Heater Core: Service and Repair

CAUTION:
- All SRS wire harnesses are covered with yellow insulation. Before you disconnect any part of an SRS wire harness, disconnect the airbag connectors.
- Whenever the ignition switch is ON (II), or has been turned OFF for less than three minutes, be careful not to bump the SRS unit; the airbags could accidentally deploy and cause damage or injuries.
- For additional precautions, refer to Air Bags and Seat Belts.

NOTE: The original radio has a coded theft protection circuit. Be sure to get the customer's code number before:
- disconnecting the battery.
- removing the No. 39 (7.5 A) fuse from the under-hood fuse/relay box.
- removing the radio.
After service, reconnect power to the radio and turn it on. When the word "CODE" is displayed, enter the customer's 5-digit code to restore radio operation.





1. When the engine is cool, drain the engine coolant from the radiator.

WARNING: Do not remove the radiator cap when the engine is hot; the engine coolant is under pressure and could severely scald you.

2. Open the clamp, then disconnect the heater valve cable from the heater valve arm.





3. Disconnect the heater hoses from the heater unit.

CAUTION: Engine coolant will damage paint. Quickly rinse any spilled engine coolant from painted surfaces.

NOTE: Engine coolant will run out when the hoses are disconnected; drain it into a clean drip pan.






4. Remove the two mounting nuts from the heater unit.

NOTE: When removing the mounting nuts, take care not to damage or bend the fuel pipes, brake pipes, etc.

5. Remove the dashboard.

Removal Step One:

Removal Step Two:

Removal Step Three:

6. Remove the mounting bolts and mounting nuts in sequence shown, then remove the steering hanger beam.

Heater Duct:

Evaporator:

7. Remove the heater duct or the evaporator.







8. Disconnect the mode control motor connector, then remove the mounting bolt and the heater unit.







9. Remove the two self-tapping screws and the vent/ defroster duct.
10. Remove the self-tapping screw and pipe clamp.
11. Remove the self-tapping screw and core clamp.
12. Pull out the heater core.

NOTE: Be careful not to bend the inlet and outlet pipes during heater core removal.

13. Assemble heater unit in the reverse order of disassembly.
14. Install in the reverse order of removal. Make note of the following items:
- Apply sealant to the grommets.
- Do not interchange the inlet and outlet heater hoses. Make sure that the clamps are secure.
- Loosen the bleed bolt on the engine, and refill the radiator and coolant reservoir with the proper engine coolant mixture. Tighten the bleed bolt when all the trapped air has escaped and engine coolant begins to flow from it.
- Connect all cables, and make sure they are properly adjusted.