How to Replace Heater core on Toyota Tundra?

Toyota Tundra 2001-06 heater core removal details.

The procedure is mentioned with complete details and diagrams :---

2001-2004

1. Before servicing the vehicle, refer to the Precautions Section.
2. Disconnect the negative battery cable.
3. Drain the cooling system into a clean container for reuse.
4. Disconnect the heater hoses from the heater core.
5. Remove the steering wheel by performing the following procedure:
   1. Position the front wheels facing straight-ahead.
   2. Remove the steering wheel side covers.
   3. Using a Torx® wrench, loosen the 2 screws located at each side of the steering wheel until the screw-s circumference groove catches on the screw case. 
      
   4. Pull the air bag module from the steering wheel and disconnect the electrical connector.
      
      CAUTION

      Place the air bag module in a safe place with the front side facing upward.
   5. Remove the steering wheel nut.
   6. Place alignment marks on the steering wheel and the main shaft.
   7. Using a steering wheel puller, press the steering wheel from the steering column.
6. Remove the instrument panel and reinforcement by performing the following procedure:
   1. Remove the front door scuff plates, the cowl side trim and the front door opening trim.
   2. At the driver-s side, remove the 2 assist grip plugs, the 2 screws and assist grip and the front pillar garnish.
   3. At the passenger-s side, remove the 4 assist grip plugs, the 4 screws, the 2 assist grips and the front pillar garnish.
   4. Remove the instrument cluster finish panel.
   5. Remove the 2 screws and the hood lock control cable.
   6. Remove the 2 screws and the fuel lid control cable lever.
   7. Remove the lower No. 1 panel screw and the panel.
   8. Remove the lower left side panel.
   9. Remove the 3 steering column cover screws and the covers.
   10. At the steering column, disconnect the electrical connectors; then, remove the clamp, the 3 screws and the combination switch.
   11. Remove the No. 2 heater-to-register duct screw and the duct.
   12. Remove the steering column-to-instrument panel bolts and the steering column.
   13. At the combination meter, disconnect the electrical connectors; then, remove the 4 screws and the combination meter.
   14. Remove the glove compartment door stoppers, the 2 screws and the glove box door.
   15. At the passenger-s side air bag module, remove the No. 1 undercover, pull the air bag connector up from the undercover and disconnect it; then, remove the air bag.
       
       CAUTION

       Place the air bag module in a safe place with the front side facing upward.
   16. Remove the 3 lower No. 2 panel screws and the panel.
   17. Remove the center cluster; then, pry the center cluster from the dash by prying the 8 clips in the following order:
       
       
       Left side

       Right side

       Top left side

       Top right side
   18. Remove the 4 radio screws, pull the radio outward, disconnect the electrical connectors and remove the radio.
   19. At the rear console panel, remove the transfer shift lever knob; then, pry the panel upward disengaging the 4 clips (2 on each side) and remove the panel.
   20. At the rear of the console, remove the 2 rear end panel-to-console screws; then, pry the end panel rearward disengaging the 2 clips and remove the panel.
   21. If not equipped with a rear air conditioning system, disconnect the connector and control cable; then, remove the 3 rear heater control panel screws and the panel.
   22. Remove the 4 rear console box-to-chassis screws/bolts and the console box.
   23. Remove the center lower cluster finish panel by prying panel rearward disengaging the 5 clips; then, disconnect the electrical connector.
   24. Remove the 2 front console-to-chassis bolts/screws, disengage the 2 clips and remove the console.
   25. At the instrument panel, disconnect the junction connectors (the connectors can be disconnected by loosening the bolts), the instrument panel-to-chassis 8 bolts and 2 nuts. Using an assistant, remove the instrument panel.
   26. Disconnect the electrical connector and remove the ECM.
   27. Remove the No. 3 and No. 4 heater-to-register ducts.
   28. Remove the floor brace, the No. 1 brace and the reinforcement.
7. Remove the evaporator housing by performing the following procedure:
   1. Discharge and recover the air conditioning system refrigerant.
   2. Remove the air conditioning liquid line clamp.
   3. Remove the air conditioning suction line clamp.
   4. Disconnect both air conditioning lines and plug the openings to prevent contamination. Discard the 4 O-rings.
   5. Remove the antenna relay electrical connector, the 2 screws and the relay.
   6. Remove the evaporator housing-to-chassis 4 screws/2 nuts and the housing.
8. Remove the heater housing by performing the following procedure:
   1. Remove the defroster nozzle.
   2. Disconnect the electrical connector.
   3. Remove the 4 nuts and the heater housing.
9. Remove the heater core-to-heater housing packing, the screw, the bracket, the clamp and the heater core. 
   
