User's Manual

Repair
3A2954D 19
Heater Core Removal and Fluid
Passage Unclogging
The heater core (68) can be removed for thorough
cleaning or replacement. See the Parts illustration that
applies to your heater on page 22 or 24.
1. Follow Pressure Relief Procedure, page 11.
2. Disconnect power.
3. Drain the Heater, page 13.
4. Loosen set screws (83) from bottom inlet housing
witha3/16in.hexkey.
5. Unscrew bottom inlet housing (65).
6. Remove nuts (90) then remove cylinder u-bolt
clamp (78).
7. Loosen set screws (83) on upper fluid housing (67).
8. Unscrew cylinder (66). Pull down to remove.
9. Remove screws (52) then remove cover (18).
10. On model 262853 only, remove RTD sensor (88).
Loosen nut on compression fitting (72). Pull nut and
sensor straight up out of heater.
11. Remove 4 screws (71) from top of plate (69).
12. Disconnect heater cartridge (81) wire leads from
wire nuts (89).
13. Pull heater core straight down out of the upper
housing (67).
14. Use a wire brush to clean outside fluid passages
until bare aluminum is visible.
NOTE: Model 24P016 Only: The capillary bulb/tube
from the thermostat (24) will slowly pull out of its hole in
the core (68). The heater core wires will pull down
through plate (69).
Reassembly Notes
• Always replace o-rings (70, 76, and 79).
• Refer to FIG.10orFIG. 11 on page 17 for wiring
connections.
• Model 262853 only: Make sure the core (68) is
aligned with the plug (82) pin in housing (67).
• Make sure gasket (47) is installed and aligned with
electrical housing screw holes.
• Secure cover (18) with screws (52). Torque screws
to 85-90 in-lb (10 N•m).
FIG.12
NOTICE
On model 262853 only, to prevent damaging the RTD
sensor (72), do not rotate the core (68) when perform-
ing the following step.
ti20065a
90
78
66
68
65
76
83
67
76
83
83
79
70
NOTICE
To prevent damage to sensors and wiring, do not turn
core (68). The core pushes straight down out of
housing (67).