Removal

REMOVAL

WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death.

WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death.

WARNING: The heater core tubes are not serviced separately from the heater core. The heater core tubes should not be repositioned, loosened or removed from the heater core. Failure to follow this warning could result in a coolant leak and possible personal injury or death.

NOTE: LHD model shown in illustrations. RHD model similar.





1. Remove the HVAC housing assembly and place it on a workbench.

2. Remove the air distribution housing from the HVAC housing.

3. Remove the two screws (1) that secure the upper front passenger side floor duct (7) to the passenger side of the air distribution housing (8) and remove the duct.

NOTE: If the foam seal for the heater core tube flange is deformed or damaged, it must be replaced.

4. Carefully remove the foam seal (4) from the heater core tube flange (5). If the seal is deformed or damaged, it must be replaced.

5. Remove the screw (2) that secures the heater core tube flange to the air distribution housing.

6. Disengage the plastic retainer (5) from around the heater core tubes (6) and remove the flange.





NOTE: If the foam insulator around the heater core is deformed or damaged, the insulator must be replaced.

7. Disengage the four plastic retaining tabs (1) that secure the heater core (2) to the passenger side of the air distribution housing (3) and carefully remove the heater core from the housing.