Have you removed the cable from the air direction control on the dash? You have to pull the cable out with the heater unit, and that means bending it through quite a severe angle, which means tugging on the heater unit. There is also a rubber block on the back of the heater unit at the bottom which fills the space between the heater unit and the bulkhead which also makes it harder to lift out (but even harder to get back with a new block!). Other than that it is 'just' a matter of pulling it up and leaning the top forwards to clear the body above it. For a pictorial blow-by-blow of removal and replacement see http://www.chicagolandmgclub.com/photos/b_heater/
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Drain the cooling system. Draining the cooling system will prevent toxic engine coolant from leaking into the passenger cabin of the vehicle during removal of the heater core. To drain the cooling system, simply disconnect the lower radiator hose from the radiator by loosening the hose clamp and pulling the hose off. Be sure to drain the fluid into a sealable container and dispose of the coolant at an appropriate disposal site.
2Pull the dashboard six inches rearward. In order to do this, you must remove the following parts; the center dash bolt (located under the defroster vent cover), the bolts under the driver and passenger kick boards, the bolt connecting the dashboard to the radio mount, and the the bolt connecting the dashboard to the rear of the glove box. The locations of these bolts are immediately apparent upon looking under the dash. Once you have removed these bolts, you can pull the dashboard rearward and secure it.
3Remove the heater core box. The heater core box is a black plastic box that surrounds the heater core. This part should be visible when looking down into the dashboard from the passenger side seat. Remove the two bolts on top holding it to the firewall and another on the bottom near the foot well. After removal of these bolts, the heater core and box are attached to the vehicle only by the coolant lines, which you can now disconnect by reaching into the box and pulling them off of the heater core (you may have to loosen the clamps first).
4Install the new heater core. This is accomplished by applying steps 1 through 3 in reverse order; re-connect heater core coolant line, re-install heater core box (be sure to apply silicon sealant to the edges of the box, hermetically sealing it), replace the dashboard and install bolts, and re-fill the cooling system.
Hello lets start by removal of the retainer bolt at the base of the dip stick tube usually 3/8 inch or 10mm ounce removed wiggle and pull out comes the dip stick tube see the o ring seal lets remove and replace it now put it back with new seal and tighten down problem should be resolved.
It is located on top of the heater box in the passenger side remove the glove box to gain acess there are two 7mm srews and a relay braket holding it in place it is a tight squeeze but can be removed with a 1/4 inch ratchet. source: fixya thanks for using fixya Hope this helps
Disconnect the battery cable, remove the carburetor air cleaner and partially drain the coolant system.
Remove the heater hoses from the heater core.
Remove the glove box liner and remove the register duct by pulling from the instrument panel register and releasing the clip at the plenum.
Disconnect the right cowl outside air inlet vacuum hose from the outside/recirculating door vacuum motor.
Remove the rear housing from under the instrument panel. Remove the outside air inlet duct from the rear housing (4 nuts and 1 bolt) and install one upper nut to retain heater housing-to-dash after rear housing is removed.
Remove two screws retaining plenum-to-dash (above transmission tunnel) and two screws to heater housing and remove the plenum.
Install a piece of protective tape on A-pillar inner cowl panel, at lower right corner of instrument panel.
Remove the lower right instrument panel-to-A-pillar bolt to hold the panel in the rearward position.
Remove the heater core (3 screws retaining 2 plates).
Remove the temperature blend door (snaps off).
Remove the temperature blend door arm support (2 screws) and pivot arm retainer (1 screw).
Remove blower motor (2 screws) and remove blower wheel.
Transfer blower to blower motor and panel assembly.
Install door arm pivot retainer (1 screw) and door arm support (2 screws).
Install the temperature blend door (snaps on).
Install heater core.
Install the plenum (4 screws).
Connect blower wires.
Remove heater housing upper retaining nut and install the heater outlet (4 nuts and 1 bolt). Position the air inlet duct.
Connect the white vacuum hose to the outside/recirculating door vacuum motor.
Reposition the instrument panel, install the retaining bolts and remove the protective tape at the A-pillar inner cowl panel, lower right corner of instrument panel.
Install the right register duct assembly and install the glove box liner.
Connect heater hoses to the heater core assembly.
Fill cooling system, install the air cleaner and connect the battery cable to the battery.
Removal & Installation
The Supplemental Inflatable Restraint (SIR) system must be disarmed before removing the blower motor assembly. Failure to do so may cause accidental deployment of the air bag, resulting in unnecessary SIR system repairs and/or personal injury.
Disconnect and isolate the negative battery cable, then wait 2 minutes before proceeding with the removal. This will effectively disable the air bag system preventing possible personal injury.
Remove the glove box from the instrument panel
The blower motor is located behind the glovebox, behind the blower motor cover
Remove the A/C-heater blower motor cover.
Disconnect the blower motor wiring connector.
Remove the blower motor wiring grommet and feed the wiring through the blower motor housing.
Remove the blower motor mounting screws.
Once the cover is removed, unplug the electrical connector and push it through the opening in the housing
The blower motor is secured to the housing with three small screws
Allow the blower motor assembly to drop downward to clear the instrument panel and remove from vehicle.
Place the blower motor assembly into position on the A/C-heater unit and tighten the mounting screws.
Route the blower motor wiring through the blower motor housing and seat the wiring grommet in the hole of the blower motor housing.
Reconnect the blower motor electrical connector.
Install the A/C-heater blower motor cover.
Install the glove box into the instrument panel.
Reconnect the negative battery cable. Check blower motor operation.
You do not have to pull the heater box out to chg. the heater core unless there is something else you are going to do. On the right side under dash there are 6 or 7 small 1/4 inch screws that have to come out and the front of the heater box will come off and there is the heater core, beware there is 1 screw thats a bear to get because you can't see it, its above the blower motor to the right, a lot of people including mechanics don't put it back in when they chg. out the core.
Drain the engine coolant into a suitable container.
the instrument panel glove compartment. Push in on the sides of the
compartment to release it, allowing access to the heater core.
The heater core can be damaged if too much force is applied to the heater core pipes during hose removal.
the heater module screws and remove the heater module assembly cover.
For vehicles equipped with A/C, remove the air conditioning evaporator
temperature sensor assembly from the heater and A/C cover.
Remove the heater core screw and clamp.
Remove the hose pipe clamp screw and the hose pipe clamp. Clamp off the heater hoses.
Fig. 1: Heater hose and pipe routing-3.4L engineFig. 2: Heater hose and pipe routing-3.8L engineFig. 3: Heater hose and pipe routing-5.7L engine
Disconnect the heater hoses from the pipes.
Remove the heater core by carefully pulling it towards you.
Fig. 4: Exploded view of the heater core removed from the heater module assemblyTo install:
Install the heater core and attach the heater hose assembly to the heater hose pipes. Note the following:
Lubricate the heater core pipes with petroleum jelly for ease of installation and to assure a good seal.
Be sure the seals around the heater pipes remain in place when installing.
verify that the seal is installed correctly, observe the seal from
inside the engine compartment. If the seal has leaks, apply a sealer
between the heater core pipes and the evaporator housing.
the hose pipe clamp and the bolt/screw. Unclamp the heater hoses.
Tighten the hose pipe clamp bolt/screw to 16 inch lbs. (1.8 Nm).
Install the heater core clamp and screw. Tighten the screw to 16 inch lbs. (1.8 Nm).
Install the heater module assembly cover and secure with the retaining screws. Tighten the screws to 18 inch lbs. (2 Nm).
Connect the negative battery cable.
Refill the cooling system. Operate the engine and check for leaks, add coolant if necessary.