Heater Core and Evaporator Core Housing

Heater/Cooler Assembly

Removal
1. Disconnect battery ground cable.
2. Recover refrigerant from air conditioning system Service and Repair
3. Drain radiator coolant only.
4. Remove instrument panel for access.






5. From under the hood: Disconnect air conditioning pipes at the evaporator.
1. Remove bolts.
2. Discard O-rings.
3. Install suitable blanking plugs.







6. Disconnect heater hoses from heater matrix pipes.
1. Release spring band clips and disconnect heater hoses.
2. Install suitable blanking plugs.







7. From inside the vehicle: remove driver footwell duct.
- Remove screw.
- Remove duct.







8. Remove upper steering column lower fixings.
1. Remove nut.
2. Remove bolt.







9. Remove upper steering column upper fixings.
1. Remove bolts.
- Allow column to rest on the floor







10. Cut cable tie which secures console harness to LH blower duct.







11. Remove LH fan motor duct.
- Remove screws.
- Remove duct.







12. Remove passenger side footwell vent.
- Remove nut.
- Remove vent.







13. Cut cable tie which secures console harness to RH blower duct.







14. Remove RH fan motor duct.
- Remove screws.
- Remove duct.







15. Disconnect heater/cooler assembly electrical connector.







16. Disconnect condensate drain tubes from heater/cooler assembly.







17. Disconnect A/CCM connectors.







18. Remove evaporator pipe support bracket fixing.







19. Remove heater/cooler assembly fixings.
1. Remove lower nut.
2. Remove upper nuts.







20. Remove tape securing RH rear footwell intermediate duct to rear duct joint.
- Displace duct to clear heater/cooler assembly.







21. Remove tape securing LH rear footwell intermediate duct to rear duct joint.
- Displace duct to clear heater/cooler assembly.







22. Remove heater/cooler assembly from vehicle.
- Guide matrix heater pipe stubs through firewall grommet and remove assembly.

Installation







1. Install heater/cooler assembly into vehicle.
- Guide matrix heater pipe stubs through firewall grommet.
- Position heater/cooler assembly against firewall.







2. Install heater/cooler assembly fixings.
- Install upper fixing nuts.
- Install lower fixing nut.







3. Install evaporator pipe support bracket fixing.







4. Position RH rear footwell intermediate duct to rear duct.
- Secure with suitable cloth tape.







5. Connect condensate drain tubes from heater/cooler assembly.







6. Connect A/CCM connectors.







7. Position LH rear footwell intermediate duct to rear duct.
- Secure with suitable cloth tape.







8. Connect heater/cooler assembly electrical connector.







9. Install LH fan motor duct.
- install duct.
- Install screws.







10. Install cable tie to secure console harness to LH blower duct.







11. Install RH fan motor duct.
- Install duct.
- Install screws.







12. Install cable tie to secure console harness to RH blower duct.







13. Install passenger side footwell vent.
- Install vent.
- Install nut.







14. Install driver footwell duct.
- Install duct.
- Install screw.







15. Position upper steering column and install upper fixings.
1. Install bolts, do not tighten.







16. Install upper steering column lower fixings.
- Tighten fixings.







17. Tighten upper fixing bolts.







18. Under hood: reconnect heater hoses to heater matrix pipes.
- Remove blanking plugs.
- Reconnect heater hoses and secure with spring band clips.







19. Reconnect air conditioning pipes at the evaporator.
- Remove blanking plugs.
- Install, fully seat and lubricate new O-ring seals.
- Install bolts
20. Install instrument panel.
21. Recharge air conditioning system Service and Repair
22. Re-fill cooling system.
23. Reconnect battery ground cable.