   
   
   Fig. Heater core housing and related components-2001-2004

To install:

1. Install the heater core, the clamp, the bracket, the screw and the heater core-to-heater housing packing.
2. Install the heater housing by performing the following procedure:
   1. Install the heater housing and the 4 nuts.
   2. Connect the electrical connector.
   3. Install the defroster nozzle.
3. Install the evaporator housing by performing the following procedure:
   1. Install the evaporator housing and the housing-to-chassis 4 screws and 2 nuts.
   2. Install the antenna relay, the 2 screws and the electrical connector.
   3. Using new O-rings, connect both air conditioning lines.
   4. Install the air conditioning liquid line and suction line clamp.
4. Install the instrument panel and reinforcement by performing the following procedure:
   1. Install the reinforcement, the No. 1 brace and the floor brace.
   2. Install the No. 3 and No. 4 heater-to-register ducts.
   3. Install the ECM and connect the electrical connector.
   4. Using an assistant, install the instrument panel, connect the junction connectors, the instrument panel-to-chassis 8 bolts and 2 nuts.
   5. Install the front the console, engage the 2 clips and install the 2 console-to-chassis bolts/screws.
   6. Connect the electrical connector; then, install the center lower cluster finish panel by engaging the 5 clips.
   7. Install the console box and the 4 rear console box-to-chassis screws/bolts.
   8. If not equipped with a rear air conditioning system, install rear heater control panel, the 3 panel screws; then, connect the connector and control cable.
   9. Install the rear of the console and engage the 2 clips; then, install the 2 rear end panel-to-console screws.
   10. Install the rear console panel and engage the 4 clips (2 on each side); then, install the transfer shift lever knob.
   11. Install the radio, connect the electrical connectors and the 4 radio screws.
   12. Install the center cluster and engage the 8 center cluster clips.
   13. Install the lower No. 2 panel and the 3 panel screws.
   14. Install the passenger-s side air bag module, connect it and install the No. 1 undercover.
   15. Install the glove box door, the 2 screws and the glove compartment door stoppers.
   16. Install the combination meter and the 4 screws; then, connect the electrical connectors.
   17. Install the steering column and the steering column-to-instrument panel bolts.
   18. Install the No. 2 heater-to-register duct and the duct screw.
   19. At the steering column, install the combination switch, the 3 screws and the clamp; then, connect the electrical connectors.
   20. Install the steering column covers and the 3 covers screws.
   21. Install the lower left side panel.
   22. Install the lower No. 1 panel and the panel screw.
   23. Install the fuel lid control cable lever and the 2 screws.
   24. Install the hood lock control cable and the 2 screws.
   25. Install the instrument cluster finish panel.
   26. At the passenger-s side, install the front pillar garnish, the 2 assist grips, the 4 screws and the 4 assist grip plugs.
   27. At the driver-s side, install the front pillar garnish, assist grip, the 2 screws and the 2 assist grip plugs.
   28. Install the front door scuff plates, the cowl side trim and the front door opening trim.
5. Install the steering wheel by performing the following procedure:
   1. Install the steering wheel to the steering column.
   2. Align the steering wheel-to-main shaft marks.
   3. Install the steering wheel nut and torque to 25 ft. lbs. (34 Nm).
   4. Install the air bag module to the steering wheel and connect the electrical connector.
   5. Using a Torx® wrench, tighten the 2 screws located at each side of the steering wheel to 78 inch lbs. (8.8 Nm).
   6. Install the steering wheel side covers.
6. Connect the heater hoses to the heater core.
7. Refill the cooling system.
8. Connect the negative battery cable.
   1. Evacuate and charge the air conditioning system refrigerant.
9. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

2005-2006

Fig. Instrument panel and related components-2005-2006 Standard and Access Cab

Fig. Instrument panel and related components-2005-2006 Double Cab

1. Before servicing the vehicle, refer to the Precautions Section.
2. Disarm the SRS system.
   
   NOTE

   Wait at least 90 seconds before starting any repair work.
3. Position the front wheels in the straight ahead position.
4. Disconnect the negative battery cable.
5. Discharge the air conditioning system.
6. Drain the engine coolant.
7. Disconnect and plug the air conditioning lines at the evaporator core, using tool SST09870-00025, or equivalent.
8. Remove the glove compartment. Remove the lower number two finish panel. Remove the lower center cover.
9. Remove the lower left finish panel. Remove the instrument panel lower cover.
10. Remove the number four heater to register duct.
11. Disconnect the electrical connectors. Remove the three retaining screws. Remove the cooling unit from the vehicle.
12. Disconnect and plug the heater hoses at the heater core.
13. Remove the front door scuff plate. Remove the cowl side trim.
14. On Double Cab, remove the right and left side trim board. Remove the side panel.
15. Remove the assist grips. Remove the front pillar garnish.
16. Remove the steering wheel lower cover number two and three. Carefully pull the steering wheel pad from its mounting and disconnect the airbag connectors and horn terminal.
    
