Replacing the heater core requires considerable mechanical aptitude and the following tools and parts:
Tools:
* Screwdrivers: Phillips and flathead, various sizes.
* Sockets and Wrenches: Metric and possibly standard, a variety of sizes.
* Pliers: Needle-nose and regular.
* Socket set with ratchet and extensions: To reach fasteners in tight spaces.
* Drain pan: To catch coolant.
* Shop towels or rags: Plenty of them!
* Coolant recovery bottle: To catch overflow coolant.
* New heater core: Specific to your 1992 Ford Aerostar (ensure you get the correct one based on engine and options). O-rings and seals are also likely needed.
* Possibly a sealant: For any connections you might have to reseal
* Pressure tester: To check for leaks after the replacement.
Procedure (General Outline - NOT a detailed guide):
1. Drain the cooling system: This is crucial to prevent a mess and coolant loss. Locate the drain plug on the engine block or radiator.
2. Disconnect the battery: This is a safety precaution to prevent electrical shorts.
3. Remove parts obstructing access to the heater core: This will likely involve removing parts of the dashboard, instrument panel, and potentially the glove compartment. This is the most time-consuming and technically challenging part of the job. Consult a repair manual for precise instructions on disassembly.
4. Disconnect the heater core hoses: Carefully disconnect the inlet and outlet hoses, keeping a drain pan underneath to catch any remaining coolant. Take note of where each hose connects.
5. Remove the heater core: This often involves removing screws and clips holding it in place. Again, this step requires careful attention and potentially some maneuvering to get it out of the tight space.
6. Install the new heater core: Carefully install the new heater core in the reverse order of removal, ensuring it's properly seated and all connections are secure. Replace any seals or O-rings as needed.
7. Reconnect the heater hoses: Reconnect the hoses securely, ensuring a tight seal to prevent leaks.
8. Reassemble the dashboard and related components: Carefully reassemble all the components you removed in steps 2-3, working in reverse order.
9. Refill the cooling system: Carefully refill the cooling system with the correct type and amount of coolant.
10. Bleed the cooling system: This is essential to remove any air pockets that could cause overheating or poor heater performance. Consult your repair manual for the proper bleeding procedure.
11. Check for leaks: Inspect all connections for leaks, and use a pressure tester to ensure the cooling system is properly sealed.
Disclaimer: This is a simplified overview. Replacing a heater core is a complex job. You should consult a detailed repair manual specific to your 1992 Ford Aerostar before attempting this repair. Incorrectly performing this repair could lead to damage to your vehicle or personal injury. If you are not comfortable with this level of automotive repair, it's best to take your Aerostar to a qualified mechanic. A Haynes or Chilton repair manual for your specific year and model is highly recommended.
