Monday, June 20, 2011

How to replace heater core on Mitsubishi car?

3000GT



  1. Disconnect the negative battery cable.
  2. Drain the cooling system into a clean container for reuse.
  3. Disconnect the heater hoses from the heater core.
  4. Disconnect the refrigerant lines from the evaporator core and discard the O-rings.
    CAUTION
    After disconnecting the negative battery cable, wait at least 60 seconds before working on the SRS module or instrument panel.

  5. Remove the passenger-s side air bag by removing or disconnecting the following:

    Glove box assembly
    Cross pipe cover
    Air bag-to-dash bolts and the air bag; then, disconnect the electrical connector

  6. Remove the floor console.
  7. Remove the instrument panel by removing or disconnecting the following:

    Hood lock release handle
    Rheostat
    Switch garnish -B-
    Knee protector assembly
    Steering column cover
    Center outlet assembly
    Heater control assembly-to-dash screws
    Meter bezel and the combination bezel
    Speaker or plug and disconnect the harness connector
    Steering column-to-dash bolts and lower the steering column
    Instrument panel-to-dash bolts
    Instrument panel from the vehicle with the help of an assistant

  8. Install or connect the following:

    Center reinforcement
    Under cover
    Foot distribution duct
    Foot shower duct
    Evaporator housing-to-heater housing nut and bolt
    Center duct
    Heater housing unit
    Heater housing plate and the heater core from the housing

    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel and related components-Mitsubishi 3000GT



    Click image to see an enlarged view

    Fig. Exploded view of the heater case and related components-Mitsubishi 3000GT



    Click image to see an enlarged view

    Fig. Exploded view of the floor console and related components-Mitsubishi 3000GT



To install:

  1. Install or connect the following:

    Heater housing plate and the heater core to the housing
    Heater housing unit
    Center duct
    Evaporator housing-to-heater housing nut and bolt
    Foot shower duct
    Foot distribution duct
    Under cover
    Center reinforcement

  2. Install the instrument panel by installing or connecting the following:

    Instrument panel to the vehicle with the help of an assistant
    Instrument panel-to-dash bolts
    Steering column-to-dash and the steering column bolts
    Speaker or plug and connect the harness connector
    Meter bezel and the combination bezel
    Heater control assembly-to-dash screws
    Center outlet assembly
    Steering column cover
    Knee protector assembly
    Switch garnish -B-
    Rheostat
    Hood lock release handle

  3. Install the floor console.
  4. Install the passenger-s side air bag by installing or connecting the following:

    Air bag-to-dash bolts and the air bag; then, connect the electrical connector
    Cross pipe cover
    Glove box assembly

  5. Using new O-rings, connect the refrigerant lines to the evaporator core.
  6. Connect the heater hoses to the heater core.
  7. Refill the cooling system.
  8. Connect the negative battery cable.

Diamante





Click image to see an enlarged view

Fig. Heater core and related components exploded view-1992-96 Diamante



Click image to see an enlarged view

Fig. Heater core and related components exploded view-1997-00 Diamante

  1. Disarm the air bag. Refer to the procedure earlier in this section.
  2. Drain the cooling system and disconnect the heater hoses from the core tubes. Plug the hoses.
  3. Remove the passenger side undercover.
  4. Remove the right side foot shower duct.
  5. To remove the console, remove the ashtray and remove the revealed screw. Then remove the 4 screws from the sides of the assembly and remove.
  6. Remove the decorative plugs from the driver's knee protector. Remove the revealed screws, the knee protector assembly and the protector support bracket.
  7. Remove the steering column covers.
  8. Remove the glove box striker, glove box, glove box outer casing and the screw below the assembly.
  9. Remove the radio bezel and the stereo entertainment system.
  10. Remove the climate control system control head.
  11. Remove the cup holder.
  12. Remove the speakers from the top of the instrument panel.
  13. Remove the instrument cluster bezel and the instrument cluster.
  14. To remove the speedometer cable adapter from the instrument panel, first disconnect the speedometer cable from the transaxle. Then unlock the adapter from the instrument panel, pull the speedometer cable slightly inwards, and remove the adapter.
  15. Detach all steering column connectors, remove the column mounting bolts, and allow the steering column to rest on the front seat. Be very careful not to allow anything to come in contact with the air bag unit.
  16. Remove the glove box lamp assembly.
  17. Remove the remaining instrument panel mounting screws and remove the instrument panel from the vehicle.
  18. Remove the left side foot shower ductwork, lap cooler duct and center duct.
  19. Remove the front and center reinforcements and center stay assembly.
  20. Remove the air distribution duct assembly.
  21. Detach all connectors from heater-box-mounted items.
  22. Remove the heater box mounting screws and nut, then remove the unit from the vehicle.
  23. Disassemble on a workbench. Remove the heater core from the heater case.

