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Ea-81 Heater Core Swap

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#1 subeman90



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  • 2,805 posts
  • Akron PA

Posted 02 January 2006 - 10:45 PM

Posted Image
e-mail Shawn Subaru EA81 Heater Core Swap

Okay, here it is. With inspiration from SubySwamper assuring me that it could be done.....

1. Remove panel on left side under the dash
2. Remove the defroster duct from the left side of the console
3. Remove the heater control valve
4. Move any wires out of the way if you have any hanging
5. Cut out a side access hole around the heater core. Because of the cramped area, and thickness of the plastic, following SubySwampers lead, I used a soldering iron to perforate the plastic around the core.
6. The plastic is "rounded over the edge of the core, so you will have to make sure to get the "cut" as far back as possible to allow room for the core to come out.
7. Remove computer so core has a spot to pull out into.
8. Remove core by pulling out from the side.
9. If the core will not come out, see #6 above.
10. Core still will not come out, you may have to remove the top edge of the opening for the defroster duct (like I did)
11. Core is removed... here is the rough opening...Posted Image ...and after a little clean-up....Posted Image
12. Here's the comparison of the 2 cores. you will notice that the new core is all aluminum, and thinner which makes it easier to get in... Posted Image Posted Image
13. Here's the new core with the new foam installed around it... (you may need to trim up some around the end opposite the pipes to ensure a good fit back into the hole... Posted Image
14. Here's the new control valve (dealer only)...Posted Image
15. Always test fit to make sure everything lines up (there's a reason there is 3 pics :) )Posted Image Posted Image Posted Image
16. And the final pics of the install... Posted Image Posted Image Posted Image

And this is done to avoid this... plus a whole lot more mess of pulling the dash out too...Posted Image

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