Heater Box, Disassembling and Assembling

Heater box, disassembling and assembling

Note: Seal off area -A- with silicon rubber compound (commercially available) when assembling the two housing halves.

The illustration shows two different heater box component arrangements:
Components marked with 1) are used with automatic climate control only
Components marked with 2) are used with manual A/C only









1. Control flap for instrument panel air outlets
2. Screw
3. Locking clips

4. Lever for footwell/defroster control flap 1)
Red

5. Turbulence flap retaining assembly
Installed position, Fig. 1

6. Fresh air blower series resistance with fuse -N24- 2)
Housing color: orange

6a. Mounting bracket for fresh air blower ambient temperature sensor-GIO9- 1)
7. Snap ring
8. Washer
9. Grommet
10. Left housing half
Aligning flaps, Fig. 2

11. Retaining clips
7x on perimeter

12. Mounting tabs for fresh air blower
Coat lightly with petroleum jelly

13. Fresh air blower -V2-
Removing and installing, Fig. 7

14. Heater core
Removing and installing, Fig. 3
Sealing left housing half, Fig. 4

15. Temperature flap
In front of heater core

16. Temperature flap
Behind heater core

17. Seal
18. Screw
19. Footwell/defroster flap 2)
19a. Footwell/defroster flap 1)
20. Stop pins 2)
21. Adhesive tabs
22. Turbulence flap

23. Sealing cord
Install around entire left housing half

24. Right housing half
25. Intake duct
26. Bearing
27. Temperature flap lever
Assembling, Fig. 5

28. Retaining washers
29. Locking clip 1)

30. Center flap lever 2)
For footwell/defroster and instrument panel air outlets

31. Flap lever 1)
For instrument panel air outlets
Blue

32. Screw

Fig. 1 Turbulence flap attachment




- Install turbulence flap retaining assembly (washer, felt ring, and locking clip -A-).

Fig. 2 Aligning flaps in left housing half




- Using aligning tool -2076 A-, install flaps -A-, -B- and -C-, left to right, as shown.

Note: On vehicles with automatic climate control, install flap -B- turned 180° (1/2-turn).

Fig. 3 Applying self-adhesive seal to heater core

Heater Core:

- Install seal (as shown) so there are no gaps around perimeter of heater core.

Fig. 4 Sealing heater core outlet (at left housing half)




- After installing heater core, fill area -A- with silicon rubber sealant (commercially available).

Fig. 5 Assembling temperature flap levers




- Assemble temperature flap levers as shown.
- Install assembly on heater box.

Fig. 7 Removing and installing fresh air blower -V2-

Fresh Air Blower -V2-:

Remove plenum tray
Remove heater box
Remove intake duct with fresh air flap
Remove locking clip, retaining washer and gromment