Hello all -- I am looking for the procedure for replacing the heater core on a 1981 XJ6 - anyone done one of these before? I did a quick look see and it doesnt look like a pleasant procedure to me - I dont want to start taking it apart without at least seeing if there is a written procedure out there somewhere that may save me time and unnecessary tear down. Thanks -

 

There are 2 ways to do the replacement.

You can pull the entire dash panel and remove the climate control module or you can cut the heater pipes and lower the steering column to access the side panel and pull the core out the left side.

I have done it both ways and have had success both ways.

If you cut the pipes, you need to coat the pipes with silicone grease and slide sections of 5/8" heater hose over the cut sections and slide the hoses back over the cut pipes.

Install clamps and check for leaks.

bob gauff

 

Thanks - I have taken the dash out of the car - by climate control module do you mean the black metal enclosure that houses all the mode doors etc ... ? I have taken the retainers that I could see out of that unit and it still seems like it is welded to the firewall and or floorboards - no movement at all with it. If I "cut" the heater pipes I presumme you mean the core feed lines coming through the firewall ? If I do that do I have to cut back the new ones, and if I do that wouldnt they be too short to come back through for hook up ? I just want some clarification as I sure dont want to have to do this again, or ruin the $125.00 new core.

 

Yes the climate control ASSY.

If you already have the dash out then remove the fasteners on the bulkhead (firewall) from the engine compartment. There are studs on the climate control housing assy. The housing assy will come out and then you don't have to cut the old or new pipes.

bob gauff

 

Bob, are you talking about the two 19mm shouldered nuts that come through the firewall from engine compartment? If so, I took them out, are they the only two that secure the whole unit ?? If thats the case this unit is still rock solidily held into position - do I just need to bull it out with pry bars? Thanks for the help.

 

It's been 15 years or more since I removed a climate unit from a Series III. I can't remember if there are some fasteners inside the car but it is probably stuck in a few places so you will have to gently pry it out (up and down, back and forth)

bob gauff

 

Those shoulder nuts you found should be all that is left holding the assembly. Attached is the blurb from the manual.

Good luck!

 

Thanks - I actually got it out by the cutting the pipes method - It sure was a pia even doing it that way - appreciate all your help.