Heater Core: Service and Repair
AR83.25-P-1100P Remove/Install Heat Exchanger
Shown on Model 203.0:
Shown on Model 203.0:
CAUTION: Installation: Replace self-locking nuts and bolts.
DANGER:
- Risk of injury to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant.
- Do not open cooling system unless coolant temperature is below 90 degrees C. Open cap slowly and release the pressure. Do not pour coolant into beverage bottles.
- Wear protective gloves, protective clothing and eye protection.
1 Completely move adjustable steering column out and downward
2 Open engine hood
3 Reduce pressure in cooling system
4.1 Detach lower engine compartment lining
NOTE: Front paneling.
4.2 Remove bottom section of sound-proofing capsule
NOTE: Front lower section.
5 Drain coolant at radiator
DANGER:
- Risk of explosion from gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury with caustic burns to eyes and skin from battery electrolyte or from handling damaged lead-acid batteries.
- No fire, sparks, naked flames or smoking.
- Wear acid-resistant gloves, clothing and eye protection. Pour battery electrolyte only into suitable and appropriately marked containers.
6 Disconnect ground cable of battery
DANGER:
- Risk of injury when carrying out test or repair work on airbag or emergency tensioning retractor units.
- Store airbag unit with expulsion area on top, do not subject to temperatures above 100 degrees C. Interrupt power supply when working on such units.
7 Remove steering wheel (7).
8 Remove cover below instrument panel (8)
NOTE: Driver's side
9 Remove instrument panel bottom section (6)
NOTE: Driver's side
10 Remove instrument cluster (A1)
11 Remove accelerator pedal
12 Fold back floor covering at front left
NOTE: Air duct to left rear compartment (9) must be accessible
13 Remove air duct to left rear compartment (9)
14 Remove jacket tube from instrument panel carrier and fold down into footwell
NOTE: Do not remove bottom steering shaft from steering coupling.
15 Remove tensioning springs (9a)
NOTE: Three tensioning springs.
16 Remove fittings (9)
17 Pull out insert forks (10)
CAUTION: Installation: Replace insert forks.
18 Pull heating water pipes (11) out of heat exchanger (12)
CAUTION:
- Coolant. Avoid contaminating passenger compartment. Plug heating water pipes (11) and openings on heat exchanger (12).
- Installation: Replace sealing rings.
- See "Special Tools - Set of Plugs" given below.
19 Unscrew bolts (13)
- See "Special Tools - Torx bit set" given below.
20 Remove bracket (14)
21 Pull out heat exchanger
CAUTION: Clean AC/heater housing from inside, if necessary remove coolant running out.
22 Install in the reverse order
23 Operational check.
Special Tools
Special Tools:
