HEATER CORE

Forester

REMOVAL & INSTALLATION

1. Disconnect the negative battery cable.

   CAUTION
   After disconnecting the negative battery cable, wait for at least 20 seconds for the air bag module to deplete its energy.

2. Drain the engine coolant into a clean container for reuse.
3. Disconnect the heater hoses from the heater core.
4. Remove the instrument panel by performing the following procedure:
   1. If equipped with a manual transmission, remove the shift knob.
   2. Remove both the front and rear console covers.
   3. Remove the console box-to-chassis screws and the console box.
   4. Remove the 3 lower left side cover assembly screws, disengage the 3 upper clips, remove the cover assembly.
   5. Using a screwdriver, disconnect the data link connector from the lower cover.
   6. Remove the knee panel.
   7. At the glove box, remove the right side cover screw, the clip and the side cover.
   8. Remove the glove box screws and remove the glove box.
   9. Remove the center panel bezel.
   10. Remove the audio assembly screws, disconnect the electrical connectors and remove the audio assembly.
   11. Remove the 2 steering column-to-instrument panel bolts and lower the steering column.
   12. Move the temperature control switch to FULL HOT, the mode selector switch to DEF and the recirculation switch to FRESH positions.
   13. Disconnect the temperature control cable and the mode control cable from the heater housing.; then, the recirculation control cable from the intake housing.
   14. Disconnect the electrical harness connectors.
   15. Remove the instrument panel-to-chassis bolts.
   16. Remove the 2 front defroster grille bolts.
   17. Carefully, remove the instrument panel.
5. Remove the steering support beam bracket nuts and the steering support beam.
6. Remove the evaporator housing by performing the following procedure:
   1. Discharge and recover the air conditioning system refrigerant.
   2. Remove the refrigerant line-to-cowl connector bolt, separate the lines, discard the O-rings and plug the openings to prevent contamination.
   3. Disconnect the electrical harness connector from the evaporator housing.
   4. Disconnect the drain hose.
   5. Remove the evaporator housing nut/bolts and the evaporator housing.
7. Remove the heater housing-to-chassis bolts and the heater housing.
8. Remove the heater core from the heater housing.

   Fig. 1: Exploded view of the instrument panel assembly-Subaru Forester

   Fig. 2: Exploded view of the steering support beam assembly-Subaru Forester

   Fig. 3: Exploded view of the heater core, heater housing and related components-Subaru Forester

   To install:

9. Install the heater core to the heater housing.
10. Install the heater housing and the heater housing-to-chassis bolts.
11. Install the steering support beam and the steering support beam bracket nuts.
12. Install the evaporator housing by performing the following procedure:
    1. Install the evaporator housing and the evaporator housing nut/bolts.
    2. Connect the drain hose.
    3. Connect the electrical harness connector to the evaporator housing.
    4. Using new O-rings, assemble the refrigerant lines and install the refrigerant line-to-cowl connector bolt.
13. Install the instrument panel by performing the following procedure:
    1. Carefully, install the instrument panel.
    2. Install the 2 front defroster grille bolts.
    3. Install the instrument panel-to-chassis bolts.
    4. Connect the electrical harness connectors.
    5. Connect the temperature control cable and the mode control cable to the heater housing. Then, the recirculation control cable to the intake housing.
    6. Install the steering column and lower the 2 steering column-to-instrument panel bolts and torque to 14-21 ft. lbs. (20-30 Nm).
    7. Install the audio assembly, connect the electrical connectors and install the audio assembly screws.
    8. Install the center panel bezel.
    9. Install the glove box and the glove box screws.
    10. At the glove box, install the right side cover, the clip and the side cover screw.
    11. Install the knee panel.
    12. Connect the data link connector to the lower cover.
    13. Install the lower left side cover assembly, engage the 3 upper clips and install the cover assembly screws.
    14. Install the console box and the console box-to-chassis screws.
    15. Install both the front and rear console covers.
    16. If equipped with a manual transmission, install the shift knob.
14. Connect the heater hoses to the heater core.
15. Refill the cooling system.
16. Connect the negative battery cable.
17. Evacuate and charge the air conditioning system refrigerant.
18. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.