Isuzu_Rodeo_Rodeo_Sport_1997-2004

Heater Core

Print

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. If equipped with an air bag, perform the following procedure:
    1. Turn the ignition to the LOCK position and remove the key.
    2.  
    3. From the lower left dash side fuse block, remove the SRS-1 fuse.
    4.  
    5. Disconnect the 2-pin yellow connector located at the base of the steering column.
    6.  
    7. Remove the glove box assembly.
    8.  
    9. Disconnect the 2-pin yellow connector located behind the glove box.
    10.  

  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. If equipped, discharge and recover the air conditioning system refrigerant.
  8.  
  9. Remove the evaporator lines at the firewall. Plug the air conditioning lines to minimize contamination.
  10.  
  11. Disconnect the cooling system hoses and drain the coolant into a clean container for reuse. Plug the cooling system hoses.
  12.  
  13. Remove the instrument panel by performing the following procedure:
    1. Remove the lower center cover screw and pull it out at the clip positions; then, disconnect the cigarette lighter connector.
    2.  
    3. Remove both the rear and front console.
    4.  
    5. Remove the dash side trim panel sill plates and the panels.
    6.  
    7. Remove the 2 glove box screws and the glove box.
    8.  
    9. Remove the 2 hood release screws, the 6 instrument panel driver-s lower cover assembly screws and the cover assembly.
    10.  
    11. Remove 5 instrument cluster screws and the 2 clips. Then, disconnect the 8 switch connectors and remove the instrument cluster assembly.
    12.  
    13. Remove the 6 driver-s knee bolster assembly bolts and screws and the knee bolster assembly.
    14.  
    15. Remove the 4 control lever assembly bolts; then, disconnect the 3 control cables (unit side) and the 3 harness connectors.
    16.  
    17. Remove the 4 radio/audio sub box assembly screws and the radio/audio sub box assembly.
    18.  
    19. Disconnect or remove the following instrument panel harness connectors or items:

      The 6 driver-s side connectors
       
      The 3 passenger-s side connectors
       
      The 2 center connectors
       
      Passenger-s inflator module connector
       
      Radio antenna cable plug
       
      Ground cable bolt on the left dash side panel
       
      The 8 instrument panel-to-chassis bolts and the 3 nuts.
       

    20.  
    21. Remove the instrument panel assembly.
    22.  

  14.  
  15. Remove the instrument panel bracket by performing the following procedure:
    1. Remove the 2 passenger-s inflator module bolts and 4 nuts.
    2.  
    3. Remove the 4 meter assembly screws. Then, disconnect the meter wiring harness connectors and remove the meter assembly.
    4.  
    5. Remove the 5 vent duct assembly screws and the assembly.
    6.  
    7. Remove the 3 lower passenger bracket screws and the bracket.
    8.  
    9. Remove the 9 passenger knee bolster reinforcement screws and the reinforcement.
    10.  
    11. Remove the 6 instrument panel center reinforcement screws and the reinforcement.
    12.  
    13. Remove the instrument panel wiring harness assembly clips and the wiring harness.
    14.  
    15. Remove the 2 instrument panel bracket nuts and 2 bolts for each bracket; then, remove the bracket(s).
    16.  

  16.  
  17. Remove the 5 cross beam assembly nuts, 2 bolts and the 6 lower bolts; then, remove the crossbeam.
  18.  
  19. Disconnect the resistor wiring connector.
  20.  
  21. Remove the duct from the heater assembly.
  22.  
  23. If equipped with air conditioning, remove the evaporator assembly.
  24.  
  25. Remove the driver-s lap vent.
  26.  
  27. Remove the lower ventilation duct.
  28.  
  29. Remove the footrest, the carpet, the 3 clips and the rear heater duct.
  30.  
  31. Remove the heater assembly.
  32.  
  33. Remove the mode control case-to-temperature control case screws and remove the mode control case; do not remove the link unit.
  34.  
  35. Remove the temperature control case screws and separate the cases.
  36.  
  37. Remove the heater core from the case.

