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99 cc 250 heater core r & r

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  #1  
Old 09-08-2011, 12:59 AM
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99 cc 250 heater core r & r

Is it a pain?? PO bypassed it and i dont wanna drop my dash and i don't wanna open my ac lines. What am i in store for??
 
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Old 09-08-2011, 10:40 AM
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You can get the heater core out without tearing the whole dash apart. In behind the glove box you will find the screws of the access panel.
I would say get a chiltons or service manual as there are afew parts you need to remove first. The toughest part is getting the heater hoses off the core because of the lack of space.
The electric blend door actuator is also a challenge as there are some blind screws you'll be dealing with.
Over all difficulty about 3 or 4. Good luck
 
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Old 09-08-2011, 06:58 PM
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This is a cake walk, I have personally done it.

They make a special tool to remove the heater hoses it costs like $10-15 and you will need a set of hose clamp pliers that use the cable/ratcheting system . I just used a cutoff wheel and replaced the hoses when I was there figured mine as well rather then do double work later. The hardest part for me was attaching the rear heater hose to the block on the 5.4 is in the back close to the middle a total pain to get to.

Take the stuff out of the glove box.
Press in slightly towards the back to remove it from the dash let hang on the hinge ( there are 2 tabs you will see that need to be cleared )
The next thing you see is a black box w/ 4 screws and some vacuum lines and an actuator on the left side of the box w/ a arm on it going to the vent door.
Take a picture w/ a phone or camera ( makes easy to put back together if you cant remember)
Disconnect remove the actuator
Take off the cover panel
Pull out heater core ( make sure coolant has been drained )
Put new one in
And install everything in reverse order.

Total time should be about 30 min unless you have issues with the heater hose on the block like I did and then it will take a hour or so.

Pliers - OTC Tools 4525 Hose Clamp Pliers Flexible 24 in Cable

Hose removal tool - Save on OTC Tools 7413 at ToolTopia.com
 
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Old 09-08-2011, 08:39 PM
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The "quick connectors" are the biggest pain. They are only quick to connect at the factory and quick to empty owners wallets when the core fails, what will happen sooner or later. There is step by step instruction in 6.0 section.
 
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Old 09-08-2011, 09:37 PM
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Thanks yall. Is the part expensive?? And recomendations on brand or source etc...
 
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Old 09-08-2011, 10:34 PM
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What is your definition of expensive? It retails over $200 from what I remember. I think the only available are the aluminum cores. When I did my core, I cut off the hoses and also the core pipe ends, install 2 valves and extended the hoses into the cabin.
Next time I will have to do it, I will not have to spend 1 hr with my head under the firewall trying to disconnect the stupid connectors.
 
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