Heater Core: Service and Repair

AR83.25-P-1100Q Remove/Install Heat Exchanger












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 Drain coolant
2 Completely move adjustable steering column out and downward

DANGER:
- Risk of explosion from explosive 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 goggles. Pour battery electrolyte only into suitable and appropriately marked containers.

3 Disconnect ground cable of battery
4 Remove entire steering column module (N80) with combination switches and clock spring contact (A45)
5 Remove bottom section of dashboard on driver's side
6 Remove left front floor covering
7 Remove air duct (1)
8 Remove jacket tube from instrument panel carrier and fold down into footwell

NOTE: Do not remove bottom steering shaft from steering coupling.

Refer to Remove/install jacket tube.

9 Detach tensioning springs (2)
10 Remove connection (3)
11 Pull out socket yokes (4) for heating water pipes (5)

NOTE: Installation: Install new socket yokes.

12 Pull out heating water pipes (5)

CAUTION: To avoid contamination of the interior caused by coolant, close heating water pipes (5) and heat exchanger openings (8).

NOTE: Installation: Install new sealing rings.

- See "Special Tools" given below.

13 Unscrew bolts (6)
14 Remove bracket (7)
15 Pull out heat exchanger (8)

CAUTION: Clean AC/heater housing from inside, if necessary remove escaping coolant.

16 Install in the reverse order
17 Check for proper function.

Special Tools

Set of Plugs, P/N# 129 589 00 91 00: