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Got the heater core out but don't want to bust duct work trying to get the evaporator out in a 93 chevy pickup. seems like something is holding it solid to the firewall. got the screws removed from inside engine compartment.got every screw out that i can find all the way to the drivers side. is there screws going up against firewall that i haven't found? book says remove blower motor and 4 screws from the evaporator housing but it don't want to come apart back by the firewall
lines are disconnected and from engine side you can feel a soft foam around the lines to seal the holes off. so don't think there is any tar there.i pulled heater core cover off and core.but can't get evaporator cover off.i can pry open the front side of that compartment but i dont know what is holding it together against the firewall.does it somehow snap together in the back to eliminate screws back there?lines are disconnected and from engine side you can feel a soft foam around the lines to seal the holes off. so don't think there is any tar there.i pulled heater core cover off and core.but can't get evaporator cover off.i can pry open the front side of that compartment but i dont know what is holding it together against the firewall.does it somehow snap together in the back to eliminate screws back there?
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Did you connect the lines? and did you break loose the tar that holds itto the car and seals the holes for the pipe? You maya have to remove the outter core cover to getto the last screws to get it out.
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Your best bet would be to take your vehicle to a qualified repair shop ! You'll have to Recover the refrigerant from A/C , drain the coolant .
Remove the evaporator outlet hose and liquid line nut from the thermal expansion valve (TXV).
Remove the evaporator outlet hose from the TXV.
Remove and discard the sealing washer from the evaporator outlet hose. Refer to Sealing Washer Replacement .
Remove the evaporator outlet hose and liquid line from the TXV.
Remove and discard the sealing washer from the liquid line. Refer to Sealing Washer Replacement .
Install a protective caps to the evaporator outlet hose and the liquid line to prevent contamination and desiccant saturation.
Reposition the heater outlet hose clamp at the heater core.
Remove the heater outlet hose from the heater core (1).
Reposition the heater inlet hose clamp at the heater core (2).
Remove the heater inlet hose at the heater core.
Plug the heater core and the evaporator core with clean towels to prevent spillage when the HVAC module is removed.
Remove the HVAC module seal nuts from the front of dash.
Remove the instrument panel (I/P) retainer. Refer to Instrument Panel Retainer Replacement .
Remove the shift control bracket. Refer to Transmission Control Replacement .
Remove the center floor air outlet duct by sliding the duct forward then up at the rear.
Remove the center I/P air outlet duct retainers from the instrument panel tie bar.
Remove the center I/P air outlet duct from the instrument panel tie bar.
Remove the instrument panel tie bar. Refer to Instrument Panel Tie Bar Replacement .
Disconnect the blower motor electrical connector from the I/P wire harness.
Disconnect the blower motor control module electrical connector from the I/P wire harness.
Disconnect the HVAC module electrical connector from the I/P wire harness.
Remove the HVAC module from the vehicle.
Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement .
Remove the heater core case cover.
Remove the heater core bracket and screw.
Remove the heater core.
Removal Procedure
Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
Remove the evaporator hose from the evaporator. Refer to Air Conditioning Evaporator Hose Assembly Replacement .
Lower the vehicle.
Remove the heater hoses from the heater core. Refer to Heater Hoses Replacement .
Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
Remove the drain tube elbow from the evaporator block heater case plate.
Remove the nuts holding the heater case plate for the heater pipes. Remove the heater case plate and the seals for the heater pipes. Remove the nuts holding the heater case plate for the evaporator block. Remove the heater case plate and seal for the evaporator block. Remove the nut for the HVAC module assembly bracket. Lower the vehicle. Remove the instrument panel (IP) carrier. Refer to Instrument Panel Carrier Replacement in Instrument Panel, Gauges, and Console. Remove the cross vehicle beam (tie bar). Remove the floor air duct from the HVAC module. Refer to Floor Air Outlet Replacement . Remove the air distribution duct. Refer to Air Distributor Duct Replacement .
Remove the daytime running lights (DRL) sensor wiring harness clip (1) from the HVAC module assembly. Disconnect the IP lamp dimmer switch electrical connector (2). Remove the wiring harness clips (3) from the HVAC module assembly bracket. Disconnect the vacuum source hose (4) from the vacuum tank.
If you have never done this before I suggest you take it to a ASE certified repair shop or the dealer .
