Question about Heating & Cooling

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Heater problem On the GMPN120-5 heater under the Status Column 5 blinks =Equipment Problem False Flame Sensor, Under the Cause column it says Sticking Gas Valve. When the heater tries to cycle on the Exhaust fans runs after 30-45 seconds, the Ignitor glows and the Gas valve clicks the the burners will light. I have checked with a DVOM and 24 volts is present when the burners are lit, after about 5 seconds I loose the 24 volts and the valve closes and the burners turn off. I have also checked and cleaned the Grounds just to be sure. Thanks for your help. jg

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  • jbg36 Dec 10, 2008

    False flame sensed



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The first thing I would look for is a blockage in the gasline, or at the gas valve.

It sounds like you are not getting gas to the ignitor/burners. This would cause it to obviosly, not sense flame.

When a unit does not sense flame, it will shut of, and usually try again up to 5 times (depending on brand/model)

So here's what happens in that scenario.

Call for heat.
Inducer motor kicks on, the sensor detects the inducer motor is working, and the ignitor starts glowing/sparking (depending on type of ignitor)

It will then send gas through the gas valve and ignite.
If the flame sensor does not detect flame, the glow coil shuts down, the gas shuts off, the inducer shuts off and you get your error code.

(Some units will then send on the blower motor, and you have to cut power to reset.)

Do you have a copper line with natural gas?
If so, replace it with stainless steel or black iron.

Coper apearantly reacts with the aditives in natural gas and tends to form a gray ashy substance that builds up in the copper tubings walls and eventually cloggs gas valves.

At the inlet side of the gas valve, there should be a screen to catch such things.

Turn off the gas, turn of the power, and remove the gas line going to the gas valve. Look for anything clogging that area, also look for kinks in the gas line.

Remember to use a "flamable gas approved" pipe dope or thread tape when reinstalling the supply line.

Lets see what you find there and then we can continue the diagnostic if needed.

Posted on Dec 10, 2008


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I have a Raypak PR 335 and have worked through a series of issues.....right now it functions BUT, the flame is very orange and I have a black smoke exhaust which is not good.......cleaned the jets and have...

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How do i fix the heater core on my ford taurus 1995

Hi there,

Remove heater/evaporator case. Remove vacuum source line from heater core tube seal. Remove seal from heater core tubes.
Remove heater core access cover screws. Remove access cover and seal from heater/evaporator case. Lift heater core and case seals out of heater/evaporator case.
If installing new heater core, transfer case seals to new core. Install heater core and seals into heater/evaporator case. Install heater core access cover on case. Install seal on heater core tubes. To complete installation, reverse removal procedure. Evacuate and charge A/C system. Refill cooling system.

