Heater Core: Service and Repair

REMOVAL
1. Remove instrument panel. Instrument Cluster / Carrier
2. Drain coolant from radiator into a clean container.
3. Disconnect heater water hoses from heater core. Plug heater core tubes or blow any coolant from heater core with low pressure air.
4. Remove two retaining screws and metal cover from A/C evaporator housing.







5. Remove three remaining retaining screws and A/C electronic blend door actuator from A/C evaporator housing.







6. Disengage spring from heater core cover and remove spring from lever.







7. Gently depress locking ramp and remove lever from secondary A/C air temperature control door end.

NOTE: Do not attempt to bend any part of the lever. It is brittle and will break.

8. Rotate primary A/C air temperature control door shaft down; then swing metal link and remove from pin.
9. Remove three heater core cover retaining screws and remove heater core cover and heater core cover seal from A/C evaporator housing.







10. Remove heater core and seal from A/C evaporator housing by pushing on heater core tubes.

INSTALLATION
1. Transfer foam core seal to new heater core.
2. Install heater core and foam core seal into A/C evaporator housing.
3. Position heater core cover and seal on A/C evaporator housing and install three retaining screws.
4. Install metal link over pin on primary A/C air temperature control door lever.
5. Install secondary A/C air temperature control door lever on metal link.
6. Install secondary A/C air temperature control door lever to secondary A/C air temperature control door end.
7. Engage spring to heater core cover and secondary A/C air temperature control door lever.
8. Install A/C electronic blend door actuator to A/C evaporator housing with three retaining screws.
9. Install metal cover to A/C evaporator housing with two retaining screws.
10. Connect heater water hoses to heater core.
11. Fill radiator to correct level with previously removed coolant or specified mixture of coolant and water.
12. Install instrument panel.
13. Check system for proper operation.