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How to Replace the Heater Core in a 1997 Diesel

A diesel vehicle's heater core is an important part of the heating ventilation and air conditioning (HVAC) system. A heater core works by transferring heat from hot engine coolant to an air intake charge that is blown into the passenger cabin of the vehicle. A faulty heater core can cause a loss of passenger cabin heat as well as coolant leaks inside the cabin. Replacement of a heater core is a fairly simple, step-by-step process that can be undertaken and successfully completed by any average do-it-yourself mechanic. The replacement process will take between three and five hours to complete.

Things You'll Need

  • Complete set of US and Metric wrenches and sockets
  • Heater hose removal tool
  • Replacement heater core
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Instructions

    • 1

      Drain the vehicle's coolant system. To drain the coolant system, simply disconnect the lower radiator hose and allow all of the engine coolant to flow out into a container. After draining the coolant system, disconnect the negative battery cable to disable the vehicle's air bag system. Be sure to wait five minutes before continuing work on the vehicle to allow the backup capacitors to discharge.

    • 2

      Prepare dashboard for removal. Start by removing the upper and lower trim panels that surround the steering column as well as the fuse box cover. Detach the hood and parking brake release handles and remove the floor duct cover panel. Remove the lower instrument panel steering column cover. Next remove the door scuff plates and cowl side trim panels on the driver and passenger sides of the vehicle. Disconnect the electrical connector from the brake switch and all electrical connections along the floor and lower right side of the passenger floorboard. Remove the instrument panel steering column opening cover reinforcement. Remove the four bolts holding the steering column in place and lower the column onto the drivers seat. Remove the instrument panel relay cover and disconnect the auto lamp sensor connector. Remove the five bolts securing the passenger side airbag module to the dashboard support frame and remove the unit. Remove the passenger side assist handle and passenger side windshield garnish molding. Remove the nine instrument panel bolts located around the instrument panel. Remove the two instrument panel retaining nuts from the bolts at the bottom of the instrument panel. Remove the right-hand instrument panel floor brace. The dashboard can now be moved away from the firewall.

    • 3

      Remove under-hood hardware. Disconnect the heater hoses from the heater core tubes at the firewall. Remove the air conditioning plenum demister adapter. Remove the vacuum line adjacent to the heater-core bracket. Remove the four screws securing the heater core bracket and remove the bracket. Remove the top cover of the heater plenum and remove the blend door assembly. Remove the heater core. The core can simply be pulled straight out.

    • 4

      Repeat steps one through three in reverse order to install the new heater core.

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