Procedures

Heating And A/C Unit, Removing/Assembly







CAUTION:
Before beginning repairs:
- Switch off all electrical consumers.
- Switch off ignition.
- Remove ignition key from ignition switch.

NOTE:
- Before carrying out any work on the A/C refrigerant system, refer to A/C refrigerant system safety measures.
- Heating and A/C unit must only be removed after discharging refrigerant system. Use Kent Moore ACR4 or equivalent.
- O-rings used on R-134a systems may be red, green, violet or black.
- Always plug open refrigerant line connections to prevent dirt and moisture contamination.

Assembly
1. Heater core
- Always replace coolant after removal/replacement
- Access release tabs for heater core after partially removing heating and A/C unit.
2. Housing, upper part
- With fresh air and recirculating air flaps
3. Evaporator seal
- Installing see Fig. 1
4. Evaporator
- Evaporator inlet/outlet seal, installing see Fig. 2
5. Housing, lower part

Removing
- Discharge refrigerant system
- Drain engine coolant.

CAUTION: The cooling system is pressurized when the engine is warm. Wear gloves and other protection and carefully release system pressure if necessary, before performing repairs.

- Remove instrument panel.
- Loosen instrument panel cross member
- Remove and clamp off coolant hoses to heater core in engine compartment at bulkhead.
- Seal off heater core inlet/outlet to prevent coolant from running out.
- Locate and remove fasteners for heating and A/C unit in engine compartment at bulkhead.
- Remove heating and A/C unit.

Fig. 1 Evaporator seal, installing







- Glue foam seal -B- around circumference of evaporator -A-.
- To allow evaporator water to drain, do not attach foam seal on evaporator in area -C-.

Fig. 2 Evaporator inlet/outlet seal, installing







- Insert seal -A- for refrigerant lines -C- in between housing halves -B-.