For 1990-2009 cars

### Removal Procedure

1. For vehicles equipped with air conditioning (A/C) remove the block connector and the refrigerant lines from expansion valve.

1.1. | Remove the bolt.

1.2. | Detach the refrigerant lines.

Important: If installation is postponed, close off lines and connections.

2. Remove the thermostatically controlled expansion valve (TXV) (1).

Insert the bolt, block connector refrigerant line in the expansion valve (2) and remove the expansion valve.

3. For vehicles equipped with A/C, remove the expansion valve retaining plate.

Important: Depressurize the cooling system by opening and re-closing closure cap on coolant compensation tank.

4. Drain the coolant.

Collect the coolant in a drip pan.

5. Remove the condensation drain hose (1).

Remove the 2 bolts.

Important: Mark the coolant hose (3) and connection (2) before removal to avoid confusion when refitting.

6. Disconnect the coolant hose.

6.1. | Detach the 2 coolant hoses.

6.2. | Release the 2 quick-release fittings.

7. Remove the instrument panel (I/P) trim panel. Refer to Instrument Panel Trim Panel Replacement .
8. Remove the inflatable restraint I/P module. Refer to Inflatable Restraint Instrument Panel Module Replacement .
9. Remove the air inlet screen (1).
10. Remove the windshield wiper arms (2).

10.1. | Remove the 2 covers.

10.2. | Remove the 2 nuts.

10.3. | Remove the 2 washers.

10.4. | Detach the 2 wiper arms from the shaft.

11. Remove the air inlet screen (1).

11.1. | Lift the air inlet screen trim in dash area.

| Important: Carefully release the clips from the dash bracket from inside outward.

11.2. | Release the 5 clips (3).

11.3. | Remove the hose (2) from the windshield washer system.

12. Remove the air distributor housing from dash outside.

Remove the 8 bolts.

13. Disconnect the wiring harness plug from the fan series resistor (2).

• | Disconnect the wiring harness plug.

• | Release and disconnect the wiring harness plug.

14. Remove the front floor console bracket (1) and (3).

Remove the 2 bolts.

15. Remove the I/P tie bar. Refer to Instrument Panel Tie Bar Replacement .
16. Remove the HVAC module assembly.

### Installation Procedure

1. With the aid of an assistant, insert the HVAC module assembly.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the HVAC module assembly to the dash outside.

Tighten
Tighten the 8 bolts to 10 N·m (89 lb in).

3. Install the I/P tie bar. Refer to Instrument Panel Tie Bar Replacement .
4. Install the center I/P bracket.

Tighten
Tighten the 2 bolts to 13 N·m (113 lb in).

5. Install the inflatable restraint I/P module. Refer to Inflatable Restraint Instrument Panel Module Replacement .
6. Attach the coolant hoses to the heater core.

6.1. | Slide the 2 locks on the quick-release fittings in the arrow direction up to the stop.

6.2. | The plastic rings (green) are covered.

6.3. | Attach the 2 quick-release fittings on the heater core (1) connections up to the stop.

6.4. | Slide 2 locks (3) on the quick-release fittings in the arrow direction up to the stop.

Note the markings applied.

6.5. | The plastic rings (green) must be visible.

6.6. | Inspect the correct seat of quick-release fittings and visibility of the plastic rings.

7. Install the air inlet screen.

7.1. | Install the windshield washer hose.

7.2. | Install the 5 clips.

Important: Ensure the screen wiper arms are correctly positioned.

8. Install the windshield wiper arms.

8.1. | Attach the 2 wiper arms to shaft.

8.2. | Install the 2 washers.

Tighten
Tighten the 2 nuts to 17 N·m (13 lb ft).

8.3. | Install the 2 cover caps.

9. Install the air inlet screen.
10. Install the I/P trim panel. Refer to Instrument Panel Trim Panel Replacement .
11. Install the condensation drain.

Tighten
Tighten the 2 bolts to 5 N·m (44 lb in).

12. For vehicles equipped with A/C, insert the retaining plate expansion valve.
13. For vehicles equipped with A/C, install the TXV.

13.1. | Use new sealing rings, before installation moisten only green colored sealing rings with mineral oil and insert.

13.2. | Install the service threaded rods (2) into the retaining clip (1) to guide expansion valve.

13.3. | Push the expansion valve onto service threaded rods until the refrigerant lines lie in the expansion valve.

13.4. | Replace the threaded rods in succession with fixing bolts.

Tighten
Tighten the expansion valve bolts to 6 N·m (19 lb ft).

14. Attach the block connector.

Use new sealing rings, before installation moisten only green colored sealing rings with mineral oil and insert.

Tighten
Tighten the block connector bolt to 7 N·m (62 lb in).

15. For vehicles equipped with A/C, recharge and top up the A/C system. Refer to Refrigerant Recovery and Recharging .
16. Fill and bleed the cooling system. Refer to Cooling System Draining and Filling .

Important: Perform inspection for leaks with utmost care as hot coolant will escape into the driver footwell if there are leaks in coolant connections at the heater core.

17. Inspect the coolant system for leaks. Refer to Cooling System Leak Testing .