S80 Heater core replacement

[muodonovan]

I had the same problem with the o-rings not compressing and had a hell of a time getting the pins over the pipes. I thought I would post my solution.

I went to home depot and purchased a an eye and eye turnbuckle.

http://www.homedepot.com/b/Tools-Hardwa ... 5yc1vZc2ga

with this i was able to adjust the length of it so i could jam it between the steering column and the heater core pipe. After doing this I was able to get the top one in. The bottom one wouldn't go in all the way. So I left the turnbuckle in place and turned the car on to warm up the pipes. The heat did the trick. The o-ring compressed and it was relatively easy to get the pin in place.
hope this helps

[aaronrothrock]

Is there a video of this anywhere?

[tactic2876]

Did anyone figure out how to remove the temperature control mechanism? I broke mine and would like to do a similar repair as the one shown.

[shea44]

What is the trick to getting those dang clips out???? One is jammed against a black box and the other is darn near accessible?? Please and thank you.

[xHeart]

What is the trick to getting those dang clips out???? One is jammed against a black box and the other is darn near accessible?? Please and thank you.

The clips are aluminum, soft material, gently rotate it out using small needle-nose plier or likes. Be careful "not to pull", rather rotate slowly to "slide" it out. Replace with same, aluminum type. No force required, let your wrist do the work.

[shea44]

Thank you x heart clips are out, core cannot get past the brake sensor and I cannot find a site that tells me where to disengaged the brake sensor? And what about the steering column? I read that is going to be in the way as well. What horror show this has turned into...

[xHeart]

Thank you x heart clips are out, core cannot get past the brake sensor and I cannot find a site that tells me where to disengaged the brake sensor? And what about the steering column? I read that is going to be in the way as well. What horror show this has turned into...

You do not need to do anything with steering column shaft for this task. However, the brake sensor in front of the pedal is extremely trick object to remove from the metal bracket. I will try to describe it here...looking for a photo in my library...stay tuned.

brake pedal sensor

MVS_0140.jpg (90.79 KiB) Viewed 2324 times

- Disconnect at red arrow first.
You are looking to pull it by grabbing it at the grey arrows. If the orientation of the sensor is same as this photo then you want to use your thumb to push downward to disengage at orange arrow tab, and then lift it out of the bracket gently while keeping the angle that disengaged it at the tab.
- orange arrow tab is what catches on to the square metal bracket.
- green arrow is a stopper elbow when fully seated.
- blue is brake pedal travel adjustment.

[shea44]

Thank you Xheart for going the extra mile and posting that picture. The trick to these jobs is knowing the dynamics to car building. I know just enough to be dangerous. The task today is to wrangle those clips back in. I cannot seem to get the pipes in tight enough to do so. I need more strength which as woman I am lacking. But I will try. Being contorted under the dash for hours yesterday left me a little sore. I have a new found respect for the wrench turners of the planet. They earn every freakin' dime! But poverty is the motivator, gotta do what ya gotta do. I so appreciate everyone's input.

[xHeart]

Thank you Xheart for going the extra mile and posting that picture. The trick to these jobs is knowing the dynamics to car building. I know just enough to be dangerous. The task today is to wrangle those clips back in. I cannot seem to get the pipes in tight enough to do so. I need more strength which as woman I am lacking. But I will try. Being contorted under the dash for hours yesterday left me a little sore. I have a new found respect for the wrench turners of the planet. They earn every freakin' dime! But poverty is the motivator, gotta do what ya gotta do. I so appreciate everyone's input.

It takes prepping of seal, lubricating surfaces and a swift push at the pipe for it to snap into position. It won't volunteer to slide in easily.

After the seal is over the pipe, insert the pipe with little angle, a portion of the seal would resist, at this point use a firm object like a trim tool (NOT SHARP OR METAL) to push the seal inward a bit more. It takes several attempts. Once pipe is seated, inserting clip is a small maneuver.

You are well on your way!
A good friend often said, "quitters don't win, winners don't quit".

PS- push the driver's seat all the way back. Lay on your back, head and shoulder close to the brake pedal, legs and feet going over the diver's seat. Wear eye protection. Work in plenty of light.

[shea44]

For getting the pipes to seat and the clips back in, the turnbuckle may have do the trick I am not strong enough and the position is so awkward to push in the pipe and put in the clip, very tight area to work in. I tried wedging a screwdriver between the steering column and pipe it kept slipping and falling. I so appreciate all the tips I am bruise, cut up and so sore from being contorted under the dash.. I just keep reminding myself of how much money I saved. I liken this project to this quote. "The greater the challenge, the fewer are those who conquer it." Let me tell you, the mechanics are worth weight in gold!