  • Disconnect negative battery cable. Drain coolant from radiator. Gently pull instrument panel away from right side of dash panel.
  • Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect heater hoses from heater core. Plug heater core tubes or drain coolant by blowing coolant from heater core using low pressure compressed air. Disconnect vacuum supply hose from inside engine compartment.
  • Disconnect A/C lines from evaporator core. Plug A/C lines and evaporator core tubes. Remove instrument panel assembly brace to evaporator case bracket screw. Remove assembly brace.
  • Remove floor register and rear floor duct from bottom of heater/evaporator case. Remove nuts securing heater/evaporator case to firewall. Remove 2 screws securing support brackets to cowl top panel. Carefully pull heater/evaporator case away from firewall. Remove heater/evaporator case.
  • To install, reverse removal procedure. Evacuate and charge A/C system. Refill cooling system.
Removal & Installation
  • Position front wheels in straight-ahead position. Disable air bag system. See AIR BAG RESTRAINT SYSTEM article in ACCESSORIES/SAFETY EQUIPMENT section. Disconnect negative battery cable. Remove steering column trim shrouds.
  • Disconnect all electrical connections from steering column switches. Remove cover from under steering column. Remove 4 bolts and reinforcement from under steering column. Disconnect parking brake release control motor from parking brake and ignition switch connector.
  • Disengage insulator retainer. Remove insulator. Remove 4 nuts and reinforcement below steering column. Remove 4 nuts securing steering column to instrument panel and lower column to front seat. Disconnect PRNDL cable (A/T models).
  • Ensure ignition switch is locked to prevent steering column from turning. Remove 4 instrument cluster retaining screws. Disconnect speed control cable and vehicle speed sensor (if equipped). Disconnect electrical connectors and remove instrument cluster. At steering column opening, remove one bolt securing instrument panel to brace. Remove one instrument panel brace bolt (below radio area).
  • Remove sound insulator under glove box by removing 2 push nuts securing insulator to studs on climate control case. Remove glove box door and compartment. Remove air cleaner housing, battery and battery tray. Disconnect wires of main wire loom in engine compartment. Disengage rubber grommet from firewall. Feed wiring into passenger compartment through hole in firewall.
  • Remove right and left kick panels. Disconnect wires from instrument panel at right and left kick panel sides. Remove screws on left and right sides of instrument panel.
  • Pull up to unsnap right and left speaker opening covers. Remove speaker covers. Working through steering column and glove box openings, reach under instrument panel and disconnect electrical connectors, vacuum hoses, A/C-heater control panel cables, and radio antenna cable.
  • Support instrument panel. Remove 3 screws attaching top of instrument panel to cowl top. Disconnect remaining wires. Remove instrument panel. To install instrument panel, reverse removal procedure.

Hope this helps...

Jan 17, 2011 | 1995 Ford Taurus

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Where is the heater core located

