Pacifica 2006-2008

Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disable the airbag system, by disconnecting the negative battery cable. Tape the end of the cable to avoid it grounding and wait 2 minutes for the system capacitor to discharge before performing any service.
    NOTE
    If the vehicle is adjustable pedals, these must be removed prior to heater core removal.

  4.  
  5. Drain the cooling system.
    WARNING
    Do not use pliers to open the plastic drain.

  6.  
  7. Remove or disconnect the following:

    Negative battery cable if not already done to disable the air bag system
     
    Silencer boot fasteners located around the base of the lower steering shaft from the dash panel so it can be moved aside
     
    Brake lamp switch from the bracket
     
    Power brake booster push rod from the pin on the brake pedal arm
     

  8.  
  9. Place plastic below the heater core inside the vehicle to protect against spills.
  10.  
  11. Remove or disconnect the following:

    Screw that secures the heater core to tube sealing plate to the supply and return ports
     
    Heater core tubes by pushing simultaneously towards the dash panel and disengaging the fittings and cap the tube fittings and heater core ports
     
    Two screws that retain the heater core mounting plate to the distribution housing
     

  12.  
  13. Push the brake pedal downward and at the same time pull the accelerator pedal up to create enough clearance to remove the heater core.

    Click image to see an enlarged view

    Fig. Heater core mounting and related components-2006 Models

  14.  

To install:

  1. Push the brake pedal downward and at the same time pull the accelerator pedal up to create enough clearance to install the heater core.

    Two screws that retain the heater core mounting plate to the distribution housing and tighten to 17 inch lbs. (2 Nm)
     

  2.  
  3. Remove the plugs from the heater core tubes and if using the same heater core the core as well. Position the heater core tubes and sealer plate as a unit beneath the instrument panel.
  4.  
  5. Position both heater core tubes and the sealing plate at the same time to the heater core supply and return ports.
  6.  
  7. The tubes have a slot that must be indexed to a location tab within each of the core ports. Adjust the tube position so that the sealing plate fits flush against the supply and return ports which will ensure the tubes are correctly indexed.
  8.  
  9. Install or connect the following:

    Screw that retains the heater core tube sealing plate to the supply and return ports and tighten to 27 inch lbs. (3 Nm)
     
    Silencer under the driver side end if the instrument panel
     
    Heater hoses to the tubes
     
    Power brake booster push rod to the pin on the brake pedal arm
     
    Brake lamp switch
     
    Silencer boot and secure the
     
    Negative battery cable
     

  10.  
  11. Fill the cooling system and operate for two thermostat cycles to assure elimination of air in the cooling system.
  12.  


CAUTION
The heater core tubes are not serviced separately from the heater core. The heater core tubes should not be repositioned, loosened or removed from the heater core. Failure to follow this warning could result in a coolant leak and possible personal injury or death.

  1. Disconnect and isolate the negative battery cable.
  2.  
  3. Remove the HVAC housing from the vehicle and place it on a workbench.
  4.  
  5. Remove the foam seal from the heater core tubes and the flange located at the front of the HVAC housing.
  6.  
  7. If equipped, remove the plastic retaining strap that secures the heater core tubes to the flange.
  8.  
  9. Remove the two screws that secure the heater core retaining bracket to the driver side of air distribution housing and remove the bracket.
  10.  
  11. Disengage the heater core tubes from the flange while carefully pulling the heater core straight out of the side of the air distribution housing.

    Click image to see an enlarged view

    Fig. Heater core tubes

  12.  

To install:

  1. Carefully install the heater core into the driver side of the air distribution housing while locating the heater core tubes to the flange.
  2.  
  3. Install heater core retaining bracket onto the air distribution housing and install the two screws. Tighten the screws to 17 inch lbs. (2 Nm).
  4.  
  5. Install the plastic retaining strap that secures the heater core tubes to the front of the HVAC housing.
  6.  
  7. Install the foam seal over the heater core tubes and flange.
  8.  
  9. Install the HVAC housing assembly.
  10.  
  11. Reconnect the negative battery cable.
  12.  
  13. If the heater core is being replaced, flush the cooling system.
  14.  
  15. Refill the engine cooling system.
  16.  
  17. Evacuate the refrigerant system.
  18.  
  19. Charge the refrigerant system.
  20.  
  21. Calibrate the A/C-heater control.
  22.  

 
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