I realized I never completed this thread -

I did replace the heater core with its new seals on both sides to the aluminum water pipes. Also replaced all the vacuum acutators while there since getting to some later was next to impossible.

The whole project spanned several weekends but actually not that hard to do. I followed the suggestions on this forum regarding going slowly, using lots of baggies to group screws and fasteners, marking them with a Sharpie as I went. I also took a lot of digital pictures.

Almost everything goes back together very logically especially since most of the connections and lines terminate where they should be connected making reassembly quite intuitive.

Be sure to note carefully how the vacuum lines for the HAC control are held in place under the glove box. Besure to return any insulation, sound deadening and insulating pieces. I didn't get the little felt piece under the right-front A-pillar cover and it squeaked.

I know this comment might seem odd, but take your time. I believe this is one of those jobs where the more time, care and the more thorough you are taking it apart makes going back together much easier. Don't rush through taking lots of parts, pieces and fasteners off and then loose track of where they go. It can happen easily and then when re-installing goes even slower because of having to figure proper fasteners and trial error times.

Haasman

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'03 E320 Wagon-Sold
'95 E320 Wagon-Went to Ex
'93 190E 2.6-Wrecked
'91 300E-Went to Ex
'65 911 Coupe (#302580)