To install:

  1. Thoroughly clean and dry the inside of the case and install the heater core and all related parts.
  2. Install the heater unit to the vehicle and install the mounting screws and nut. Be sure the evaporator case and heater case are fitted together properly. Attach all connectors to heater-box-mounted items.
  3. Install the air distribution duct assembly. Install the front and center reinforcements and center stay assembly.
  4. Install the center duct, lap cooler duct and left side foot shower duct.
  5. Install the instrument panel and mounting screws.
  6. Install the glove box lamp assembly.
  7. Secure the steering column and attach all steering column connectors.
  8. Install the speedometer cable adapter to the instrument panel.
  9. Install the instrument cluster and the instrument cluster bezel.
  10. Install the speakers to the top of the instrument panel.
  11. Install the cup holder.
  12. Install the climate control system control head.
  13. Install the stereo entertainment system and bezel.
  14. Install the screw below the glove box assembly, and the entire glove box unit.
  15. Install the steering column covers.
  16. Install the knee protector support bracket, the protector and the decorative plugs.
  17. Install the console and the ashtray.
  18. Install the right side foot shower duct.
  19. Install the passenger side undercover.
  20. Connect the heater hoses to the core tubes.
  21. Fill the cooling system.
  22. Connect the negative battery cable and check the entire climate control system for proper operation and leaks.

  1. Disconnect the negative battery cable.
  2. Drain the cooling system into a clean container for reuse.
  3. Discharge and recover the air conditioning system refrigerant.
  4. Remove or disconnect the following:
    CAUTION
    After disconnecting the negative battery cable, wait at least 60 seconds before working on the SRS module or instrument panel.



    Heater hoses from the heater core
    Refrigerant lines from the evaporator core and discard the O-rings

  5. Remove the passenger-s side air bag by removing or disconnecting the following:

    Dash undercover
    Glove box assembly
    Glove box case
    Air bag-to-dash bolts and the air bag; then, disconnect the electrical connector

  6. Remove or disconnect the following:

    Floor console
    Front pillar trim at both sides

  7. Remove the instrument panel by removing or disconnecting the following:

    Steering column covers
    Hood lock release handle
    Parking brake release handle
    Lower left side instrument panel cover
    Ignition key cylinder panel
    Instrument panel ECU and remove the ECU
    Instrument panel meter bezel and the combination meter
    Center air outlet assembly
    Ashtray
    Air conditioning control panel assembly and the audio unit
    Console side cover assembly
    Floor carpet rear reinforcement
    Electrical harness connector and plug
    Steering column mounting bolts and lower the steering column assembly
    Instrument panel with the help of an assistant

  8. Remove or disconnect the following:

    ECU bracket
    Center stay assembly
    Heater hose connection and the center duct assembly
    Foot distribution duct and the breather hose
    Refrigerant lines from the evaporator and discard the O-rings
    Air conditioning housing drain hose and remove the evaporator housing
    Heater housing unit
    Heater core support and the heater core

    Click image to see an enlarged view

    Fig. Exploded view of the heater core, heater housing and related components-Diamante



To install:

  1. Install or connect the following:

    Heater core support and the heater core
    Heater housing unit
    Air conditioning housing drain hose and Install the evaporator housing
    Refrigerant lines to the evaporator using new O-rings
    Foot distribution duct and the breather hose
    Heater hose connection and the center duct assembly
    Center stay assembly
    ECU bracket

  2. Install the instrument panel by installing or connecting the following:

    Instrument panel with the help of an assistant
    Steering column assembly and the steering column mounting bolts. Torque the bolts to 84 inch lbs. (10 Nm)
    Electrical harness connector and plug
    Floor carpet rear reinforcement
    Console side cover assembly
    Air conditioning control panel assembly and the audio unit
    Ashtray
    Center air outlet assembly
    Instrument panel meter bezel and the combination meter
    Instrument panel ECU and connect the ECU electrical connector
    Ignition key cylinder panel
    Lower left side instrument panel cover
    Parking brake release handle
    Hood lock release handle
    Steering column covers

