Mechanics

HEATER CORE REMOVAL

2004 Chrysler PT Cruiser • 4 cylinder FWD Automatic • 60,000 miles

I need complete info on how to remove and replace heater core on 2004 pt cruiser 2.4 no turbo. This is gonna be an ordeal. Can you help me?
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DOUG
August 3, 2011.



HEATER CORE REMOVAL: Remove the HVAC housing. See HVAC HOUSING.
Disassemble the HVAC housing to access the heater core. See HVAC HOUSING.
Lift the heater core out of the lower half of the housing.

HVAC HOUSING
REMOVAL
The HVAC housing must be removed from the vehicle and the two halves of the housing separated for service access of the heater core, evaporator and the mode, recirculation and blend doors.
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. SEE AIR BAG RESTRAINT SYSTEMS ARTICLE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

WARNING: REVIEW THE WARNINGS AND CAUTIONS IN PLUMBING BEFORE PERFORMING THE FOLLOWING OPERATION.

Recover the refrigerant from the refrigerant system. See STANDARD PROCEDURE.
Partially drain the engine cooling system. See COOLING SYSTEM MECHANICAL article.
Disconnect and isolate the battery negative cable.
Remove the coolant recovery container. See COOLING SYSTEM MECHANICAL article.
Remove the screw that secures the accumulator mounting bracket to the body.
Remove the two bolts securing the accumulator tubes to the evaporator terminal block and disconnect the tubes from the terminal block.
Remove the seals from the refrigerant lines fittings and discard.
Install plugs in, or tape over all of the opened refrigerant line fittings and evaporator tubes.
Disconnect the vacuum harness at the power brake booster.
Fig. 39: Disconnecting A/C Vacuum Line
Courtesy of DAIMLERCHRYSLER CORP.
Remove the rubber drain tube extension from the condensation drain tube.
Fig. 40: Removing Dash Panel
Courtesy of DAIMLERCHRYSLER CORP.
Disconnect the heater hoses from the heater core tubes. Install plugs in, or tape over the opened heater core tubes to prevent coolant spillage during housing removal.
Remove three HVAC housing retaining nuts located on the dash panel in the engine compartment.
Remove the instrument panel from vehicle. See BODY article.
Remove the mode door and temperature control cables from the mode door and blend-air door levers and the HVAC housing. See MODE DOOR CABLE and TEMPERATURE CONTROL CABLE.
Remove the defroster and floor distribution ducts from the HVAC housing. See DEFROSTER DUCTand FLOOR DISTRIBUTION DUCTS.
Disconnect the wire harness connectors.
Remove the outboard HVAC housing retaining screw located in the passenger compartment.
Fig. 41: Removing Housing Screws
Courtesy of DAIMLERCHRYSLER CORP.
Remove the remaining nut located on the dash panel stud.
NOTE: Use care to ensure that the interior is covered in case of loss of residual fluids from the heater and evaporator cores.

Remove the HVAC housing from the vehicle.


Rasmataz
Oct 7, 2011.
See below


Rasmataz
Oct 7, 2011.