Heater Core Tubes

REMOVAL

WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

1. Drain the engine cooling system.
2. Disconnect and isolate the battery negative cable.
3. Disconnect the heater hoses from the heater core tubes.
4. Remove the silencer from beneath the driver side end of the instrument panel.

NOTE: Take the proper precautions to protect the carpeting below the heater core from spilled engine coolant and have absorbent toweling readily available to clean up any spills.

Heater Core Tubes - LHD Shown, RHD Typical:

5. Remove the screw that secures the heater core tube sealing plate to the heater core supply and return ports.
6. Push both heater core tubes simultaneously toward the dash panel far enough to disengage their fittings from the heater core supply and return ports.
7. Install plugs in, or tape over the opened heater core tube fittings and both heater core ports.
8. Pull both heater core tubes simultaneously slightly away from the distribution housing and rearward far enough to disengage the engine compartment ends of the tubes from the dash panel seal.
9. Remove the heater core tubes and sealing plate as a unit from beneath the instrument panel.
10. Use absorbent toweling to dean up any engine coolant spills from the preceding operation.

INSTALLATION
1. Remove the plugs or tape from both heater core tube fittings and both heater core ports.
2. Position the heater core tubes and sealing plate as a unit beneath the instrument panel.
3. Align the engine compartment ends of both heater core tubes with the openings in the dash panel seal and push them simultaneously forward through the seal far enough to engage the heater core ends of the tubes with the heater core supply and return ports.
4. Position both heater core tubes and the sealing plate simultaneously to the heater core supply and return ports.

NOTE: The heater core tubes each have a slot that must be indexed to a location tab within each of the heater core ports. Adjust the position of the tubes as required so that the sealing plate fits flush against the heater core supply and return ports, which indicates that the tubes are properly indexed.

5. Index both heater core tubes to the heater core ports.
6. Install the screw that secures the heater core tube sealing plate to the heater core supply and return ports. Tighten the screw to 3 Nm (27 in. lbs.).
7. Install the silencer under the driver side end of the instrument panel.
8. Connect the heater hoses to the heater hose tubes.
9. Reconnect the battery negative cable.
10. Refill the engine cooling system.