front heater matrix

[Safraneman]

how do I remove the front heater matrix?
the outlet pipe has sheared leaving only 5mm protruding through the bulkhead

[Safraneman]

followed the pictures on Facebook Bongo - but there are no instructions - I have loosened all six 10mm nuts - but how the pipes were pulled through the bulkhead - or the matrix slid out of the heater casing, is beyond me, perhaps at 70, I didnt use the force required. Hoses have been removed - any suggestions appreciated.

[Safraneman]

swapped the new matrix into the heater housing, but cannot wiggle the inlet/ outlet pipes back through the bulkhead - the heater seems to have dropped 20mm and we cannot push it back up, or guide the pipes through - any suggestions much appreciated

[g8dhe]

Only just seen this as my broadband has been playing up some pictures here that might help ? http://www.g8dhe.net/bongo_images/Paul_ ... placement/

[Safraneman]

Thanks, the second photo shows the outlet pipes lined up with the corresponding holes in the bulkhead

my fitted replacement heater matrix outlet pipes are about 20mm lower down and we cannot seem to find a way of lifting the heater matrix plastic casing to allow the pipes to pop through the holes. There is a 15 mm gap between the plastic casing and the bulkhead, because the pipes are jammed up against the bulkhead. No amount of forceful manipulation seems to work. Any clues as to what could be obstructing this procedure -

preferably without dismantling the dashboard, or romving the fan heater installation, under the bonnet - would be apprecaited. Cheers

[Doone]

Weve never had this problem. But have heard others say theyve had to put a lever bar underneath, to lever the plastic case, to give enough room to push the pipes through.

[Safraneman]

smashed the old matrix with a heavy plastic mallet - in the interests of science...
then used the lesser, appropriate, force to "tap" the (£40 2nd hd replacement) matrix inlet outlet pipes over towards
and then through the bulkhead holes.
Further tapping to shift the whole heater casing over the three protruding ten mm studs
- next time would cut (dremel) slots in the casing - to allow this act of persuasion to proceed without violence.
Had to stop, as arms too weary to refit hoses - hoses must be refitted from underneath and outside the buklhead next.
As there is not enough room to slide them on.
Once the upper rubber hose clamp is tight, the inner nuts can be tightened onto the three studs.
(changing the steering rack was a lot easier) The Facebook Bongo pictorial guide was useful - but from the comments - easier than my '95 TD