REMOVAL & INSTALLATION
See Figures 1 and 2
The heater housing must be removed from the vehicle to service the heater core. This is a lengthy and time-consuming procedure requiring the removal of a number of interior trim pieces. Use care when working with plastic trim pieces. Most are held in place with clips of several different types. Use care not to break trim pieces during service. The air conditioning system must be discharged and the refrigerant recovered and recycled using the appropriate equipment. A DRB III scan tool or equivalent is required when performing this procedure.
- Disconnect negative battery cable. Disarm the air bag system using the recommended procedure.
- Have a qualified technician discharge the R-134A refrigerant from the air conditioning system.
- Remove the air cleaner hose and the air distribution duct from the engine.
- Place a drain pan under the radiator. Open the radiator drain cock located at the lower right side of the radiator. Do NOT use pliers to open the plastic drain fitting. Drain the cooling system.
- Disconnect the heater hoses at the dash panel. Plug the heater core inlet and outlet tubes to keep coolant from leaking inside of the vehicle during removal. If an appropriate plug cannot be found, pull back the carpet and use caution when removing the unit.
- Remove both air conditioning lines from the expansion valve, using tool 7193 or equivalent, to disengage the quick-connectors at the air conditioning lines. After removing the lines, cap (rubber plugs, duct tape, etc.) the expansion valve openings to prevent system contamination.
The lubricant used in this air conditioning system absorbs moisture readily. Do not leave any portion of the system open to the atmosphere for any extended period of time.
- Remove the instrument panel. Refer to Body & Trim .
- Remove the three attaching bolts which holds the heater housing to the dash panel. Carefully roll the heater housing out of the vehicle.
- Remove the drain tube from the heater housing. It will later be installed from underneath the vehicle after the heater housing is reinstalled.
- With the heater housing out of the vehicle, pull the heater core retainer clips back and pull the heater core from the case.
- Install the heater core into the housing and install the retainer brackets. Secure using the screws supplied with the new heater core.
- Install the housing into the vehicle and secure using the three attaching bolts. Install the heater housing drain tube to the heater housing from underneath the vehicle.
- Install the instrument panel. Refer to Body & Trim .
- Install both air conditioning lines to the expansion valve using new O-rings at the connections.
The O-rings used in this system are made of a special type of rubber that is not affected by R-134A refrigerant or the special oil used with R-134A. Do not substitute an O-ring not manufactured for R-134A refrigerant type system or leakage will occur within a short period of time.
- Reconnect the heater hoses at the dash panel and refill the cooling system.
- Install the air cleaner hose and the air distribution duct to the engine.
- Enable the air bag system.
- Connect the negative battery cable. Evacuate and charge the refrigerant system.
- Add coolant as required and bleed the cooling system.
- Start and warm the engine to check heater system operation.