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If it is necessary to remove the heater assembly, the cooling system must be drained before removing the heater core.
When a heater core leaks, a new heater core is installed or the old one repaired. Heater Housing
The heater housing is usually under the dash and must be removed to gain access to the heater core.
Procedures for replacing the heater core vary with the year, make, and model of car. It threfore necessary to consult the manufacturer's repair manuals for the proper procedure for replacement.
The heater housing is disassembled to get to the heater core.
Remove the access panels(s) or the split heater/air conditioning case to gain acess to the heater core.
Remove the heater coolant hoses.
Remove the cable and/or vacuum control lines (if equipped).
Remove the heater core securing brackets and/or clamps.
Lift the core from the case. Do not use force. Take care not to damage the fins of the heater core when removing.
To reinstall the heater core, reverse the removal steps.
When the heater core leaks and must be repaired or replaced, it is a very difficult and time-consuming job primarily because of the core's location deep within the firewall of the car. For this reason always leak test a replacement heater core before installation.
Fig. 1: Exploded view of a common heater core and case
Disconnect the negative battery cable and properly drain the
engine cooling system to a level below the heater core.
Disconnect the heater hoses from the core tubes near the cowl.
The instrument panel carrier is designed not only to provide access
to parts through removal of the carrier components, but the carrier will
also tilt downward as a complete assembly to allow access from the top.
If this is desired, remove the retainer screws along the top and bottom
of the carrier assembly (refer to the figure). The instrument panel
will then tilt as an assembly into the cab. It is necessary to unbolt
and lower the steering column from the carrier to allow for maximum
movement of the instrument panel.
The instrument panel must be removed or repositioned for
access to the heater core case. Unbolt and either tilt the instrument
panel forward or disengage the instrument panel components and remove
the panel from the vehicle. In most cases, tilting the panel forward
should be sufficient for the necessary access.
Unfasten the heater core rear case retaining screws, then remove
the rear case for access to the heater core.
Loosen the retainers and remove the heater core retaining straps.
Remove the heater core and seals.
Install the heater core and seals, taking care not to damage the
core tubes when inserting them through the cowl.
Install and secure the core retaining straps.
Install the rear case and secure using the screws.
Reposition and secure the instrument panel and components. Tighten
the cowl screws to 17 inch lbs. (1.9 Nm) and the lower instrument panel
screws to 66 inch lbs. (7.5 Nm).
Connect the heater hoses to the core tubes.
Connect the negative battery cable, then properly refill the
engine cooling system.
Run the engine at normal operating temperature, then check for
on 1992 s10 remove the heater outlets and duck from under instrument panel. Remove air distribution model assembly,heater and seal. Disconnect neg batt cable. Drain eng coolant. Remove hoses at core. Remove rear case screws. Remove heater core from case.
This is a big job which involves discharging and removing parts of the A/C system as well as removing parts of the dash. I had the core done on a 94 Sable years ago and it was a very labor intensive and expensive job. Here are some instructions I found for a 94 Taurus which should be the same thing or similiar, but I don't guarantee that. Please note that these instructions were not tested by me and may contain errors or be incomplete in some way. For example "remove instrument panel" sounds simple but in reality is a process in itself requiring the removal of many screws. Naturally you would have to recharge the A/C and refill the coolant when done.
1. Remove instrument panel and lay it on front seat. 2. Remove A/C evaporator housing as outlined. 3. Remove vacuum source line from heater dash panel seal (18529). 4. Remove heater dash panel seal from heater core tubes (refer to Heater Case Assembly). 5. Remove four heater core access cover retaining screws and remove heater core cover (18B300) from A/C evaporator housing. 6. Lift heater core and seals from A/C evaporator housing. ________________________________________________ Installation
1. Transfer three foam core seals to new heater core. 2. Install heater core and seals into A/C evaporator housing. 3. Position heater core cover on A/C evaporator housing. Install four retaining screws. 4. Install heater dash panel seal on heater core tubes. 5. Install vacuum source line through heater dash panel seal. 6. Install A/C evaporator housing into vehicle as outlined.
7. Reinstall dashboard components.
You have to remove the dash in layers. There's a whole bunch of screws to take out. The heater core is located in the middle of the dash near windshield when you get that far. There are a couple of brackets that hold the heater core in place, remove the heater hoses and pull out heater core. It's quite a long process so give yourself plenty of time.