Heater Core Case: Service and Repair

Heater Assembly Replacement

Removal Procedure

1. Remove the HVAC module from the vehicle.




2. Remove the heater core cover fasteners and cover.




3. Remove the heater core.




4. Remove the lower HVAC case screws.




5. Unsnap and open the passenger compartment filter door.
6. Remove the lower HVAC case.

Installation Procedure






Important: Make certain that the orifice plate is correctly positioned in the HVAC module. Make certain that the lower HVAC case is properly positioned and is fully seated on the HVAC module before installing the screws. Be sure to install all lower HVAC case screws.

1. Install the lower HVAC case.






Notice: Refer to Fastener Notice.

2. Install the lower HVAC case screws.

Tighten the screws to 1.8 N.m (15 lb in).

3. Close and secure the passenger compartment filter door.




4. 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.
5. Install the heater core into the HVAC module.





Important: Make certain that the heater core cover is properly positioned and is fully seated on the HVAC module before installing the screws. Be sure to install all heater core cover screws.

6. Install the heater core cover and fasteners.

Tighten the screws to 1.8 N.m (15 lb in).




7. Replace the drain tube seal.




8. Replace the front of dash seal.
9. Inspect and replace the HVAC module seals if damaged:

* The defrost duct seal
* The HVAC module to cross car duct seal
* The center air outlet duct seal
* The center floor air outlet duct seal
* The air inlet seal

10. Install the HVAC module in the vehicle.
11. Fill the cooling system. Refer to Draining and Filling Cooling System (2.0L (LSJ) Static Fill) Draining and Filling Cooling System (2.2L (L61), 2.4L (LE5) Static Fill) Draining and Filling Cooling System (GE 47716 Fill).