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SECTION 7A

REPAIR INSTRUCTIONS

ON-VEHICLE SERVICE



D108A501
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CONTROL ASSEMBLY AND CONTROL CABLES

(Left-Hand Drive Shown, Right-Hand Drive Similar)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the instrument cluster housing trim panel. Refer to Section 9E, Instrumentation/Driver information.
  3. Remove the control assembly.


  4. D108A502
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    D108A503
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    D108A504
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    D108A505
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  5. Disconnect the control cables from the control assembly.


D108A506
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Installation Procedure

  1. Connect the control cables to the control assembly.
  2. Connect the recirculating/fresh air door cable to the blower module.
  3. Install the glove box to the instrument panel. Refer to Section 9E, Instrumentation/Driver Information.
  4. Connect the temperature control cable and the mode control cable to the heater module.
  5. Connect the electrical connectors.
  6. Install the control assembly with the screws.
  7. Install the instrument cluster housing trim panel. Refer to Section 9E, Instrumentation/Driver Information.
  8. Connect the negative battery cable.


D108A507
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BLOWER MOTOR AND COOLING HOSE

(Left-Hand Drive Shown, Right-Hand Drive Similar)

Removal Procedure

  1. Remove the blower motor cooling hose.


  2. D108A508
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  3. Remove the blower motor.


D108A509
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Installation Procedure

  1. Install the blower motor by turning the motor clockwise.
  2. Connect the motor electrical connector.
  3. Install the blower motor cooling hose.


D108A510
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BLOWER RESISTOR

(Left-Hand Drive Shown, Right-Hand Drive Similar)

Removal Procedure

  1. Remove the blower resistor.


D108A511
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Installation Procedure

  1. Install the blower resistor with the retaining screws.
  2. Connect the blower resistor connector.


D108A512
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BLOWER MOTOR SWITCH

(Left-Hand Drive Shown, Right-Hand Drive Similar)

Removal Procedure

  1. Remove the control assembly. Refer to "Control Assembly and Control Cables" in this section.
  2. Remove the blower motor switch.


  3. D108A513
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D108A514
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Installation Procedure

  1. Install the blower motor switch with the screw.
  2. Install the switch knob.
  3. Install the control assembly. Refer to "Control Assembly and Control Cables" in this section.


D18A515A
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HEATER HOSES

(Left-Hand Drive Shown, Right-Hand Drive Similar)
Tools Required

DW100-020 Hose Remover/Installer.

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Drain the coolant.
  3. Remove the heater inlet hoses.


  4. D108A516
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    D18A517A
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  5. Remove the heater outlet hoses.


  6. D108A518
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D108A521
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Installation Procedure

  1. Install the heater outlet hoses.


  2. D18A522A
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    D108A519
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  3. Install the heater inlet hoses.


  4. D18A520A
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  5. Refill the coolant. Refer to Section 1D, Engine Cooling.
  6. Connect the negative battery cable.


D108A523
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HEATER MODULE

(Left-Hand Drive Shown, Right-Hand Drive Similar)

Removal Procedure

  1. Disconnect the heater hoses from the heater module. Refer to "Heater Hoses" in this section.
  2. Remove the instrument panel and the lower tie bar center. Refer to Section 9E, Instrumentation/Driver Information.
  3. Remove the heater module-to-blower module connection tube on the vehicle not equipped with A/C.
  4. a. Heater module-to-blower module connection tube.


    D108A524
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  5. Remove the evaporator on the vehicle equipped with A/C. Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning System.


  6. D108A525
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  7. Remove the heater module.


  8. D108A526
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D18A527B
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Installation Procedure

  1. Install the heater module with the nuts.
  2. Tighten
    Tighten the heater module lower nuts to 3-5 N·m (27-44 lb-in) (1).
    Tighten the heater module upper nuts to 3-5 N·m (27-44 lb-in) (2).

  3. Install the evaporator on the vehicle equipped with A/C. Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning System.
  4. Install the heater module-to-blower module connection tube on the vehicle not equipped with A/C with the screw.


