Heater repairs Mk2 GL

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Goz
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Heater repairs Mk2 GL

Post by Goz » Tue Feb 11, 2020 12:51 pm

This was a job id been putting off all summer but as it turned out, it was easy enough...

My Capri developed a burning smell. Smelt a bit like clutch burning but it turned out to be only when the heater was on. I managed to pull the wires off the heater resistor so i could ignore it for the rest of the summer

There's a lot of information on the interweb but i thought it might help if i put what i did on here

Firstly you don't need to strip the whole dash out, see photo. Only the lower dash pieces need removing, glove box, ashtray panel, flimsy pedal cover and center console. the hardest part was getting the bracket, holding the red relay, off (single 10mm hex bolt hidden under wiring loom)
car interior.jpg
To remove the heater, drain radiator, remove hoses from bulkhead pipes, flush through heater with clean water to prevent carpet staining. Remove oval bulkhead plate and seal. inside car, disconnect heater cables from side of box, in drivers footwell. They just lever out when outercable is unbolted. remove wires from resistor. then undo the four 10mm nuts fixing heater to the car. with a bit of a wiggle the whole assembly can be lowered and slid out into the passenger footwell
heater box.jpg
Once out of the car the heater can be split into 2 half's, there's 2 metal clips by the motor, then the rest just levers apart carefully
you can then see the state of the motor, the resistor and the mouldy foam on the flaps. My motor was all melted, the resistor was rusty but complete. I decided to change it anyway

You can buy properly made resistors off the Capri sites, but all you need is a 2.2ohm 10w resistor like this one, eBay item number:262310244799, £2.39 posted. i mounted it on a bit of ally plate and put the wires out through rubber grommets. not exactly concourse or original but if it works i don't care
new resitor.jpg
fitted in box, it just clears fan so should get plenty of cooling
resitor stripped box.jpg
as i said, the old motor was all melted. a bit of research found that a mercedes sprinter one fitted (bosch part number 0130 007 027) which i found on ebay for £21.50 (eBay item number:172804792531). When it finally arrived (royal mail 48, cough 6 days! delivery) it was exactly the same as the old one! the plastic holder fitted perfect and even the wiring terminals were the same.
i carefully prised the fan off the old motor. sawing the motor apart to gain better access
old motor.jpg
i then put some new bits of foam around the heater matrix and cleaned the flaps. then put it all back together. tested the fan with a battery on both speeds for a while
the refitting is a reverse of removal, as they say in the manuals...

i managed to fix my heater for less than £30, with about 5hrs labour.
i hope this is useful information and helps somebody out

EDIT....
my MK2 has a BEHR plastic heater fitted to it, which i believe is the same as MK3s but different to the earlier metal heaters
behr.jpg
Last edited by Goz on Tue Feb 11, 2020 1:17 pm, edited 1 time in total.

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pbar
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Re: Heater repairs Mk2 GL

Post by pbar » Tue Feb 11, 2020 1:04 pm

That's a superb write up of a job which a lot of people fear. Good one. Wonder if the MK2 and MK3 heater boxes/components are the same, it looks like it from your pics. Good cheap fix with the resistor too.

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Re: Heater repairs Mk2 GL

Post by stevemarl » Tue Feb 11, 2020 1:05 pm

Fantastic write-up - sure to be of help to people in the future! Thanks for taking the time.
(you beat me to it Paul !!!)

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Re: Heater repairs Mk2 GL

Post by Bug » Tue Feb 11, 2020 1:22 pm

pbar wrote:
Tue Feb 11, 2020 1:04 pm
That's a superb write up of a job which a lot of people fear. Good one. Wonder if the MK2 and MK3 heater boxes/components are the same, it looks like it from your pics. Good cheap fix with the resistor too.
They are the same, yes, unless you get a very early Mk2 which may still have the original Smiths heater. They were basically the same, but metal cased.

