Caliber 2007

Removal & Installation

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  1. Disconnect the negative battery cable.
  2.  
  3. Disable the air bag system.
  4.  
  5. Recover the refrigerant from the HVAC system.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove the heat shield located on the dash panel in the engine compartment.
  10.  
  11. Remove the bolt that secures the A/C liquid and suction line assembly to the A/C evaporator.
  12.  
  13. Disconnect the A/C liquid and suction line assembly from the A/C evaporator and remove and discard the dual-plane seals.

    Click image to see an enlarged view

    Fig. Remove the bolt (1) that holds the A/C liquid and suction lines (2) to the evaporator (3). Disconnect the heater hoses and cap the open core tubes.

  14.  
  15. Cap the opened refrigerant line fittings and the evaporator ports.
  16.  
  17. Disconnect the heater hoses from the heater core tubes. Install plugs in, or tape over the opened heater core tubes to prevent coolant spillage during housing removal.
  18.  
  19. Remove the instrument panel as follows:
    1. Remove the left and right end caps using a trim stick to pry them off.
    2.  
    3. Remove both left and right knee air bag covers, if equipped.
    4.  
    5. Remove the two screws attaching the upper steering column shroud to the lower shroud. After removing the screws, unclip the shrouds from each other by applying hand pressure along the seams where the shrouds connect on the sides, then remove the upper shroud and lower steering column cover.
    6.  
    7. Disconnect the steering column wiring harness.
    8.  
    9. Remove the shift knob and remove the shifter bezel.
    10.  
    11. Remove the center console shifter housing.
    12.  
    13. Remove the center bezel.
    14.  
    15. Remove the shifter assembly.
    16.  
    17. Remove the left and right A-pillar trim.
    18.  
    19. Remove the top cowl panel.

      Click image to see an enlarged view

      Fig. Use a trim stick to disengage the panel clip (2) to remove the top cowl panel (1) from the instrument panel (3)-Instrument panel removal

    20.  
    21. Remove the left cowl panel.
    22.  
    23. Disconnect the instrument panel wiring harness from the electrical connectors from behind the cowl panel.
    24.  
    25. Disconnect the wiring harness clipped along the A-pillar.
    26.  
    27. Remove the glove box.
    28.  
    29. Remove the right side cowl trim panel.
    30.  
    31. Disconnect the antenna wire from the radio harness.
    32.  
    33. Remove the mounting bolts and remove the front seats. Disconnect the electrical connectors before removal them from the vehicle.
    34.  
    35. Remove the center console.
    36.  
    37. Remove the left and right B-pillar trim panels.
    38.  
    39. Remove the left and right door sill scuff plate.
    40.  
    41. Pull back the carpet to gain access to the center console wiring harnesses.
    42.  
    43. Disconnect the instrument panel center console wiring harness.
    44.  
    45. Remove the left and right floor ducts.
    46.  
    47. Remove the four bolts behind the center bezel and one behind the glove box.
    48.  
    49. Remove the bolts holding the instrument panel to the cowl panel. Three bolts are located behind the left cap and one is at the bottom of the instrument panel.
    50.  
    51. Remove the condensation drain tube.
    52.  
    53. Remove the fence line bolts from the upper cowl panel.
    54.  
    55. Disconnect the HVAC wiring harness connectors.

      Click image to see an enlarged view

      Fig. Remove the fence line bolts (2) from the upper cowl panel (1)-Instrument panel removal

    56.  
    57. With the aid of an assistant, remove the instrument panel through the driver-s side door.
    58.  

  20.  
  21. Remove the nut that secures the passenger side of the HVAC housing to the dash panel.
  22.  
  23. Pull the HVAC housing rearward and remove the HVAC housing assembly from the passenger compartment.
  24.  
  25. Remove the foam seal from the flange located on the front of the HVAC housing.
  26.  
  27. Remove the screw that secures the flange to the front of the HVAC housing and remove the flange.
  28.  
  29. Remove the screw that secures the retaining bracket for the heater core tubes to the left side of the air distribution housing.
  30.  
  31. Carefully pull the heater core out of the driver-s side of the air distribution housing.

    Click image to see an enlarged view

    Fig. Heater core components-Foam seal (1), flange (2), screw (3), retaining bracket (4), air distribution housing (5), Heater core (6), heater core tubes (8), HVAC housing (9), screw (10)

  32.  

To install:

  1. Carefully install the heater core into the left side of the air distribution housing.
  2.  
  3. Install the retaining bracket that secures the heater core tubes. Tighten the screw to 10 inch lbs. (1.2 Nm).
  4.  
  5. Install the flange that secures the heater core tubes to the front of the HVAC housing.
  6.  
  7. Tighten the screw that secures the flange to the HVAC housing to 10 inch lbs. (1.2 Nm).
  8.  
  9. Install the foam seal onto the flange.
  10.  
  11. Installation is the reverse order of the removal process.
  12.  
  13. If the heater core was replaced, the cooling system must be flushed.
  14.  
  15. Charge the refrigerant system.
  16.  
  17. Refill the cooling system to the correct level.
  18.  
  19. Start the engine and check for leaks.
  20.  

 
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