  5. D18A528B
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  6. Install the instrument panel and the lower tie bar. Refer to Section 9E, Instrumentation/Driver Information.
  7. Connect the heater hoses to the heater module. Refer to "Heater Hoses" in this section.


D108A529
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BLOWER MODULE

(Left-Hand Drive Shown, Right-Hand Drive Similar)

Removal Procedure

  1. Remove the glove box from the instrument panel. Refer to Section 9E, Instrumentation/Driver Information.
  2. Remove the heater module-to-blower module connection tube on the vehicle not equipped with A/C. Refer to "Heater Module" in this section.
  3. Remove the evaporator on the vehicle equipped with A/C. Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning System.


  4. D108A530
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  5. Remove the blower resistor. Refer to "Blower Resistor" in this section.
  6. Disconnect the blower motor connector. Refer to "Blower Motor and Cooling Hose" in this section.
  7. Remove the blower module.


D18A531B
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Installation Procedure

  1. Install the blower module with the nuts.
  2. Tighten
    Tighten the blower module retaining nuts to 3-5 N·m (27-44 lb-in).

  3. Connect the wiring harness.
  4. Connect the blower motor connector. Refer to "Blower Motor and Cooling Hose" in this section.
  5. Install the blower resistor. Refer to "Blower Resistor" in this section.
  6. Install the evaporator on the vehicle equipped with A/C. Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning System.
  7. Install the heater module-to-blower module connection tube on the vehicle not equipped with A/C. Refer to "Heater Module" in this section.
  8. Install the glove box to the instrument panel. Refer to Section 9E, Instrumentation/Driver Information.


D108A532
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DEFROSTER DUCT AND HOSES

(Left-Hand Drive Shown, Right-Hand Drive Similar)

Removal Procedure

  1. Remove the instrument panel. Refer to Section 9E, Instrumentation/Driver Information.
  2. Remove the defroster duct and hoses retaining screws.
  3. a. Retaining screw.
  4. Remove the defroster duct and hoses.
  5. b. Defroster duct and hoses.


D108A533
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Installation Procedure

  1. Install the defroster duct and hoses with the screws.
  2. Install the instrument panel. Refer to Section 9E, Instrumentation/Driver Information.


D18A534A
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VENTILATION DUCT

(Left-Hand Drive Shown, Right-Hand Drive Similar)

Removal Procedure

  1. Remove the instrument panel. Refer to Section 9E, Instrumentation/Driver Information.
  2. Remove the ventilation duct retaining screws.
  3. a. Retaining screw.
  4. Remove the ventilation duct.
  5. b. Ventilation duct.


D108A535
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Installation Procedure

  1. Install the ventilation duct with the screws.
  2. Install the instrument panel. Refer to Section 9E, Instrumentation/Driver Information.

UNIT REPAIR



D108A701
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HEATER CORE

Disassembly Procedure

  1. Remove the heater module. Refer to "Heater Module" in this section.
  2. Remove the heater core.


D108A702
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Assembly Procedure

  1. Install the heater core to the heater module.
  2. Install the heater core cover.
  3. Install the heater module. Refer to "Heater Module" in this section.

SPECIFICATIONS

GENERAL SPECIFICATIONS

Application
Unit
Description
Maximum Heating Capacity
cal/h
7,300
Blower Motor Resistance
1 st
2.25 - 2.75
2 nd
1.08 - 1.32
3 rd
0.36 - 0.44
4 th
-

FASTENER TIGHTENING SPECIFICATIONS

Application
N·m
Lb-Ft
Lb-In
Heater Module Nuts
3 - 5
-
27 - 44
Blower Module Nuts
3 - 5
-
27 - 44

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS TABLE


D102B119
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DW 100-020 Spring Clamp Remover/Installer

SCHEMATIC AND ROUTING DIAGRAMS

NON-A/C DIAGRAMS


D18A201B
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AIR FLOW THROUGH DUCTS (NON-A/C)

(Left-Hand Drive Shown, Right-Hand Drive Similar)

D108A202
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