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How to remove the heater core on 94 mercury cougar

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Removing the Old Core

  • Disconnect the Mercury Cougar's negative battery cable. Remove the center console from the interior. Disarm the car's air bag system and remove the bag's diagnostic monitor and bracket.

  • Take the heater outlet floor duct out of the car. Remove the screw holding the air transfer duct and push it into the outlet duct. Unscrew the screws retaining the outlet duct to the heater core cover and release the retaining tabs on each side to remove the duct.

  • Raise and support the Mercury Cougar, using multiple jackstands. Drain the engine coolant by removing the drain plug on the bottom of the radiator. Replace the drain plug after all the liquid flows into a clean container and disconnect the heater hoses from the core

  • Withdraw the black vacuum supply hose from the vacuum source (you can now lower the vehicle). Disconnect the same hose from the air conditioner's vacuum reservoir tank.

  • Detach the heater core cover that holds the core by releasing the retaining tabs and removing the clips. Remove the dash panel seal, vacuum hose and heater core bracket from the cover.

  • Remove the heater core from the cover and the case seal from the core

Posted on Dec 20, 2016

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