Heater Core REMOVAL & INSTALLATION NOTE: Be sure to consult the laws in your area before beginning any procedure which requires servicing the air conditioning system. In some states, it is illegal to perform repairs involving refrigerant unless the work is done by a certified technician. CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old. NOTE: When removing the instrument panel, it may be beneficial to have a friend or assistant help you. Without Air Conditioning
  1. Disconnect the negative battery cable.
  2. Remove the instrument panel on 1986-89 vehicles as follows:
    1. Remove the four screws retaining the steering column opening cover, then remove the cover.
    2. Remove the sound insulator under the glove compartment by removing the two push nuts securing the insulator to the studs on the climate control case.
    3. Remove the steering column trim shrouds, then tag and disengage all electrical connections from the steering column switches.
    4. Remove the four screws at the steering column bracket to remove the steering column.
    5. Remove the screws retaining the lower left and radio finish panels, then remove the panels by snapping them out.
    6. Remove the cluster opening finish panel retaining screws. On Taurus remove the jam nut behind the headlight switch and the screw behind the clock or clock cover. Remove the finish panel by rocking the upper edge toward the driver.
    7. Disconnect the speedometer cable by reaching up under the instrument panel and pressing on the flat surface of the plastic connector. The panel can be removed with the cluster installed.
    8. Release the glove compartment assembly by depressing the side of the glove compartment bin and swinging the door/bin down.
    9. Using the steering column, cluster and glove compartment openings and by reaching under the instrument panel, tag and disengage all electrical connections, vacuum hoses, heater control cables and the radio antenna cable.
    10. Tag and disengage all underhood electrical connectors of the main wire loom. Disengage the rubber grommet from the dash panel and push the wire and connectors into the instrument panel area.
    11. Remove the right and left speaker opening covers by snapping them out.
    12. Remove the two lower instrument panel-to-cowl side retaining screws from the right and left side. Remove the instrument panel brace retaining screw from under the radio area. On Sable, remove the defroster grille by snapping it out.
    13. Remove the three instrument panel upper retaining screws, then remove the instrument panel.
  3. Remove the instrument panel on 1990-95 vehicles as follows:
    1. Position the front wheels in the straight-ahead position.
    2. Disconnect the positive battery cable.
    3. Remove the ignition lock cylinder and, if equipped, remove the tilt lever.
    4. Remove the steering column trim shrouds. Tag and disengage all electrical connections from the steering column switches.
    5. Remove the four bolts and opening cover, and the two bolts and reinforcement from under the steering column.
    6. Disengage the insulator retainer and remove the insulator. Remove the four nuts and reinforcement from under the steering column. NOTE: Do not rotate the steering column shaft.
    7. Remove the four nuts retaining the steering column to the instrument panel, disconnect the shift indicator cable and lower the column on the front seat. Install the lock cylinder to make sure the steering column shaft does not turn.
    8. Remove bolt at the steering column opening attaching the instrument panel to the brace. Remove instrument panel brace retaining bolt from under the radio area.
    9. Remove the sound insulator under the glove compartment by removing the two push nuts that secure the insulator to the studs on the climate control case.
    10. Disconnect the wires of the main wire loom in the engine compartment. Disengage the rubber grommet from the dash panel, then feed the wiring through the hole in the dash panel into the passenger compartment.
    11. Remove the right and left cowl side trim panels. Disconnect the wires from the instrument panel at the right and left cowl sides.
    12. Remove screw each from the left and right side retaining the instrument panel. Pull up to unsnap the right and left speaker opening covers and remove.
    13. Release the glove compartment assembly by depressing the side of the glove compartment bin and swinging the door/bin down.
    14. Using the steering column and glove compartment openings and by reaching under the instrument panel, tag and disengage all electrical connections, vacuum hoses, heater control cables, speedometer cable and radio antenna cable.
    15. Close the glove compartment door, support the panel and remove the three screws attaching the top of the instrument panel to the cowl top and disconnect any remaining wires. Remove the panel from the vehicle.
  4. Drain the coolant from the radiator.
  5. Disconnect and plug the heater hoses at the heater core. Plug the heater core tubes.
  6. Disconnect the vacuum supply hose from the inline vacuum check valve in the engine compartment. Remove the screw holding the instrument panel shake brace to the heater case and remove the shake brace.
  7. Remove the floor register and rear floor ducts from the bottom of the heater case. Remove the three nuts attaching the heater case to the dash panel in the engine compartment.
  8. Remove the two screws attaching the brackets to the cowl top panel. Pull the heater case assembly away from the dash panel and remove from the vehicle.
  9. Remove the vacuum source line from the heater core tube seal and remove the seal from the heater core tubes.
  10. Remove the four heater core access cover attaching screws and remove the access cover from the heater case. Lift the heater core and seals from the heater case. To install:
  11. Transfer the three foam core seals to the new heater core. Install the heater core and seals into the heater case.
  12. Position the heater case access cover on the case, then install the four retaining screws.
  13. Install the seal on the heater core tubes, then install the vacuum source line through the seal.
  14. Position the heater case assembly to the dash panel and cowl top panel at the air inlet opening. Install the two screws to attach the support brackets to the cowl top panel.
  15. Install the three nuts in the engine compartment to attach the heater case to the dash panel. Install the floor register and rear floor ducts on the bottom of the heater case.
  16. Install the instrument panel shake brace and screw to the heater case.
  17. Install the instrument panel by reversing the removal procedure.
  18. Connect the heater hoses to the heater core. Connect the black vacuum supply hose to the vacuum check valve in the engine compartment.
  19. Fill the radiator and bleed the cooling system.
  20. Connect the negative battery cable and check the system for proper operation. Fig. 1: Location of the vacuum source line 86876016.gif
    Fig. 2: Heater core cover location 86876017.gif

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How to replace heater hose. they are the hoses a e back of the engine by the fire wall

Taurus And Sable - Removal And Installation
  1. Disconnect the negative battery cable.
    CAUTION After disconnecting the negative battery cable, wait for at least 1 minute for the SRS or air bag module to deplete its energy.

