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Hi Bob;
I did this job about 5-6
years ago on my 86 5kCSqs. No, you don't have to remove the dash, but that's
about the only thing you leave in!
As I recall the job, you
remove the parcel shelf on the drivers side and the glove box on the passengers
side. Remove the heat distribution ducting for the footwells. Remove the side
panels on the centre console to get at the rear of the climate control unit.
Remove the electrical connector on the harness going to the fan motor. This is a
special connector which comes apart so the wiring harness can be pulled through
the grommet in the firewall as a loose collection of wires and
terminals.
On the other side of the
firewall, drain the coolant and remove the heater hoses from the heater box.
Remove the other obvious paraphenalia and the box mounting strap. On my car the
box was a very tight fit and I had to get a buddy to help me pull it out. When
it is removed, there is a very impressive hole into the passenger compartment.
You will need a new expanded foam gasket from the dealer to seal the box to the
firewall when you re-install it.
The heater core is removed by
opening up the heater box. Some of the screws are hard to find, so if it doesn't
come apart, don't force it! Look for the screw(s) you have missed. The heater
core is sealed into the box with silicone rubber, so you will have to do the
same with your replacement core. Once the box is opened, you can replace your
heater motor. I just cleaned the pine needles and leaves out of mine, lubed the
bearings, & put it back in.
Re-assembly is mostly the
reverse of the removal procedure. There is a rubber sleeve in the centre of the
console which connects the heater box to the rear seat air vents; don't forget
to attach it.
My heater core was leaking at
the head tanks. The plastic head tanks are crimped to the aluminium core over
hollow rubber gaskets with an aluminium flange. Aluminium isn't known for it's
spring tension, and it appeared to have relaxed enough to allow coolant to
escape. The core itself was in fine shape.
It's been a while since I did
this job, so I may have forgotten some of the finer details. It took 6-7 hours
to complete and wasn't one of the most enjoyable afternoons I had
spent.
Good luck!
Fred Munro
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