Heater Matrix Swap

[panky]

The drivers side carpet continues to get wet and a piece of kitchen roll pushed up the centre console heater vent shows that it's coolant, red oily Evans Waterless So all prepped with a new matrix and seals, system drained, relevant lower dash trim removed and a big towel in the foot well I contorted myself enough to remove the four bolts securing the pipes to the heater valve and the two self tappers locating the matrix, what a palaver. Had to drop the steering column to wiggle the old matrix out, it didn't come out in one piece.

Shiny new one

So it came to fit the new one, simply a reversal of the removal - yeh right. I got it in OK but the outlet flanges were about half an inch away (too long) from meeting up with the heater valve, there was no way it was going to fit. Wrong matrix?

Looks OK to me

So I tried to put the old one back in and it's the same 1/2" out. I'm stumped as there doesn't seem to be anyway anything could have moved, it's all solidly mounted.
Had enough today so I'll think on it and try again tomorrow. Any and all suggestions would be welcome.

[panky]

After another frustrating day on my back in the footwell I managed to get the new matrix in through brute force and ignorance. Using a well greased scraper blade between the flanges I managed to force the heater onto the valve and bolted up. Unfortunately when I re-filled the system the joint pi$$ed out so I guess the new seals got displaced when the scraper was pulled out, luckily I bought a couple of sets.
I'm having day away from it today as I have a feeling nothing good will happen when I pull the matrix back out If it does come out in one piece I might try shaving some of the fins off to git a little more clearance.

[panky]

Trumpets sound and Angels cry for joy hallelujah hallelujah hallelujah hallelujahhhhhhhh - it's in and not leaking The seals had been displaced but luckily I'd bought two sets by mistake (thought they were sold in singles). So I shaved a couple of mm off each edge face of the fins and offered it back up. A lot less difference in the hight of the faces this time and so using the greasy scraper I prised them over each other easily and carefully drew the blade out ( which wasn't tight) and buttoned it back up. I made a platform to lie on this time made from a caravan step an a sheet of ply which made it a lot more comfortable.

Ran the engine at full temperature for twenty minutes and not a drop was dripped

Just need to put it all back together now.

[Meter rat]

So that’s what it all looks like, deep in the depths. Glad I’ve not had to do any work in that department.

[panky]

Indeed, Others have done it without to much of an issue but it seems my car is just an awkward bugger, the upper left hand bolt is a bit of a swine to get to but a quarter drive 7mm socket and extension does the job. I was looking at a matrix from a later car as they are smaller but with the same connections - but everywhere sold out. I also sent for more seals - just in case.

[deltic]

Well done!

[Jaba]

We always win in the end, but what a pain it is sometimes.

[panky]

It certainly is, especially in me dodgy hip

[saintjamesy89]

Crikey, well done John! Not a job I look forward to if ever needed... I can sympathise with the pain, a few weeks ago I was doing something similar with my Volvo 740 (blower fan replacement, its similarly integral to the HVAC) and a fractured rib - contorting underneath the dash and HVAC was quite painful. I won in the end but did have to have a lie down

[panky]

A lie down and a couple of Birra Morettis speeded up the recovery