Procedures

Removing and installing oil-water heat exchanger - Engine installed

Removing oil-water heat exchanger

1. Put body-protection covers on.
2. Disconnect battery.
3. Remove cap on coolant expansion tank.





4. Undo drain plug on the coolant guide housing and drain the coolant.
5. Equip drain plug with a new sealing ring and fit in the coolant guide housing. Tightening torque: 10 + 5 Nm (7.5 + 3.5 ft. lbs.).








6. Remove the air cleaner assembly.





7. In vehicles with air conditioning, the additional assembly operations must be performed:
Suck Pentosin fluid out of the reservoir until the level is just below the joint.
7.1 Turn bayonet lock in the direction indicated by the arrow and pull off the reservoir. Immediately seal the lower reservoir with a suitable plug (30 mm [diameter]).




Bayonet lock open





7.2 Disconnect battery positive at B+ disconnection point. Undo the hexagon nuts and set the box aside.








7.3 Remove drive belt. Mark belt travel direction with a colored pen. Slacken belt, turning the tensioning pulley (wrench size 24 mm) clockwise, hold still and simultaneously take the belt off the drive pulleys.





7.4 Undo front compressor fastening screws (2 ea.). Undo rear fastening screw between the intake pipes of cylinders 4 and 5. Disconnect the electrical plug connection.
7.5 Lift the compressor out, set it down with the hoses connected and secure it against being dropped.
8. Undo the support between the throttle body and crankcase.
9. Loosen outer hose clamps at intake distributor.
10. Undo hexagon-head bolts (6 ea.) on intake distributor and take off intake distributor.
11. Remove oil-water heat exchanger. Undo hexagon socket head bolts. Lift oil-water heat exchanger and simultaneously place a cloth or drip tray underneath it. Remove heat exchanger.


Installing oil-water heat exchanger

1. Insert new sealing rings and install oil-water heat exchanger. Tightening torque of the hexagon socket head bolts 10 Nm (7.5 ft. lbs.).
2. Fit intake distributor with new gaskets. Tightening torque: 10 Nm (7.5 ft. lbs.)
3. Fasten support between the throttle body and crankcase.








4. Install air-conditioning compressor. Before installation, check whether the spacer sleeve is fitted or present at the rear fastening point. Grease sleeve before fitting if necessary.
5. Fit B+ box.
6. Remove plugs and install reservoir for power steering system.





6.1 Turn adjusting ring counterclockwise to its original position.





6.2 Push reservoir downward and turn adjusting ring clockwise until the marks line up.
6.3 Fill in Pentosin. Observe the specification for bleeding.





7. Check grooves of drive belt for foreign bodies. Fit drive belt. Observe sequence when fitting the belt and direction of motion if the belt was run.
8. Fit air cleaner assembly.
9. Fill in coolant and bleed the system.
10. Perform tightness test.