For 1990-2009 cars

### Removal Procedure

#### Tools Required

J 38185 Hose Clamp Pliers

1. Remove the air cleaner cover and duct assembly. Refer to Air Cleaner Element Replacement in Engine Controls.
2. Drain the cooling system. Refer to Cooling System Draining and Filling Engine Cooling.
3. Disconnect the wiper linkage. Refer to Wiper Motor Crank Arm Replacement in Wiper Washer System.
4. Disconnect both of the heater hoses from the heater core using the J 38185 .
5. Remove the heater core outlet cover. Refer to Heater Core Cover Replacement .
6. Remove the screws retaining the heater core cover.
7. Remove the heater core cover.
8. Remove and discard the cavity (1), whistle (2), and permagum (3) seals from the heater core cover.
9. Remove and discard the heater core outer seal (5) from the heater core.
10. Remove the heater core retaining clamp screw (1).
11. Remove the heater core retaining clamp.
12. Remove the heater core pipe retainer clamp screw (2).
13. Remove the heater core from the HVAC module.
14. Remove and discard the heater core lower seal (4) from the HVAC module case.
15. Remove and discard the heater core center seal (3) from the HVAC module case.
16. Remove and discard the heater core upper seal (2) from the HVAC module case.
17. Remove the heater core pipe retainer clamp from the heater core pipes.

Using a flat bladed tool, release the retaining tab and open the clamp.

### Installation Procedure

#### Tools Required

J 38185 Hose Clamp Pliers

1. Install the heater core pipe retainer clamp to the heater core pipes.

Align the depression in the clamp to the ridge on one of the heater core pipes, then close the clamp to secure.

2. Install new heater cores side seals (1) to the HVAC module case.
3. Install a new heater core upper seal (2) to the HVAC module case.
4. Install a new heater core center seal (3) to the HVAC module case.
5. Install a new heater core lower seal (4) to the HVAC module case.
6. Install the heater core to the HVAC module case.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

7. Install the heater core pipe retaining clamp screw (2).

Tighten
Tighten the screw to 1.6 N·m (14 lb in).

8. Install the heater core retaining clamp.
9. Install the heater core retaining clamp screw (1).

Tighten
Tighten the screw to 1.6 N·m (14 lb in).

10. Install a new heater core outer seal (5) to the heater core.
11. Install a new cavity (1), whistle (2), and permagum (3) seals to the heater core cover.
12. Install the heater core cover.
13. Install the heater core cover retaining the screws.

Tighten
Tighten the screws to 1.6 N·m (14 lb in).

14. Install the heater core outlet cover. Refer to Heater Core Cover Replacement .
15. Connect both of the heater hoses and the clamps to the heater core using the J 38185 positioning the clamps as indicated.
16. Install the wiper linkage. Refer to Wiper Motor Crank Arm Replacement in Wiper Washer System.
17. Refill the coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
18. Install the air cleaner cover and duct assembly. Refer to Air Cleaner Element Replacement in Engine Controls.