Flap Housing, Disassembling/Assembling

Heater core removal and installation












Removal

1. Disconnect the negative battery cable
2. Drain cooling system using the following procedure
a. Fully open the heater controls
b. Open expansion tank cap
c. Position a catch pan under water pump
d. Disconnect the lower coolant hose from the water pump connection pipe and the center coolant hose from the water pump
e. Drain system to a level below the heater core
3. Disconnect electrical, vacuum and cables from the flap housing
4. Remove flap housing from under the instrument panel
5. Remove the upper flap housing and pull heater core from the housing.

Installation

1. Install heater core into flap housing and install upper flap housing
2. Under instrument panel install the flap housing assembly
3. Reconnect all electrical, vacuum and cable connections that were previously disconnected
4. Reconnect battery cable
5. Refill the cooling system using the floowing procedure
a. Set the heater controls to the warm position
b. Open the breather valve at the top of the radiator
c. Fill expansion tank to the brim, so it remains full
d. Operate the engine at 2500 RPM until the coolant flows at the breather valve with no bubbles
e. Close the breather valve
f. Check coolant level and top off, as necessary
g. Close the expansion tank cap
5. Inspect operation of heater system