Heater Core: Service and Repair

HEATER CORE REPLACEMENT

TOOLS REQUIRED
J 38185 Hose Clamp Pliers

REMOVAL PROCEDURE




1. Remove the fuel injector sight shield (3.8L only).
2. Drain the coolant. Refer to Draining and Filling Cooling System in Cooling System.
3. Use J 38185 in order to position aside the heater hose inlet and outlet clamps at the heater core (3.1L).
4. Disconnect the inlet and outlet heater hose from the heater core (3.1L).




5. Use J 38185 in order to position aside the heater hose inlet and outlet clamps at the heater core (3.8L).
6. Disconnect the inlet and outlet heater hose from the heater core (3.8L).
7. Remove the lower the floor console.
8. Remove the right instrument panel insulator.
9. Remove the left instrument panel insulator.

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




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




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




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




20. Remove the heater core from the HVAC lower case.




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




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




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




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

INSTALLATION PROCEDURE




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




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




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




4. Install the heater core lower seal (4) to the HVAC case.




5. Install the heater core to the HVAC lower case.

NOTE: Refer to Fastener Notice in Service Precautions.




6. Install the heater core line clamp screw (2).

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

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

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




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




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




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

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




13. Install the heater core outlet cover.
14. Install the heater core outlet cover screws.

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

15. Install the lower the floor console.
16. Install the right instrument panel insulator.
17. Install the left instrument panel insulator.




18. Connect the inlet and Outlet heater hose to the heater core (3.1L).

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

19. Use J 38185 in order to reposition the heater hose inlet and outlet clamps (3.1L).




20. Connect the inlet and outlet heater hose to the heater core (3.8L).

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 clamps (3.8L).
22. Install the fuel injector sight shield (3.8L only).
23. Refill the coolant. Refer to Draining and Filling Cooling System in Cooling System.