| How to replace the heater core. This project was performed on a β91 NA, 2+2 with automatic climate control. This project is not hard but it is very tedious and time consuming. I would say it takes 10-15 hrs to complete the first time. This project entails disconnecting several electrical connectors, and several screws and bolts. A good system for keeping track of each part is advisable, or towards the end it will get very messy and you will not be able to put your car back together . There are some people that say the heater core (h.c.) can be replaced without removing the h.c. box. It is definetely worth a try. [ http://www.neuralmotion.com/forum/tech/heater/heatercore.htm ] In my experience there was no way of getting to the right screws w/o tearing it all down. 1.-Remove the cluster gauge and pods completely. 2.-Remove the center console to include stereo. 3.-Reomove the dashboard completely. The trick is to completely remove the frame around the glove box.
[ http://www.twinturbo.net/ttnetfaq/FAQpages/dashboard.html ] Once you remove the frame around the globe box the dashboard comes off easily. 
3a.-Remove all the air ducts running across the bottom of the windshield and the bottom ducts on the passenger side and driver side. 
3b.-There is no need to remove any of the T-connectors (top and front) at the h.c. box since the whole unit comes off. 
3c.-There is a bar that goes across the front of the cabin that needs to be removed completely. 
3c.-There is also a brown control box on the side of the h.c. box. All you have to do is remove the two Phillip screws at the bottom of the box and move it to the side. No need to disconnect any connectors except for the white connector in the front.
4.-Once all of the above has been removed you can get a clean look at the h.c. box, a/c box and the blower fan (on the passenger side). 5.-The three boxes above are interlocked with the a/c in the center holding the other two in place. The trick is to remove the a/c box first and then the other two will come out easily.
5a.-Remove the bottom bar that holds the boxes in place just above the ecu.
5b.-There are a number of clips that hold the a/c box together. In my experience I found that this small tool did a great job.
5c.-On back of the a/c box there are 4 clips that need to be removed.
Unfortunately there is no room between the a/c box and the firewall for a person to be able to look up there.
The best you can do is to feel you way around the back of the box and take off the clips. Although I removed all the clips from the back of the a/c box I could not get it to budge and I was not able to take it apart. 6.-Since the lower leg of the h.c. box is behind the a/c box I had to cut the lower leg of the h.c. box (hack saw).
As soon as I cut the leg off the whole unit just came right out.
Be careful because there is still some antifreeze inside the h.c. and it will spill inside the cabin. 
7.-Go to the engine compartment and look for the two h.c. hoses between the engine and the firewall. I went ahead and cut these hoses instead of trying to remove them. Itβs much easier to buy new rubber hoses for about $8.00 each.
8.-Once the h.c. box is out, drain the antifreeze and take the box to your bench. On the LHS of the box you will remove a plastic cover, a metal bracket and a cable/spring in order to be able to slide the h.c. right out of the box.
9.-Replace h.c. with the new one and start putting you car back together.
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How to replace your heater core - 
