Heater core replacement procedure(NO PICS)
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Heater core replacement procedure(NO PICS)
BEFORE YOUR START:
Have you’re a/c evacuated.
Drain coolant
Disconnect battery
WHAT YOU’LL NEED.
6mm,7mm,8mm,10mm, 7/16, ½” sockets. Some in deep sockets
Phillips screwdriver
Flathead screwdriver
Duct tape
Self adhering weather-stripping
5/8 and ½ a/c disconnect tool
In the engine bay, undo a/c lines, heater core lines, and vacuum line.
Head inside the truck. Remove bezel from around instrument cluster. Just pulls off.
Remove gauge cluster. 4 screws. Before you pull the cluster head under the steering column and disconnect the shift indicator cable. It just unhooks. Once that’s done and the screws are out pull it.
Remove headlight switch. 3 screws. Slide the red tabs to the left to “unlock” the plugs. There are two of them.
Remove lower steering column panel. 3 screws.
Remove hvac controls. 4 scrws. On the back side, undo the plug, remove the vacuum lines by undoing the two nuts and pull the lines straight off. To get the cable off, pull that white clip out and maneuver the cable loose.
Remove radio. Mine was aftermarket so undo main harness, rca cables, antenna. 2 bolts.
Remove panel under radio. Unplug ashtray light(just pulls out), cig lighter, power source. The airbag shut off is bolt to the panel from the back. 3 bolts.
Remove driver side kick panel. Just pulls off. Undo ½ bolt that’s holding steel bracket. Look up six inches. Undo that ground with the two wires going to it.
Remove passenger side kick panel. Undo ½ inch bolt. Undo plugs connected to that module. No ground.
Move to driver side under steering column. Unhook e-brake release. Just pull white clip down and the bar should slide out.
Undo hood release from bracket. 2 screws.
Undo the bracket that holding the OBD port. 4 screws.
Above the transmission hump hidden behind the carpet there are two bolts.
Undo fuse panel located between dashboard and driver side door.
Drop your steering column. 4 nuts to undo.
Undo 5 screws at top of dashboard.
Pull the dash away and rest it against the seats. I chose to NOT remove it from the truck and just left it against the seats.
With the dash pulled away you should now be able to see the hvac box. On the passenger side, undo the harness located at the windshield. Undo the harness with the two green wires. And undo the connection for the antenna behind the glove box.
Undo the air duct that is bolted to the top of the hvac box. 2 bolts
Undo the steel bracket holding the hvac box. Take it right off or it gets in the way.
Now head out to the engine bay. Undo the studs holding the box in place. There should be 5 or 6.
The box should now be free. Remove it from the truck by dragging it along the floor. It will fit between the door jamb and dashboard.
Take the hvac box in the garage. Remove the actuator by undoing the two bolts. Then follow the arm to the white clip. You’ll see it held on with a press fit washer. Pry the washer up with a flathead screwdriver. SAVE IT! And the you can maneuver the arm out of the clip.
Undo all the screws holding the top of the box on. About 20 of them. And 1 press fit washer again. Save the washer.Pull the lid off.
Remove the old core. If you have an aftermarket core it’s a little bigger than the factory one. So see the plastic tabs in the bottom of the box, you may have to snap them off. I did.
Test fit your core until your satisfied. Fill in any gaps with the weatherstripping you purchased.
Secure the lid and all the screws and washer.
Reattach the actuator.
At this point I chose to seal any air gaps around the lid with duct tape.
Go ahead and reinstall the hvac box and secure it to the firewall.
BEING REASSAMBLY.
Have you’re a/c evacuated.
Drain coolant
Disconnect battery
WHAT YOU’LL NEED.
6mm,7mm,8mm,10mm, 7/16, ½” sockets. Some in deep sockets
Phillips screwdriver
Flathead screwdriver
Duct tape
Self adhering weather-stripping
5/8 and ½ a/c disconnect tool
In the engine bay, undo a/c lines, heater core lines, and vacuum line.
Head inside the truck. Remove bezel from around instrument cluster. Just pulls off.
Remove gauge cluster. 4 screws. Before you pull the cluster head under the steering column and disconnect the shift indicator cable. It just unhooks. Once that’s done and the screws are out pull it.
Remove headlight switch. 3 screws. Slide the red tabs to the left to “unlock” the plugs. There are two of them.
Remove lower steering column panel. 3 screws.
Remove hvac controls. 4 scrws. On the back side, undo the plug, remove the vacuum lines by undoing the two nuts and pull the lines straight off. To get the cable off, pull that white clip out and maneuver the cable loose.
Remove radio. Mine was aftermarket so undo main harness, rca cables, antenna. 2 bolts.
Remove panel under radio. Unplug ashtray light(just pulls out), cig lighter, power source. The airbag shut off is bolt to the panel from the back. 3 bolts.
Remove driver side kick panel. Just pulls off. Undo ½ bolt that’s holding steel bracket. Look up six inches. Undo that ground with the two wires going to it.
Remove passenger side kick panel. Undo ½ inch bolt. Undo plugs connected to that module. No ground.
Move to driver side under steering column. Unhook e-brake release. Just pull white clip down and the bar should slide out.
Undo hood release from bracket. 2 screws.
Undo the bracket that holding the OBD port. 4 screws.
Above the transmission hump hidden behind the carpet there are two bolts.
Undo fuse panel located between dashboard and driver side door.
Drop your steering column. 4 nuts to undo.
Undo 5 screws at top of dashboard.
Pull the dash away and rest it against the seats. I chose to NOT remove it from the truck and just left it against the seats.
With the dash pulled away you should now be able to see the hvac box. On the passenger side, undo the harness located at the windshield. Undo the harness with the two green wires. And undo the connection for the antenna behind the glove box.
Undo the air duct that is bolted to the top of the hvac box. 2 bolts
Undo the steel bracket holding the hvac box. Take it right off or it gets in the way.
Now head out to the engine bay. Undo the studs holding the box in place. There should be 5 or 6.
The box should now be free. Remove it from the truck by dragging it along the floor. It will fit between the door jamb and dashboard.
Take the hvac box in the garage. Remove the actuator by undoing the two bolts. Then follow the arm to the white clip. You’ll see it held on with a press fit washer. Pry the washer up with a flathead screwdriver. SAVE IT! And the you can maneuver the arm out of the clip.
Undo all the screws holding the top of the box on. About 20 of them. And 1 press fit washer again. Save the washer.Pull the lid off.
Remove the old core. If you have an aftermarket core it’s a little bigger than the factory one. So see the plastic tabs in the bottom of the box, you may have to snap them off. I did.
Test fit your core until your satisfied. Fill in any gaps with the weatherstripping you purchased.
Secure the lid and all the screws and washer.
Reattach the actuator.
At this point I chose to seal any air gaps around the lid with duct tape.
Go ahead and reinstall the hvac box and secure it to the firewall.
BEING REASSAMBLY.