Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Remove the fuel injector sight shield (3.8L only). Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical-3.8L. 2. Drain the coolant. Refer to Cooling System Draining and Filling in Engine Cooling. 3. UseJ 38185 in order to position aside the heater hose inlet and outlet clamps at the heater core. 4. Disconnect the inlet and outlet heater hose from the heater core. 5. Remove the vacuum tank. Refer to Vacuum Tank Replacement in HVAC System – Manual. 6. Remove the floor carpet. Refer to Front Floor Panel Carpet Replacement in Interior Trim. 7. Remove the rear floor air outlet duct from the holes in the floor reinforcement. 8. Disconnect the rear floor air outlet duct from the heater core outlet cover. 9. Remove the bolts from the vaccum harness bracket and position bracket aside. Important: Position the heater core outlet cover downward and rearward in order to disconnect the cover from the rear area floor duct assembly. 10. Remove the heater core outlet cover screws. 11. Remove the heater core outlet cover. 12. Remove the heater core cover screws. 13. Remove the heater core cover. 14. Remove and discard the seals (1,2) from the heater core cover. 15. Remove the caulk (3) from the heater core cover. 16. Remove and discard the heater core outer seal (5) from the heater core. 17. Remove the heater core clamp screw (1). 18. Remove the heater core retaining clamp. 19. Remove the heater core pipe retainer clamp screw (2). 20. Remove the heater core from the HVAC lower case. 21. Remove the heater core pipe retainer clamp from the heater core pipes. 22. Remove and discard the heater core lower seal (4) from the HVAC case. 23. Remove and discard the heater core center seal (3) from the HVAC case. 24. Remove and discard the heater core upper seal (2) from the HVAC lower case. 25. Remove and discard the heater core side seals (1) from the HVAC lower case. Installation Procedure

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NOTE: If a heater core leak is suspected, the heater core must be pressure leak tested before it is removed from the vehicle. For additional information, refer to Section 412-00. 1. Drain the radiator. For additional information, refer to Section 303-03A. 2. Remove the instrument panel. For additional information, refer to Section 501-12. 3. Disconnect the heater core hose couplings. For additional information, refer to Section 412-00. 4. Remove the A/C plenum demister adapter. 1. Remove the screw. 2. Remove the A/C plenum demister adapter. 5. Remove the screws and position aside the relay bracket. 6. Disconnect the vacuum line. 7. Remove the plenum chamber top. 1. Remove the 15 screws. 2. Remove the plenum chamber top. 8. Remove the blend door assembly from the case. 9. Remove the heater core. 10. To install, reverse the removal procedure. Lubricate the coolant hoses with coolant hose lubricant or plain water only, if needed.

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1. Remove the heater air plenum chamber (18471) assembly as outlined. 2. Remove the four retaining screws from the heater core cover (18B300) and remove the heater core cover from the heater air plenum chamber assembly. Heater Core Removal 3. Pull the heater core (18476) assembly from the heater air plenum chamber assembly. Installation 1. Carefully install heater core assembly into the heater air plenum chamber assembly. Visually check to ensure that heater core case seal (18658) is properly positioned. 2. Position the heater core cover and install the four retaining screws. 3. Install the heater air plenum chamber assembly as outlined. Heater Air Plenum Chamber Removal 1. Disconnect battery ground cable (14301). Refer to Section 14-01. 2. Disconnect the heater water hoses (18472) from the heater core tubes. Plug the ends of the heater water hoses to prevent coolant loss. 3. Plug heater core tubes securely to prevent coolant leakage from heater core (18476) during heater air plenum chamber removal. 4. Remove three nuts located below the windshield wiper motor (17508) retaining the LH end of the heater air plenum chamber (18471) to the dash panel (01610). 5. Remove one nut retaining the upper LH corner of the A/C evaporator core housing (19A559) to the dash panel. 6. Remove LH and RH lower instrument panel insulators. 7. Disconnect two vacuum supply hoses from vacuum source. Push grommet and vacuum supply hose into passenger compartment. 8. Remove all instrument panel retaining screws and pull the instrument panel (04320) back as far as possible without disconnecting any wire harnesses. 9. Loosen the RH door sill plate and remove the RH side cowl trim panel. 10. Remove cross body brace and disconnect wiring harness from A/C electronic door actuator motor (19E616) and disconnect the sensor tube from the evaporator case connector. 11. Disconnect the vacuum jumper harness at the multiple vacuum connector near the heater outlet floor duct (18C433). 12. Disconnect the white vacuum hose from the heater and A/C air inlet duct door vacuum

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If a heater core leak is suspected, the heater core must be leak tested before it is removed from the vehicle. For additional information, refer to Section 412-00. 1. Drain the radiator. For additional information, refer to Section 303-03. 2. Remove the instrument panel. For additional information, refer to Section 501-12. 3. If equipped with the 5.4L 4V engine, remove the junction block splash shield. 4. If equipped with the 5.4L 4V engine, remove the bolts and disconnect the cable ends from the starter relay. 5. If equipped with the 5.4L 4V engine, remove the junction block bracket. 1. Disengage the wire harness connector. 2. Remove the bolts. 3. Remove the junction block bracket. 6. Disconnect the heater core hose couplings. For additional information, refer to Section 412-00. 7. Remove the A/C plenum demister adapter. 1. Remove the screw. 2. Remove the A/C plenum demister adapter. 8. Disconnect the vacuum line.

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NOTE: New O-ring seals must be installed before reconnecting any A/C fitting that has been disconnected. 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. NOTE: If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it is removed from the vehicle. 1. Recover the refrigerant. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging in this section. 2. Drain the engine cooling system. For additional information, refer to Section 303-03. 3. Remove the instrument panel. For additional information, refer to Section 501-01. 4. Remove the engine appearance cover. 5. Remove the parts in the order indicated in the following illustrations and tables. To remove individual parts, only carry out the 6. To install, reverse the removal procedure. Install new O-ring seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to Refrigerant Oil Adding in this section. 7. Fill the engine cooling system. For additional information, refer to Section 303-03. 8. Evacuate, leak test and charge the refrigerant system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging in this section. Item 6: Heater Hose Clamp Removal Note 1. Detach the wiring harness bracket and position the harness aside at the dash panel.