After getting the heater pipe out of the manifold using a propane torch, it is time to reinstall it. It won't go in all the way - I can't get the last 3mm to go so that the flange is flush with the manifold surface. There is a gap where the rear mounting bolt flange sits against the plenum mount by the same amount, so I'm sure it needs to sit flush. A hammer and a drift did not work. I read about how difficult removal is, hence the propane torch method. I can't use heat or it will ruin the o-ring. Advice appreciated.

 

Are you talking about the heater core?



@Best4x4 has a trick I believe..

 

My trick was for the lines on the core side. The intake side has the O-Ring & 10mm bolt that hold it into place. Are the bolts further back that hold the two metal heater pipes together loose? One is held onto the intake, and one bolts the two together as one unit. It sounds like it’s bound up or not sitting flush. Was it badly corroded?

 

No, it seems to be the metal elbow with trangle flange and three bolts to secure. It has an o-ring where it mates to the center front of the engine.

 

This one? The PO used about 3/4 tube of Ultra Black on mine. Took a wire wheel and cleaned the pipe and manifold really well, bit of Vaseline on the o-ring and mine went in without much trouble. Wasn’t perfectly flush, but closer than 3mm I think. My rear bolt still did not mate well so i had to gently bend the pipe just a bit.

 

My husband came home and pointed out that there is a raised area where the bolt goes, the same thickness as the gap. I panicked, it is supposed to be that way. I found the stud and spacer for the bracket that bolts to the intake plenum. All is good, except I really should replace the o-ring instead of just putting silicone grease on it...

 

You only need the o ring. Rtv just makes a mess. When installing stuff like that, I use assembly grease or some motor oil on install. You can damage o rings and parts forcing them in dry.

The hose is held up on a small machined base on the intake. So the ring around the metal hose will be elevated a bit. It won't sit flush. It isn't ment to. The elevation will get the pipe in the right position to be secured to the intake.

 

When I removed mine it was covered in rtv. I put new o ring in and tightened it down...needless to say the o ring pinched and I did not know till I had put everything back together and refilled the coolant. Well...after a lot of rtv, I sealed it.