Heater Core Replacement

HEATER CORE REPLACEMENT

TOOLS REQUIRED
SA9111E Hose Clamp Pliers

CAUTION: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result.

REMOVAL PROCEDURE




1. Remove the surge tank cap.
2. Raise and support the vehicle. Refer to Vehicle Lifting.




3. Place a drain pan under the water pump drain port.
4. Loosen the water pump drain bolt and drain the coolant from the water pump.
5. Close and tighten the water pump drain bolt.

NOTE: Refer to Fastener Notice in Service Precautions.

Tighten
Tighten the water pump drain bolt to 10 N.m (88 lb in).

6. Lower the vehicle.




7. Reposition the heater outlet hose clamp at the heater core using SA9111E.
8. Remove the heater outlet hose from the heater core.




9. Reposition the heater inlet hose clamp at the heater core using SA9111E.
10. Remove the heater inlet hose from the heater core.
11. Remove the heater core cover.




12. Remove the heater core.

INSTALLATION PROCEDURE




1. Inspect the foam heater core seal on the lower HVAC case. If damaged, replace using Kent Industries adhesive black foam tape P/N 46480 or equivalent.
2. Install the heater core into the HVAC module.
3. Install the heater core cover.




4. Install the heater outlet hose to the heater core.
5. Install the hose clamp to secure the hose using SA9111E.




6. Install the heater inlet hose to the heater core.
7. Install the hose clamp to secure the hose using SA9111E.
8. Fill the cooling system. Refer to Draining and Filling Cooling System (2.0L (L61)) Draining and Filling Cooling System (2.0L (LSJ)) in Cooling system.