One of my 240s heater boxes is leaking AC condensate out the center seam. Water is running down into the driver side floor pan. I first suspected a clogged drain hole or hose, but both were fine. It looks like I'm going to have to pull the heater box, open it up and re-seal the seam. What is the best sealant to use between the two heater box halves? I don't want to have to pull it all back apart again a couple of years from now.

I will probably replace the fan motor while I'm in there too. It's starting to make a little noise. Should I also replace the heater core too? It is a 1990 with only 110K. I know some of the original parts can be far superior to any aftermarket ones. Is this the case with the heater core? How long do they typically last?

The HVAC system is one of the few gripes I have with this otherwise super fine automobile. Its like they built the whole car around the heater box. I also noticed that if the car is sitting level, the condensate drain is not the lowest point in the box, so some amount of water will always stand in there. I guess I could park backward on a hill and partially alleviate the issue.

Thanks,
Preston

check out Art Benstein's great sites
fan & resistor
http://cleanflametrap.com/
heater core
http://cleanflametrap.com/heater_core/

if you acquire the fan & resistor from eeuroparts ($58 free shipping)
http://www.eeuroparts.com/productdetail.aspx?searchResults=1&code=6172
be advised:
the one i got had fan motor wires a bit too short, adding 4" each would help the situation

also not a bad idea to replace the heater control valve ($50)
http://www.eeuroparts.com/productdetail.aspx?searchResults=1&code=6173
mechanical control seems to work forever and allows for incremental adjustments superior and cheaper than the degrading original that may only provide very hot

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rich in central arkansas - 62 544 132k, 85 244 282k, 95 855 182k

I used white silicone RTV from Sherwin Williams to seal up all cracks and joints. The result is that I haven't had a single leak. Whatever you do, avoid latex based sealant as it will eventually degrade and leak under water exposure.

When I pulled the "climate control assembly" out of our 92, id did replace the fan motor, heater core, and fan resistor assembly. If you are in there, just do it!

jorrell
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92 245 245K miles, IPD'd to the hilt, 06 XC70, 00 Eclipse custom Turbo setup...currently close to running again!

Thanks Jorrel for all the great climate control info! Looks like I'll be ordering a new heater core as well.

Preston