Heater Core: Service and Repair
HEATER COREREMOVAL
1. Disconnect negative battery cable.
CAUTION: DO NOT ATTEMPT TO OPEN COOLANT CAP WHILE COOLING SYSTEM IS UNDER PRESSURE.
2. Remove coolant cap from coolant surge tank.
CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON THE HOIST. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.
3. Raise vehicle.
4. Remove lower cradle splash shield to cradle and wheelhouse fasteners and remove splash shield.
IMPORTANT: Failure to use a drain hose will result in uncontrolled coolant flow direction.
5. Slide a pliable piece of hose with an inside diameter of 3/8 in. over radiator drain tube.
IMPORTANT: A 7.6 L (8 qt) coolant container will be needed.
6. Route hose rearward and down to an approved coolant container.
NOTE: Only open the drain valve 1-2 turns.
7. Use a flat blade screwdriver or pliers to open radiator drain valve and drain coolant.
Approximately 3.5 L (4 qts) of coolant can be drained from the radiator. Additional coolant will remain in some cooling system components. When completely drained, close coolant drain valve and remove drain hose.
8. Install lower cradle splash shield by sliding shield (1) between wheelhouse linen (2) and wheelhouse (3). Install splash shield to wheelhouse and cradle fasteners.
Torque:
Splash Shield-to-Wheelhouse and Cradle Fasteners: 5 N.m (44 in-lbs)
9. Lower vehicle.
10. Remove heater inlet hose:
^ From thermostat outlet.
11. Remove heater return hose:
^ From block inlet.
12. Place end of heater return hose in a container and apply low pressure (34 kPa, 5 psi) shop air to the heater inlet hose to blow coolant out of heater core.
13. Remove right console extension.
CAUTION: HEATER CORE PIPES MAY BE HOT!
14. Remove heater core pipe to heater core clamps. Clamps may need to be rotated to gain access to clamp retaining tab.
15. Gently pull pipes forward to remove from heater core end tank.
16. Place absorbent rags under heater core pipe joints to catch any residual coolant.
17. Remove heater core retaining screw and strap.
NOTE: Use care not to spill any residual coolant on carpet or seats.
IMPORTANT: Center console forward edge may need to be pulled outward to allow core to be removed.
18. Pull heater core out of HVAC module and into passenger foot area.
INSTALLATION
1. Slide heater core into HVAC module being careful not to damage foam seals.
2. Install heater core retaining strap and screw.
Torque:
Heater Core Retaining Strap Screw: 1.0 N.m (9 in-lbs)
3. Install bushings and O-rings onto heater core pipes.
4. Ins tall heater pipes into core and install plastic clamps. Heater pipe clamps will only go on one way. Lower clamp hinge fits into tab of beater core retaining strap.
5. Install right console extension.
6. Install heater inlet hose to thermostat outlet.
7. Install clamp at 12:00 position.
8. Install heater return hose to thermostat inlet.
9. Install clamp at 12:00 position.
10. Rinse off any coolant that was spilled in engine compartment.
11. Connect negative battery cable.
Torque:
Battery Terminal Bolts: 17 N.m (13 ft-lbs)
IMPORTANT: Vehicle must be level when filling cooling system.
12. Slowly add a mixture of 50/50 DEX-COOL(R) antifreeze and clean water to coolant surge tank until the level reaches Cold indicator (Surge tank seam).
Cooling system volumes, including heater core
7.0 L (7.4 qt.)
13. Start engine and check for cooling system leaks.
14. Run engine until thermostat has opened, use Tech 2 to verify ECT is 188°F or greater. Add coolant as necessary to bring level up to coolant surge tank Cold line.
15. Install coolant surge tank coolant cap.