Heater Core Case: Service and Repair

Heater Radiator Assy Part 1:

Heater Radiator Assy Part 2:

Instrument Panel/Meter Part 1:

Instrument Panel/Meter Part 2:

Instrument Panel/Meter Part 3:

HEATER RADIATOR ASSEMBLY

OVERHAUL
1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
2. DISCONNECT SUCTION HOSE SUB ASSEMBLY
SST 09870-00015
3. DISCONNECT LIQUID TUBE SUB ASSEMBLY A
SST 09870-00025




4. DISCONNECT HEATER WATER INLET HOSE A
a. Using pliers, grip the claw of the clip and slide the clip to disconnect the heater water inlet hose A.

5. DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)

HINT: Disconnect of the heater water outlet hose A (from heater unit) is the same way as the heater water inlet hose A.

6. REMOVE INSTRUMENT PANEL SUB ASSEMBLY W/PASSENGER AIRBAG ASSEMBLY

HINT: Refer to the instructions for removal of the instrument panel sub assembly w/passenger airbag assembly.

7. REMOVE INSTRUMENT PANEL SUB ASSEMBLY LOWER W/HEATER DUCT

HINT: Refer to the instructions for removal of the instrument panel sub assembly lower w/heater duct.

8. REMOVE ECM
9. REMOVE AIR CONDITIONING BLOWER ASSEMBLY
10. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY




11. REMOVE DEFROSTER NOZZLE ASSEMBLY
a. Remove the clip.
b. Disengage the 2 claws and remove the defroster nozzle assembly




12. REMOVE INSTRUMENT PANEL BRACE SUB ASSEMBLY NO.1
a. Disconnect the wire harness.
b. Remove the 4 bolts, the nut and instrument panel brace sub assembly No.1.




13. REMOVE DEFROSTER DAMPER CONTROL CABLE SUB ASSEMBLY
a. Disconnect the outer cable.
b. Disconnect the inner cable and remove the defroster damper control cable sub assembly.




14. REMOVE AIRMIX DAMPER CONTROL CABLE SUB ASSEMBLY
a. Disconnect the outer cable.
b. Disconnect the inner cable and remove the airmix damper control cable sub assembly.




15. DISCONNECT AIR DUCT REAR NO.2
a. Disconnect the air duct rear No.2.

16. DISCONNECT AIR DUCT REAR NO.1

HINT: Disconnection of the air duct rear No.1 is the same as that of the air duct rear No.2.
17. REMOVE HEATER RADIATOR ASSEMBLY
a. Disconnect the 3 connectors.




b. Remove the bolt and separate the earth bolt from the PTC heater.



c. Remove the 2 nuts and the heater radiator assembly.




18. REMOVE AIR DUCT ASSEMBLY
a. Disengage the 4 claws and remove the air duct assembly.




19. REMOVE HEATER COVER
a. Remove the screw.
b. Disengage the 2 claws and remove the heater cover.




20. REMOVE THERMISTOR ASSEMBLY
a. Disengage the claw and remove the clamp.
b. Remove the thermistor assembly.

21. REMOVE HEATER RADIATOR UNIT SUB ASSEMBLY




a. Remove the 5 screws and the cooler wiring No.2.




b. Remove the screw and the bracket.
c. Disengage the clamp and disconnect the connector.
d. Remove the heater radiator unit sub assembly.




22. INSTALL DEFROSTER DAMPER CONTROL CABLE SUB ASSEMBLY
a. Set the arm in the FACE position in.
b. Install the inner cable end to the control lever with the arm in the FACE position.
c. Install the outer cable in the cable clamp while slightly pressing it in the direction of the arrow.

NOTE:
- Be careful not to bend the cable wire.
- If the cable wire bends, the heater control & accessory assembly operation may be affected.

HINT: Operating the mode control lever, check that it properly stops at both ends of FACE and DEF and no recoil is identified.




23. INSTALL AIRMIX DAMPER CONTROL CABLE SUB ASSEMBLY
a. Set the arm in the MAX.COOL position.
b. Install the inner cable end in the control lever with the arm in the MAX.COOL position.
c. Install the outer cable in the cable clamp while slightly pressing it in the direction of the arrow.

NOTE:
- Be careful not to bend the cable wire.
- If the cable wire bends, the heater or control & accessory assembly operation may be affected.

HINT: When operating the mode control lever, check that it properly stops at both ends of MAX.COOL and MAX.HOT and no recoil is identified.

24. INSTALL ECM
25. INSTALL INSTRUMENT PANEL SUB ASSEMBLY LOWER W/HEATER DUCT
26. INSTALL INSTRUMENT PANEL SUB ASSEMBLY W/PASSENGER AIRBAG ASSEMBLY
27. INSTALL LIQUID TUBE SUB ASSEMBLY A
28. INSTALL SUCTION HOSE SUB ASSEMBLY
29. ADD COOLANT
30. CHARGE REFRIGERANT
SST 07110- 58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117- 78050, 07117-88060, 07117-88070, 07117-88080)

Specified amount: 460 ± 30 g (16.2 ± 1.1 oz.)

31. WARM UP ENGINE
32. CHECK FOR ENGINE COOLANT LEAKS
33. INSPECT LEAKAGE OF REFRIGERANT