Heater Core: Service and Repair

Air Conditioning and Heater Module Assembly Removal and Installation

Tools Required

- J 39400-A Halogen Leak Detector

Removal Procedure

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging Service and Repair.
2. Drain the cooling system. Refer to Cooling System Draining and Filling Service and Repair.
3. Remove the left sheet metal diagonal brace. Refer to Front End Sheet Metal Diagonal Brace Replacement Service and Repair.
4. Disconnect the A/C lines at the evaporator. Refer to Air Conditioning Evaporator Tube Replacement Service and Repair.
5. Disconnect the heater hoses at the heater core. Refer to Heater Hoses Replacement Service and Repair.
6. Remove the trim pad from the instrument panel. Refer to Instrument Panel Trim Pad Replacement Service and Repair.
7. Remove the cross vehicle beam. Refer to Instrument Panel Tie Bar Replacement Service and Repair.






Important: Position the heater core cover downward and rearward in order to disconnect the cover from the rear area floor duct assembly.

8. Remove the heater core outlet cover screws.
9. Remove the heater core outlet cover.






10. Remove the evaporator drain elbow.






11. Remove the HVAC module assembly to dash nuts.
12. Disconnect the vacuum hoses.
13. Disconnect the electrical connectors.
14. Remove the HVAC module assembly.






15. Remove all of the outer HVAC module assembly seals (1, 2, 3).

Installation Procedure






1. Install new outer HVAC module assembly seals (1, 2, 3).
2. Install the HVAC module assembly to the vehicle.






Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the HVAC module assembly to dash nuts.

Tighten
Tighten the HVAC module assembly to dash nuts to 10 Nm (89 lb in).






4. Install the evaporator drain elbow.
5. Connect the electrical connectors.
6. Connect the vacuum hoses.
7. Install the cross vehicle beam. Refer to Instrument Panel Tie Bar Replacement Service and Repair.
8. Install the trim pad to the instrument panel. Refer to Instrument Panel Trim Pad Replacement Service and Repair.
9. Connect the heater hoses at the heater core. Refer to Heater Hoses Replacement Service and Repair.
10. Install the A/C lines at the evaporator. Refer to Air Conditioning Evaporator Tube Replacement Service and Repair.
11. Refill the coolant. Refer to Cooling System Draining and Filling Service and Repair.
12. Install the left sheet metal diagonal brace. Refer to Front End Sheet Metal Diagonal Brace Replacement Service and Repair.
13. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging Service and Repair.
14. Leak test the fittings of the component using J 39400-A.