  2. Place the front wheels in the straight-ahead position.
  3. Lock the steering column.
  4. Remove or disconnect the following:
    SRS bolt covers from both sides of the steering wheel SRS module-to-steering wheel bolts SRS module and disconnect the electrical connector Steering wheel bolt and discard it
  5. Press the steering wheel from the steering column.
    Lower steering column shaft bolt 2 lower instrument panel cover-to-instrument panel screws and unsnap the lower cover from the instrument panel
  6. Turn ignition switch to the RUN position
  7. Insert a 1 / 8 in. (3mm) wire or pin punch in the lower steering column shroud hole, under the ignition switch; then, press on the pin while pulling out on the ignition switch lock cylinder and remove it from the steering column lock cylinder housing.
  8. Remove or disconnect the following:
    3 steering column shroud screws and the shrouds Shift control selector lever boot Gearshift lever pin from the manual control lever and remove the lever Wiring connector at the bottom of the steering column and remove the wiring from the column, (if equipped with an overdrive lockout switch on the manual control lever) Electrical connectors Multi-function switch screws and move it aside Shift indicator cable from the shifter tube Shifter indicator-to-column adjustment cable screw Interlock cable and actuator (if equipped with a column shift) 4 steering column-to-instrument panel bracket nuts and steering column Push pins and the lower instrument cover from the instrument panel reinforcement (at the passenger-s side) Console finish panel
  9. Under the steering column, 2 instrument panel brace screws, the courtesy lamp socket, the 2 Diagnostic Link Connector (DLC) screws and the instrument panel brace.
  10. If not equipped with an Electronic Automatic Temperature Control (EATC), disconnect the electrical connectors and the vacuum harness from the evaporator housing and the blower motor.
  11. If equipped with an Electronic Automatic Temperature Control (EATC), remove the sensor hose/elbow and disconnect the electrical harness connectors and the vacuum hose harness from the evaporator housing.
  12. Insert the Radio Removing tools 415-001into the integrated control panel faceplate; then, push the tools in approximately 1 1 / 2 in. (38mm) to release the retaining clips. Spread the tools slightly and pull the integrated control panel from the instrument panel.
  13. Remove or disconnect the following:
    Electrical connectors and the automatic temperature control sensor hose and elbow, if equipped 6 console center finish panel screws and the panel, (if equipped with a floor shift) 4 instrument panel finish panel screws and panel, located at the right side of the steering column, (if equipped with a column shift) Instrument cluster finish panel-to-instrument panel clips and pull the finish panel straight out 4 instrument cluster-to-instrument panel screws, the electrical connectors and the instrument cluster Upper finish panel (located at the top of the instrument panel) Light sensor amplifier connector, (if equipped with an autolamp) Instrument panel finish end panels on both sides of the instrument panel Front scuff plates and pull the door weatherstrip away from the instrument panel (on both sides of the instrument panel) 3 instrument panel-to-upper cowl top panel screws 2 screws at each end of the instrument panel Instrument panel electrical connectors and the parking brake switch Instrument panel
  14. Drain the cooling system into a clean container for reuse
  15. Remove or disconnect the following:
    WARNING Do not attempt to bend any part of the lever, for it is brittle and will break. Heater hoses from the heater core and plug the openings 4 air conditioning electronic blend door actuator-to-heater/air conditioning housing assembly screws and the actuator Metal cover, disengage the spring from the heater core cover and from the lever Gently, depress the locking ramp and remove the lever from the secondary air temperature control door end
  16. Rotate the primary air conditioning air temperature control door shaft downward, swing the metal link counterclockwise and remove it from the pin.
  17. Remove the 3 heater core cover-to-heater/air conditioning housing assembly screws, the cover and the seal.
  18. Press on the heater core tubes and remove the heater core from the heater/air conditioning housing assembly.

Hope helps (remember rated this).

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Heater core

18901fc.gifHere is an exploded view of the heating/air conditioning blower box. This contraption is located on the passengerside under the dash. I've changed heater cores on other cars but never worked on a caravan so not sure how difficult it'll be. You may need to remove a few cover panels to access this and the heater core #22 is located behind the distribution box #6 containing parts 7-18 and hopefully comes off as a unit. I wouldn't want to put it back together just looking at the pic. You may just need to remove the heater tube cover #4 to access the connections and slide out the core.....NAH couldn't be that simple!!! Hope this was of some help. Good luck.

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