Things You'll Need:
- Heater Core
- Antifreeze
- Torx screws Drivers
- Ratchet set with metric sockets
- Screw Drivers
- Right angle screw driver, extenders, and mini sockets
- Patience
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Step 1
Slip on the foam removed from the old heater core onto the new heater core.
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Step 2
At this point you have one bracket on the right side hanging in place. Loosen the screw but do not remove it.
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Step 3
Locate the hole in the firewall that the heater core pipes feed through.
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Step 4
Feed the heater core pipes into the hole in the firewall. You must also get the new heater core under the hanging bracket as well. If it gets stuck, it is because the pipes are hitting something in the engine compartment. You may have the bend the pipes slightly to get the pipes past the obstacles in the engine compartment. It also helps to have a partner helping for this step.
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Step 5
With the pipes through and the heater core firmly in its case, install the pipe bracket in the engine compartment. Do not tighten the screw all the way and do not push the pipes into the bracket at this point.
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Step 6
Install the left bracket on the heater core and install the screw on the top through the glove compartment. Do not tighten the screw all the way.
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Step 7
Install the screw on the bottom right bracket. Do not tighten the screw all the way.
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Step 8
Install the screw on the bottom left bracket. Do not tighten the screw all the way.
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Step 9
Tighten the screw on the top left bracket. A right angle screw driver works wonders at this point. Then tighten the remaining 3 screws on the brackets. The screw on the top right bracket can only be tightened with a right angle screw driver.
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Step 10
In the engine compartment, slide the pipes into the pipe bracket and tighten the screw. Install the heater hoses per the instructions in the resources section.
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Step 11
Take the heater core case cover and insert it up and over the heater core starting with the right side of the case cover so it goes in on an angle with the top right side of the cover up and the bottom left side down. You then have to wiggle and finagle the cover into place.
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Step 12
Once you have it correct, the left side of the cover should slide into the duct work on the left. Make sure the foam and tape is inside and not sticking out.
The hard part is now making sure that the cover is in correctly. The front cover has grooves that slip over the edges of the back cover. If they are not correctly aligned, the front cover will not be flat against the back cover. You will know when the cover is in correctly when it sits flat against the back part of the cover on all sides and that all screw holes in the front cover are pushed flat against the back cover. -
Step 13
The hardest screw to install is the top middle screw. It is not perfectly accessible through the glove box so I was able to use my right angle screw driver from the radio area, across through the back of the glove box to get this screw in. Tighten all the way.
The picture shows a red line which traces the path of the screw driver. -
Step 14
Install the bottom middle screw.
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Step 15
Install the top left screw through the radio / ash tray area.
The picture shows a red line which traces the path of the screw driver. -
Step 16
Install the bottom left screw.
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Step 17
Using a right angle screw driver, install the top right screw.
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Step 18
Using a right angle screw driver, install the bottom right screw. At this point, the heater core cover is completely installed.
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Step 19
Install the vent deflector sitting on the hump in the center of the two seats. There are two screws to install.
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Step 20
Install the vent deflector in the top of the heater core cover. You’ll have to wiggle and finagle it through the glove compartment to get it in. There are tabs on it that lock it in place. They may have been bent out of shape during the removal process, so gently bend them out before you install the vent deflector.
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Step 21
Connect the foam covered hose to the right side of the vent deflector just installed.
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Step 22
Connect the foam covered hose to the left side of the vent deflector just installed.
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Step 23
Lift the dashboard and slide it back towards the firewall and on top of the dash board bolt base. Install the dashboard bolt.
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Step 24
Install the bolt to the left of the dash bolt holding a bracket in place with wires connected to it. Ensure all the wires are connected properly.
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Step 25
Install the bolt to the left of the bolt just Installed, in the center of the dash. The bolt is holding a bracket.
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Step 26
Position the foot well trim and install the 5 long screws in the top to the bottom of the dash board.
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Step 27
Install the 2 short screws on the bottom of the foot well trim holding the foot well trim to the firewall.
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Step 28
Install the passenger kick panel and install the 4 screws holding it in place.
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Step 29
Install the glove box access panel by installing the two screws in the back of the glove compartment.
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Step 30
Slide the clip holding the light that is in the ash tray into the ash tray and snap it into place. Slide the ash tray into place.
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Step 31
Install the glove box door wiggling in the rounded arm and installing the two screws holding it in.
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Step 32
Install the radio. See Resources for details.
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Step 33
Install the rear view mirror. See Resources for details.
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Step 34
Reconnect the negative battery cable.
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Step 35
Fill up the radiator with a 50/50 mix of antifreeze and water. Do not put the radiator cap on.
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Step 36
Start the truck. Turn the heater on and fill up the radiator again. Let the truck run for 10 minutes while you watch the radiator. If it starts to overflow, put the cap on. If the antifreeze decreases, add more.
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Step 37
Check for leaks at the point where the heater hoses connect to the heater core.
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Step 38
Turn off the truck and fill up the antifreeze reservoir to the appropriate level.
