Heater Core: Service and Repair

Removing And Installing Heat Exchanger

Preliminary work
1. Drain engine coolant.
2. Unclip cover for instrument panel into place on left and right.
3. Remove front footwell vent on left and right.
4. Remove Kessy control unit.
5. Remove vehicle electrical system control unit.
6. Remove relay carrier.

Removing heat exchanger







1. Unclip wiring harness on the left heat exchanger cover.







2. Unscrew both fastening screws on the left heat exchanger cover and unclip the cover.
3. Pull the retaining clips -Arrows A- of the coolant supply line and return line downward.







NOTE: Line the drivers footwell with very absorbent material.

4. Pull the interior carpet away from the coolant lines and put in a suitable collecting container.







5. Slowly pull out the lines from the heat exchanger -Arrows B- and drain the coolant into the collecting container.
6. Unscrew the fastening screw of the right heat exchanger cover and unclip the cover.







7. Unscrew the fastening screw of the heat exchanger holding tray on the left and right side.

NOTE:
- There is a retaining pin on the left side above the heat exchanger which joins the lower holding tray (where the heat exchanger is located) to the air conditioning unit.
- As soon as the retaining pin has been pulled out, the heat exchanger with the holding tray can be folded down.

8. Turn retaining pin out of the latch -Arrow 1- and pull out -Arrow 2-.







9. Fold down holding tray with heat exchanger.
10. Pull out heat exchanger carefully to the left.







Installing heat exchanger
1. Insert heat exchanger carefully into the holding tray. Make sure not to damage the heat exchanger plates on the retaining stays in the holding tray.







2. Lift up the holding tray, slide the retaining pin through the guide -Arrow 2- and lock the retaining pin into the holding tray -Arrow 1-.







NOTE: Always replace O-rings.

3. Insert the coolant supply line and return line -Arrows B- into the heat exchanger.







4. Push on the retaining clips -Arrows A- until the clips click into place.
4.1. Install relay carrier.
4.2. Install vehicle electrical system control unit.
4.3. Install Kessy control unit.
4.4. Top up engine coolant.
4.5. Install front footwell vent on right and left.

5. Check the heating system for leaks.
6. Screw down the fastening screw of the heat exchanger holding tray on the left and right side. Tightening torque: 1.0 ftlb.







7. Clip in right cover and screw down with the fastening screw. Tightening torque: 1.0 ftlb.
8. Clip left cover and secure with the fastening screws. Tightening torque: 1.0 ftlb.







9. Clip in wiring harness on the left heat exchanger cover.

Subsequent work
Clip cover for instrument panel into place on left and right.