    NOTE

    If the airbag connector is disconnected with the ignition switch in the ON or ACC position, DTC codes will be set.
17. Remove the steering wheel pad. When storing the pad assembly, keep the upper surface of the pad facing upward. Never disassemble the steering wheel pad.
    
    NOTE

    When removing the pad, take care not to pull on the airbag wire harness.
18. Remove the steering wheel locknut. Using a steering wheel removal tool, remove the steering wheel from the vehicle. Disconnect the connector.
19. Remove the three screws and the upper and lower steering column covers.
20. Disconnect the connectors and screws. Remove the combination switch. Remove the spiral cable assembly.
21. Remove the two screws and hood lock release lever. Remove the four bolts and lower finish panel. Disconnect the connectors.
22. Remove the switch base assembly. Remove the number two heater to register duct. Remove the brake pedal return spring.
23. Matchmark the sliding yoke and number two intermediate shaft assembly. Remove bolt -A- and bolt -B-. Slide the sliding yoke and remove it.
    
    
    

    

    Fig. Sliding yoke bolt location-2005-2006
24. Remove the three bolts and the column hole cover number two.
25. If equipped with automatic transmission, disconnect the control cable from the column shift lever assembly.
26. Disconnect the electrical connectors. Remove the four steering column set nuts. Pull out the steering column assembly with the number two universal joint assembly.
27. Matchmark the steering column assembly and the number two universal joint assembly. Remove the bolt and the number two universal joint assembly.
    
    
    

    

    Fig. Universal joint and intermediate shaft markings-2005-2006
28. Matchmark the number two intermediate shaft assembly and the control valve shaft. Remove the bolt and the number two intermediate shaft assembly.
29. Remove the cluster finish panel.
30. Remove the combination meter retaining screws. Remove the combination meter. Disconnect the electrical connectors.
31. Remove the three control knobs. Remove the five retaining screws. Remove the control panel by pulling carefully at the inside air conditioning grille assemblies. Disconnect the electrical connectors.
32. Remove the radio assembly retaining screws. Remove the radio assembly.
33. Disconnect the heater control cables. Remove the heater control assembly and disconnect the connectors.
34. To disconnect the passenger-s side airbag connector, use a clip remover and disengage the connector clamp.
    
    NOTE

    When handling the airbag connector, take care not to damage the airbag wire harness.
35. Remove the glove box door. Remove the lower number two finish panel.
36. If equipped, remove the lower center cover.
37. If equipped, remove the front console box assembly.
38. On Double Cab, remove the shifting hole cover. Remove the upper console panel. Remove the rear console box. Remove the console box pocket.
39. Remove the front console box. Remove the lower instrument cover.
40. Remove the two bolts which hold the passenger-s side airbag assembly and instrument panel.
41. Remove the bolt which holds the passenger-s side airbag assembly and instrument panel reinforcement.
42. Remove the passenger-s side airbag assembly. When storing the pad assembly, do not place the airbag assembly with the airbag deployment side facing down.
    
    NOTE

    When removing the pad, take care not to pull on the airbag wire harness.
43. If equipped, remove the rear console box. Remove the number four heater to register duct.
44. Remove the retaining nut located in the center of the combination meter housing. Disconnect the connectors. Remove the instrument panel from the vehicle.
45. Remove the center heater to register duct.
46. Disconnect the connectors. Remove the bolt and door control receiver. Remove the three bolts, nut and number one brace.
47. Remove the bolt, nut and number two brace.
48. Remove the three bolts, four nuts and instrument panel reinforcement bar assembly.
49. Remove the defroster nozzle and heater to register duct.
50. Remove the three heater unit retaining screws. Remove the heater unit from the vehicle.
51. Remove the heater core from the heater nit.
    
    
    

    

    Fig. Heater core and related component-2005-2006 Standard and Access Cab
    
    
    
    

    

    Fig. Heater core and related components-2005-2006 Double Cab

To install:

1. Installation is the reverse of the removal procedure.
2. Tighten the number two intermediate shaft assembly bolt to 26 ft. lbs.
3. Tighten the number two universal joint assembly bolt to 26 ft. lbs.
4. Tighten the steering column set nuts to 19 ft. lbs.
5. Tighten bolts -A- and -B- of the sliding yoke to 26 ft. lbs.
6. When installing the center spiral cable, check that the front tires are in the straight ahead position. Turn the cable counterclockwise by hand until it feels firm. Rotate the cable clockwise about 2 ½ turns to align the marks.
   
   NOTE

   The cable will rotate about 2 ½ turns to both the right and left from the center.
   
   
   
   
   

   

   Fig. Spiral cable alignment-2005-2006
7. Tighten the steering wheel retaining bolt to 37 ft. lbs.
8. Fill the cooling system with the proper grade and type engine coolant.
9. Properly recharge the air condition system.
10. Start the engine and check for leaks, correct as required.

These details will help.

Thanks.

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