Heater Core

And the answer is ...... when a Taurus is being assembled, they start by hanging the heater core on a piece of a wire, and then assembling the car around it :) It is a horrible job but it is doable with the right space, time, tools and patience.

And they used the same technique for my Contour's waterpump.

Couldn't have they used the *accessory* belt instead of the timing belt?

It's not really the nightmare that many folks claim, it's just time consuming. You have to remove the instrument panel. You will need the Ford Shop Manual for the step by step. The basic rundown is: 1. Drain the coolant and evacuate the AC 2. Disconnect the main electrical bulkhead connector at the firewall. 3. Remove the kick panels and windshield pillar trim 4. Remove or lower the steering column (I prefer to remove it completely). 5. Disconnect electrical connectors at each end of the inst. panel under the kick panels. There are uauslly some for things like the blower motor, radio antenna, brake lamp switch, e-brake switch. 6. Remove bolts at both bottom corners of the inst panel, and usually one somewhere in the center. 7, Remove 5-6 screws along the top of the panel near the defrost ducts. 8. With a helper, remove the IP from the vehicle.

1. Disconnect heater hoses and AC lines at the firewall. 10. Remove 5-6 bolts holding the HVAC case to the firewall and remove it from the vehicle. 11. Split the HVAC case halves, clean the inside well and install the replacement core. 12. Reverse to reassemble.

Note: I find it is often helpful to remove the front seats (at least the passenger side)for clearance and working room. Usually 4 bolts per seat and they are out of your way.

Start early on a Saturday,have a buddy or 2 available to help and for moral support, order pizza and beer about lunchtime. You should be done about dark. It's certainly not a job for someone with no mechanical experience, but very doable for a tinkerer or competent DIYer.