  3. Front pillar trim at both sides
  4. Floor console
  5. Install the passenger-s side air bag by installing or connecting the following:

    Air bag-to-dash bolts and the air bag; then, connect the electrical connector
    Glove box case
    Glove box assembly
    Dash undercover
    Refrigerant lines to the evaporator core using new O-rings
    Heater hoses to the heater core

  6. Refill the cooling system.
  7. Connect the negative battery cable.
  8. Evacuate, charge and leak test the air conditioning system.
  9. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

Eclipse



1999 Models

CAUTION
If equipped with an air bag, wait for 1 minute after disconnecting the negative battery cable before working inside the vehicle. The air bag system is set to deploy for a short period of time after the battery is disconnected.

  1. Drain the engine coolant into a suitable container.
  2. Remove the instrument panel, as outlined in Section 10 of this manual.
  3. Disconnect the heater hose connections.
  4. Remove the center stay and duct.
  5. Remove the semi rear heater duct.
  6. Remove the foot distribution duct.
  7. If equipped with A/C, remove the cooling unit bolt and nut.
  8. Remove the retaining clip by using a Philips-head screwdriver to push the pin (in the center of the clip) in about 0.08 in. (2mm), then pull the clip out to remove it.
    WARNING
    Do not push the pin in more than necessary because the grommet may be damaged or the pin may fall in.

  9. Remove the heater unit after sliding the cooling unit toward you slightly.
  10. Remove the heater core from the vehicle.

    Click image to see an enlarged view

    Fig. Heater core and related components-1999 Eclipse


To install:

  1. Position the heater core in the vehicle.
  2. Install the heater unit.
  3. Install the retaining clip by inserting with the pin pulled out, then pushing the pin inward until the head is flush with the grommet.
  4. If equipped with A/C, install the cooling unit bolt and nut.
  5. Connect the foot distribution duct.
  6. Install the semi rear heater duct.
  7. Install the center duct and stay.
  8. Attach the heater hose connection(s).
  9. Install the instrument panel, as outlined in Section 10 of this manual.

2000-03 Models

CAUTION
If equipped with an air bag, wait for 1 minute after disconnecting the negative battery cable before working inside the vehicle. The air bag system is set to deploy for a short period of time after the battery is disconnected.

  1. Before servicing the vehicle, refer to the Precautions section.
  2. Disconnect the negative battery cable.
  3. Drain the cooling system into a clean container for reuse.
  4. Disconnect the heater hoses from the heater core tubes at the firewall. Do not allow the coolant to damage the vehicle speed sensor located below the heater hoses on the non-turbo manual transmission vehicles.
    WARNING
    To prevent damage to the air bag control unit during removal or installation of the floor console, avoid shocks or impact. Do not drop.

  5. Remove the floor console by removing or disconnecting the following:

    Center console trim panel
    Ashtray and cup holder assembly
    Shift lever knob on manual transmission
    Retaining screws
    Floor console assembly

  6. Locate the rectangular plugs in the knee protector on either side of the steering column. Pry these plugs out and remove the screws.
  7. Remove or disconnect the following:

    Driver-s side air bag assembly, the steering wheel and the passenger-s side air bag assembly
    Lap cooler duct and steering column covers
    Instrument cluster bezel and then the instrument cluster
    Radio
    Glove box
    Center air outlet assembly
    Hood release handle and the lower cover
    Heater control assembly
    Front speakers and the instrument panel switch
    Steering shaft support bolts and lower the steering column
    Instrument panel mounting hardware and remove the instrument panel from the vehicle
    Stamped steel center reinforcement
    Lower ductwork from the heater box
    Evaporator case mounting bolt and nut to allow clearance for the heater unit removal
    Heater unit
    Heater core from the heater unit

    Click image to see an enlarged view

    Fig. Exploded view of the heater core, heater case and related components-Eclipse



To install:

  1. Install or connect the following:

    Heater core to the heater unit
    Heater unit
    Evaporator case mounting bolt and nut
    Lower ductwork to the heater box
    Stamped steel center reinforcement
    Instrument panel and the instrument panel mounting hardware
    Steering column and the steering shaft support bolts
    Front speakers and the instrument panel switch
    Heater control assembly
    Hood release handle and the lower cover
    Center air outlet assembly
    Glove box
    Radio
    Instrument cluster and the instrument cluster bezel
    Steering column covers and the lap cooler duct
    Steering wheel, the driver-s side air bag assembly and the passenger-s side air bag assembly
    Screws and the rectangular plugs in the knee protector on either side of the steering column

  2. Install the floor console by installing or connecting the following:

    Floor console assembly
    Retaining screws
    Shift lever knob on manual transmission
    Ashtray and cup holder assembly
    Center console trim panel
    Center console trim panel

  3. Connect the heater hoses to the heater core tubes at the firewall.
  4. Refill the cooling system.
  5. Connect the negative battery cable.
  6. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

2004-05 Models

CAUTION
Wait for 1 minute after disconnecting the negative battery cable before working inside the vehicle. The air bag system is set to deploy for a short period of time after the battery is disconnected.

  1. Disconnect the negative battery cable. Drain the cooling system. Discharge the air conditioning system. Be sure the front tires are in the straight ahead position.
  2. Remove the center console box assembly, lid assembly (except Eclipse RS), door mirror control switch and harness, accessory socket harness, ashtray, top switch and harness (Spyder), shift lever panel assembly and boot (manual transaxle) and garnish (automatic transaxle)
  3. Remove the front and rear floor console retaining screws. Remove the front and rear consoles.
  4. Remove the driver-s air bag module. Remove the steering wheel nut. Remove the steering wheel. Remove the cover.
  5. Remove the auto-cruise control switch. Remove the instrument panel under cover switch. Remove the lower column cover. Remove the upper column cover.
  6. Remove the clock spring and column switch assembly.
  7. If equipped with automatic transaxle remove the cover and key interlock cable.
  8. Remove the steering shaft assembly. Remove the steering cover assembly.
    NOTE
    The tilt lever should be held in the lock position until the steering column is reinstalled in the vehicle. If the column is removed with the lever released, or the lever released after the column is removed from the vehicle, the steering column cannot be reinstalled correctly. If the steering column is installed incorrectly, the collision energy absorbing mechanism may be damaged.

  9. Remove the front pillar trim panel. Remove the instrument panel side cover. Remove the fog lamp switch assembly.
  10. Remove the hood release handle. Remove the meter bezel assembly. Remove the center panel assembly.
  11. Remove the center air outlet. Remove the radio assembly. Remove the heater control assembly.
  12. Remove the center hood. Remove the multi center display. Remove the center speaker. Remove the inner and outer glove box and light switch. Remove the glove box striker.
  13. Remove the passenger-s side air bag module. Remove the instrument panel assembly.
  14. Remove the instrument panel reinforcement and both knee absorbers.
  15. Remove the auto-cruise control ECU and the immobilizer ECU.
  16. Remove the instrument panel center reinforcement. Remove the joint duct.
  17. Remove the strut tower bar assembly.
  18. Remove the air intake hose. Remove the air conditioning pipe connection, expansion valve, heater hose, thermistor sensor.
  19. Remove the evaporator. Remove the automatic compressor controller. Remove the water shut motor.
  20. Remove the heater core.

    Click image to see an enlarged view

    Fig. Heater core and related components-2004-2005 Eclipse


To install:

  1. Installation is the reverse of the removal procedure.
    NOTE
    The tilt lever should be held in the lock position until the steering column is reinstalled in the vehicle. If the column is removed with the lever released, or the lever released after the column is removed from the vehicle, the steering column cannot be reinstalled correctly. If the steering column is installed incorrectly, the collision energy absorbing mechanism may be damaged.

  2. Be sure to fill the cooling system with the proper grade and type coolant.
  3. Recharge the air conditioning system.

Evolution




CAUTION
Wait for 1 minute after disconnecting the negative battery cable before working inside the vehicle. The air bag system is set to deploy for a short period of time after the battery is disconnected.

