If a heater core leak is suspected, the heater core must be pressure leak tested before it is removed from the vehicle.
- Remove the heater core and evaporator core housing, as outlined in this section.
- Remove the 6 floor duct screws and the floor duct.
- Remove the heater core tube dash panel seal.
- Remove the heater tube bracket screw and the heater tube bracket.
- Remove the 5 fresh air inlet duct screws and the fresh air inlet duct.
- Disconnect the wire harness from the plenum chamber.
- Remove the 7 lower facing plenum chamber screws.
- Adjust the heater core and evaporator core housing so the plenum chamber is upright.
- Remove the upper facing plenum chamber screw.
Remove the 2 plenum chamber clips and remove the plenum chamber being careful not to allow the evaporator core to become dislodged from the installed position.
WARNINGDo not handle the heater core by the inlet and/or outlet tube to remove. Handling the heater core by the tubes may damage the joints and lead to failure of the heater core.
Remove the heater core, as follows:
- Grasp the heater core by the core-side of the heater tube connections and partially remove it from the plenum chamber.
Grasp the heater core by the top of the core and remove it from the plenum chamber.
NOTEIt is not necessary to perform this step if the evaporator core has not become dislodged from the installed position during this procedure.
- If the evaporator core has been moved at any point during heater core removal, remove the evaporator core, verify that the drain seal is installed in the correct position and install the evaporator core in the correct position.
Installation is the reverse of the removal procedure.