Remove/install heat exchanger

AR83.20-P-1100FF

Remove/install heat exchanger

13.7.04



Remove

 Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray.
Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage bottles.

Wear protective gloves, protective clothing and eye protection.

AS20.00-Z-0001-01A



Notes on coolant

AH20.00-N-2080-01A

1

Turn cooling system sealing cap on the radiator half a turn counterclockwise, release excess pressure, then remove cooling system sealing cap

2

Remove paneling on center piece in front of the windshield

AR88.00-P-2792FF

3

Use suitable pliers to clamp off coolant hoses (1)

4

Remove nuts (2) from the accelerator pedal sensor (B37)

5

Remove accelerator pedal sensor (B37) and place aside with plug (3) still connected

6

Remove bolt (5) and remove bracket (6)

7

Remover glove compartment (7)

AR68.10-P-1400FF

8

Fold back floor covering (8) and remove panel (9)

9

Remove bolt (10) and place cover (11) aside

10

Remove clamps (12, 13)

11

Pull coolant pipe (14) out of the heating system heat exchanger (16) and coolant pipe (15) out of the coolant pipe (18) and press toward the rear

 Carefully press coolant pipes (14, 15) to the rear to avoid damaging the coolant pipes (14, 15).

 Collect the escaping coolant in a suitable container.

12

Remove sealing rings on the coolant pipes (14, 15)

13

Pull heating system heat exchanger (16) out of the heater/A/C housing

14.1

Remove coolant pipe (18) with sealing ring and clamp (17) from the heating system heat exchanger (16)

When installing a new heating system heat exchanger (16).



Install

15.1

Insert coolant pipe (18) with new sealing ring into the heating system heat exchanger (16) and secure using clamp (17)

When installing a new heating system heat exchanger (16).

 Install a new clamp (17) for the coolant pipe (18).

16

Insert heating system heat exchanger (16) into the heater/A/C housing

 Carefully press coolant pipes (14, 15) to the rear to avoid damaging the coolant pipes (14, 15).

17

Insert coolant pipe (14) with new sealing ring into the heating system heat exchanger (16) and secure using clamp (12)

 Install a new clamp (12) for the coolant pipe (14).

18

Insert coolant pipe (15) with new sealing ring into the coolant pipe (18) and secure using clamp (13)

 Install a new clamp (13) for the coolant pipe (15).

19

Position cover (11) and screw in bolt (10)

20

Position bracket (6) and screw in bolt (5)

 Ensure bracket (6) is seated correctly.

21

Position accelerator pedal sensor (B37) and screw on nuts (2)

 Replace self-locking nuts (2).



*BA29.10-P-1004-02E

22

Remove pliers from the coolant hoses (1)

23

Install covering on center section in front of windshield

AR88.00-P-2792FF

24

Top up coolant and check cooling system for leaks in the vicinity of the coolant pipes (14, 15, 18)

 See:

Drain/fill with coolant

Engines 122.9, 134.9, 135.9

AR20.00-P-1142FF

Engine 639.9

AR20.00-P-1142FG

25

Install panel (9) and position floor covering (8) in the vehicle

26

Install glove compartment (7)

AR68.10-P-1400FF

Number

Designation

Model
454.0

BA29.10-P-1004-02E

Nut, accelerator pedal to splash wall

Nm

7