Scorpio heater core replacement
Scorpio heater core replacement
Hello,
I must admit the owning a Scorpio is a commitment of sorts and a labor of love. I got some issues with mine and they really test my patience. This time it is a heater core. Two years ago my original core developed a leak flooding passenger's floor with coolant. OK, I got a new part and paid my local mechanic to install. Even though, I prepped the work for them, removing front dash items for easier access they still managed to damage plastic lower dash cover. Took the car back, but noticed the cooling system never pressurized itself and the upper radiator hose stayed limp after engine warm up. Coolant loss from the bottle was steady but not dramatic. Given the system pressure a leak would be more prominent and here it is not so. What worried me the most was the presence of moisture in the passenger floor area. I cleaned and dried it repeatedly but when I place a paper towel on the floor with carpet pulled up it still comes damp. Suspect some damage of the core or maybe rubber hoses. So, recapping this rather long introduction, how difficult is it take out the core without relaying on mechanic's shop? Have anyone done this work in the past and can offer some tips for me? Appreciate your feedback. Thank you,
PeterP11c.
I must admit the owning a Scorpio is a commitment of sorts and a labor of love. I got some issues with mine and they really test my patience. This time it is a heater core. Two years ago my original core developed a leak flooding passenger's floor with coolant. OK, I got a new part and paid my local mechanic to install. Even though, I prepped the work for them, removing front dash items for easier access they still managed to damage plastic lower dash cover. Took the car back, but noticed the cooling system never pressurized itself and the upper radiator hose stayed limp after engine warm up. Coolant loss from the bottle was steady but not dramatic. Given the system pressure a leak would be more prominent and here it is not so. What worried me the most was the presence of moisture in the passenger floor area. I cleaned and dried it repeatedly but when I place a paper towel on the floor with carpet pulled up it still comes damp. Suspect some damage of the core or maybe rubber hoses. So, recapping this rather long introduction, how difficult is it take out the core without relaying on mechanic's shop? Have anyone done this work in the past and can offer some tips for me? Appreciate your feedback. Thank you,
PeterP11c.
- andyofcolumbusmerkur
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Re: Scorpio heater core replacement
According to people on here the xr and scorpio heater core is the same part. Looks like you could get a new plastic one (nos parts under classifieds) or Mike's all metal replacement. Taking everything apart is not super hard. I remember fighting with little clips trying to get to a heater blower motor at the junkyard. I just cut it out instead. And took all the clips as extras since they may shoot across the garage and get lost. When I removed the inside half of the hvac on my own car I had the dash out and it wasn't very hard. Could be a chore on a Scorpio however.
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- brokencase
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Re: Scorpio heater core replacement
It's tough to keep any 30 year old car going. Even a Scorpio. A worn heater core is not unexpected.
However it seems to me, from your description, that your mechanic screwed up. Can't you hold him responsible?
However it seems to me, from your description, that your mechanic screwed up. Can't you hold him responsible?
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Re: Scorpio heater core replacement
The guy is pretty nice but his employees change frequently. The legal recourse in today's environment is rather ineffective. Covid19 shut down small claims court as well. Besides I didn't witness the work being done, so it would be a chore to prove my case. My concern is to get the car operational and find the leak in the system. Have some other work to do and will take my Scorpio to another shop. A system pressure check should reveal the leak, I suppose. Then, either I will let them do it or try it myself. Not sure if I am up to the job. The core access is tight from the inside and it looks like a full day job. Yes, keeping a 30 year old car running is not a small feat.
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Re: Scorpio heater core replacement
You didn't note if the current dampness in the footwell is clearly coolant or not (rain water). The cause and solution would be different if it is water.
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Re: Scorpio heater core replacement
The car is parked in the building garage all the time. So rain water is out of the question. The amount of dampness is puzzling since a damaged core or a hose would result in a substantial leak and here I see moisture only. The other factor is that after the repair the system has not been not pressurized, with upper radiator hose being limp on warm engine. I will try to dismantle to dash cover over the weekend and probe with flashlight for signs of coolant. The core removal seems like a bigger job, perhaps too big for my abilities. Presently, I got a TFI unit and one sway bar bushing. Still shopping around for a second one. Then, with this work planned I think about getting my Scorpio to a Pep Boys shop for a cooling system pressure check to ascertain the problem.
Re: Scorpio heater core replacement
Peter
Heater Core R&R in Scorpio - Been there / done that
You wrote
"Coolant loss from the bottle was steady but not dramatic."
The reservoir and cap must hold pressure! If not, the cooling system will NOT hold pressure.
Replace reservoir & cap.
"presence of moisture in the passenger floor area."
"Suspect some damage of the core or maybe rubber hoses."