Usually a sign of a faulty blend door under the dash. The blend doors direct air thru the heater core and evaporator core, along with the ducts to the vents.
Fig. 1: When installing the new heater core take great care not to bend or damage the fins or tubing
[IMG]http://i665.photobucket.com/albums/vv17/technovative/Isuzu-Pickup-Heater-Core.gif[/IMG] Click here if image doesn't display.
Disconnect the negative battery cable.
Drain the engine coolant into a suitable container.
CAUTION When draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.
Disconnect the heater hoses. Be careful not to damage the core by pulling on the hose to remove. Cut the hoses if they will not come off easily.
Remove the instrument panel.
Disconnect the resistor assembly.
If possible, disconnect and move the duct (non air conditioning) or the evaporator housing (air conditioning) to the right to gain clearance for the heater unit. If equipped with air conditioning, do not disconnect air conditioning system until absolutely necessary. Refer to Section 1 for discharging, evacuating and recharging the system.
Remove the instrument panel stay and heater unit.
Disassemble the heater unit by removing the duct, mode control case, core assembly and heater core.
To install:
Assemble the heater unit by installing the duct, mode control case, core assembly and heater core.
Install the heater unit and instrument panel stay.
Connect the duct (non air conditioning) or the evaporator housing (air conditioning) to the heater unit. Evacuate and recharge the air conditioning system if the system was discharged to remove the evaporator assembly.
Connect the resistor assembly.
Install the instrument panel as outlined in this section.
Connect the heater hoses. Be careful not to damage the core by pulling on the hose.
Refill the engine coolant into a suitable container.
Connect the negative battery cable and check for leaks.
Drain the engine coolant into a suitable container.
CAUTION
When draining engine coolant, keep in mind that cats and dogs are
attracted to ethylene glycol antifreeze and could drink any that is
left in an uncovered container or in puddles on the ground. This will
prove fatal in sufficient quantity. Always drain coolant into a
sealable container. Coolant should be reused unless it is contaminated
or is several years old.
Disconnect the heater hoses. Be careful not to damage the core by
pulling on the hose to remove. Cut the hoses if they will not come off
easily.
Remove the instrument panel.
Disconnect the resistor assembly.
If possible, disconnect and move the duct (non air conditioning)
or the evaporator housing (air conditioning) to the right to gain
clearance for the heater unit. If equipped with air conditioning, do
not disconnect air conditioning system until absolutely necessary.
Refer to
for discharging, evacuating and recharging the system.
Remove the instrument panel stay and heater unit.
Disassemble the heater unit by removing the duct, mode control case, core assembly and heater core.
To install:
Assemble the heater unit by installing the duct, mode control case, core assembly and heater core.
Install the heater unit and instrument panel stay.
Connect the duct (non air conditioning) or the evaporator housing
(air conditioning) to the heater unit. Evacuate and recharge the air
conditioning system if the system was discharged to remove the
evaporator assembly.
Connect the resistor assembly.
Install the instrument panel as outlined in this section.
Connect the heater hoses. Be careful not to damage the core by pulling on the hose.
Refill the engine coolant into a suitable container.
Connect the negative (-) battery cable and check for leaks.
big job, dificulty 8 on a 10 scale
Heater Air Plenum Chamber
Removal
Remove heater outlet floor duct (18C433) as described.
Remove instrument panel (04320). Refer to Section 01-12 .
Instrument Panel
SPECIAL SERVICE TOOL(S) REQUIRED
Description
Tool Number
Radio Removing Tool
415-001 (T87P-19061-A) Removal and Installation
Disconnect battery ground cable (14301).
Remove RF wheel and tire assembly. Refer to Section 04-04 .
Remove three nuts in radiator coolant recovery reservoir area.
Remove bolt retaining front fender apron (16054) to front fender (16005) .
Position front fender splash shield out of the way.
Lower vehicle.
Tag and remove main harness connector from jumper harness (located in front of blower motor).
Remove steering column. Refer to Section 11-04 .
Remove RH cowl side trim panel (02344) and LH cowl side trim panels (02345) .
Tag and disconnect wiring connectors in LH and RH cowls.
Remove ground wire located on LH cowl side.