  1. Disconnect the negative battery cable. Drain the cooling system. Discharge the air conditioning system. Be sure the front tires are in the straight ahead position.
  2. Remove the front seat.
  3. Remove the column cover. Remove the meter bezel. Remove the combination meter.
  4. Remove the instrument panel ornament. Remove the under cover, switch panel, switch holder and lower frame.
  5. Remove the heater control knob, center panel and heater control assembly.
  6. Remove the radio and CD player.
  7. Remove the center air outlet panel and the center lower case, if equipped.
  8. If equipped with a CD changer, remove the center lower panel.
  9. Remove the stopper, glovebox and harness cover. Remove the instrument panel side cover.
  10. Remove the passenger-s side air bag module mounting bolt and air bag module.
  11. Remove the steering column cover. Remove the driver-s side air bag module. Remove the steering wheel.
  12. Remove the steering column clock spring and column switch assembly. Remove the shaft cover.
  13. Remove the steering column shaft assembly. Remove the cover assembly.
    NOTE
    The tilt lever should be held in the lock position until the steering column is reinstalled in the vehicle. If the column is removed with the lever released, or the lever released after the column is removed from the vehicle, the steering column cannot be reinstalled correctly. If the steering column is installed incorrectly, the collision energy absorbing mechanism may be damaged.

  14. Remove the instrument panel assembly.
  15. Remove the console side cover, shift lever knob and front floor console assembly.
  16. Remove the front floor console panel. If equipped with manual transaxle remove the shift lever cover.
  17. Remove the shift lever bezel, lighter and ashtray.
  18. Remove the console retaining screws. Remove the console from the vehicle. Remove the electrical harness and bracket assembly, as required.
  19. Remove the front deck crossmember. Remove the heater hoses. Remove the air conditioning lines. Remove the center duct. Remove the heater unit, intake duct and blower assembly from the vehicle.
  20. Remove the heater core.

    Click image to see an enlarged view

    Fig. Heater core and related components-Evolution


To install:

  1. Installation is the reverse of the removal procedure.
    NOTE
    The tilt lever should be held in the lock position until the steering column is reinstalled in the vehicle. If the column is removed with the lever released, or the lever released after the column is removed from the vehicle, the steering column cannot be reinstalled correctly. If the steering column is installed incorrectly, the collision energy absorbing mechanism may be damaged.



    Click image to see an enlarged view

    Fig. Steering column installation-Evolution

  2. If the steering column shaft was removed accidentally, remove the steering column assembly and be sure to insert the steering column shaft using the alignment illustration.
  3. Be sure to fill the cooling system with the proper grade and type coolant.
  4. Recharge the air conditioning system.

Galant



  1. Disconnect the negative battery cable.
    CAUTION
    After disconnecting the negative battery cable, wait at least 60 seconds before working on the SRS module or instrument panel.

  2. Drain the cooling system into a clean container for reuse.
  3. Disconnect the heater hoses from the heater core at the firewall.
    WARNING
    To prevent damage to the air bag control unit during removal or installation of the floor console, avoid shocks or impact. Do not drop.

  4. Remove the floor console by removing or disconnecting the following:

    Shift lever knob on manual transmission vehicles or the shift indicator plate on automatic transmissions
    Coin holder behind the shifter, then the center console trim cover in front of the shifter
    Center console retaining bolt cover plugs, then remove the bolts
    Console assembly, then the brackets

  5. Remove or disconnect the following:

    Steering column covers
    Instrument cluster bezel and then the instrument cluster
    Instrument panel switch, hood lock release handle and the lower duct work
    Driver-s knee protector and the left side air outlet cover
    Center panel assembly
    Glove box undercover, then the glove box and the right side panel cover
    Radio and cup holder
    Cables from the heater assembly and the blower, then pull out the heater control panel assembly, noting the location of the boss in the center reinforcement
    Cool air bypass damper lever cable connection
    Passenger-s side air bag module and disconnect the harness connector, if equipped
    Steering column bolts and lower the column
    Harness connector at the lower left side of the instrument panel
    Instrument panel mounting hardware and remove the instrument panel from the vehicle
    Joint duct between the heater case and the blower assembly (on models without air conditioning)
    Both stamped steel center reinforcement piece
    ECM bracket
    Evaporator retaining nut and remove the heater case assembly, if equipped with air conditioning
    Heater core from the case

    Click image to see an enlarged view

    Fig. Exploded view of the heater core, heater housing and related components-1999-2003 Galant



To install:

  1. Install or connect the following:

    Heater core to the case
    Evaporator retaining nut and Install the heater case assembly, if equipped with air conditioning
    ECM bracket
    Both stamped steel center reinforcement pieces
    Joint duct between the heater case and the blower assembly (on models without air conditioning)
    Instrument panel and install the instrument panel mounting hardware
    Harness connector at the lower left side of the instrument panel
    Steering column bolts
    Passenger-s side air bag module and connect the harness connector, if equipped
    Cool air bypass damper lever cable connection
    Cables to the heater assembly and the blower and install the heater control panel assembly
    Radio and cup holder
    Glove box undercover, then the glove box and the right side panel cover
    Center panel assembly
    Left side air outlet cover and the driver-s knee protector
    Lower duct work, the instrument panel switch and hood lock release handle
    Instrument cluster and the instrument cluster bezel
    Steering column covers

  2. Install the floor console installing or connecting the following:

    Console assembly brackets and the console
    Center console retaining bolts, then the bolt cover plugs
    Coin holder behind the shifter, then the center console trim cover in front of the shifter
    Shift lever knob on manual transmission vehicles or the shift indicator plate on automatic transmissions
    Heater hoses to the heater core at the firewall

  3. Refill the cooling system.
  4. Connect the negative battery cable.
  5. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

2004-05 Models

CAUTION
Wait for 1 minute after disconnecting the negative battery cable before working inside the vehicle. The air bag system is set to deploy for a short period of time after the battery is disconnected.

  1. Disconnect the negative battery cable. Drain the cooling system. Discharge the air conditioning system. Be sure the front tires are in the straight ahead position.
  2. Remove the front seat. Remove the glovebox assembly.
  3. Remove the instrument panel parcel box and glovebox lock. Remove the hood release handle.
  4. Remove the instrument panel under passenger-s side cover. Remove the instrument lower panel. Remove the instrument center panel assembly.
  5. Remove the radio and CD player. Remove the CD changer, if equipped. Remove the accessory box.
  6. Remove the console meter hood. Remove the passenger-s side air bag indicator light and passenger-s seat belt warning light.
  7. If equipped, remove the multi center display. Remove the center console assembly.
  8. Remove the instrument panel cover. Remove the combination meter assembly. Remove the front pillar trim.
  9. Remove the front speaker covers. Remove the speakers. Remove the instrument panel side cover. Remove the instrument panel side air outlet.
  10. Remove the driver-s side air bag module. Remove the steering wheel. Remove the steering column cover. Remove the clock spring connector and clock spring and column switch assembly.
  11. Disconnect the electrical connections for the ignition switch. Remove the key interlock cable.
  12. Remove the steering shaft pad. Remove the steering column retaining bolts. Remove the steering column assembly. Pinch the steering column shaft clip with a pliers, and pull up the shaft to disengage the steering column assembly.
    NOTE
    The tilt lever should be held in the lock position until the steering column is reinstalled in the vehicle. If the column is removed with the lever released, or the lever released after the column is removed from the vehicle, the steering column cannot be reinstalled correctly. If the steering column is installed incorrectly, the collision energy absorbing mechanism may be damaged.

  13. If equipped with automatic temperature, remove the interior temperature sensor and photo sensor. Remove the instrument panel front end garnish.
  14. Remove the gearshift lever handle, heated seat switch, accessory socket, socket cover, front plate and front box.
  15. Remove the lid lock lever, hinge, lid, liner box, accessory socket and cover.
  16. Remove the floor console retaining screws. Remove the floor console. Remove the accessory socket harness and rear bracket.
  17. Remove the cowl side trim. Remove the passenger-s side air bag module.
  18. Remove the instrument panel assembly from the vehicle.
  19. If equipped remove the strut tower retaining bolts and remove the strut tower bar. Remove the battery. Remove the air cleaner body.
  20. Remove the heater hoses, and air condition lines from the evaporator.
  21. Remove the rear heat duct. Remove the heater unit and deck crossmember assembly.
  22. Remove the heater core from the heater case.

    Click image to see an enlarged view

    Fig. Heater core and related components-2004-2005 Galant


To install:

  1. Installation is the reverse of the removal procedure.
    NOTE
    The tilt lever should be held in the lock position until the steering column is reinstalled in the vehicle. If the column is removed with the lever released, or the lever released after the column is removed from the vehicle, the steering column cannot be reinstalled correctly. If the steering column is installed incorrectly, the collision energy absorbing mechanism may be damaged.