I used to save up old heater assemblies, then people could provide whatever new components they needed, I'd build up a new assembly, then do a straight swap over at their convenience.

My record was 45 minutes from start to finish, using the same method shown above.

Only difference was, I used to remove the dash panel and then take the whole heater control assembly out with the box. (Again, i had spares available). That way I could set up the control cables and be sure they had full range of movement before I put it all back in.

One final point........... I'm sure the four retaining screws were actually 11mm?
May sound trivial, but not when you're upsidedown in the footwell wondering why the socket won't fit :D

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Re: Heater repairs Mk2 GL

Post by pbar » Tue Feb 11, 2020 1:52 pm

Thanks very much Martin, all read, understood, and noted :)

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Goz
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Re: Heater repairs Mk2 GL

Post by Goz » Tue Feb 11, 2020 6:03 pm

Bug wrote:
Tue Feb 11, 2020 1:22 pm
pbar wrote:
Tue Feb 11, 2020 1:04 pm

One final point........... I'm sure the four retaining screws were actually 11mm?
May sound trivial, but not when you're upsidedown in the footwell wondering why the socket won't fit :D
apologies, ive just checked and you are right. they are 11mm nuts.

tried to edit my post but it wont let me....

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Re: Heater repairs Mk2 GL

Post by Jasonmarie » Tue Feb 11, 2020 6:13 pm

:applaud: Well done that man as everybody says not a easy job and you need a good back to get under that dash :beer:
Ford Capri 2.0 Laser 1987 Mercury Grey ....... :beer:

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Re: Heater repairs Mk2 GL

Post by Bug » Tue Feb 11, 2020 6:49 pm

Goz wrote:
Tue Feb 11, 2020 6:03 pm
Bug wrote:
Tue Feb 11, 2020 1:22 pm
pbar wrote:
Tue Feb 11, 2020 1:04 pm

One final point........... I'm sure the four retaining screws were actually 11mm?
May sound trivial, but not when you're upsidedown in the footwell wondering why the socket won't fit :D
apologies, ive just checked and you are right. they are 11mm nuts.

tried to edit my post but it wont let me....
No prob. I appreciate that you took the time to document it all.

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Re: Heater repairs Mk2 GL

Post by Not_Anumber » Tue Feb 11, 2020 9:16 pm

Thats a very good write up

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pbar
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Re: Heater repairs Mk2 GL

Post by pbar » Wed Feb 12, 2020 7:14 am

Goz wrote:
Tue Feb 11, 2020 6:03 pm

tried to edit my post but it wont let me....
I think you only have a time limit of one hour to do that. Don't worry though. Superb write up and info, it will help a lot of people out, one of the best threads around here at the moment.

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Re: Heater repairs Mk2 GL

Post by STEVEW » Thu Feb 13, 2020 7:25 am

Hi Goz

Tips, tricks and alternative parts - a super post.
Many thanks.
:applaud:

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stevemarl
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Re: Heater repairs Mk2 GL

Post by stevemarl » Thu Feb 13, 2020 11:50 am

STEVEW wrote:
Thu Feb 13, 2020 7:25 am
alternative parts
Especially that. £72 ?

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Re: Heater repairs Mk2 GL

Post by STEVEW » Thu Feb 13, 2020 7:47 pm

Spot on Stevemarl

:agree:

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Re: Heater repairs Mk2 GL

Post by atomic4 » Sun Feb 16, 2020 6:03 am

Been there, done that a couple of times over the years of my ownership of capris. Have to admit, a job well done when it all works tho. :applaud: :woot:

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Re: Heater repairs Mk2 GL

Post by Andrew 2.8i » Sun Feb 16, 2020 8:20 am

As said by the others, that's a great write-up that is sure to prove to lots of people in the future.
I'm particularly interested in the use of an alternative Bosch heater motor, especially as there is a significant cost saving over the Capri item. It's reassuring to know that the motors are identical and won't need any modifications to fit.

Andrew.
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