Heater Core: Service and Repair
CORE-HEATERNOTE: LHD model with A/C shown in the following illustrations. RHD and heater-only models are similar.
REMOVAL
NOTE: The HVAC housing assembly must be removed from vehicle for service of the heater core.
1. Remove the HVAC housing assembly and place it on a workbench.
2. Remove the left floor distribution duct.
3. Remove the three screws (1) that secure the heater core cover (2) to the driver side of the air distribution housing (3) and the HVAC housing (4) and remove the cover.
NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced.
4. Remove the foam seal (1) from the flange (2) located on the driver side of the HVAC housing (6).
5. Remove the two screws (4) that secure the heater core (5) to the driver side of the air distribution housing (3).
6. Carefully pull the heater core out of the driver side of the air distribution housing.
7. If required, remove the retaining clips that secure the heater core tubes to the heater core and disconnect the tubes from the heater core and remove and discard the O-ring seals.
INSTALLATION
1. If removed, lubricate new O-rings with clean engine coolant and install them onto the heater core tubes. Connect the tubes to the heater core (5) and install the retaining clips.
2. Carefully install the heater core into the driver side of the air distribution housing (3).
3. Install the two screws (4) that secure the heater core to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.).
NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced.
4. Install the foam seal (1) onto the flange (2) located on the driver side of the HVAC housing (6).
5. Position the heater core cover (2) onto the driver side of the air distribution housing (3) and HVAC housing (4).
6. Install the three screws (1) that secure the heater core cover to the air distribution housing and HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
7. Install the left floor distribution duct.
NOTE: If the heater core is being replaced, flush the cooling system.
8. Install the HVAC housing assembly.