Heater Core Case: Service and Repair

Heating and A/C unit, removing and installing

CAUTION!
Before beginning repairs on the electrical system:
Obtain the anti-theft radio security code.
Switch off all electrical consumers.
Switch ignition off and remove ignition key.
Disconnect negative ( - ) battery terminal.
When disconnecting and reconnecting battery terminals, observe all applicable notes and torque specifications, as well as instructions on performing OBD program and electrical system function checks as specified Repair Manual

Notes:
Before carrying out any work on the A/C refrigerant system, refer to all CAUTIONS and WARNINGS in A/C refrigerant system safety measures
Service refrigerant system using Kent More ACR 4 or equivalent
During servicing, all couplings, fittings and related fasteners must be torqued to specifications.






1 - Heating and A/C unit Contains:
Heater core
Evaporator

Removing

- Discharge refrigerant system. Refer to Heating and Air Conditioning - Service and Repair - Procedures Service and Repair
- Drain engine coolant engine. Refer to Engine, Cooling and Exhaust - Cooling System - Service and Repair - Procedures
- Remove instrument panel. Service and Repair
- Remove coolant hoses at heater core Fig. 1.
- Seal off inlet and outlet at heater core to prevent coolant from escaping.
- Remove refrigerant lines at evaporator Fig. 2.
- Remove Heating and A/C unit mounting screws -2- and -3-.
- Remove footwell vent assembly -6-.
- Remove support -5-.
- Disconnect all electrical connections and wiring harness tie straps at heating and A/C unit.
- Carefully pull out and remove complete housing - 1 - from vehicle.
- Loosen instrument panel cross member -4- if necessary.

2 - Mounting screws 12 Nm
3 - Mounting screw 3.5 Nm

4 - Instrument panel cross member
Always follow installation instructions for bolt.

5 - Support
6 - Footwell vent assembly

Assembly

- Refer to Heater Core - Service and Repair - Procedures

Installing

- Install in reverse order of removal, noting the following:

Notes:
Inspect all heating and A/C unit housing seals for damage and replace if necessary before installation. Evaporator inlet/outlet seal, Fig. 2 Evaporator seal, Fig. 3.
Ensure all electrical harness tie straps are replaced and installed in their original locations.
Replace both evaporator inlet/outlet O-rings.
Ensure refrigerant pipes are reinstalled stress free.
Ensure evaporator water drain and drain valve are installed and function properly, Fig. 1.

Fig. 1 Coolant hoses at heater core, removing






- Note Installation orientation of coolant hoses -A- (inlet and outlet) in engine compartment.
- Clamp off both coolant hoses to heater core using 3094 hose clamps (or equivalent).
- Release both coolant hose clamps using suitable pliers and pull hoses off from heater core inlet and outlet.

Fig. 2 Refrigerant lines at evaporator, removing






- Remove screw -3- (15 Nm).
- Gently rock flange with refrigerant lines -2- up and down until they release from evaporator.

CAUTION! Immediately plug open connections on A/C components and lines to prevent dirt and moisture contamination.

Note: Always replace both O-rings -1-.