I had been procrastinating on changing my leaking heater core for about the last year and finally decided to do it last week.

I ordered the parts form FCP Groton and allowed myself plenty of time after reading all the posts I could and reviewing the Haynes Manual. The following are some things I learned by trial and error.

Unlike Norm the master carpenter on "This Old House" who never makes a mistake on PBS carpenter jobs, I made a few which you may benefit from.

1. Haynes says to tightly clamp the heater hose lines in the engine compartment--I did that and still was flooded with coolant on my drivers side floor. Lesson: Drain and flush your whole coolant system when changing the heater core.

2.The interior and exterior lines are heat fused to the snap-on coupling and are difficult to remove. My vigorous attempt to remove these lines caused the snap-on coupling to break. Replace the part-$40

3. I dropped the plastic heater core housing and cracked a section out of it. Replace the part -$50

The snap-on coupler and the heater core are non-stock special order parts at your local Volvo dealer. (two day wait) --I took the subway.

4. The new snap-on coupler come with the rubber and plastic and rubber o-rings included--you do not need another packet for $10.

5. Regarding the snap-on coupling--the interior o-ring fasteners have one ear the exteriors have two ears. The o-ring kits may be incorrect regaring the rype of o-ring fasteners needed (too many two ear fasteners not enough one ear fasteners).

6.Follow the instruction to remove the screw at the base of the heater core which holds the core to the silver plastic metal heater tubes. I did not understand this instruction for a while and wasted much time.

7. If you are changing your upper and lower hoses for your cooling system be prepared to cut the screw clamps of with a hacksaw blade as the screws are rusted in place and will not turn.

Cost of job:

heater core, hoses and o-rings $175.00
snap-on coupling and heater core casinng $100 (breakage)
Time: three days (including special order parts wait)

Educational Benefit: Priceless (I now know how to do this job and it will go more smoothly in the hopefully distant future).


Dan -The Bull in a China Shop and Driveway Tinkerer


PS: The techs who do this for a living, earn every cent of their pay. I felt line a contortionist trying to reach everyting inside the car. It was quite an experience.