Heater Core: Service and Repair
ENGINE COMPARTMENT DISASSEMBLY1. Remove water box cover at cowling.
2. Remove windshield wiper assembly.
Hold Down Strap And Heater Hose Location:
3. Remove heater box retaining band, clamp heater hoses off and remove.
Heater Blower Wiring Harness:
4. Disconnect wiring harness plugs at left side of engine compartment, and remove tie wraps to free up harness.
Bowden Cable And Vacuum Hose Location:
5. Disconnect vacuum hose and bowden cable from right side of heater box, push vacuum hose and cable through grommet at rear of heater box.
UNDER DASH DISASSEMBLY
1. Remove center console for access.
Color Coded Vacuum Hose Location:
2. Remove the 3 colored coded vacuum lines from the servos. disconnect remaining vacuum hose at side of heater box.
NOTE Center console on turbo models is not removable. Remove climate control assembly to gain access to vacuum lines behind center console.
Heater Duct Location:
3. Disconnect and remove where possible all heater ducts.
Plug Connector:
4. Disconnect electrical plugs at bottom of heater box.
Special Tool For Heater Box Removal:
5. Remove heater box housing from outside of car.
NOTE The heater box will need to be pried up from its seal at the body. Special tool #2075 or equivalent must be used to do this or possible damage to the housing may occur. Place tool at lip on front of housing at case seam and using a pry bar lift heater housing free of body and remove.
HEATER HOUSING DISASSEMBLY
Exploded View Heater Box Components:
Heater Flap "E" Clip, Felt Washer And Thrust Washer:
1. Remove screws and spring clips holding case halves together, be sure to remove "E" clip holding heater flap to case.
2. Cut foam insulation strips and split case, slide heater core out of housing.
Heater Core:
3. The new heater core must be sealed without gaps with foam insulation before installing in heater box.
4. Slide the heater core into the right side heater box, making sure no gaps exist around insulation.
Flaps From Heater Box With Special Tool:
5. Using heater flap fixture tool #2076A or equivalent, position flaps so the case halves can be joined. Install spring clips, retaining screws and secure foam insulation.
6. Be sure "E" clip is installed on heater flap, making sure felt ring and thrust washer are installed correctly.
Sealing Location Using Silicone Sealant:
7. Seal the heater core opening (left side of heater box housing) with commercial silicone sealer.
8. Before reinstalling the heater box housing assembly, a new seal needs to be installed at the body opening.
9. Reverse procedure to install heater box, starting with underhood procedures first, making sure wiring harness and bowden cable are in position before seating heater box to opening.
10. Be sure to top coolant off and check for leaks when finished.