and the heater core tube assembly from the heater core.
9. Remove the heater core tube seals and discard.
10. Install plug in, or tape over the opened heater core fittings.
11. Remove the evaporator core from the heater housing.

ASSEMBLY
1. Install the evaporator core into the heater housing.
2. Remove the tape or plugs from the heater core fittings.
3. Lubricate two new rubber O-ring seals with clean engine coolant and install them onto the heater core fitting.
4. Connect the heater core tube assembly to the heater core and install the three retaining bolts. Tighten the bolts to 5 N.m (45 in. lbs.).
5. Install the wire harness.
6. Install the heater core into the heater housing.
7. Install the heater housing cover onto the heater housing.
8. Install the 12 screws that secure the two housing halves together. Tighten the screws to 2 N.m (17 in. lbs.).
9. Install the gasket for the evaporator and heater core tube outlets and the gasket that seals the ventilation housing to the heater housing.
10. Install the heater and ventilation housings.