Astro, Safari 1997-2005

Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine cooling system.
  4.  
  5. Disconnect negative battery cable.
  6.  
  7. Remove heater hoses from the heater core.
  8.  
  9. Remove heater core cover-to-heater assembly screws and the cover.
  10.  
  11. Remove heater core-to-heater assembly strap screws and the straps.
  12.  
  13. Remove heater core.
  14.  

To install:

  1. Install heater core.
  2.  
  3. Install heater core straps and the straps-to-heater assembly screws, then tighten the screws to 18 inch lbs. (2 Nm).
  4.  
  5. Install heater core cover and the cover-to-heater assembly screws, then tighten the screws to 18 inch lbs. (2 Nm).
  6.  
  7. Install heater hoses to the heater core.
  8.  
  9. Connect negative battery cable.
  10.  
  11. Refill the cooling system.
  12.  
  13. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  14.  

Front



  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine cooling system into a clean container for reuse.
  4.  
  5. Disconnect the heater hoses from the heater core.
  6.  
  7. Remove the heater core cover-to-heater assembly screws and the cover.
  8.  
  9. Remove the heater core-to-heater assembly strap screws and the straps.
  10.  
  11. Remove the heater core.
  12.  

To install:

  1. Install the heater core.
  2.  
  3. Install the heater core straps and the straps-to-heater assembly screws, then tighten the screws to 18 inch lbs. (2 Nm).
  4.  
  5. Install the heater core cover and the cover-to-heater assembly screws, then tighten the screws to 18 inch lbs. (2 Nm).
  6.  
  7. Connect the heater hoses to the heater core.
  8.  
  9. Refill the cooling system.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  14.  

Rear Heater Core



  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine cooling system into a clean container for reuse.
  4.  
  5. Remove the body side front lower interior trim panel.
  6.  
  7. Remove the clamps from the rear auxiliary heater hoses.
  8.  
  9. Disconnect the heater hoses from the rear auxiliary heater case.
  10.  
  11. From the right side of the heater core, remove the screws and band clamp.
  12.  
  13. From the left side of the heater core, remove the screw and band clamp.
    NOTE
    Place a cloth on the floor to catch any coolant that may spill from the heater core.

  14.  
  15. Remove the heater core from the rear auxiliary case assembly.
  16.  
  17. Remove the seals from the heater core.
  18.  

To install:

  1. Install new seals to the heater core.
  2.  
  3. Install the heater core to the rear auxiliary case assembly.
  4.  
  5. To the left side of the heater core, install the screw and band clamp, then tighten to 18 inch lbs. (2 Nm).
  6.  
  7. To the right side of the heater core, install the screws and band clamp, then tighten to 18 inch lbs. (2 Nm).
  8.  
  9. Connect the heater hoses to the rear auxiliary heater case.
  10.  
  11. Install the clamps to the rear auxiliary heater hoses.
  12.  
  13. Install the body side front lower interior trim panel.
  14.  
  15. Refill the engine cooling system.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  20.  

 
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