    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel



    Click image to see an enlarged view

    Fig. View of the heater and air conditioning housing assemblies and related components



    Click image to see an enlarged view

    Fig. Exploded view of the heater housing assembly

  38.  

To install:

  1. Install the heater core to the case.
  2.  
  3. Assemble the temperature control cases and install the case screws.
  4.  
  5. Install the mode control case and the mode control case-to-temperature control case screws.
  6.  
  7. Install the heater assembly.
  8.  
  9. Install the rear heater duct, the footrest, the carpet, and the 3 clips.
  10.  
  11. Install the lower ventilation duct.
  12.  
  13. Install the driver-s lap vent.
  14.  
  15. If equipped with air conditioning, install the evaporator assembly.
  16.  
  17. Install the duct to the heater assembly.
  18.  
  19. Connect the resistor wiring connector.
  20.  
  21. Install the crossbeam, the 5 crossbeam assembly nuts, 2 bolts and the 6 lower bolts.
  22.  
  23. Install the instrument panel bracket by performing the following procedure:
    1. Install the instrument panel bracket and the 2 nuts and 2 bolts for each bracket.
    2.  
    3. Install the instrument panel wiring harness assembly and the wiring harness clips.
    4.  
    5. Install the instrument panel center reinforcement and the 6 reinforcement screws.
    6.  
    7. Install the passenger knee bolster reinforcement and the 9 reinforcement screws.
    8.  
    9. Install the lower passenger bracket and the 3 bracket screws.
    10.  
    11. Install the vent duct assembly and the 5 vent duct assembly screws.
    12.  
    13. Install the meter assembly and the 4 meter assembly screws. Then, connect the meter wiring harness connectors.
    14.  
    15. Install the 2 passenger-s inflator module bolts and 4 nuts.
    16.  

  24.  
  25. Install the instrument panel by performing the following procedure:
    1. Install the instrument panel assembly.
    2.  
    3. Connect or install the following instrument panel harness connectors or items:

      The 6 driver-s side connectors
       
      The 3 passenger-s side connectors
       
      The 2 center connectors
       
      Passenger-s inflator module connector
       
      Radio antenna cable plug
       
      Ground cable bolt on the left dash side panel
       
      The 8 instrument panel-to-chassis bolts and the 3 nuts.
       

    4.  
    5. Install the radio/audio sub box assembly and the 4 radio/audio sub box assembly screws.
    6.  
    7. Connect the 3 control cables (unit side) and the 3 harness connectors. Install the 4 control lever assembly bolts.
    8.  
    9. Install the knee bolster assembly and the 6 driver-s knee bolster assembly bolts and screws.
    10.  
    11. Install the instrument cluster assembly. Connect the 8 switch connectors. Install 5 instrument cluster screws and the 2 clips.
    12.  
    13. Install the 2 hood release screws, the 6 instrument panel driver-s lower cover assembly screws and the cover assembly.
    14.  
    15. Install the glove box and the 2 glove box screws.
    16.  
    17. Install the dash side trim panel sill plates and the panels.
    18.  
    19. Install both the rear and front console.
    20.  
    21. Connect the cigarette lighter connector and install the lower center cover screw.
    22.  

  26.  
  27. Connect the cooling system hoses.
  28.  
  29. Refill the cooling system.
  30.  
  31. Install the evaporator lines at the firewall.
  32.  
  33. If equipped, evacuate and charge the air conditioning system.
  34.  
  35. Connect the negative battery cable.
  36.  
  37. If equipped with an air bag, perform the following procedure:
    1. Turn the ignition to the LOCK position and remove the key.
    2.  
    3. Connect the 2-pin yellow connector located behind the glove box.
    4.  
    5. Install the glove box assembly.
    6.  
    7. Connect the 2-pin yellow connector located at the base of the steering column.
    8.  
    9. At the lower left dash side fuse block, install the SRS-1 fuse.
    10.  
    11. Turn the ignition switch to ON and verify that the AIR BAG warning light flashes 7 times and turns OFF.
    12.  

  38.  
  39. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  40.  

Rodeo
 
label.common.footer.alt.autozoneLogo