Heater Core Replacement
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- Percival McGee
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1 Page 1 of Chevrolet Impala : Heating, Ventilation, & Air Conditioning > Repair Instructions > Heater Core Replacement Heater Core Replacement HEATER CORE REPLACEMENT Tools Required J (Image 1) Hose Clamp Pliers Removal Procedure 1. Remove the fuel injector sight shield, if equipped with 3.8L. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical-3.8L. 2. Drain the coolant. Refer to Cooling System Draining and Filling in Engine Cooling. 3. UseJ (Image 1) in order to position aside the heater hose inlet and outlet clamp at the heater core. 4. Disconnect the inlet and outlet heater hose from the heater core. 5. Remove the vacuum tank. Refer to Vacuum Tank Replacement in HVAC System - Manual. 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.
2 Page 2 of Disconnect the rear floor air outlet duct from the heater core outlet cover. 9. Remove the bolts from the vaccum harness bracket and position bracket aside. NOTE Important: Position the heater outlet cover downward and rearward in order to disconnect the cover from the rear area floor duct assembly. 10. Remove the heater outlet cover screws. 11. Remove the heater outlet cover.
3 Page 3 of Remove the heater core cover screws. 13. Remove the heater core cover.
4 Page 4 of Remove and discard the seals (1,2) from the heater core cover. 15. Remove the caulk (3) from the heater core outlet cover. 16. Remove and discard the outer seal (5) from the heater core. 17. Remove the heater core pipe retainer clamp screw (2) from the heater core retainer clamp. 18. Remove the heater core retaining clamp screw (1) from the heater core.
5 Page 5 of Remove the retaining clamp from the heater core. 20. Remove the heater core from the HVAC lower case. 21. Remove the heater core pipe retainer clamp from the heater core pipes. 22. Remove and discard the heater core lower seal (4) from the HVAC case.
6 Page 6 of Remove and discard the heater core center seal (3) from the HVAC case. 24. Remove and discard the heater core upper seal (2) from the HVAC lower case.
7 Page 7 of Remove and discard the heater core side seals (1) from the HVAC lower case. Installation Procedure 1. Install new heater core side seals (1) to the HVAC lower case.
8 Page 8 of Install a new heater core upper seal (2) to the HVAC lower case. 3. Install a new heater core center seal (3) to the HVAC case.
9 Page 9 of Install a new heater core lower seal (4) to the HVAC case. 5. Install the heater core retaining clamp to the heater core pipes. 6. Install the heater core in to the HVAC lower case.
10 2003 Chevrolet Impala - Heating, Ventilation, & Air Conditioning > Repair Instructions > Heate... Page 10 of 14 NOTE 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 screw (2) to the heater core retaining clamp. Tighten Tighten the clamp screw to 1.5 N m (13 lb in). 8. Install the heater core mounting clip with a screw (1). Tighten Tighten the screw to 1.5 N m (13 lb in).
11 2003 Chevrolet Impala - Heating, Ventilation, & Air Conditioning > Repair Instructions > Heate... Page 11 of Install heater core outer seal (5) to the heater core. 10. Install new seals (1,2) to the heater core cover. 11. Install the caulk (3) on to the heater core outlet cover.
12 2003 Chevrolet Impala - Heating, Ventilation, & Air Conditioning > Repair Instructions > Heate... Page 12 of Install the heater core cover. 13. Install the heater core cover screws. Tighten Tighten the cover screws to 1.5 N m (13 lb in).
13 2003 Chevrolet Impala - Heating, Ventilation, & Air Conditioning > Repair Instructions > Heate... Page 13 of Install the heater core outlet cover. 15. Install the screws to the heater core outlet cover. Tighten Tighten the screws to 1.5 N m (13 lb in). 16. Install the HVAC vaccum harness bracket. 17. Install the screws to the HVAC vaccum harness bracket. Tighten Tighten the screws to 1.5 N m (13 lb in). 18. Connect the rear floor air outlet duct to the heater core outlet cover. 19. Install the rear floor air outlet duct to the holes in the floor reinforcement. 20. Install the floor carpet. Refer to Front Floor Panel Carpet Replacement in Interior Trim. 21. Install the vacuum tank. Refer to Vacuum Tank Replacement in HVAC System - Manual. 22. Connect the inlet and outlet heater hose to the heater core. NOTE Important: Reposition the heater core hose clamps in the indicated location.
14 2003 Chevrolet Impala - Heating, Ventilation, & Air Conditioning > Repair Instructions > Heate... Page 14 of UseJ (Image 1) in order to reposition the heater hose inlet and outlet clamp to the heater core. 24. Refill the coolant. Refer to Cooling System Draining and Filling in Engine Cooling. 25. Install the fuel injector sight shield, if equipped with 3.8L. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical-3.8L. REFERED IMAGES LIST: (Image 1) J 38185
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