Heater core type 44

["Matt Martinsen" <mattmartinsen@hotmail.com>]

Just replaced my heater core this weekend on my 86 5KTQ so here's my 
procedure.
-drain coolant
-remove plenum cover
-remove wiper assembly
-remove fastening strap over HVAC box
-disconnect heater hoses at core
-disconnect temp control cable
-disconnect vacuum line tri-adapter on top of HVAC box
-disconnect all electrical connectors for AC system (follow wiring harness 
that comes through HVAC box)
-inside car remove glovebox, panel under steering wheel, and remove footwell 
ducts and disconnect large elbow ducts from HVAC box
-remove right side console panel
-remove radio (to gain easier access to next step)
-disconnect vacuum lines at servos (phillips head screws)(yellow, green, 
blue)
-disconnect red vacuum line from white line going through grommet in HVAC 
box
-pull temp. control cable through grommet
-slide accordian hose from evaporator off of HVAC box
-follow ac wiring harness through HVAC box, into dash and disconnect
-remove HVAC box, angle upward and keep wires from snagging on corners
-with HVAC box out of car remove many clamps holding box together
-remove three recessed phillips screw holding box together
-separate box and remove heater core, careful not to disturb/damage air flow 
control flaps
-install new core and carefully put box together lining up the air flaps 
(may take a few tries)
-put it all back together


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