There is a way to replace the heater core without pulling the dash. I pulled this from 3ZC for those that are not members. This procedure was created by PearlTTZ on 3ZC and is simple and easy to use.
Well, I know many of us have this problem but we just do not want to admit this. Yes, a leaking Heater Core… What can be more frustrating than a cup of hot coolant spilling on your girlfriend’s feet while you are trying to show her how cool your Z is? Anyways, I’ve had this problem for a while now and the first time I attempted to fix this, I bought a used heater core and of course it failed again. I decided to do it the right way this time.
With this approach, you get every necessary thing replaced and save yourself a load of time.
You WILL NOT need to pull the dash.
What you need:
1. NEW heater core from dealer (MSRP $127)
2. Basic tools (Philips, flathead, 14mm, 10mm, 8mm, short Philips, Dremel metal cutter, 2 pieces of rubber hose (I used 5/8” heater hose from HD, 4 clamps.
3. Absorbent towels
4. Needle nose pliers
5. Patience.
Step 1. Remove your seat (4 14mm bolts)
Step 2. Remove the cover in driver’s knee area (4 10mm bolts)
Step 3. Remove the side vent cover and remove the two air guide tubes exposed after the
knee cover removal.
Step 4. Remove the black cover of the climate control unit. I do not care how, you can
even break it, that part is useless… just like the 4th back bolt on the A/C
compressor that pissed me off during my engine pull!!!
Step 5. Look at this picture closely. If it looks like this, then you in fact are a h0m0
Sapiens, if not, reassemble and go to a mechanic.
You can see the climate control unit with 4 plugs going into it from the top. The unit is being held by 3 8mm bolts. 2 are visible and one is hidden from your view (location shown in the images below), but accessible. Not only are they 8mm, but they are also Philips bolts as well. The locations of bolts are shown with YELLOW circles. Remove the bottom ones first and then stick the screwdriver between plugs 2 and 3 on top. You can wiggle the unit around to get a glimpse of where the 3rd bolt is hiding. One the 3 bolts and plugs (RED arrows) are removed, place the unit in a safe place and proceed.
Step 6. Look at this picture closely.
Now, remove the spring RED (there’s a hook on the left)
Now place a THICK towel here (LIME GREEN)
Now, unbolt the 8 screws (YELLOW) connecting the coolant pipes to the core.
BE CAREFUL!!! Not to spill too much coolant on the carpet… you’ll have to spend the rest of your day drying it…
Step 7. Look at this picture. Should look something like this.
BLUE you can see the location of the 3rd climate control unit bolt that was previously hidden.
You will need to unbend the valve opening cable (YELLOW) with a pair of needle nose pliers.
Now comes the patented by Pearl_TTZ part… You will need to make 2 cuts on the pipes leading to the heater cores (marked RED). Do not worry, this is absolutely safe and you will be with a new heater core installed in no time…
To make a cut, use these…
http://www.homedepot.com/webapp/wcs/...cStoreNum=8125
http://www.homedepot.com/webapp/wcs/...cStoreNum=8125
Step 8. Separate the pipes leading into the heater core from the heater core itself. There will be coolant pouring out, so do your best to catch as much of it as possible with a towel. Remove the 8 Philips bolts holding the pipes down.
Step 9. Using the circulating Dremel/Black & Decker tool, make the cuts like so.
Step 10. Now clean up the cut off locations on the heater pipes. Make them look nice, perpendicular and remove the imperfections with file/sandpaper.
Step 11. Now you need to prepare the parts of the pipe that will go into the heater core. Basically use the pieces you cut off and cut the same exact size/shape off a NEW heater pipes.
Step 12.
Now slide the new heater core back into the slot in the airbox. There are clip holding it down initially that I do not show in this review because they are not necessary and I removed them when I replaced my first heater core.
Step 13.
Connect the little pipes going to the heater core and the car’s heater hoses. It would be easier to put the rubber hoses on pipes loosely, secure the little pipes to the heater core and THEN clamp down the hose pieces with clamps onto the pipes. Should look like this.
Step 15.
Run the car for 10 min with heater “ON” and make sure there are no leaks coming from the core/hoses/pipes. If all ok, replace the knee panel and breathe easy… you are now ready for winter!!!
...I need to get to work for hours 50-70...
