Heater core — removal and installation Ford F150

Warning: The vehicles covered by this manu­al are equipped with a Supplemental Restraint System (SRS), more commonly known as airbags. Always disable the airbag system be­fore working in the vicinity of any airbag sys­tem components to avoid the possibility of ac­cidental deployment of the airbag, which could cause personal injury (see Chassis electrical system).

Note: The heater and evaporator cores are mounted in a large housing under the instru­ment panel. The instrument panel must be re­moved for access to the housing, and this is a difficult procedure for the home mechanic, involving many hard-to-find/reach fasteners and electrical connectors.

Removal

1. Have the air conditioning system discharged by a licensed air conditioning technician.

2. Drain the cooling system (see Tune-up and routine maintenance).

Ford F150 Cooling, heating and air conditioning systems_Heater core - removal and installation _Press the plastic tabs on the heater hose fittings to release the heater hoses

Press the plastic tabs on the heater hose fittings to release the heater hoses

3. Detach the heater hoses from the heater core pipes on the engine compart­ment side of the firewall (see illustration). Plug the heater core pipes to prevent leak­age when the HVAC housing is removed.

Ford F150 Cooling, heating and air conditioning systems_Heater core - removal and installation _Refrigerant line manifold nut at the TXV (A) and HVAC housing mounting nut (B)

Refrigerant line manifold nut at the TXV (A) and HVAC housing mounting nut (B)

4. Remove the nut and detach the refrig­erant lines from the Thermostatic Expansion Valve (TXV) at the firewall (see illustra­tion). Plug the lines and ports. Also remove the HVAC housing nut accessible from the engine compartment side of the firewall.

5. Remove the instrument panel (see Body).

6. Detach all electrical connectors and wiring harness clips from the HVAC housing.

Ford F150 Cooling, heating and air conditioning systems_Heater core - removal and installation _HVAC housing-to-firewall nut locations

HVAC housing-to-firewall nut locations

7. Unscrew the nuts securing the HVAC housing to the firewall and remove the HVAC housing from the passenger compart­ment (see illustration).

Note: It’s a good idea to cover the floor with plas­tic sheeting in case some coolant leaks out of the heater core when the HVAC housing is removed. Note: On models with a duct that leads to the rear seating area, detach the HVAC housing from the firewall and tilt the top to the rear do detach it from the duct.

Ford F150 Cooling, heating and air conditioning systems_Heater core - removal and installation _Remove the heater core cover screws

Remove the heater core cover screws…

Ford F150 Cooling, heating and air conditioning systems_Heater core - removal and installation _

… then separate the cover from the case — heater/evaporator case removed for clarity

8. Remove the heater core cover screws and cover (see illustrations).

Ford F150 Cooling, heating and air conditioning systems_Heater core - removal and installation _Use a small screwdriver to pry up the clip lock, then remove the clip

Use a small screwdriver to pry up the clip lock, then remove the clip…

Ford F150 Cooling, heating and air conditioning systems_Heater core - removal and installation _

… and separate the tubes from the heater core

9. Disconnect the heater core tube clips at the heater core and disconnect the tubes from the heater core (see illustrations). Always replace the 0-ring and clips with new ones.

Ford F150 Cooling, heating and air conditioning systems_Heater core - removal and installation _Lift the heater core out of the case and replace the 0-rings on the heater core tubes

Lift the heater core out of the case and replace the 0-rings on the heater core tubes

10. Remove the heater core from the case (see illustration).

Installation

11. Installation is the reverse of removal, noting for the following:

  1. Replace the heater core tube 0-rings and the tube clips with new ones.
  2. Fill the cooling system with the correct type and amount of coolant (see Tune-up and routine maintenance).
  3. Start the engine and check for leaks.
  4. Have the air conditioning system recharged by the shop that discharged it.
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