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Heater Core Case: Service and Repair

HEATER CORE AND EVAPORATOR CORE HOUSING


Part 1:






Part 2:






Removal and Installation

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

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

4. Remove the rear footwell duct.
5. Remove the powertrain control module (PCM) and PCM bracket.
6. Disconnect the 2 heater hose quick-disconnect fittings at the heater core.







7. Remove the bolt and detach the thermostatic expansion valve (TXV).
- Discard the O-ring seals.
- To install, tighten to 8 Nm (71 lb-in).

8. Disconnect the evaporator outlet fitting.
- Discard the O-ring seals.

9. Disconnect the evaporator inlet fitting.
- Discard the O-ring seals.

10. Remove the thermostatic expansion valve bracket nut.
- To install, tighten to 5 Nm (44 lb-in).

11. Remove the 3 heater core and evaporator core housing nuts.
- To install, tighten to 5 Nm (44 lb-in).







12. Disconnect the 2 vacuum lines at the top of the heater core and evaporator core housing.
13. Detach the wire harness connectors from the bracket below the air inlet duct.
14. Remove the air inlet duct bracket nut.
- To install, tighten to 7 Nm (62 lb-in).

15. Remove the plenum chamber nut.
- To install, tighten to 5 Nm (44 lb-in).

16. Remove the heater core and evaporator core housing.
17. To install, reverse the removal procedure.
- Install new O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
- Clean and lubricate the coolant hoses with plain water only if needed.

18. Fill the engine coolant level.
19. Evacuate, leak test and charge the refrigerant system.
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