Remove RH instrument panel upper moulding (04268) and LHinstrument panel moulding (04389) from instrument panel (04320) by pulling away from instrument panel and snapping out of retainers. Disconnect wiring connectors as required.
Remove glove compartment (06010).
Remove instrument panel upper finish panel (044A90) and disconnect the A/C sunload sensor (19E663) and anti-theft indicator, if equipped.
Disconnect the heater water hoses (18472) from the heater core tubes. Plug the ends of the heater water hoses to prevent coolant loss.
Plug heater core tubes securely to prevent coolant leakage from heater core (18476).
Remove one nut retaining the upper LH corner of the A/C evaporator core housing (19A559) to the dash panel (01610) .
Disconnect two vacuum supply hoses from vacuum source. Push grommet and vacuum supply hose into passenger compartment.
Disconnect wiring harness from A/C electronic blend door actuator.
Disconnect the white vacuum hose from the heater and A/C air inlet duct door vacuum control motor (18A318).
Remove nuts from the studs along the lower flange of the heater air plenum chamber (18471).
Disconnect connectors to A/C electronic blend door actuator and electronic module on side of heater air plenum chamber.
Remove heater air plenum chamber by pulling rearward.
Heater Air Plenum Chamber and Air Inlet Duct
Item
Part Number
Description
1
19C836
Suction Accumulator/Drier
2
56956-S2
Screw (2 Req'd)
3
386877-S36
Screw
4
45445-S36
Nut and Washer Assy
5
19C928
A/C Recirculating Air Duct Screen
6
386877-S36M
Screw (2 Req'd)
7
45332-S12
Nut and Washer
8
19B762
A/C Air Inlet Door Inner Seal
9
19C590
A/C Recirculating Air Duct
10
18471
Heater Air Plenum Chamber
11
18C433
Heater Outlet Floor Duct
12
55734-S2
Nut
13
19A559
A/C Evaporator Core Housing
14
45332-S2
Nut and Washer
A
—
Tighten to 2.5-3.2 Nm (23-28 Lb-In) Installation
Route the vacuum supply hose through the dash panel and seat the grommet in the opening.
Position the heater air plenum chamber under the instrument panel with the A/C register duct opening up and the heater core tubes down. Connect wire harness connector to A/C electronic blend door actuator and electronic module on side of heater air plenum chamber .
Rotate the heater air plenum chamber up behind the instrument panel and position the heater air plenum chamber to the dash panel. Insert the heater core tubes and mounting studs through their respective holes in the dash panel and the A/C evaporator core housing.
Install three nuts on the studs along the lower flange and one on the upper flange of the heater air plenum chamber.
Install three nuts below the windshield wiper motor (17508) to retain the LH end of the heater air plenum chamber to the dash panel.
Install one nut to retain the upper LH corner of the A/C evaporator core housing to the dash panel .
Connect the white vacuum hose to the heater and A/C air inlet duct door vacuum control motor.
Connect the vacuum jumper harness to the plenum harness at the multiple vacuum connector near the heater outlet floor duct. Install heater outlet floor duct.
Connect the sensor tube to the evaporator case connector on EATC-equipped vehicles.
Connect vacuum supply hose to vacuum supply.
Unplug the heater core tubes and connect the heater water hoses to the heater core tubes.
Fill the cooling system with coolant to replace coolant lost during removal of the heater air plenum chamber.
Install heater outlet floor duct as described.
Install instrument panel. Refer to Section 01-12 .
Section 12-03A: Air Conditioning System—Manual A/C-Heater
1998 Crown Victoria, Grand Marquis Workshop Manual
REMOVAL AND INSTALLATION
Heater Core
Removal NOTE: If a heater core leak is suspected, the heater core must be pressure leak tested before it is removed from the vehicle. Refer to Section 12-00 .
Remove the heater air plenum chamber (18471) assembly as described.
Remove the heater dash gasket (18570) from the heater air plenum assembly.
Remove the four retaining screws from the heater core cover (18B300) and remove the heater core cover from the heater air plenum chamber assembly.
Drain the engine coolant. Refer to Section 03-03 for the procedure.
Disconnect the battery ground cable (14301).
Disconnect the heater water hoses (18472) from the heater core (18476) at the bulkhead.
Remove the instrument panel lower center panel (04494). Refer to Section 01-12 for the removal procedure.
