Subaru ff-1/1300/1400/1600/1800/Brat 1970-1984 Repair Guide

Heater Assembly

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REMOVAL & INSTALLATION



1972-73 GL and DL Models

CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

The blower motor and the heater core are located in the heater unit. In order to service either of these components, the heater unit must be removed from the vehicle. In order to remove the heater unit from the vehicle, the entire instrument panel has to be removed.

  1. Disconnect the negative (-) terminal of the battery.
  2.  
  3. Unscrew the nuts which retain the instrument panel to the body at both ends.
  4.  
  5. Remove the screws which hold the upper panel face of the instrument panel to the body bracket which is attached to the firewall.
  6.  
  7. Remove the bolts which retain the steering bracket and the steering shaft.
  8.  
  9. Loosen the nuts which hold the lower side of the instrument panel to the steering bracket.
  10.  
  11. Disconnect the defroster hoses.
  12.  
  13. Disconnect the heater control rod and wiring harness.
  14.  
  15. Disconnect and tag the following wiring and cables:
  16.  
    1. Remove the speedometer cable hanger spring.
    2.  
    3. Disconnect the speedometer cable from the speedometer.
    4.  
    5. Disengage all of the electrical wiring connected to the instrument panel.
    6.  
    7. Disconnect the antenna lead.
    8.  

  17. Remove the instrument panel from the vehicle being careful of interference between the side end of the instrument panel and the front pillars.
  18.  
  19. Drain the coolant from the radiator.
  20.  
  21. Disconnect the heater hoses on the engine side, both the inlet and the outlet hoses.
  22.  
  23. Remove the console by removing the six attaching screws.
  24.  
  25. Disconnect the heater control assembly and the heater unit by disengaging the room shutter cable and the two air inlet control rods.
  26.  
  27. Disconnect the wiring harnesses of the fan motor, the main harness, and the motor control switch wirings.
  28.  
  29. Remove the heater unit mounting bolts.
  30.  
  31. Lift the assembly to the side being careful of the stopper at the bottom of the unit.
  32.  
  33. Remove the grommet on the firewall at this time.
  34.  
  35. Remove the unit assembly.
  36.  
  37. Remove the blower fan motor, and the heater core.
  38.  

To install:

  1. Install the blower fan motor and heater core, then secure the unit with the mounting bolts.
  2.  
  3. Connect the motor control switch wiring, the main harness and the fan motor harness.
  4.  
  5. Install the air inlet control rods, and the room shutter cable to the heater unit, then connect the heater control assembly.
  6.  
  7. Install the console and tighten the six attaching screws securely.
  8.  
  9. Install the heater hoses.
  10.  
  11. Install the instrument panel and front pillars.
  12.  
  13. Engage the antenna lead and all electrical wiring connected to the instrument panel.
  14.  
  15. Connect the heater control rod and wiring harness.
  16.  
  17. Install the upper panel face to the instrument panel.
  18.  
  19. Install the steering bracket and shaft and tighten securely.
  20.  
  21. Install and tighten the nuts on both ends of the instrument panel.
  22.  
  23. Connect the negative battery cable.
  24.  
  25. Fill the cooling system, start the engine then check the heater system to make sure it is operating properly and does not leak.
  26.  

1974 Models

The heater unit contains the core and blower. The entire assembly must be removed from the car before either the blower or core can be serviced. To remove the heater unit:

  1. Disconnect the negative (-) battery cable.
  2.  
  3. Drain the coolant from the radiator.
  4.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Disconnect the heater water hoses at the engine.
  2.  
  3. Remove the console by unfastening its screws and lifting it out.
  4.  
  5. Unfasten the screws which secure the parcel shelf and remove it from under the instrument panel.
  6.  
  7. Remove the instrument cluster.
  8.  
  9. Pull the knob off the ventilator lever.
  10.  
  11. Remove the ventilator grille by unfastening the two screws at each end.
  12.  
  13. Disconnect the control cables from the heater valve by unfastening the cable clamp and retaining nut.
  14.  
  15. Detach the control rod from the heater shutter (door).
  16.  
  17. Disengage the heater blower multi-connector.
  18.  
  19. Unfasten the heater housing securing bolts and remove the housing from underneath the dash.
  20.  
  21. Unfasten the two housing screws and spring, then remove the housing.
  22.  
  23. Separate the defroster duct from the heater assembly.
  24.  
  25. Remove the water hoses.
  26.  
  27. Unfasten the two heater valve screws and remove the valve.
  28.  
  29. Remove the shutter control rod from the link.
  30.  
  31. Unfasten the link screws, and remove the link.
  32.  
  33. Remove the heater core assembly.
  34.  
  35. Disconnect the fan motor wiring harness, loosen its 3 retaining screws, and separate it from the core, complete with blower.
  36.  

