Heater Core: Service and Repair

HEATER CORE REPLACEMENT

TOOLS REQUIRED
J 38185 Hose Clamp Pliers

REMOVAL PROCEDURE
1. For a 3.8L engine, remove the fuel injector sight shield.
Drain the coolant.




2. Use J 38185 in order to position aside the heater hose inlet and outlet clamp at the heater core.
3. Disconnect the inlet and outlet heater hose from the heater core.
4. Remove the vacuum tank.
5. Remove the floor carpet.
6. Remove the rear floor air outlet duct from the holes in the floor reinforcement.
7. Disconnect the rear floor air outlet duct from the heater core outlet cover.
8. Remove the bolts from the vacuum harness bracket and position bracket aside.




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

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

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 support bracket.
17. Remove the heater core support bracket.
18. Remove the screw (2) from the heater core pipe retainer clamp.




19. Remove the heater core from the HVAC lower case.
20. Remove the heater core pipe retainer clamp from the heater core pipes.




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




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




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




24. 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 pipe retainer clamp to the heater core pipes.
6. Install the heater core to the HVAC lower case.




7. Install the screw (2) to the heater core retainer clamp.

NOTE: Refer to Fastener Notice in Service Precautions.

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

8. Install the screw (1) to the heater core support bracket.

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




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




10. Install new seals number (1) and (2) to the heater core cover.
11. Install the caulk (3) on to the heater core cover.




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

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




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

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

16. Install the HVAC vacuum harness bracket.
17. Install the screws to the HVAC vacuum harness bracket.

Tighten
Tighten the screws to 10 N.m (89 lb in).

18. Connect the rear floor air outlet duct to the heater core outlet cover.
19. Install the rear floor air outlet duct to the holes in the floor reinforcement.
20. Install the floor carpet.
21. Install the vacuum tank.




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

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

23. Use J 38185 in order to reposition the heater hose inlet and outlet clamp to the heater core.
24. For a 3.8L engine, install the fuel injector sight shield.
25. Fill the coolant.