Heater Core Case: Service and Repair

Auxiliary Heater Core and Evaporator Core Housing

Removal

WARNING: Since injury such as scalding could be caused by escaping steam or coolant, do not remove the filler cap from the coolant expansion tank while the system is hot.

CAUTION: Make sure that all openings are sealed. Use new blanking caps.
1 Disconnect the battery ground cable. For additional information, refer to Specifications
2 Evacuate the air conditioning (A/C) system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging - 5.0L NA V8 - AJ133/5.0L SC V8 - AJ133 Service and Repair
3
WARNING: Make sure to support the vehicle with axle stands.
Raise and support the vehicle.




4 Reposition the exhaust center heat shield.
- Remove the 8 nuts.




5 Clamp the auxiliary heater core coolant hoses.
- Clamp the hoses to minimize coolant loss.




6
WARNING: Since injury such as scalding could be caused by escaping steam or coolant, allow the vehicle cooling system to cool prior to carrying out this procedure.
CAUTION: Engine coolant will damage the paint finished surfaces. If spilt, immediately remove the coolant and clean the area with water.
NOTE:
Some fluid spillage is inevitable during this operation.
Disconnect the auxiliary heater core coolant hoses.
- Carefully release the 2 clips.
- Position a container to collect the fluid.
7 Remove the floor console. For additional information, refer to Floor Console




8 Disconnect the auxiliary heater core and evaporator core housing electrical connector.




9 Remove the auxiliary heater core inlet and outlet pipe brackets.
- Remove the 2 screws.





10
WARNING: Since injury such as scalding could be caused by escaping steam or coolant, allow the vehicle cooling system to cool prior to carrying out this procedure.
NOTE:
Some fluid spillage is inevitable during this operation.
Undo and remove the heater core inlet and outlet pipe clamps.
- Position a container to collect the fluid.
- Position an absorbent cloth to collect fluid spillage.
- Disconnect the heater core inlet and outlet pipes.
- Remove and discard the two O-ring seals.
- Install blanking caps to the exposed ports.





11
CAUTION: Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.
Disconnect the A/C pipes.
- Remove the 2 bolts.
- Discard the O-ring seals.





12
NOTE:
Left-hand shown, right-hand similar.
Remove the auxiliary heater core and evaporator core housing rear bolts.
- Remove the 2 bolts.





13 Remove the auxiliary heater core and evaporator core housing front RH bolt.





14 Remove the auxiliary heater core and evaporator core housing.
- Remove the auxiliary heater core and evaporator core housing front bolt.

Installation
1 Install the auxiliary heater core and evaporator core housing.
- Install the 4 auxiliary heater core and evaporator core housing bolts.
- Tighten to 4 Nm (3 lb.ft).
2 Connect the A/C pipes.
- Remove the blanking caps from the ports.
- Lubricate and install the new O-rings.
- Install the 2 bolts and tighten to 2 Nm (1.5 lb.ft).
3 Install the auxiliary heater core inlet and outlet pipe clamps.
- Remove the blanking caps from the ports.
- Lubricate and install the new O-ring seals.
- Connect the heater core inlet and outlet pipes.
- Remove the container.
- Remove the absorbent cloth.
4 Install the auxiliary heater core inlet and outlet pipe brackets.
- Install the 2 screws.
5 Connect the auxiliary heater core and evaporator core housing electrical connector.
6 Install the floor console. For additional information, refer to Floor Console
7 Connect the auxiliary heater core coolant hoses.
- Install the 2 clips.
- Remove the container.
8 Remove the coolant hose clamps.
9 Install the exhaust center heat shield.
- Reposition the exhaust center heat shield.
- Install the 8 nuts.

10 Recharge the A/C system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging - 5.0L NA V8 - AJ133/5.0L SC V8 - AJ133 Service and Repair

11 Connect the battery ground cable.For additional information, refer to Specifications

12 Check and top-up the coolant.

13 Start and run the engine.
- Hold the engine speed at 2,500 RPM for 30 seconds.
- Return the engine to idle for 30 seconds.
- Repeat the above procedure a further 4 times.

14 Switch on the auxiliary heater.
- Set the heater controls to HOT.
- Make sure the auxiliary heater is emitting hot air.

15 Switch the engine off and allow to cool.

16 Check and top-up the coolant.