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The heater-A/C housing assembly must be removed from the vehicle and disassembled for service access of the blower motor, blower motor wheel, heater core, evaporator coil, blend-air door, and each of the various mode control doors. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel from the vehicle. Refer to: “Body and Frame : Interior Moulding/Trim : Dashboard/Instrument Panel : Service and Repair” See: Body and Frame\Interior Moulding / Trim\Dashboard / Instrument Panel\Service and Repair 3. If the vehicle is not equipped with air conditioning, go to Step 6. If the vehicle is equipped with air conditioning, recover the refrigerant from the refrigerant system. Refer to: “Heating and Air Conditioning : Service and Repair” See: Service and Repair 4. Disconnect the liquid line refrigerant line fitting from the evaporator inlet tube. 5. Disconnect the accumulator inlet tube refrigerant line fitting from the evaporator outlet tube. Install plugs in, or tape over all of the opened refrigerant line fittings. 6. Drain the engine cooling system. Refer to: “Engine, Cooling and Exhaust : Cooling System : Service and Repair” See: Engine, Cooling and Exhaust\Cooling System\Service and Repair 7. Disconnect the heater hoses from the heater core tubes. Install plugs in, or tape over the opened heater core tubes. 8. Remove the four nuts from the heater-A/C housing mounting studs on the engine compartment side of the dash panel. 9. Remove the nut that secures the heater-A/C housing mounting brace to the stud on the passenger compartment side of the dash panel. 10. Pull the heater-A/C housing rearward far enough for the mounting studs and the evaporator condensate drain tube to clear the dash panel holes. 11. Remove the heater-A/C housing from the vehicle. DISASSEMBLY 1. Place the heater-A/C housing on a work bench, with the heater-A/C housing cover facing down. 2. Remove the two screws that secure the heater-A/C housing cover to the top of the blower motor housing cover. 3. If the vehicle is so equipped, unplug the two vacuum harness connectors from the recirculation air door actuator. 4. Unplug the vacuum harness connector from the panel-defrost door actuator. 5. Remove the four screws that secure the floor duct to the bottom of the heater-A/C housing and remove the duct from the housing.

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HEATER CORE – LHD WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. DO NOT OPEN THE RADIATOR DRAIN COCK OR DISCONNECT COOLANT HOSES WHEN THE SYSTEM IS HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT CAN OCCUR. REMOVAL 1. Disconnect the negative battery cable. 2. Drain the cooling system. Refer to: “Engine, Cooling and Exhaust : Cooling System : Service and Repair” See: Engine, Cooling and Exhaust\Cooling System\Service and Repair 3. Evacuate the refrigerant system. Refer to: “Heating and Air Conditioning : Service and Repair” See: Service and Repair 4. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Procedures, See: Body and Frame\Interior Moulding / Trim\Dashboard / Instrument Panel\Service and Repair\Instrument Panel Service Procedures\Instrument Panel Assembly Replacement 5. Remove the refrigerant lines from the evaporator connections. 6. Remove the heater core coolant supply hoses from the heater core. 7. Working from inside the engine compartment, remove the A/C-heater housing retaining fasteners from the bulk head. 8. Remove the A/C-heater housing drain tube. Remove the spring clip from the A/C-heater housing and body attachement point. 9. Remove the A/C-heater housing retainer bolts. 10. Disconnect the electrical connectors from the A/C-heater housing. 11. Remove the A/C-heater housing from the vehicle and place the assembly on a bench. 12. Dissemble the heater core. 13. Remove the heater core from the housing. INSTALLATION Install heater core into HVAC housing. Assemble the HVAC housing. Take the HVAC housing from the work bench and place into vehicle. Install HVAC housing to vehicle. Install underhood HVAC housing drain tube to housing and install spring retainer clip. 6. Install electrical connectors to HVAC housing. 7. Install heater supply hoses to heater core connections. 8. Install refrigerant lines to the evaporator. 1. 2. 3. 4. 5.

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The heater-A/C housing assembly must be removed from the vehicle and disassembled for service access of the blower motor, blower motor wheel, heater core, evaporator coil, blend-air door, and each of the various mode control doors. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel from the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement 3. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Recovery, See: Service and Repair/Refrigerant Recovery 4. Remove the front expansion valve from the evaporator tube mounting flange. Install plugs in, or tape over all of the opened refrigerant line fittings. Refer to: Heating and Air Conditioning, Expansion valve, Service and Repair, Expansion Valve Removal and Installation, See: Expansion Valve/Service and Repair 5. Drain the engine cooling system. 6. Disconnect the heater hoses from the heater core tubes.

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LINE-A/C LIQUID WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: The A/C liquid line is serviced in two sections. The rear section of the liquid line is serviced as an assembly with the rear section of the A/C suction line. FRONT SECTION REMOVAL 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. Remove the air cleaner housing. 4. Raise and support the vehicle. 5. Remove the front end splash shields. 6. Remove the nut (3) that secures the front section of the A/C liquid line (4) to the A/C condenser (5). 7. Disconnect the A/C liquid line from the A/C condenser and remove and discard the dual plane seal. 8. Install plugs in, or tape over the opened liquid line fitting and condenser outlet port. NOTE: LHD model shown. RHD model similar.

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REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Recover the refrigerant from the refrigerant system. 2. Remove the air cleaner housing from the right side of the engine compartment. 3. Remove the screw that secures the liquid line front section fitting to the top of the filter-drier. 4. Disconnect the liquid line fitting from the filter-drier inlet port. 5. Remove the seal from the liquid line fitting and discard. 6. Install plugs in, or tape over the opened liquid line fitting and the filter-drier inlet port. 7. Remove the screw that secures the liquid line rear section fitting to the top of the filter-drier. 8. Disconnect the liquid line fitting from the filter-drier outlet port. 9. Remove the seal from the liquid line fitting and discard. 10. Install plugs in, or tape over the opened liquid line fitting and the filter-drier outlet port. 11. Remove the two nuts that secure the filter-drier mounting bracket to the weld studs on the side of the right front strut tower. 12. Remove the filter-drier and mounting bracket unit from the studs.