Heater Core - Removal

REMOVAL

Special Tools:






WARNING: Refer to the applicable Warnings and Cautions for this system before performing the following operation Warning and Caution . Failure to follow these instructions may result in possible serious or fatal injury.

WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable and 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 follow these instructions may result in accidental airbag deployment and possible serious or fatal injury.

NOTE: LHD model shown. RHD model similar.






NOTE: Left side shown. Right side similar.

1. Disconnect and isolate the negative battery cable.
2. Drain the engine cooling system Service and Repair.
3. Remove the left and right side instrument panel silencers Silencer Panel - Removal.
4. Using (C-4755) or equivalent, remove the left and right side instrument panel end caps (1).





5. Remove the steering column Steering Column - Removal.
6. Remove the center floor console Floor Console - Removal.
7. Remove the two bolts (1) that secure the center of the instrument panel to the floor pan.






NOTE: Left side shown. Right side similar.

8. Remove the left and right side A-pillar trim panels (1) A-Pillar Trim Panel - Removal.





9. Using (C-4755) or equivalent, remove the defroster grille (1).





10. Remove the three screws (2) that secure the top of the instrument panel (4) to the spring nuts (1).
11. Remove the two bolts (3) that secure the top of the instrument panel to the cowl panel.
12. Remove the two bolts (5) that secure the left and right side of the instrument panel to the body.
13. Disengage the retaining tabs that secure the left and right side of the instrument panel to the body.

NOTE: Make sure to leave the right side door open when repositioning the left side of the instrument panel.

14. For clearance, carefully position the left side of the instrument panel rearward approximately 50 mm (2 in.).





15. When equipped with power adjustable pedals, disconnect the adjuster cable (1) from the accelerator pedal adjuster motor (2) and position the cable out of the way.






NOTE: Take proper precautions to protect the carpeting and interior trim from engine coolant. Have absorbent toweling readily available to clean up any spills.

NOTE: If required, use your fingers to rotate the clamps to gain access to the clamp retaining screws.

16. Remove the two clamps (2) that secure the heater core tubes (1) to the heater core (5).
17. Disconnect the heater core tubes from the heater core and position the tubes out of the way.
18. Remove and discard the heater core tube O-ring seals and install plugs in, or tape over, the opened tubes and heater core ports.
19. Remove the retaining screw (4) that secures the heater core bracket (3) to the driver side of the HVAC air distribution housing (6) and remove the bracket.

NOTE: If the foam seal around the heater core is deformed or damaged, it must be replaced.

20. Carefully pull the heater core straight out of the air distribution housing.