Heater Core: Service and Repair

HEATER ASSEMBLY REMOVAL







CAUTION:
- All SRS electrical wiring harnesses are covered with yellow outer insulation.
- When disconnecting the SRS wire harness, install the short connector on the airbag, then disconnect the wire harness.
- Replace the entire affected SRS harness assembly if there is an open circuit or damage to the wiring.

1. When the engine is cool, drain the coolant from the radiator.

WARNING:
- Do not remove the radiator cap when the engine is hot; the coolant is under pressure and could severely scald you.
- Keep hands away from the radiator fan. The fan may start automatically without warning and run for up to 30 minutes, even after the engine is turned off.

CAUTION: Radiator coolant will damage paint. Quickly rinse any spilled coolant from painted surfaces.







2. Disconnect the heater hoses at the heater.

NOTE: Coolant will run out when the hoses are disconnected, drain it into a clean drip pan.

3. Disconnect the heater valve cable from the heater valve.
4. Remove the dashboard.
5. Remove the heater duct.







6. Remove the dashboard support tube.
7. Remove the heater mounting nuts (4), then remove the heater assembly.







HEATER CORE REPLACEMENT
1. Remove the air mix rod from the clip.
2. Remove the self-tapping screws (2) and heater core cover.
3. Remove the self-tapping screw and clamp.
4. Pull out the heater core from the heater housing.
5. Install the heater core in the reverse order of removal.
6. After installing the heater assembly, make the following adjustments:
- Heater linkage Adjustments
- Air mix rod

HEATER ASSEMBLY INSTALLATION
Install in the reverse order of removal, and:
- Apply sealant to the grommets.
- Do not interchange the inlet and outlet hoses. Make sure that the hose clamps are secure.
- Loosen the bleed bolt on the engine and refill the radiator and reservoir tank with the proper coolant mixture.
Tighten the bleed bolt when all the trapped air has escaped and coolant begins to flow from it.
- Connect all cables and make sure they are properly adjusted.

MODE CONTROL MOTOR, (BUTTON TYPE ONLY)
- When installing the mode control motor, be careful when connecting the linkage.
- Try the mode control motor in every mode for two minutes, and make sure the motor operates correctly in each mode.