Remove the glove compartment and LH instrument panel lower cover (044L97). Refer to Section 01-12 for the removal procedure.
Remove the instrument panel ash receptacle (04810).
Remove the two upper center instrument panel finish panel screws and the two lower center instrument panel finish panel screws.
Remove the center instrument panel finish panel (044D70) and disconnect the cigar lighter socket and cigar lighter illumination lamp electrical connectors.
Remove the four radio chassis bracket screws and pull the radio chassis (18806) and climate control assembly from the instrument panel (04320). Disconnect the radio chassis electrical connectors, the antenna lead, the three climate control electrical connectors and remove the radio chassis and climate control assembly.
Remove the two heater outlet floor duct screws. Remove the heater outlet floor duct (18C433).
Remove the four RH instrument panel lower reinforcement bolts and the RH instrument panel lower reinforcement (045F08), then the four LH instrument panel lower reinforcement and the LH instrument panel lower reinforcement.
Remove the anti-lock brake control module (2B373). Refer to Section 06-09 for the removal procedure.
If equipped, remove the speed control amplifier. Refer to Section 10-03 for the removal procedure.
Remove the electronic door lock control processor (14B001). Refer to Section 01-14A for the removal procedure.
Remove the passive restraint control module. Refer to Section 01-20B for the removal procedure.
Remove the two center duct screws and remove the center duct (19D633).
Remove the two ground wire bolts.
Remove the three U-bracket-to-chassis nuts.
Remove the four U-bracket bolts and remove the U-bracket.
Remove the two RH and the two LH instrument panel bracket bolts and remove the instrument panel brackets (042C74).
Remove the RH inner duct.
Remove the LH inner duct.
Remove the two accelerator pedal and shaft bolts and then the accelerator pedal and shaft (9725).
Remove the accelerator pedal stop screw and then the accelerator pedal stop (9816).
Remove the heater outlet duct screw and remove the heater outlet duct.
Remove the temperature blend/panel bypass door actuator motor. Refer to the procedure in this section.
Remove the panel/floor/defrost door actuator motor. Refer to the procedure in this section.
Remove the three A/C evaporator register duct screws and remove the A/C evaporator register duct.
NOTE: The A/C evaporator/blower motor assembly does not have to be removed in order to remove the heater assembly.
Remove the four A/C evaporator/blower motor assembly screws to aid in the removal of the heater assembly.
Ok , I will try to guide you as simple as I can :
1- Remove the Heater / Cooler unit this is how :
* Disconnect Battery ground cable * Recover AC gas or empty it in open space * Drain radiator coolant only * Remove instrument panel for access * From under the hood disconnect AC pipes at the evaporator , by removing bolts , discarding O-Rings and make sure to install blanking plugs so that no dirt goes in. * Disconnect heater hoses from heater matrix pipes , by releasing the spring band clips and make sure to blank the pipes * From inside the car , remove driver footwell duct , by removing the screw and then removing the duct * Remove upper steering column lower fixing , nuts and bolts * Remove upper steering column upper fixings (Bolts) , and allow column to rest down o the floor * Cut cable tie which secures console harness to LH blower duct * Remove LH fan motor duct (screws) * Remove passenger side footwell vent (nut) * Cut cable tie securing console harness to RH blower duct. * Remove RH fan motor duct (screws) * Disconnect Heater/Cooler Connector * Disconnect drain tubes from Heater/cooler assembly * Disconnect A/CCM connectors * Remove evaporator pipe support bracket fixing. * Remove Heater/Cooler assembly fixing , by removing lower nut and upper nut * Remove tape securing RH rear footwell intermediate duct joint. Remove duct to clear access * Remove tape securing LH rear footwell duct * Remove Heater/Cooler assembly from car.
2- Remove AC control module
3- Remove evaporator pipe seal plate
4- Disconnect heater tempreture sensor
5- Remove footwell servo motor from heater/cooler unit
* Disconnect connector * Remove screws * Remove motor complete with bracket
6- Disconnect evaporator sensor connector
* Detach heater/cooler connector * Detach evaporator sensor connector * disconnect connector
7- By now you can see one upper and one lower case
* Remove heater/coolent unit upper case from lower case * Remove screw * Remove 15 clips * Remove upper case from lower
8- Remove evaporator from case
* Remove sensor and clip
You are done , make sure to replace all seals that you see to make sure that every thing is ok and you do not have any leaks after installation.
