HVAC Systems (Service Information): Plumbing: Core-Heater: Removal

NOTE: The HVAC housing assembly must be removed from vehicle for service of the heater core.

NOTE: LHD model with A/C shown in the following illustrations. RHD and heater-only models are similar.

Fig 1: Removing/Installing Cover - Heater Core

Courtesy of DAIMLERCHRYSLER CORP.

1. Remove the HVAC housing assembly and place it on a workbench (Refer to HEATING & AIR CONDITIONING/DISTRIBUTION /HOUSING-HVAC - HOUSING-HVAC ASSEMBLY - REMOVAL) .
2. Remove the left floor distribution duct (Refer to HEATING & AIR CONDITIONING/DISTRIBUTION/DUCTS-FLOOR DISTRIBUTION - REMOVAL) .
3. Remove the three screws (1) that secure the heater core cover (2) to the driver side of the air distribution housing (3) and the HVAC housing (4) and remove the cover.
   Fig 2: Removing/Installing Heater Core

   Courtesy of DAIMLERCHRYSLER CORP.
   NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced.
4. Remove the foam seal (1) from the flange (2) located on the driver side of the HVAC housing (6).
5. Remove the two screws (4) that secure the heater core (5) to the driver side of the air distribution housing (3).
6. Carefully pull the heater core out of the driver side of the air distribution housing.
7. If required, remove the retaining clips that secure the heater core tubes to the heater core and disconnect the tubes from the heater core and remove and discard the O-ring seals.