I followed Sven's guide and got the $%^& heater matrix bolts (2 days of rust remover and dremel cutter..) and clip off, but I can't seem to get the heater tubes loose from the matrix. Someone mentioned an 'inaccessible' screw on the firewall. Is there another screw which needs to be removed in order to free the tubes from the matrix?? Or, are mine just frozen into the matrix? I did NOT do a full dash removal, but rather went the glove-box route.

Speedy reply appreciated--getting cold now! Thanks!

Jeff

If you have the room, keep twisting the hoses the one way, they will give after a while. Years of coolant will practically glue them to the matrix. In my situation the engine was out...

There are 3 screws that hold pipes to matrix. Remove all 3 and remove holding plate, too.
When changing matrix put on NEW original o-rings and grease them a little.

Thanks, Fiat37. I did get the 3 bolts and the '3'-shaped clip off, but I can't extract the now free tubes from the matrix. That's why I was wondering whether I have to loosen the bracket that is smack dab in the middle of the heater assembly at the bulkhead/firewall. Any ideas on this part? Or did yours just come loose after freeing the bolts and clip?

Screw near firewall does not have impact on pipes. When you will pull them away from matrix they will rotate. You just need to hold pipe away from matrix (down) and matrix a little in opposide side (up). It is tight but that is the only way to change heater.
And one more thing. When you will put new heater matrix in, dismount ventilator case first, not to hurt new matrix.

Well, I finally got the tubes off of the old matrix, but I only did so by breaking off the plastic flange and first inch or so of the plastic tubes on the unit in order to free the rusted-in aluminum tubes. I assume the tubes are re-usable if I clean the ends with emory cloth, yes?

Yes, it's quite tight getting the old one out, and, I had to cut away a little bit of the black plastic holder right above it which holds two connectors (one black one white, both of which I moved out of the way first.)

It appears however that I will indeed need more clearance in order to install the new one. Is the ventilator removal straightforward? Is there a pictorial or step-by-step guide you can refer me to? THANKS again for all of your help.

(This may need a different thread, but, in an effort to access the area under the heater assembly, I attempted to remove my center console. In the end it wouldn't clear the handbrake lever, but, I did remove the gear shifter knob, and, I moved it with the knob off! Now, after re-assembly, the gear shifter goes into: P, N, R, D, and 3, but not down to 2 or 1. Also, it sounds rather 'springy' while I move the lever. Q: Serious problem?? (Hope not...) Or only requires a minor fix?)

Yes, tubes are reusable. But you need to change both O-rings, change them with original ones, otherwise you may have problems witl leaking. Grease O-rings before mounting.
Vent. case is easy to remove, just unscrew three or two (I forgot) bolts and rotate case. There you will get enough room to mount matrix wihout hurting it.


About gear stick, I think something has stucked there. You will have to be gentle and carefull to dismount console and see what is the problem