Heater Core: Service and Repair

REMOVAL PROCEDURE




1. Remove the air cleaner assembly.
2. Remove the fuel injector sight shield, if equipped with 3.8L.
3. Drain the coolant. Refer to Draining and Filling Cooling System in Cooling System.
4. Use J 38185 in order to position aside the heater hose inlet and outlet clamp at the heater core with.
5. Disconnect the inlet and outlet heater hose from the heater core.
6. Remove the right instrument panel insulators.
7. Remove the left instrument panel insulators.
8. Remove the lower the floor console.
9. Remove the bolts and position the HVAC wiring harness bracket aside.

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




10. Remove the heater outlet cover screws.
11. Remove the heater outlet cover.




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




14. Remove and discard the seals (1,2) from the heater core cover.
15. Remove the caulk (3) from the heater core outlet cover.




16. Remove and discard the outer seal (5) from the heater core.




17. Remove the pipe retainer clamp screw (2) from the heater core.
18. Remove the heater core line clamp screw (1) from the heater core.
19. Remove the retaining clamp from the heater core.




20. Remove the heater core from the HVAC tower case.
21. Remove the tube support bracket from the heater core.




22. Remove and discard the heater core lower seal (4) from the HVAC case.




23. Remove and discard the heater core center seal (3) from the HVAC case.




24. Remove and discard the heater core upper seal (2) from the HVAC lower case.




25. Remove and discard the heater core side seals (1) from the HVAC lower case.

INSTALLATION PROCEDURE




1. Install new heater core side seals (1) to the HVAC lower case.




2. Install a new heater core upper seal (2) to the HVAC lower case.




3. Install a new heater core center seal (3) to the HVAC case.




4. Install a new heater core lower seal (4) to the HVAC case.
5. Install the heater core tube support bracket clamp.




6. Install the heater core from the HVAC lower case.

NOTE: Refer to Fastener Notice in Service Precautions.




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

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

8. Install the heater core mounting clip with a screw (1).

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




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




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




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

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

16. Install the HVAC wiring harness bracket. Install the bolts to the HVAC wiring harness bracket.

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

17. Install the lower floor console.
18. Install the right instrument panel insulators.
19. Install the left instrument panel insulators.




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

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

21. Use J 38185 in order to reposition the heater hose inlet and outlet clamp to the heater core.
22. Refill the coolant. Refer to Draining and Filling Cooling System in Cooling System.
23. Install the fuel injector sight shield, if equipped with 3.8L.
24. Install the air cleaner assembly.