Legacy

REMOVAL AND INSTALLATION

1. Disconnect the negative battery cable.

   CAUTION
   If equipped with an air bag system, wait 10 minutes after disconnecting the negative battery cable before performing any further work while the system fully de-energizes in order to avoid accidental deployment. All air bag system wiring is yellow. Do not use electrically powered test equipment on these circuits.

2. Drain the cooling system into a clean container for reuse.
3. Disconnect the heater hoses from the heater core. Plug the heater core and heater hoses.
4. Remove the radio box or console.
5. Remove the instrument panel by:
   • Remove the center console retaining screws and remove the center console assembly.
   • Remove the instrument panel retaining bolt covers by prying them from the panel.
   • Remove the lower part of the front A pillar trim. Remove the instrument panel under covers from the driver's and passenger's sides.
   • Remove the hood release cable from the hood release lever.
   • Disconnect the wiring harness connectors under the instrument panel.
   • Remove the instrument cluster assembly. Remove the glove box assembly
   • Disconnect the ventilation control cables and electrical connectors at the heater unit. Disconnect the vacuum line at the blower housing.
   • Disconnect the radio antenna feeder wire. Disconnect the main harness connector at the fuse box.
   • Remove the lower steering column covers. Remove the steering column retaining bolts and allow the column to hang down.
   • Remove the instrument panel retaining bolts.

   NOTE: When removing the instrument panel, check that all wiring and cables are disconnected before pulling it completely away from the firewall.

6. With the help of an assistant, lift and remove the instrument panel from the vehicle.
7. Disconnect the heater control cables and the fan motor wiring harness.
8. Disconnect the duct between the heater unit and the blower heater unit. Lift up and out on the heater unit and remove it.
9. Remove the evaporator case assembly by performing the following procedure:
   • Discharge and recover the air conditioning system refrigerant.
   • Disconnect the low and high pressure line from the evaporator outlet and cap the fittings.
   • Remove the inlet and outlet pipe grommets.
   • Remove the glove box and support bracket.
   • Disconnect the air conditioning wiring harness from the evaporator. Disconnect the drain hose from the evaporator.
   • Remove the evaporator mounting nut and bolt.
   • Remove the evaporator case assembly from the vehicle.
10. With the heater assembly out of the vehicle, remove the heater core tube retaining clamps and lift the core from the heater case.
11. Remove the heater core.

    Exploded view of the heater assembly — Legacy

    To install:

12. Install the heater core into the heater case. Secure it in place with the retaining clamps and screws.
13. Install the heater assembly to its mounting position under the dash.
14. Install the mounting bolts. Torque the mounting bolts to 48–84 inch lbs. (5–9 Nm).
15. Install the evaporator by performing the following procedure:
    • Install the evaporator case assembly and the nuts and bolts.
    • Adjust the position of the evaporator assembly so the inlet and outlet connections are aligned with the heater and blower unit connections.
    • Install the drain hose. Connect the air conditioning wiring harness.
    • Install the inlet and outlet pipe grommets.
    • Install the glove box and the lower support bracket.
    • Using new O-rings, lubricate them with clean refrigerant oil and install them on the pipe fittings.
    • Connect the suction hose to the evaporator inlet fitting.
    • Connect the discharge hose to the evaporator outlet fitting.
16. Connect the heater control cables and fan motor wiring harness connectors.
17. Install the instrument panel.
18. Install the radio and console assemblies.
19. Connect the heater hoses in the engine compartment.
20. Refill the cooling system.
21. Connect the negative battery cable.
22. Evacuate, charge and leak test the air conditioning system.
23. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.