Tools Required

J 38185 Hose Clamp Pliers

1. Remove the following component:

•	For a 3.1L engine, remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls-3.1L.

•	For a 3.8L engine, remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical-3.8L.

2. Remove the cross vehicle brace. Refer to Cross Vehicle Brace Replacement in Body Front End.
3. Drain the coolant. Refer to Cooling System Draining and Filling in Engine Cooling.



4. UseJ 38185 in order to position aside the heater hose inlet and outlet clamp at the heater core.
5. Disconnect the inlet and outlet heater hose from the heater core.
6. Remove the floor carpet. Refer to Front Floor Panel Carpet Replacement in Interior Trim.
7. Remove the rear floor air outlet duct from the holes in the floor reinforcement.
8. Disconnect the rear floor air outlet duct from the heater core outlet cover.
9. Remove the bolts from the vacccum harness bracket and position bracket aside.




Important: Position the heater core outlet cover downward and rearward in order to disconnect the cover from the rear area floor duct assembly.

10. Remove the screws from the heater core outlet cover.
11. Remove the heater core outlet cover.



12. Remove the screws from the heater core cover.
13. Remove the heater core cover.



14. Remove and discard the seals (1,2) from the heater core cover.
15. Remove the caulk (3) from the heater core cover.



16. Remove and discard the outer seal (5) from the heater core.



17. Remove the screw (1) from the heater core line clamp.
18. Remove the heater core retaining clamp.
19. Remove the screw (2) from the heater core pipe retainer clamp.



20. Remove the heater core from the HVAC lower case.



21. Remove and discard the lower seal (4) from the HVAC case.



22. Remove and discard the center seal (3) from the HVAC case.



23. Remove and discard the upper seal (2) from the HVAC lower case.



24. Remove and discard the side seals (1) from the HVAC lower case.

1. Install the side seals (1) to the HVAC lower case.



2. Install the upper seal (2) to the HVAC lower case.



3. Install the center seal (3) to the HVAC case.



4. Install the lower seal (4) to the HVAC case.



5. Install the heater core to the HVAC lower 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.

6. Install the screw (2) to the heater core line clamp.

Tighten
Tighten the screw to 1.5 N·m (13 lb in).

7. Install the screw (1) to the heater core mounting clip.

Tighten
Tighten the screw to 1.5 N·m (13 lb in)




8. Install outer seal (5) to the heater core.



9. Install new seals(1,2) to the heater core cover.
10. Install the caulk (3) on to the heater core cover.



11. Install the heater core cover.
12. Install the heater core cover screws.

Tighten
Tighten the screws to 1.5 N·m (13 lb in).




13. Install the heater core outlet cover.
14. Install the screws to the heater core outlet cover.

Tighten
Tighten the screws to 1.5 N·m (13 lb in).

15. Install the HVAC vaccum harness bracket.
16. Install the bolts to the HVAC vaccum harness bracket.

Tighten
Tighten the screws to 1.5 N·m (13 lb in).

17. Connect the rear floor air outlet duct to the heater core outlet cover.
18. Install the rear floor air outlet duct to the holes in the floor reinforcement.
19. Install the floor carpet. Refer to Front Floor Panel Carpet Replacement in Interior Trim.



20. Connect the inlet and outlet heater hose to the heater core.

Important: Reposition the heater core hose clamps in the indicated location.

21. UseJ 38185 in order to reposition the heater hose inlet and outlet clamp to the heater core.
22. Fill the coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
23. Install the cross vehicl brace. Refer to Cross Vehicle Brace Replacement in Body Front End.
24. Install the following component:

•	For a 3.1L engine, install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.1L.

•	For a 3.8L engine, install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical - 3.8L.