TYC 96007 Heater Core Installation and Operation Manual

1. Product Overview

The TYC 96007 Heater Core is engineered as a direct Original Equipment (OE) replacement component, designed for precise fitment and efficient heat distribution within the vehicle's cabin. This unit facilitates the transfer of heat from the engine's coolant to the air circulating through the vehicle's HVAC system, providing warmth to the interior.

Key features include:

• Perfect Fit: Designed for direct OE replacement, ensuring precise fitment and straightforward installation.
• Premium Quality: Constructed with premium-grade aluminum tubes and precision-folded, louvered aluminum fins for optimal and efficient heat distribution.
• Exceptional Performance: Features comparable tube and fin pitch to OE counterparts, producing similar coolant flow volume to meet or exceed OE performance standards.
• Proven Reliability: Each unit is individually leak-tested prior to packaging to ensure proper function upon installation.

Figure 1: Main view of the TYC 96007 Heater Core, showcasing the core fins and the two inlet/outlet pipes.

2. Safety Information

Automotive repair and component replacement can be complex and potentially hazardous. Adhere to all safety precautions to prevent injury or damage to the vehicle.

• Always disconnect the vehicle's battery before beginning any work to prevent electrical shorts or accidental activation of vehicle systems.
• Allow the engine and cooling system to cool completely before handling coolant or components to avoid burns.
• Wear appropriate personal protective equipment (PPE), including safety glasses and gloves.
• Coolant is toxic. Handle with care and dispose of it responsibly according to local regulations.
• Refer to the vehicle's service manual for specific procedures and torque specifications.
• If you are not confident in your ability to perform this installation, seek assistance from a qualified automotive technician.

3. Package Contents

Verify that all components are present and undamaged upon opening the package.

• 1 x TYC 96007 Heater Core

4. Installation Guide

The replacement of a heater core in a 1999-2011 Chevrolet Silverado is an involved procedure that typically requires significant disassembly of the vehicle's dashboard and HVAC system. This process demands advanced mechanical skills and specialized tools. Professional installation is highly recommended.

4.1. Required Tools and Materials (Not Included)

• Standard automotive hand tools (sockets, wrenches, screwdrivers)
• Coolant drain pan
• New engine coolant (specific to your vehicle)
• Hose clamp pliers
• Specialized AC/Fuel line disconnect tool (e.g., Lisle 37000 kit or similar)
• Vacuum pump for AC system (if AC lines are disconnected)
• Shop towels/rags

4.2. Pre-Installation Steps

1. Park the vehicle on a level surface and engage the parking brake.
2. Disconnect the negative terminal of the vehicle's battery.
3. Allow the engine to cool completely.
4. Drain the engine coolant from the radiator.
5. If the AC system lines need to be disconnected to access the heater core, the AC system must be professionally discharged and recovered by a certified technician.

4.3. Removal of Old Heater Core (General Steps)

The following steps are generalized. Consult your vehicle's specific service manual for detailed instructions.

1. Access the heater core housing, which typically involves removing portions of the dashboard, center console, and HVAC assembly. This is often the most time-consuming part of the process.
2. Locate the heater core inlet and outlet pipes.
3. Using the appropriate disconnect tool, carefully detach the heater hoses from the heater core pipes. Be prepared for residual coolant to spill.
4. Remove any retaining clips, screws, or clamps securing the heater core within its housing.
5. Carefully extract the old heater core from the vehicle.

4.4. Installation of New Heater Core (General Steps)

Figure 2: Close-up view of the barb connectors on the TYC 96007 Heater Core, where the heater hoses attach.

1. Inspect the new TYC 96007 Heater Core for any shipping damage.
2. Carefully insert the new heater core into its housing. Ensure it seats correctly and aligns with the mounting points.
3. Secure the heater core with any retaining clips, screws, or clamps that were removed.
4. Reconnect the heater hoses to the new heater core pipes. Ensure a secure connection to prevent leaks. Some users have noted that the angle of the bends on aftermarket cores may require slight manipulation of surrounding components (e.g., transmission dipstick tube) or careful alignment to connect hoses.
5. Reassemble the HVAC assembly, dashboard, and any other components removed during the process.
6. Reconnect the negative battery terminal.

4.5. Post-Installation

1. Refill the cooling system with the appropriate coolant mixture according to your vehicle's specifications.
2. Bleed the cooling system to remove any trapped air. This typically involves running the engine with the heater on high and the radiator cap off (or using a specialized funnel) until no more air bubbles appear.
3. If AC lines were disconnected, the AC system must be professionally recharged.
4. Inspect for any coolant leaks around the heater core connections and throughout the cooling system.
5. Test the heater function by running the engine and verifying that warm air is produced from the vents.

5. Operating Principles

The heater core operates as a small radiator located within the vehicle's dashboard. Hot engine coolant flows through its tubes, transferring heat to the fins. As the vehicle's blower motor pushes air across these heated fins, the air absorbs the heat and is then directed into the cabin, providing warmth. The TYC 96007 is designed to facilitate this heat exchange efficiently, ensuring consistent and effective cabin heating.

6. Maintenance

The TYC 96007 Heater Core itself requires no specific maintenance beyond ensuring the overall health of the vehicle's cooling system. Regular maintenance of the cooling system will prolong the life and efficiency of the heater core.

• Coolant Levels: Regularly check and maintain proper coolant levels. Low coolant can lead to reduced heating performance and potential damage.
• Coolant Quality: Ensure the coolant is clean and free of contaminants. Flush and replace coolant at manufacturer-recommended intervals to prevent corrosion and blockages within the cooling system, including the heater core.
• System Leaks: Periodically inspect all cooling system components, including hoses and connections to the heater core, for any signs of leaks.

7. Troubleshooting

If you experience issues with your vehicle's heating system after heater core replacement, consider the following common troubleshooting steps:

• No Heat or Insufficient Heat:
  • Check coolant level: Ensure the cooling system is full and properly bled of air. Air pockets can prevent coolant from circulating through the heater core.
  • Thermostat: A faulty thermostat stuck open can prevent the engine from reaching operating temperature, leading to cold heat.
  • Blower motor: Verify the blower motor is functioning and moving air through the vents.
  • Blend door actuator: A malfunctioning blend door actuator can prevent the system from directing warm air into the cabin.
• Coolant Leak:
  • Inspect hose connections: Ensure heater hoses are securely clamped to the heater core pipes.
  • Heater core integrity: Although leak-tested, inspect the core itself for any signs of damage or manufacturing defects.
  • Other cooling system components: Check radiator, hoses, water pump, and expansion tank for leaks.
• Foggy Windows / Sweet Smell in Cabin: These are strong indicators of an internal heater core leak. If these symptoms appear, the heater core may be leaking coolant into the cabin.

8. Specifications

Detailed specifications for the TYC 96007 Heater Core:

Figure 3: Side view of the TYC 96007 Heater Core, illustrating its compact design.

9. Warranty and Support

Specific warranty details for the TYC 96007 Heater Core are typically provided at the point of purchase or can be found on the official TYC website. It is recommended to retain your purchase receipt for warranty claims.

For technical assistance, product inquiries, or warranty support, please refer to the manufacturer's official contact channels:

• Manufacturer: TYC
• Website: Visit the TYC Store on Amazon or search for the official TYC Americas website.

Figure 4: TYC Americas logo, representing the product manufacturer.