The heater core has plastic tubes, there is a good chance they either cracked one or didn't secure it properly to the hoses or if hoses are OEM, they are nfg.
Disconnect the hoses in the engine bay and have it pressure tested. If it leaks, definitely get OEM replacement hoses. Contact our sponsors - they'll have correct hoses. Reservoir, doesn't have to be OEM and the sponsors will have correct replacement.
"they still managed to damage plastic lower dash cover"
Takes a bit of maneuvering to get lower dash out and almost impossible to replace without breaking it when reinstalling. That's why the workshop manual says to remove the gear shift by disconnecting the linkage. It's already broken, so you might as well do it yourself. I'm only 5"7" and access was easy, but if you're a big person, I suggest you remove the passenger seat.
No special tools needed! Take the lower dash out. Get water hose barb & female connector fitting from local auto parts store. Connect water hose to 1 heater core hose in the engine bay & use temporary plug in other hose. Turn water hose on & check for leaks. Easier if you have a "friend" regulate the water hose pressure
Bob
610-248-1481 cell
Heater Core R&R in Scorpio - Been there / done that
You wrote
"Coolant loss from the bottle was steady but not dramatic."
The reservoir and cap must hold pressure! If not, the cooling system will NOT hold pressure.
Replace reservoir & cap.
"presence of moisture in the passenger floor area."
"Suspect some damage of the core or maybe rubber hoses."
The heater core has plastic tubes, there is a good chance they either cracked one or didn't secure it properly to the hoses or if hoses are OEM, they are nfg.
Disconnect the hoses in the engine bay and have it pressure tested. If it leaks, definitely get OEM replacement hoses. Contact our sponsors - they'll have correct hoses. Reservoir, doesn't have to be OEM and the sponsors will have correct replacement.
"they still managed to damage plastic lower dash cover"
Takes a bit of maneuvering to get lower dash out and almost impossible to replace without breaking it when reinstalling. That's why the workshop manual says to remove the gear shift by disconnecting the linkage. It's already broken, so you might as well do it yourself. I'm only 5"7" and access was easy, but if you're a big person, I suggest you remove the passenger seat.
No special tools needed! Take the lower dash out. Get water hose barb & female connector fitting from local auto parts store. Connect water hose to 1 heater core hose in the engine bay & use temporary plug in other hose. Turn water hose on & check for leaks. Easier if you have a "friend" regulate the water hose pressure
Bob
610-248-1481 cell
Re: Scorpio heater core replacement
Hello,
OK. I have been doing some other work on the Scorpio, mainly replacing broken side marker front lamps, broken position lamp and cleaning and removing front lamps. Concurrently, I have pulled the passenger floor carpeting up and placed a piece of paper towel on the floor when the foot-well goes up. There is a little dip in floor insulation lining that marks connecting two sheets installed at the factory. It goes across the floor and over there I noticed coolant that dripped from the dash. So, the evidence is there.
Next, in the past I have been dismantling the entire dashboard, including the radio and removing the gearbox knob. Know how to do it, no problem.
The coolant bottle is quite new, including the cap and the system always pressurized itself before the heater core work. Strongly suspect, my mechanic shoved in the core and damaged one of the plastic hoses. My rubber cooling system hoses were already replaced over time due to wear and tear. So the engine hoses are not an issue.
Please confirm the correct step. The heater core being inside heater assembly should be taken out from the passenger side and then opened to reveal the core itself.
Given the past experience with local mechanics I was loath to give them another try. Seems like I could do this by myself. Appreciate your input. Bob, do you mind me giving you a call to talk about this a little more?
OK. I have been doing some other work on the Scorpio, mainly replacing broken side marker front lamps, broken position lamp and cleaning and removing front lamps. Concurrently, I have pulled the passenger floor carpeting up and placed a piece of paper towel on the floor when the foot-well goes up. There is a little dip in floor insulation lining that marks connecting two sheets installed at the factory. It goes across the floor and over there I noticed coolant that dripped from the dash. So, the evidence is there.
Next, in the past I have been dismantling the entire dashboard, including the radio and removing the gearbox knob. Know how to do it, no problem.
The coolant bottle is quite new, including the cap and the system always pressurized itself before the heater core work. Strongly suspect, my mechanic shoved in the core and damaged one of the plastic hoses. My rubber cooling system hoses were already replaced over time due to wear and tear. So the engine hoses are not an issue.
Please confirm the correct step. The heater core being inside heater assembly should be taken out from the passenger side and then opened to reveal the core itself.
Given the past experience with local mechanics I was loath to give them another try. Seems like I could do this by myself. Appreciate your input. Bob, do you mind me giving you a call to talk about this a little more?
Re: Scorpio heater core replacement
You wrote
"Please confirm the correct step. The heater core being inside heater assembly should be taken out from the passenger side and then opened to reveal the core itself."
