Auxiliary Heater and/or Air Conditioner Assembly

Remove

1. Discharge refrigerant from A/C system if an auxiliary A/C is installed.
. Remove first bench seat, if so equipped.






3. Remove auxiliary heater and/or air conditioner cover retaining screws and remove cover (Fig. 6).
4. Disconnect heater hoses from heater core tubes and plug hoses with suitable 15.875mm (5/8-inch) plugs. Plug heater core tubes to prevent coolant spill during removal.
5. Using a backup wrench to prevent component damage, disconnect liquid line from expansion valve, and suction line from evaporator core (if equipped with auxiliary A/C).
6. Cap lines and fittings to prevent entrance of dirt and moisture into refrigerant system
7. Working under vehicle, disconnect blower motor wires at connectors and disengage wiring harness from retaining strap.






8. Remove case assembly retaining screws (Fig. 16). Then, lift case assembly, disengage wiring harness grommet from floor seal, and remove case assembly from vehicle.

Installation

1. Ensure that all seals are in place on bottom of case assembly. Place case assembly near installed position and route wire harness through floor seal. Seat harness grommet in floor seal.
2. Position case assembly over floor seal, refrigerant lines and heater hoses, and to body side.
3. Install case assembly attaching screws (fig. 16).
4. Working under vehicle, route blower motor wires through support strap and connect wires at harness connectors.
5. Remove plugs from heater hoses.
6. Connect heater hoses to heater core, if equipped with an auxiliary heater. Tighten hose clamps only to 14-20 N.m (12-18 in-lb).
7. If equipped with an auxiliary air conditioner, remove caps from refrigerant lines. Then, connect refrigerant lines to expansion valve and evaporator core. Use new O-rings lubricated with clean refrigerant oil. Tighten all fittings using a backup wrench to prevent component damage.
8. Fill cooling system to specification and check for coolant leaks (if equipped with an auxiliary heater).
9. Leak-test, evacuate and charge refrigerant system following recommended procedures, if equipped with auxiliary A/C.






10. Install auxiliary heater and/or air conditioner cover assembly (Fig. 5).
11. Install bench seat, if so equipped. Tighten retaining bolts to 34-61 N.m (25-45 ft-lb).