Heater Core Case: Service and Repair

HEATER CORE AND EVAPORATOR CORE HOUSING











Removal and Installation

NOTE:
- Installation of a new suction accumulator is not required when repairing the air conditioning system, except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator.
- If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it is removed from the vehicle.

1. Drain the engine coolant.
2. Recover the refrigerant.
3. Remove the wiper motor and pivot assembly.
4. Remove the instrument panel. Refer to: Body and Frame, Interior Moulding/Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, Removal and Installation

5. Remove the 2 fresh air inlet duct nuts.
6. Remove the fresh air inlet duct.
7. Disconnect the evaporator core outlet fitting.
- Discard the O-ring seals.

8. Disconnect the evaporator core inlet fitting.
- Discard the O-ring seals.

9. Remove the cowl drain tube nut.
10. Remove the cowl drain tube pin-type retainers.
11. Remove the cowl drain tube.
12. Disconnect the 2 heater hoses at the heater core.
13. Remove the 4 heater core and evaporator core housing nuts.
14. Remove the heater core and evaporator core housing support bracket bolt.
15. Remove the heater core and evaporator core housing support bracket nut.
16. Remove the heater core and evaporator core housing support bracket.
17. Remove the rear seat floor duct adapter.
18. Remove the heater core and evaporator core housing.
19. To install, reverse the removal procedure.
- Install new O-ring seals lubricated in clean mineral oil.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.

20. Fill the engine cooling system.
21. Evacuate, leak test and charge the refrigerant system.