Heater Core Case: Service and Repair

COMPONENTS

REMOVAL
1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM

INSTALLATION HINT: Evacuate air from refrigeration system.

Charge system with refrigerant and inspect for leakage of refrigerant.
Specified amount:
800 ± 50 g (28.22 ± 1.76 oz.)




2. DRAIN ENGINE COOLANT FROM RADIATOR REMOVAL

REMOVAL HINT: It is not necessary to drain out all the coolant.

3. DISCONNECT WATER VALVE CONTROL CABLE FROM WATER VALVE

INSTALLATION HINT: For installing the control cable, Heater Control Valve




4. DISCONNECT WATER HOSES FROM HEATER RADIATOR PIPES

INSTALLATION HINT:
^ Push the water hose onto the heater radiator pipe as far as the second ridge the on the pipe and install the hose clip.
^ Install the hose clip in a position, as shown in the illustration.

5. REMOVE THESE PARTS:
a. Blower unit Blower Motor
b. Instrument panel and reinforcement




6. DISCONNECT LIQUID AND SUCTION TUBES
Remove the bolt and slide the plate, then disconnect both tubes.
Torque: 10 Nm (100 kg.cm, 7 ft.lb)

REMOVAL NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system.

INSTALLATION HINT: Lubricate 2 new O-rings with compressor oil and install the tubes.




7. REMOVE A/C UNIT
a. Slide the floor carpet backward.
b. Remove the rear heater ducts.
c. Disconnect the connectors.
d. Remove the 2 nuts and A/C unit.

DISASSEMBLY

1. REMOVE THESE PARTS:
a. Side air duct LH, RH
b. Foot air duct LH, RH

2. REMOVE EVAPORATOR TEMP. SENSOR
Remove the screws and pull out the sensor.

3. REMOVE EVAPORATOR
a. Remove the 6 screws and evaporator cover.

REASSEMBLY HINT: Do not reuse the evaporator cover.

b. Pull out the evaporator.

REASSEMBLY HINT: If evaporator was replaced, add compressor oil to compressor.

Add 40 cc (1.4 fl.oz.)
Compressor oil:
ND-OIL 8 or equivalent

4. REMOVE EXPANSION VALVE
Using a hexagon wrench, remove the 2 bolts and separate the evaporator and expansion valve.
Torque: 5.4 Nm (55 kg.cm, 48 in.lb)

REASSEMBLY HINT: Lubricate 4 new O-rings with compressor oil and install the tubes.

5. REMOVE AIR MIX SERVOMOTOR
a. Remove the 3 screws and servomotor.
b. Remove the water valve control cable from the servomotor.

6. REMOVE AIR OUTLET SERVOMOTOR
Remove the 2 screws and servomotor.

7. REMOVE HEATER RADIATOR
a. Release the 3 claws and remove the heater protector.
b. Remove the 2 screws and 2 clamps, then pull out the heater radiator.
c. Remove the 2 screws, 2 clamps and heater radiator pipes from the heater radiator.

8. REMOVE BLOWER RESISTOR
a. Disconnect the connector.
b. Remove the 2 screws and blower resistor.

9. REMOVE BLOWER MOTOR LINEAR CONTROLLER
a. Disconnect the connector.
b. Remove the 2 screws and blower motor linear controller.

10. REMOVE WIRE HARNESS
Release the claw and remove the wire harness.

REASSEMBLY
Reassembly is in the reverse order of disassembly.

INSTALLATION
Installation is in the reverse order of removal.