Klaus,

I had considered starting a new thread but it seemed that this was still relating to the original post. I like these forums when problems get resolved all the way thru in one thread so another user searching for similar info in the future can get a good idea of the whole project.

Anyways, the delete mod does away with those lousy couplings entirely and you use standard 5/8" heater hose. I found a good DIY on Matthews VS. You gut the coupling to use it as a plug thru the firewall and hose clamp either end. Done. Not quite as neat as the original, but it seems much better in that its not all plastic garbage which can fail at any time. Unlikely, yes, I know, but I digress...

I did take your advice and get the $40 ebay heater core. Looks OK, my only concern is it looks identical ( clamped flange type tank, not OEM style) as the one that failed TERRIBLY in the first place, ruining the first motor. I am keeping my fingers crossed that was just a fluke.

Thanks for your advice on the intake vac line, I will look into that when I get a chance! I think you are correct, as it was originally routed under the intake as was the original.