Heater Core Removal and Replacement
Step-by-step heater core removal procedure for late-model 944 and 968 without removing the dashboard, including glove box access, duct removal, and wire loom management.
Introduction
The factory manual instructs removing the dashboard to access the heater core. In practice, dashboard removal is unnecessary — and makes the job much harder overall. The procedure below was performed on a 1992 968 and applies to late-model 944 (1985.5–1991) and 968 as well.
Tools
- Stubby Phillips head screwdriver
- Regular Phillips head screwdriver
- Small flat-tip screwdriver
- Metric wrench (for the battery negative terminal)
Removal
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Disconnect the battery negative terminal.
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Drain the coolant system.
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Remove the glove box.
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Disconnect the rubber hose for the thermometer (if equipped) and remove the plastic air duct.
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Two plastic duct pieces must now be removed.
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The lower duct piece is secured with one screw. Remove the screw and remove the piece.
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Cut the zip-tie holding a wire to the upper duct piece.
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The upper duct piece is secured with three screws. Remove the first screw.
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Remove the remaining two screws.
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With all three screws removed, pull and remove the upper duct piece. Note the shape and orientation for reinstallation.
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Place a container under the heater core pipe connections to catch spilling coolant. Using a screwdriver, pry off the two clips on the heater core pipes. Do not lose these clips.
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Move the vacuum elements and any other components obstructing the foam-padded heater core out of the way.
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Begin pulling out the heater core.
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The core will encounter the wire looms circled in the photo below. It appears the wiring was routed after the core was installed, leaving very little clearance. Undo the plastic strap on the wire loom and remove it completely. Then push and pull on the wires while tugging the core out.
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With patience, the core will squeeze past and emerge fully from its housing.
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The dotted circle in the photo below shows the minor damage that will inevitably occur to the wire loom insulation during this process. As long as no insulation is broken through to bare wire, this is acceptable. The arrow indicates the stud from which the plastic strap was removed.
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The heater core is now out.
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Installation is the reverse of removal.