On the heater core removal, just a couple of weeks ago, I noticed a
difference between heater cores that may be the cause of Paul's (and my)
problem. The core on my SV was very difficult to pull out. It was too
wide for the hole. I finally got it out after a bit of pulling and
scraping on the sides of the hole. I had it cleaned out and put it back in
with the same difficulty. Then just the other week, I had the opportunity
to look at another heater core. It was the same exact build as mine,
except the sides of the tank did not bow out like mine did. Without that
bowing of the sides, I am sure that heater core would drop right in. My
guess is that after 30 years of holding hot water (because certainly the
heater valve failed years ago), the metal sides fatigued and spread out.
I don't know what to suggest on removal now. You could try to somehow push
the side in a bit so that you can get it out. Then bring it to a radiator
shop that can remove the sides, flatten them and then put them on again. I
would be worried that the same thing would happen again quickly. Maybe if
there is a way to reattach the sides in further that would work. I believe
the sides are like two halves of a box - like a shoe box - where the
outside part pushes on. Maybe the inside part can be shaved down so the
outside part will rest further in.
Or, you can be like me - totally disconnect the heater since I never use
it.
Good luck.
Jay
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