  2. If the steering column shaft was removed accidentally, remove the steering column assembly and be sure to insert the steering column shaft using the alignment illustration.
  3. Be sure to fill the cooling system with the proper grade and type coolant.
  4. Recharge the air conditioning system.

    Click image to see an enlarged view

    Fig. Typical heater unit crossmember assembly-all models



    Click image to see an enlarged view

    Fig. Typical strut tower bar assembly-all models


Lancer



  1. Disconnect the negative battery cable.
  2. Drain the cooling system into a clean container for reuse.
  3. Discharge and recover the air conditioning system refrigerant.
  4. Remove or disconnect the following:

    Instrument panel
    Front seat assembly
    Front console assembly
    Front floor carpet
    Steering shaft attachment bolt
    Front deck crossmember
    Heater hoses
    Flexible suction hose
    Liquid pipe B connection
    Center duct

    Click image to see an enlarged view

    Fig. Exploded view of the heater core and related components-Lancer

    Heater unit
    Intake duct
    Blower assembly

  5. Disassemble the heater unit as necessary for access to components,

    Click image to see an enlarged view

    Fig. Disassembly of the heater unit-Lancer


To install:

  1. Assemble the heater unit as necessary.
  2. Install or connect the following:

    Blower assembly
    Intake duct
    Heater unit
    Center duct
    Liquid pipe B connection
    Flexible suction hose
    Heater hoses
    Front deck crossmember
    Steering shaft attachment bolt
    Front floor carpet
    Front console assembly
    Front seat assembly
    Instrument panel

  3. Refill the cooling system.
  4. Connect the negative battery cable.
  5. Evacuate, charge and leak test the air conditioning system.
  6. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

Mirage





Click image to see an enlarged view

Fig. Exploded view of the heater core and related components-1990-92 Mirage



Click image to see an enlarged view

Fig. Heater core and related components-1993-96 Mirage



Click image to see an enlarged view

Fig. Exploded view of the heater core and related components-1997-00 Mirage

  1. Disconnect the negative battery cable.
  2. Drain the cooling system and disconnect the heater hoses.
  3. Remove the front seats by removing the covers over the anchor bolts, the underseat tray, the seat belt guide ring, the seat mounting nuts and bolts and disconnect the seat belt switch wiring harness from under the seat. Then lift out the seats.
  4. Remove the floor console by first taking out the coin holder and the console box tray. Remove the remote control mirror switch or cover. All of these items require only a plastic trim tool to carefully pry them out.
  5. Remove the rear half of the console.
  6. Remove the shift lever knob on manual transmission vehicles.
  7. Remove the front console box assembly.
  8. A number of the instrument panel pieces may be retained by pin type fasteners. They may be removed using the following procedure:

  1. Press down on the center pin with a suitable blunt pointed tool. Press down a little more than 1 / 16 in. (2mm) to release the clip. Pull the clip outward to remove it.
  2. Do not push the pin inward more than necessary because it may damage the grommet or the pin may fall in if pushed in too far. Once the clips are removed, use a plastic trim stick to pry the piece loose.

  1. Remove both lower cowl trim panels (kick panels).
  2. Remove the ashtray.
  3. Remove the center panel around the radio.
  4. Remove the sunglass pocket at the upper left side of panel and the side panel into which it mounts.
  5. Remove the driver's side knee protector and the hood release handle.
  6. Remove the steering column top and bottom covers.
  7. Remove the radio.
  8. Remove the glove box striker and box assembly.
  9. Remove the instrument panel lower cover, 2 small pieces in the center, by pulling forward.
  10. Remove the heater control assembly screw.
  11. Remove the instrument cluster bezel and pull out the gauge assembly.
  12. Remove the speedometer adapter by disconnecting the speedometer cable at the transaxle pulling the cable sightly towards the vehicle interior and giving a slight twist on the adapter to release it.
  13. Insert a small flat-tipped tool to open the tab on the gauge cluster connector. Remove the harness connectors.
  14. Remove, by prying with a plastic trim tool, the right side speaker cover and the speaker, the upper side defroster grilles and the clock or plug to gain access to some of the instrument panel mounting bolts.
  15. Lower the steering column by removing the bolt and nut.
  16. Remove the instrument panel bolts and the instrument panel.
  17. Disconnect the air selection, temperature and mode selection control cables from the heater box and remove the heater control assembly.
  18. Remove the connector for the MFI control relay.
  19. Remove both stamped steel instrument panel supports.
  20. Remove the heater ductwork.
  21. Remove the heater box mounting nuts.
  22. Remove the automatic transmission ELC control box.
  23. Remove the evaporator mounting nuts and clips.
  24. With the evaporator pulled toward the vehicle interior, remove the heater unit. Be careful not to damage the heater tubes or to spill coolant.
  25. Remove the cover plate around the heater tubes and the core fastener clips. Pull the heater core from the heater box, being careful not to damage the fins or tank ends.

To install:

  1. Thoroughly clean and dry the inside of the case. Install the heater core to the heater box. Install the clips and cover.
  2. Install the evaporator and the automatic transmission ELC box.
  3. Install the heater box and connect the duct work.
  4. Connect all wires and control cables.
  5. Install the instrument panel assembly and the console by reversing their removal procedures.
  6. Install the seats.
  7. Refill the cooling system.
  8. Connect the negative battery cable and check the entire climate control system for proper operation. Check the system for leaks.

  1. Disconnect the negative battery cable.
  2. Drain the cooling system into a clean container for reuse.
  3. Remove the air cleaner cover and the air intake hose.
  4. Disconnect the heater hoses from the heater core.
  5. If equipped with air conditioning, discharge and recover the air conditioning system refrigerant.
  6. If equipped with air conditioning, disconnect the refrigerant lines from the evaporator core and discard the O-rings.
    CAUTION
    After disconnecting the negative battery cable, wait at least 60 seconds before working on the SRS module or instrument panel.

  7. Remove the passenger-s side air bag by removing or disconnecting the following:

    Glove box assembly
    Air bag-to-dash bolts and the air bag; then, disconnect the electrical connector

  8. Remove the floor console.
  9. Remove the instrument panel by removing or disconnecting the following:

    Rheostat
    Hood release handle
    Knee protector plug and the knee protector assembly
    Steering column cover
    Meter bezel and the combination meter
    Mirror control switch or plug, if equipped
    Auto-cruise main switch, fog light switch or plug, if equipped
    Side air outlet assembly
    Radio and tape player
    Cup holder
    Heater control panel
    Heater control assembly
    Steering column bolts and lower the steering column
    Instrument panel assembly with the help of an assistant

  10. If not equipped with air conditioning, remove the blower motor-to-heater housing joint duct.
  11. If equipped with air conditioning, remove the evaporator housing-to-heater housing fasteners and remove the evaporator housing.
  12. Remove or disconnect the following:

    Center reinforcement
    Center ventilation duct
    Foot distribution duct
    Heater housing
    Heater core from the heater housing

    Click image to see an enlarged view

    Fig. view of the joint duct and blower motor assembly-Mirage



    Click image to see an enlarged view

    Fig. Exploded view of the heater core, heater housing and related components-Mirage



To install:

  1. Install or connect the following:

    Heater core to the heater housing
    Heater housing
    Foot distribution duct
    Center ventilation duct
    Center reinforcement

  2. If equipped with air conditioning, install the evaporator housing and the evaporator housing-to-heater housing fasteners.
  3. If not equipped with air conditioning, install the blower motor-to-heater housing joint duct.
  4. Install the instrument panel by installing or connecting the following:

    Instrument panel assembly with the help of an assistant
    Steering column and install the steering column bolts
    Heater control assembly
    Heater control panel
    Cup holder
    Radio and tape player
    Side air outlet assembly
    Auto-cruise main switch, fog light switch or plug, if equipped
    Mirror control switch or plug, if equipped
    Combination meter and the meter bezel
    Steering column cover
    Knee protector assembly and the knee protector plug
    Hood release handle
    Rheostat
    Floor console

  5. Install the passenger-s side air bag by installing or connecting the following:

    Electrical connector; then, install the air bag and the air bag-to-dash bolts
    Glove box assembly

  6. If equipped with air conditioning, use new O-rings and connect the refrigerant lines to the evaporator core.
  7. Install or connect the following:

    Heater hoses to the heater core
    Air cleaner cover and the air intake hose

  8. Refill the cooling system.
  9. Connect the negative battery cable.
  10. If equipped with air conditioning, evacuate, charge and leak test the air conditioning system refrigerant.
  11. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

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