Heating System - Air Separator Installation
Group: 83Number: 245
Date: August 1990
Work Instructions
SUBJECT:
INSTALLATION OF AIR SEPARATOR IN HEATING SYSTEM TO PREVENT GURGLING NOISES MODEL 124 WITH ENGINES 103 AND 104
Procedure
1. Open hood to vertical position.
2. Drain coolant and set aside for reuse.
3. Remove coolant expansion tank.
4. Transfer coolant level sending unit from old to new expansion tank.
5. Cut coolant supply hose (arrows, Figures 1, 2 and 3).
Also cut curved hose (a) at supply hose (except vehicles with engine 104).
6. Install air separator (3) with vent line in horizontal position. Drill 6.5 mm diameter hole, apply zinc dust to bare metal, and mount separator with screw (11) and nut (12) (Figure 4).
7. Install steel tubing (2, Figures 4 & 5). On vehicles with windshield washer tank heater, fasten air separator with existing screw on right side of fire wall. Place clip behind windshield washer heater line, fasten with double clip (8, Figure 4) or clips (6 and 7, Figure 5).
On vehicles without windshield washer tank heater, remove plug from right side of fire wall, and fasten separator with screw (11) and nut (12). Install clip at center of fire wall with screw (13) (in existing hole behind sound dampening material)
8. Install coolant expansion tank (1, Figure 7)
9. Install hose (4) between steel tubing (2) and coolant expansion tank (1) and fasten with hose clamps (10) (Figure 7).
10. Install hose (5) between steel tubing (2) and separator (3) and fasten with hose clamps (10) (Figures 4 and 8).
11. Connect separator (3) with existing heater hose and fasten with hose clamps (9). Install curved hose (a), previously cut at heater supply hose, between connecting pipe and windshield washer heater pipe and fasten with clamps (10) (Figure 4). (This does not apply to vehicles with engine 104).
12. Install double clips (6 and 7) between hoses (Figure 7).
13. Set temperature selector to "MAX" or depress "DEF".
14. Fill cooling system with coolant. Start and run engine at various speeds until thermostat opens.
15. Pressure test the coolant system.
Check coolant level and correct as necessary:
hot: 2-3 cm above the cold coolant level.
cold: 1 cm above the mark.
Note:
It is imperative that the system is bled properly. The procedure (step 13 and 14) may have to be repeated to assure that.
Parts Information
Note:
Individual parts numbers are for reference only. Please order by parts kit number.
In Case of warranty