Yes it's in bottom of assembly and pulls out at passenger's left foot.
Disconnect the hoses in the engine bay because the tubes from the heater core extend through the fire wall. Slide the heater core out towards passenger side.
You should be able to see it with the lower dash removed.
"Please confirm the correct step. The heater core being inside heater assembly should be taken out from the passenger side and then opened to reveal the core itself."
Yes it's in bottom of assembly and pulls out at passenger's left foot.
Disconnect the hoses in the engine bay because the tubes from the heater core extend through the fire wall. Slide the heater core out towards passenger side.
You should be able to see it with the lower dash removed.
Re: Scorpio heater core replacement
Great picture. OK. I am awaiting the delivery of a new core. Over next weekend, I will slowly dismantle top and bottom dashboard and start the work. So the heater assembly stays in place, you only slide out the core from it's housing. Thank you for the tip. Appreciate it. Peter
Re: Scorpio heater core replacement
You only pull this when your grabbing everything before it goes to the crusher.
Small panel at top with controller. That controller controls the fan speed. Workshop Manual has inst how to test it.
Below the solenoid is a seam with rusted clips. This separates the top & bottom halves to access the motor. Many people will cut along top seam to remove motor. The top half can be removed intact with lots of patience. I think I removed the distributer for clearance.
Small panel at top with controller. That controller controls the fan speed. Workshop Manual has inst how to test it.
Below the solenoid is a seam with rusted clips. This separates the top & bottom halves to access the motor. Many people will cut along top seam to remove motor. The top half can be removed intact with lots of patience. I think I removed the distributer for clearance.
Re: Scorpio heater core replacement
Here is some progress report on my quest to fix heater core.
1. Got a new core of the original design. Carried one dent on the top, I gently pulled up those aluminum fins and one line at the end was pushed in, but this one I left alone. Filled it up with hot water, not pressurized mind you, but not leaking. Good sign.
2. Dismantled top dash, radio, amplifier but when it came to the lower dash, troubles began. It was already damaged by the previous mechanic's sloppy work, but I didn't anticipate the scale of injuries. After a long struggle got it out. There are many cracks at edges, banged in openings for bolts and plastic holding tabs for radio/amplifier metal frame are totally broken.
3. First, I put it in the tub and gently washed of 30 years of dust, grime and residue from the entire area.
4. Let it dry out and assessed the damage. Some broken plastic parts were retrieved and glued back using cray glue and flex plastic tape for better binding.
5. Next, the J-B Weld Epoxy to the rescue. Mixed epoxy in small batches and distributed over repair areas. This work is still in progress. Once, all complete, I will let it sit for a few days.
6. With lower dash out, I have visual of the heater core and reached out with my hand underneath to probe for some moisture. Didn't find any but with the car not running in the past week that was OK.
7. According to the Manual Book, I have to take out two holding screws of the heater assembly. Haven't located them yet.
8. The vents are also supposed to be disconnected, hope it wouldn't be a chore. Doing all in small steps, but each day brings me closer to the goal. Has anybody done this work before and can share some work progress pictures?
Thank you. Peter P11c.
1. Got a new core of the original design. Carried one dent on the top, I gently pulled up those aluminum fins and one line at the end was pushed in, but this one I left alone. Filled it up with hot water, not pressurized mind you, but not leaking. Good sign.
2. Dismantled top dash, radio, amplifier but when it came to the lower dash, troubles began. It was already damaged by the previous mechanic's sloppy work, but I didn't anticipate the scale of injuries. After a long struggle got it out. There are many cracks at edges, banged in openings for bolts and plastic holding tabs for radio/amplifier metal frame are totally broken.
3. First, I put it in the tub and gently washed of 30 years of dust, grime and residue from the entire area.
4. Let it dry out and assessed the damage. Some broken plastic parts were retrieved and glued back using cray glue and flex plastic tape for better binding.
5. Next, the J-B Weld Epoxy to the rescue. Mixed epoxy in small batches and distributed over repair areas. This work is still in progress. Once, all complete, I will let it sit for a few days.
6. With lower dash out, I have visual of the heater core and reached out with my hand underneath to probe for some moisture. Didn't find any but with the car not running in the past week that was OK.
7. According to the Manual Book, I have to take out two holding screws of the heater assembly. Haven't located them yet.
8. The vents are also supposed to be disconnected, hope it wouldn't be a chore. Doing all in small steps, but each day brings me closer to the goal. Has anybody done this work before and can share some work progress pictures?
Thank you. Peter P11c.
Re: Scorpio heater core replacement
Two screws to remove heater core are in the top edge [front & rear] of the plastic end cap w hose connectors].