Installation :
Reverse order and after installing make sure to do a pressure test to make sure that there are no leaks
here is a step by step diagram to replace your heater core
Front
Disconnect the negative battery cable.
Drain the cooling system.
Remove the instrument panel glove compartment.
Tag and unplug all electrical leads as necessary.
Remove the center air distribution duct from the floor.
If necessary, remove the ECM and mounting tray.
Remove the hinge pillar trim panels.
Remove the blower motor cover and then remove the motor.
Remove the steering wheel and tilt back the instrument panel slightly.
Remove the coolant overflow tank. Disengage the heater hoses at the core connections.
Unfasten the attaching screws and nut and then remove the heater case.
Remove the seven screws and lift off the heater case cover.
Remove the fasteners and brackets that hold the heater core to the case and lift the core from the case.
To install:
Install the heater core in the case.
Install the heater case bottom plate. Make sure there is a good seal.
Install the heater case into the truck. Tighten the 4 lower screws to 17 inch lbs. (2 Nm); the upper screw to 97 inch lbs. (11 Nm); and the nuts to 25 inch lbs. (2.8 Nm).
Connect the heater hoses at the core tubes.
Install the coolant overflow tank.
Install the instrument panel and the steering wheel.
Install the blower motor and cover.
Install the trim panels and if removed, the ECM. Install the air distribution duct and reconnect all electrical leads.
Install the glove compartment. Fill the cooling system and connect the battery cable.
Disconnect the negative battery cable.
Drain the engine cooling system into a clean container for reuse.
Disconnect the heater hoses from the heater core.
Remove the instrument panel storage compartment.
Disconnect the electrical connectors, as necessary, that may be in the way.
Remove the center floor air distribution duct.
Remove the hinge pillar trim kick panels.
Remove the blower motor cover screws and the cover.
Remove the blower motor screws and the blower motor.
Remove the steering wheel and the steering column (standard & tilt).
Remove the instrument panel fasteners and pull the instrument panel back far enough to gain access to the heater assembly.
While holding the heater assembly against the firewall, remove the screw located on the interior side near the evaporator pipe, if equipped.
In the engine compartment, remove the 4 heater assembly-to-chassis screws and the 2 heater assembly-to-chassis nuts.
NOTE
Removal of the heater assembly may require the help of an assistant.
Remove the 7 heater cover-to-heater assembly screws and the cover.
Remove the heater core from the heater assembly.
View of the front heater assembly—Chevy/GMC C/K-Series, Blazer, Jimmy, Sierra, Suburban, Tahoe, Yukon Click to Enlarge
Location of the front heater assembly-to-chassis fasteners—Chevy/GMC C/K-Series, Blazer, Jimmy, Sierra, Suburban, Tahoe, Yukon Click to Enlarge
To install:
Install the heater core to the heater assembly.
Install the heater cover and the 7 heater cover-to-heater assembly screws.
NOTE
Installation of the heater assembly may require the help of an assistant.
In the engine compartment, install the 4 heater assembly-to-chassis screws and the 2 heater assembly-to-chassis nuts. Torque the screws to 17 inch lbs. (1.9 Nm) and the nuts to 25 inch lbs. (2.8 Nm).
While holding the heater assembly against the firewall, install the screw located on the interior side near the evaporator pipe, if equipped. Torque the screw to 97 inch lbs. (11 Nm).
Install the instrument panel and the instrument panel fasteners.
Install the steering column (standard & tilt) and the steering wheel.
Install the blower motor and the blower motor screws.
Install the blower motor the cover and the cover screws.
Install the hinge pillar trim kick panels.
Install the center floor air distribution duct.
Connect the electrical connectors that were disconnected.
Install the instrument panel storage compartment.
Disconnect the heater hoses to the heater core.
Refill the engine cooling system.
Connect the negative battery cable.
Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
lines are disconnected and from engine side you can feel a soft foam around the lines to seal the holes off. so don't think there is any tar there.i pulled heater core cover off and core.but can't get evaporator cover off.i can pry open the front side of that compartment but i dont know what is holding it together against the firewall.does it somehow snap together in the back to eliminate screws back there?
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