Heater Core Replacement - Dash is removed

[SubversionX]

So, the heater core needs to be replaced, and I've got the dash removed. I've got the two bolts and two screws that retain assembly on top removed, as well as the topside of the heating box. I'm a little stuck right now, as to how to reach the heater core at this point. Do I need to remove the entire air box located behind where the passenger air bag sits? I feel like I'm probably missing a few screws and bolts, but I don't know exactly where to look?

This is what the dash looks like currently. Thanks in advance!

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[SubversionX]

Alright, with a little patience and insight, I was able to get the whole unit jostled loose. I drained the coolant and disconnected the tubing through the firewall to the heater core. I tried pulling the core out of the heater box, but it seems pretty stuck in there. Do I have to disassemble the heater box to take it out? or do I just need to pry it out a little harder?

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[beihl304]

I am also interested. I am going to replace mine this weekend.

 

[SubversionX]

I know it's been a minute since I've posted, but I wanted to say; I feel like an idiot not being able to take out the heater core at first. I ended up yanking the whole heater box out of the dash and tearing it apart, before I realized that there are two small screws that hold the heater core to the box, next to the inlet/outlet tubing. And then it slid right out. So, big tip: only two screws hold the heater core in the heater box. Again: only two screws hold the heater core in the heater box.

 

[2geclipse565]

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Man how did you get it to this point? I cant find a write up or anything detailed that tells me how to get from your first post to your second post. I cant get the dam thing loose. Iv taken out the 8 bolts holding the unit it.

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Also the ac lines on the underhood side of the firewall. What am I missing?

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this was the best write up I could find but it is a little hard to follow without the pics
http://www.dsmtuners.com/forums/articles-exterior-interior/353047-heater-core-replacement-dash-removal.html

 

[SubversionX]

When I first attempted to pull out the dash, I tried following that tech article, but like you said, it's sort of hard to follow without the pictures. It ends up just being a hunt for bolts and screws that hold everything in place, so I'll try to break it down into shorter steps.

1. Remove the steering wheel, including the clock spring, and un-clipping all the wire clips.

2. Pry off the little panels on the dash, about 1x1", and all the stuff that the 10mm bolts hide behind, as well as the plastic vents that lead to the door-jam. (On the top of the dash near the windshield, there are the two speakers. Use a small screwdriver to gently pry these out, and there is a 10mm bolt behind each one.)

3. Remove the gauge cluster (a couple small black screws hold in the plastic bezel, and then a few more screws hold in the bezel, and the gauge should just pop right out.

4. Remove the glove compartment, and the passenger air bag. (The air bag is held in by bolts from inside the glove compartment area, and there is a red wire connector that leads to the left side, that should be un-clipped prior.

5. Take out all the bolts that are holding the dash in. I took out all the ones I could find visually, and then would tug firmly on the dash until I could find where I had missed a few.

Eventually, your entire dash will be freed and you can pull it a little ways from the frame, before you need to trace the wire connectors from the dash, to underneath. You should probably label these, but for the most part, they've only got a single match in that area. It's easier to have a friend to help pull out your dash, so you don't damage it.

6. You'll see large black plastic ducting from the passenger side, to the center of the dash, and it will look like it vents upwards. The top part of the open area ducting can be taken off easily.

7. Then, unbolt and remove the little metal clippings (using a small flat-head screwdriver) to loosen all three air box pieces under the dash. The plastic air box on the far left, houses your heater core, shown in the last image posted.

After you have the coolant lines drained and pulled off of the heater core from the engine bay, you can begin to remove the heater core itself. The first time I did this, I nearly disassembled the entire heater box. You don't need to do that. All you have to do, is try to push the box downward so you have a little lei-way to maneuver it, and turn it around so that the heater core is facing toward you. Then, you'll see two little screws that hold the heater core in place, and it'll slide right out.

It's hard to find how-to's that are very accurate, or a lot of support for this job, but with enough patience and band-aids, you'll get it. The second time I did this, it was at a junkyard, and I was able to do everything including removing the dash, in just about 30 minutes, using a power drill with a 3/8" and 1/4" socket driver adapter, with the screwdriver bits. (I did cheat though, by just using a hammer to bust down the plastic air ducting, however.)

The toughest part about this job, is getting the hoses off of the heater core itself, and maneuvering the box at an angle to get behind it with a screwdriver.

In the first of your two pictures, it shows the plastic air boxes. The one of the three on the far left, that ducts upwards, is where your heater core is located in. The three boxes are held together with screws and little metal clips in the shape of a "C" that keep them together. If you undo all the boxes from each other, you'll be able to pull out the one on the far left, more easily. You'll have to pull it toward you, as it's hung up on the bolt that a 1/2" nut was on.

On your second pic, you posted a picture of the refrigerant line. you need to find a pair of large rubber hosing that are vertical from each other, that goes through the center of your firewall behind your intake mani. They should have coolant/anti-freeze, meaning you should drain your radiator. They're a real pain in the butt to get to, to get the clamps off of.

 

[2geclipse565]

Thank you for the help but i am still stuck I have everything off as described but it feels like there is still something that is not giving up. Im not sure the terms but as desribed the box on the left (heater core feals loose as does the one on the right its just the center one still feels like it is connected to something? is there something I missed? heres a poor non informative video but oh well

75356fe8.mp4 video by nickp565 - Photobucket

On your second pic, you posted a picture of the refrigerant line. you need to find a pair of large rubber hosing that are vertical from each other, that goes through the center of your firewall behind your intake mani. They should have coolant/anti-freeze, meaning you should drain your radiator. They're a real pain in the butt to get to, to get the clamps off of.

Got those lines already thank you tho

 

[SubversionX]

Did you get all of the 1/2" bolts holding the air boxes to the firewall? There are a few on the bottom in the back that you need to get to. You need to pull the heater core air box pretty hard to get it off of the wall, and free from the rest of the boxes. If you need to, pull between the other two boxes, to give yourself a little more flexibility.

 

[2geclipse565]

I had to throw in the towell I have to get the car back on the rode. I could not get the heater box to turn around like that. Im just going to to bypass the heater core. So close but so far, on a plus side though, taking out the dash was incredibly easy and im not hesitatnt to do it again. Im going to talk to a few friends and see if we cant give it another try before winter comes. thanks for all the help though it was greatly appreciated

 

[SubversionX]

Understood; having a few extra hands is always good. The worst part for me was when I re-assembled everything back together, and put the dash back in. After all was back together, I found a flapper for the inside of the heater box, outside the car; so I had to take everything back out again, to put it back in. Feel free to contact me again when you decide to work at this again, I'll be glad to help.

 

[josh1095]

subversion: you sir are a MECHANIC! excellent work getting the whole damn dsh out. this puts the fear in me tho, god lets all hope our a-coils/heater cores never go.
i can only add that i have done this in a ford f150 and recently my buddys cavalier. the manuals said to remove the dash but i found a way around that. still an 8 hr job tho

 

[SubversionX]

it's always a daunting task. I just had a co-worker who came to me with her cobalt because her heater core needs replacing. I suppose it's important to know, and it's tedious to work with, but I'm really glad that I know how to do it now that I've tried it a few times.

- and thanks Josh for the comment; totally made my day

 

[2geclipse565]

Understood; having a few extra hands is always good. The worst part for me was when I re-assembled everything back together, and put the dash back in. After all was back together, I found a flapper for the inside of the heater box, outside the car; so I had to take everything back out again, to put it back in. Feel free to contact me again when you decide to work at this again, I'll be glad to help.

Thanks for everything man and I definitely will because it has to get done. Il message you or something. yea next time im definitely calling in the troops try and get some friends to help me out.