Heater Core: Service and Repair

HEATER CORE REPLACEMENT

TOOLS REQUIRED
J 38185 Hose Clamp Pliers

REMOVAL PROCEDURE




1. Remove the following component:
^ For a 3.1L engine, remove the air cleaner assembly.
^ For a 3.8L engine, remove the fuel injector sight shield.
2. Remove the cross vehicle brace.
3. Drain the coolant. Refer to Draining and Filling Cooling System in Cooling System.
4. Use J 38185 in order to position aside the heater hose inlet and outlet clamp at the heater core.
5. Disconnect the inlet and outlet heater hose from the heater core.




6. Remove the lower floor console.
7. Remove the right instrument panel insulator.
8. Remove the left instrument panel insulator.

IMPORTANT: Position the heater core outlet cover downward and rearward in order to disconnect the cover from the rear area floor duct assembly.

9. Remove the screws from the heater core outlet cover.
10. Remove the heater core outlet cover.




11. Remove the screws from the heater core cover.
12. Remove the heater core cover.




13. Remove and discard the seals (1,2) from the heater core cover.
14. Remove the caulk (3) from the heater core cover.




15. Remove and discard the outer seal (5) from the heater core.




16. Remove the screw (1) from the heater core line clamp.
17. Remove the heater core retaining clamp.
18. Remove the screw (2) from the heater core pipe retainer clamp.




19. Remove the heater core from the HVAC lower case.




20. Remove and discard the lower seal (4) from the HVAC case.




21. Remove and discard the center seal (3) from the HVAC case.




22. Remove and discard the upper seal (2) from the HVAC lower case.




23. Remove and discard the side seals (1) from the HVAC lower case.

INSTALLATION PROCEDURE




1. Install the side seals (1) to the HVAC lower case.




2. Install the upper seal (2) to the HVAC lower case.




3. Install the center seal (3) to the HVAC case.




4. Install the lower seal (4) to the HVAC case.




5. Install the heater core to the HVAC lower case.

NOTE: Refer to Fastener Notice in Service Precautions.




6. Install the screw (2) to the heater core line clamp.

Tighten
Tighten the screw to 1.5 N.m (13 lb in).

7. Install the screw (1) to the heater core mounting clip.

Tighten
Tighten the screw to 1.5 N.m (13 lb in).




8. Install outer seal (5) to the heater core.




9. Install new seals(1,2) to the heater core cover.
10. Install the caulk (3) on to the heater core cover.




11. Install the heater core cover.
12. Install the heater core cover screws.

Tighten
Tighten the screws to 1.5 N.m (13 lb in).




13. Install the heater core outlet cover.
14. Install the screws to the heater core outlet cover.

Tighten
Tighten the screws to 1.5 N.m (13 lb in).

15. Install the lower floor console.
16. Install the right instrument panel insulator.
17. Install the left instrument panel insulator.




18. Connect the inlet and outlet heater hose to the heater core.

IMPORTANT: Reposition the heater core hose clamps in the indicated location.

19. Use J 38185 in order to reposition the heater hose inlet and outlet clamp to the heater core.
20. Fill the coolant. Refer to Draining and Filling Cooling System in Cooling System.
21. Install the cross vehicle brace.
22. Install the following component:
^ For a 3.1L engine, install the air cleaner assembly.
^ For a 3.8L engine, install the fuel injector sight shield.