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The dreaded heater core!

20K views 6 replies 5 participants last post by  samhunt1 
#1 ·
2004 Aerio SX. My heater core is leaking. Can't seem to buy just the core. You have to buy the entire heater assembly for $1200 (something like that). Also, you have to remove the entire dash to get to the heater assembly.

Anyway, after removing a few dash parts, I'm able to see that the heater core slides into an opening on the side of the heater assembly case. I could slide the core right out if it wasn't for the two pipes on it, that run behind the assembly case and out to the firewall.

So, here's my thought: I could cut the aluminum pipes, close to where the core fits into the assembly. Then I could slide the core out and examine it. I'm guessing it will not be repairable. Then, if I could buy just a heater core from a junkyard, I could cut the pipes off at the same spot I cut the original, put the new on in place and reconnect the pipes.

The two big question marks are:

1. Finding a heater core only
2. What do I use to reconnect aluminum tubing that has been cut?
 
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#2 ·
Not recommended

Hi, I have done this repair numerous times, I would not recommend doing the repair that way because you may not be able to reseal it properly, then you would be back to square one with your leak issue. The best way is to pop off the dash I do not know your mechanical backround but with some good tools it can be done by person at their home in less than a day depediong on your backround. If you would like I could fax your the removal procedure from Suzuki to help you. I am a Suzuki certified Master Technician and can get you diagrams to help if you need them.
 
#6 ·
Hi, I have done this repair numerous times, I would not recommend doing the repair that way because you may not be able to reseal it properly, then you would be back to square one with your leak issue. The best way is to pop off the dash I do not know your mechanical backround but with some good tools it can be done by person at their home in less than a day depediong on your backround. If you would like I could fax your the removal procedure from Suzuki to help you. I am a Suzuki certified Master Technician and can get you diagrams to help if you need them.
could you email me the replacement guide on the heater core, maybe some illustrations, we're having some trouble removing the dash
 
#3 ·
Success!!

OK.

1. I cut the pipes and removed the heater core out of the heater assembly unit.

2. I found the pinhole leak in the heater core.

3. I repaired the leak with JB Weld.

4. I slid radiator hose onto the cut pipes under the dash. I had to slide the majority of the hose onto the pipes. That way, I'd have room to line up the cut ends and slide the hoses up over the pipe connections. This was hard to do.

5. I slid the heater core back in place

6. I slid the hoses up onto the pipes that were attached to the heater core.

7. I clamped the hoses that connected the cut pipe.

8. I changed the anti-freeze and took it for a ride with the heat blasting.

9. Two weeks later. So far, so good.
 
#4 ·
Update

I had to repair the core again, about a month after the first repair. It leaked again, a few days later.

Then I bought a used heater core online. The core arrived with a pinhole. I brought it to a local radiator guy and he explained a few things.

If you don't change your antifreeze, it loses it's lubricants and your left with, basically, acid, that eats away at everything - especially an aluminum heater core. The core might look fine on the outside, but inside it's all eaten away. Radiator guy pushed his thumbnail against the pinhole and made it a 1/4" gash.

I was able to find a brand new heater core online. It was $335.00. Still a lot cheaper than the $2000 to replace entire heater assembly.
 
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