Heater Core Case: Service and Repair

REMOVAL
1. Remove the instrument panel. For additional information, refer to: Dashboard/Instrument Panel. Service and Repair
2. Drain the coolant from the radiator so the coolant level is below the heater core.







3. Disconnect the heater water hoses.







4. Inside the vehicle, remove the nut.







5. Disconnect the vacuum hoses.

NOTE: Mark the locations of the vacuum hoses.







6. Disconnect the vacuum hose.







7. Remove the pin-type retainers and remove the vacuum harness.







8. Disconnect the connector.







9. Remove the nuts.







10. Disconnect the connectors.







11. Remove the in-car temperature sensor hose (if equipped).







12. Position back the carpet from the plenum chamber. Cut each side of the rear footwell duct and bend back the duct.

CAUTION: Do not excessively cut the rear footwell duct. Make sure to only cut the rear footwell duct to the point that allows the heater floor duct to be removed with the plenum chamber as an assembly.







13. Remove the plenum chamber.

INSTALLATION







1. For installation, reverse the removal procedure.
- Clean and lubricate the coolant hose with MERPOL (R) or plain water only if needed.
- Close the rear footwell duct around the heater outlet floor duct, install a tie strap, and position back the carpet.

NOTE: Make sure to sufficiently seal the rear footwell duct to the heater outlet floor duct.