E 150 V8-5.4L (2008)
Heater Core: Testing and Inspection
HEATER CORE
1. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good and did not require installation of a new heater
core. If a heater core leak is suspected, the heater core must be tested by following the plugged heater core component test before the heater core
pressure test. Carry out a system inspection by checking the heater system thoroughly as follows:
Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow
the heater core tube to the heater core and appear as a leak in the heater core.
2. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at
the heater water hose connection and damage the heater core.
Check the integrity of the heater water hose clamps.
Heater Core - Plugged
1. Check to see that the engine coolant is at the correct level.
2. Start the engine and turn on the heater.
3. When the engine coolant reaches operating temperature, feel the heater core inlet and outlet hose to see if they are hot.
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If the inlet hose is not hot:
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the thermostat is not working correctly.
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If the outlet hose is not hot:
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the heater core may have an air pocket.
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the heater core may be restricted or plugged.
Heater Core - Pressure Test
Use the Radiator/Heater Core Pressure Tester to carry out the pressure test.
1. NOTE: Due to space limitations, a bench test may be necessary for pressure testing.
Drain the coolant from the cooling system. Refer to Cooling System.
2. Disconnect the heater hoses from the heater core.
3. Install a short piece of heater hose, approximately 101 mm (4 in) long on each heater core tube.
4. Fill the heater core and heater hoses with water and install Plug BT-7422-B and adapter BT-7422-A from the radiator/heater core pressure tester in
the heater hose ends. Secure the heater hoses, plug and adapter with hose clamps.
5. Attach the pump and gauge assembly from the Radiator/Heater Core Pressure Tester to the adapter.
6. Close the bleed valve at the base of the gauge. Pump 138 kPa (20 psi) of air pressure into the heater core.
7. Observe the pressure gauge for a minimum of 3 minutes.
8. If the pressure drops, check the heater hose connections to the core tubes for leaks. If the heater hoses do not leak, remove the heater core from the
vehicle and carry out the bench test.
Heater Core - Bench Test
1. Remove the heater core from the vehicle.
2. Drain all of the coolant from the heater core.
3. Connect the 101 mm (4 in) test heater water hoses with plug and adapter to the core tubes. Then connect the radiator/heater core pressure tester to
the adapter.
4. Apply 138 kPa (20 psi) of air pressure to the heater core. Submerge the heater core in water.
5. If a leak is observed, install a new heater core.
