Heater Core: Service and Repair

HEATER UNIT REMOVAL

1. Disconnect negative battery cable from battery.






2. Discharge refrigerant in refrigerant system.
3. Remove cooling unit.Service and Repair
4. Drain engine coolant from radiator and engine drain cocks.






5. Remove water hose from heater unit.
(a) Remove the clamp and the control cable from the water valve.
(b) Remove 2 bolts and the water valve.






(c) Remove the nut and 2 bolts and the EGR pipe.






(d) Grip the claws of the hose clip with pliers and slide the clip along the hose to a place where it does not clamp the hose to the pipe.
(e) Disconnect the water hose from the heater unit.






6. Remove Driver's seat and Passenger's seat













7. Remove instrument panel and console box duct.
8. Remove instrument panel brace and reinforcement.






9. Remove heater ducts ( Driver's and Passenger's seat)
(a) Remove 2 caps and 2 screws.






(b) Pull out the NO.5 air duct toward the rear.
(c) Remove the floor carpet.
(d) Remove the nut and pull out the air duct guide while lifting up the rear side.
(e) Remove the screw and the rear air duct.






10. Remove heater to register No. 3 duct.
(a) Remove the screw and the heater to register No.3 duct.







11. Remove wire harness. Remove the bolts, nuts and screws and the wire harness.






12. Remove heater unit.
(a) Remove 2 bolts and 2 nuts and the heater unit.





HEATER UNIT DISASSEMBLY






1. Remove air outlet damper control servomotor.






(a) Remove 3 screws and the air outlet damper servomotor.






2. Remove heater air duct.
(a) Remove 2 screws.
(b) Loosen 2 claws and remove heater air duct.






3. Remove air mix link cover.
(a) Remove 3 screws and the air mix link cover.






4. Remove max cool damper control servomotor.
(a) Remove the clamp and disconnect the shaft.
(b) Disconnect the connector.
(c) Remove 2 screws and the max cool damper control servomotor.






5. Remove air mix damper control servomotor
(a) Remove the clamp and the water valve control cable.
(b) Remove the clamp and disconnect the shaft.
(c) Remove 3 screws and the air mix damper control servomotor.






6. Remove water temperature sensor.
(a) Disconnect the connector.
(b) After pulling off the clamp, pull out the sensor.






7. Remove heater radiator (heater core) unit.
(a) Remove 5 screws and pipe clamps.
(b) Pull out the heater radiator unit with 2 heater return pipe.



HEATER UNIT ASSEMBLY


1. Install heater radiator (heater core) unit.
2. Install water temperature sensor.






3. Install air mix damper control servomotor
(a) Install the air mix damper control servomotor with 3 screws.
(b) Connect the shaft to the air mix damper control servo- motor.
(c) Connect the water valve control cable.






4. Install max cool damper control servomotor.
(a) Install the max cool damper control servomotor with 3 screws.
(b) Connect the shaft to the max cool damper control servomotor.
(c) Connect the connector.

5. Install air mix link cover.
8. Install heater air duct.






7. Install air outlet damper control servomotor
(a) Insert the bush of the air outlet damper control motor to the lever.






(b) Install the air outlet damper control servomotor with 3 screws.



HEATER UNIT INSTALLATION

Install by following the removal procedure in reverse order. Note the following:

1. Install heater unit
2. Install the cooling unit.
3. Connect water valve control cable
(a) Turn the ignition switch ON.
(b) Set the blower switch ON.






(c) Set the TEMP switch to Max Cool.
(d) Set the water valve lever on Max Cool. connect the water valve control cable on the white mark and lock the clamp.

Note: When the water valve control cable is installed, evacuate the air in the system and charge system with refrigerant.

Specified amount: 850 +/- 50 g (29.92 +/- 1.76 oz.)

After operations are completed, check for leakage of refrigerant and check the operation of the A/C.