Repair Procedure

1. Secure vehicle on hoist.

2. Raise vehicle and locate Rear Heater Pipe (Rear) in right rear wheel well.

3. Remove black plastic pipe cover.

NOTE:
Discard black plastic pipe cover. Cover will not be reused.





4. Inspect Rear Heater Pipe (Front) and Rear Heater Pipe (Rear) for signs of coolant seepage.

NOTE:
The rear-side bracket is more likely to be rusted. If there is no rust or rust is very light (white rust), replacement is not required.





5. Remove the seeping side of the rear heater pipe according to Workshop Manual (section 07-11 HEATER PIPE AND HOSE COMPONENT REMOVAL/INSTALLATION).

NOTE:
IT IS NOT NECESSARY TO REMOVE THE FRONT CROSSMEMBER AND STABILIZER BAR TO REMOVE THE REAR HEATER PIPE (FRONT).

NOTE:
Do not reinstall the black plastic pipe cover. Cover will not be reused.








6. If the rear-side of the rear heater pipe is seeping and needs to be replaced, inspect heater pipe attachment bracket for rust, corrosion, or breakage after Rear Heater Pipe (Rear) is removed.





7. Using a power cutting tool, cut top of bracket off leaving only welded bracket flanges.

WARNING:
Be sure to wear safety goggles when using power cutting/grinding tools.

CAUTION:
After cutting top of bracket off, grind any sharp edges off flanges.





8. Place new bracket on top of welded flanges.

9. Mark holes using new bracket as a template.

10. Using a 4 mm drill bit, drill two (2) holes.

11. Apply rust preventative sealer inside the new holes.

12. Attach the new bracket to body using two (2) self-tapping screws.





13. Once bracket is secured, apply silicon based sealer on top of screws and flanges.





14. Install new Rear Heater Pipe (Rear) securing it to bracket.

15. If the Rear Heater Pipe (Front) is also seeping and needs to be replaced, install a new one.

NOTE:
IT IS NOT NECESSARY TO REMOVE THE FRONT CROSSMEMBER AND STABILIZER BAR TO INSTALL THE REAR HEATER PIPE (FRONT).





16. Add coolant to the cooling system according to the Workshop Manual (Section 01-12 ENGINE COOLANT REPLACEMENT).

NOTE:
If vehicle is equipped with a Water Valve (under hood), ensure valve is in the "OPEN" position. If valve is closed, the front heater will not provide heat. Refer to service bulletin 07-004/04 (MPV - Lack of Warm Air From Front Heater) issued Aug. 02, 2004 for additional information.

17. Verify proper heater operation once repair is complete.

18. Complete an "Authorized Modification Label" with "SSP65" written on sticker and affix it to vehicle's hood.