To install:

  1. Connect the heater core and blower to the fan motor wiring harness then secure the unit with the 3 retaining screws.
  2.  
  3. Connect the shutter control rod to the heater control link.
  4.  
  5. Install the heater valve and connect the water hoses.
  6.  
  7. Connect the defroster duct to the heater assembly.
  8.  
  9. Reassemble the heater housing and install it into the vehicle.
  10.  
  11. Engage the heater blower multi-connector.
  12.  
  13. Connect the heater control rod to the shutter.
  14.  
  15. Connect the control cable to the heater valve.
  16.  
  17. Position the vent grill and install the retainer screws.
  18.  
  19. Place the vent knob onto the lever.
  20.  
  21. Install the instrument cluster and parcel shelf.
  22.  
  23. Install the console.
  24.  
  25. Connect the heater water hoses.
  26.  
  27. Fill the radiator with coolant.
  28.  
  29. Connect the negative battery cable.
  30.  
  31. Start the engine and check for leaks.
  32.  
  33. Adjust the shutter control rod as follows:
  34.  
    1. Loosen the screw which attaches the air intake shutter (door) control rod to its link.
    2.  
    3. Push the link down as far as it will go.
    4.  
    5. Slide the heater control lever to CIRC.
    6.  
    7. Fasten the shutter control rod and link securing screw.
    8.  

  35. Adjust the heater valve cable as follows:
  36.  
    1. Slide the temperature control lever to COOL.
    2.  
    3. Pull the lever on the heater valve toward the driver's side and secure the control cable to it with the clamp.
    4.  
    5. Slide the temperature control to WARM and push the heater valve lever outward.
    6.  
    7. Fasten the outer cable to the heater valve cable with the clamp.
    8.  


1975-79 Models

The heater unit contains the core and blower. The entire assembly must be removed from the car before either the blower or core can be serviced. To remove the heater unit:

  1. Disconnect the the negative (-) battery cable.
  2.  
  3. Remove the console, luggage shelf, meter and visor assembly, and center ventilation grill.
  4.  
  5. Drain the coolant and disconnect the two heater hoses in the engine compartment.
  6.  
  7. Disconnect the heater control cable and the fan motor harness.
  8.  
  9. Disengage the control rod connecting the air flow fan switch control lever on the instrument panel to the heater unit, on the right side.
  10.  
  11. Unfasten the two mounting bolts and remove the heater unit.
  12.  

To install:

  1. Install the heater unit and tighten the mounting bolts securely.
  2.  
  3. To reconnect the control rod push up the link provided at the side of the heater unit to its full stroke, set the air/fan switch control lever to vent and then connect the rod to the link.
  4.  
  5. To reconnect the heater control cable set the temperature control lever to cold, the heater control lever on the heater unit to off then engage the cock cable.
  6.  
  7. Install the console, and luggage shelf.
  8.  
  9. Install the meter and visor assembly.
  10.  
  11. Install center ventilation grill.
  12.  
  13. Fill the radiator with coolant.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Start the vehicle and check for leaks.
  18.  

1980-84 Models

The heater unit contains the core and blower. The entire assembly must be removed from the car before either the blower or core can be serviced.



Click image to see an enlarged view

Fig. Fig. 2 Exploded view of the heater unit and duct assembly

To remove the heater unit:

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant through the radiator drain plug.
  4.  
  5. Disconnect the heater hoses in the engine compartment.
  6.  



Click image to see an enlarged view

Fig. Fig. 3 Remove the two mounting bolts at the top sides of the heater unit

  1. Remove the rubber grommet the heater hoses run through on the kick panel inside the car. The location is slightly above and to the right of the accelerator pedal.
  2.  
  3. Remove the radio box or console.
  4.  
  5. Remove the instrument panel.
  6.  
  7. Remove the luggage shelf, if equipped.
  8.  
  9. Disconnect the heater control cables and fan motor harness.
  10.  
  11. Disconnect the duct between the heater unit and blower assembly.
  12.  
  13. Remove the right and left defroster nozzles.
  14.  
  15. Remove the two mounting bolts at the top sides of the heater unit.
  16.  
  17. Remove the retaining bracket and screws at the bottom of the heater unit.
  18.  
  19. Lift the heater unit up and out.
  20.  

To install:

  1. Install retaining bracket and screws at the bottom of the heater unit.
  2.  
  3. Install the heater unit and tighten the two mounting bolts securely.
  4.  
  5. Connect the duct between the heater unit and blower assembly.
  6.  
  7. Install the left and right defroster nozzles.
  8.  
  9. Connect the fan motor harness and heater control cables.
  10.  
  11. Install the luggage shelf, if equipped.
  12.  
  13. Install the instrument panel, console and radio box.
  14.  
  15. Install the heater hose rubber grommets and connect the heater hoses.
  16.  
  17. Fill the radiator with coolant.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Start the engine and check for leaks.
  22.  

 
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