Heater Core Installation

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Dec 3, 2004 | 10:52 AM

CharlestonSC

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Heater Core Installation

I'm new here. I've read posts and articles. I've gotten more info than the Haynes Manuel offers. I cannot get the hoses to "click" onto the heater core. I know the core sticks through the firewall far enough. I know the couplings fit, because they fit outside the van before I put it in. The only thing I haven't done by the book, is use silicon spray. I lubed the parts up with white multi-purpose grease. I don't get it. It works fine when I try it before installing it. Then, I put all the pieces in, and it won't slip on. I'm starting to think maybe I haven't lined the pieces up EXACTLY. What's the problem? Any ideas?

Dec 3, 2004 | 11:50 AM

M.Herrington

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according to the service cd...
Heater Core

Removal and Installation

1. Allow engine to cool. Following all safety precautions (refer to «Section 03-03») and using a thick cloth, turn the radiator cap slowly to the first stop. Step back while pressure is released. When pressure has been released, tighten the radiator cap on the radiator.

2. Disconnect heater hoses from the heater core tubes using Heater Hose Tool T85T-18539-AH as outlined. Plug hoses.

3. In the passenger compartment, remove five screws attaching heater core access cover to the plenum assembly. Remove access cover.

4. Pull heater core rearward and down, removing it from the plenum assembly. Remove seal.

For installation, follow removal steps in reverse order. Make sure heater core and seal snaps into retainer bracket at top of core. Check and add coolant. Refer to «Section 03-03». Check system for proper operation and coolant leaks.

Dec 3, 2004 | 12:02 PM

CharlestonSC

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Done that. Still a "no go". For whatever reason, the couplings won't click onto the heater core once the heater core is in the van.

Dec 3, 2004 | 01:15 PM

cookkd

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From: Houston, TX

this might be a stupid question.....
are the connectors from the core protruding far enough into the engine compartment? Maybe the core is not seated properly inside the housing in the passenger compartment.

Dec 3, 2004 | 01:37 PM

CharlestonSC

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There are no stupid questions.

Yes, the protrude far enough. It's been checked and re-checked. I'll be off the forum the rest of the night. I'll get back on another day and post again.

Dec 3, 2004 | 08:58 PM

aerocolorado

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First of all, welcome to FTE and the Aerostar forum!

No insult intended here (because I did this myself on the first go around), but are you putting the o-rings, spacer and plastic bail into hose connector itself, or are you putting the plastic bail on the heater core tube and trying to snap the hose connector over that? If everything is inside the bell shaped hose connector it should just snap right into place with minimal effort and you will hear a distinctive 'click' when it happens. Also, if you look inside the bell shaped hose connector, you will see a small groove. There is a corresponding notch on the plastic bail that needs to mate to that groove.

A second possiblity is the flanges on the core tube(s) may have caught on the firewall edges during installation and are slightly bent. If you are using an aftermarket core, the third possibility is the length of tubing extending from the flange to end is a silly millimeter too long and will prevent the coupling. I had this happen with one of the tubes on an aftermarket replacement. The first one snapped right on but the next one just would not seat properly driving me crazy until I measured them both. Had to pull it all out and file down the offending tube to correct length.

Last edited by aerocolorado; Dec 3, 2004 at 09:04 PM.

Dec 4, 2004 | 10:56 PM

pauliemac

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I just did my core last week (read a post by aerocolorado, thanks for the many tips) and just replaced the stock hoses with some lengths bought at o'reilly's with regular worm gear clamps. Did it on Thanksgiving day and it is holding just fine. It did take awhile to get the plastic off of the old core so that the tubes would pass through the firewall but that was about the biggest problem.