I don't remember having to remove "vents" to change heater core. Most likely disconnecting the duct immediately above the core will make it easier.
I've had very little success gluing plastic parts of the Merkurs. Considering how broken your lower dash is, I'd call Jeff Herson 847-688-1234 and ask him best glue to use and how much for a lower dash panel. Ask Jeff about gear shift lever disconnecting it vs leaving it in place when installing lower dash. I suspect he's going to strongly suggest disconnecting it to make it easier to install dash without breaking it.
Ford Nationals July 31 - Aug 2 in Carlisle PA. Members do a lot of parts swap there to save shipping costs. I'm in eastern PA and got a Scorpio engine from Jeff in Chicago via this MCA annual gathering.
Bob
PS Open your "Profile" and enter your city & state. It makes it easier to buy & sell parts. You get really lucky when someone lives close to you and physically helps you.
I don't remember having to remove "vents" to change heater core. Most likely disconnecting the duct immediately above the core will make it easier.
I've had very little success gluing plastic parts of the Merkurs. Considering how broken your lower dash is, I'd call Jeff Herson 847-688-1234 and ask him best glue to use and how much for a lower dash panel. Ask Jeff about gear shift lever disconnecting it vs leaving it in place when installing lower dash. I suspect he's going to strongly suggest disconnecting it to make it easier to install dash without breaking it.
Ford Nationals July 31 - Aug 2 in Carlisle PA. Members do a lot of parts swap there to save shipping costs. I'm in eastern PA and got a Scorpio engine from Jeff in Chicago via this MCA annual gathering.
Bob
PS Open your "Profile" and enter your city & state. It makes it easier to buy & sell parts. You get really lucky when someone lives close to you and physically helps you.
Re: Scorpio heater core replacement
Bob, thank you for continuous support. Much appreciated. Yesterday, I went about dismantling heater ducts, the middle top one short and the right one. Being dusty, I took them out for some soap washing. Then, I was able to spot these two mounting screws. The one on the right has a nice and easy access, the one on the left not so. Being a #13, only a socket wrench with extension will do the job. The heater core mounting screws are Phillips, perhaps a small screwdriver will get them out.
I plan to take out the big mounting screws first and see how much wiggle room I get to move the heater assembly forward. I figure, I need about 4 inches to get the plastic hoses clear out of the fire wall. Then, I will disconnect rubber hoses in the engine compartment where again access is very limited. Sliding out the core and replacing shouldn't be that hard.
On the lower dash issue, I took it out and it did break in the narrow end. Spent entire weekend repairing the broken piece and other cuts and breaks using a combination of crazy glue with electric tape, then J&B Weld steel reinforced epoxy. Took my time restoring broken pieces, first drawing then on paper then cutting matching pieces from 1mm plastic sheet glued in two layers. Achieved remarkable success restoring mounting tabs for radio/amplifier holder. Once covered with epoxy and dried out they are stronger than original part.
This job showed me what a shoddy job they did on my Scorpio. Because of the damage to the lower dash they omitted mounting screws at the end wall metal tabs holding glove compartment box. Pity to look at this butchery, but I feel with TLC it will be brought back. In hindsight, if not for the leak, I would have never removed the front dash and repaired the damage. Since I live in Los Angeles, CA I am probably alone in the Scorpio world, as I haven't seen another one in many years.
Well, more small steps to take and looking forward to the end of this odyssey.
I plan to take out the big mounting screws first and see how much wiggle room I get to move the heater assembly forward. I figure, I need about 4 inches to get the plastic hoses clear out of the fire wall. Then, I will disconnect rubber hoses in the engine compartment where again access is very limited. Sliding out the core and replacing shouldn't be that hard.
On the lower dash issue, I took it out and it did break in the narrow end. Spent entire weekend repairing the broken piece and other cuts and breaks using a combination of crazy glue with electric tape, then J&B Weld steel reinforced epoxy. Took my time restoring broken pieces, first drawing then on paper then cutting matching pieces from 1mm plastic sheet glued in two layers. Achieved remarkable success restoring mounting tabs for radio/amplifier holder. Once covered with epoxy and dried out they are stronger than original part.
This job showed me what a shoddy job they did on my Scorpio. Because of the damage to the lower dash they omitted mounting screws at the end wall metal tabs holding glove compartment box. Pity to look at this butchery, but I feel with TLC it will be brought back. In hindsight, if not for the leak, I would have never removed the front dash and repaired the damage. Since I live in Los Angeles, CA I am probably alone in the Scorpio world, as I haven't seen another one in many years.
Well, more small steps to take and looking forward to the end of this odyssey.
Re: Scorpio heater core replacement
I'm mystified why you're messing with the heat box and all the vents. Remove the 2 screws in top of heater core end cap and slide it out.