Heater Core: Service and Repair
Heat exchanger, replacing
Special tools:
115 8957 HOSE PLIERS 115 8957 Hose Pliers
951 1506 Test dummy 951 1506 Test Dummy
Note! The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.
Preparatory work
Caution! Cars with DSTC systems. When working on the steering or wheel alignment, the adaptation of the steering wheel angle must be set to zero using the diagnostic tool. Test drive according to: Test Drive Form (DSTC (dynamic stability and traction control) /brake control module), description Test Drive Form (DSTC (Dynamic Stability And Traction Control) /Brake Control Module), Description.
Removing the steering wheel
Remove the driver's airbag module according to: Airbag driver and passenger (SRS), replacing Airbag Driver and Passenger (SRS), Replacing.
Remove the lock screw from its "parking hole" in the steering wheel and install it in the contact reel.
Remove the steering wheel screw.
Make sure that the front wheels and steering wheel are pointing straight ahead
Remove the steering wheel.
Note! Take care to ensure that the connector does not catch on the steering wheel during removal.
Removing steering column covers
Remove the steering column covers. See: Combined instrument panel surround Combined Instrument Panel Surround.
Removing soundproofing panels
Remove the soundproofing panel. See: Soundproofing panel, replacing Soundproofing Panel, Replacing.
Removing the steering wheel lock module
Disconnect the connectors.
Press in the snap fastener and remove the steering wheel lock unit.
Removing cable for key interlock
Note! Applies to cars with automatic transmission.
Remove the ignition switch interlock cable.
Move the ignition key to position I.
Press up the lock facing and pull out the cable.
Removing the lever console
See Gear selector assembly and steering wheel module Gear Selector Assembly and Steering Wheel Module.
Remove the floor lighting.
Loosen the cable casing from the steering column and lay it on the floor.
Removing universal joint from lower steering shaft
Remove the screw for the lower steering shaft's attachment in the universal joint.
Remove the universal joint from the steering shaft.
Removing steering column and steering shaft
Remove the four screws that hold the steering column.
Pull the steering column backwards from the three guides.
Pull out the steering column slightly and turn it half a turn to the left, to upside-down position.
Pull out the steering column at an angle backward to the left.
Removal
Removing heat exchanger
Remove:
- the heater hoses in the engine compartment, use special pliers: 115 8957 HOSE PLIERS 115 8957 Hose Pliers
- the seal and the plate.
- the brake light switch according to: Stop lamp switch, replacing Service and Repair
Remove:
- the tie strap for the pipes
- the screws for the heat exchanger
- the mounting brackets for the pipes.
Position plenty of paper under the heat exchanger and around the pipes
Drain the coolant in a suitable container.
Loosen the pipes and position them out of the way.
Pull out the heat exchanger.
Installation
Installing heat exchanger
Note! Always use new O rings.
Install the heat exchanger carefully.
Screw the heat exchanger into place.
Install the upper pipes.
Install the lock bracket using round-nosed pliers.
Press in the pipes using a screwdriver and the lock catch using pliers.
Install the lower pipes.
Install the lock bracket using round-nosed pliers.
Press in the pipe using a screwdriver and the lock bracket using round-nosed pliers
Install the strip clamp for the pipes.
Install the seal and the plate.
Install the heater hoses in the engine compartment.
Installing the Steering column / Steering shaft
Insert the steering column in upside-down position.
Turn it to the right to correct position.
Note! Check that the rear seat rails are undamaged.
Hook the steering column into the three guides.
Install the screws and tighten with 25 Nm.
Tighten the rear screw first.
Installing steering shaft's universal joint on lower steering shaft
Install the steering shaft on lower steering shaft.
Set the front wheels straight ahead.
Install the upper steering shaft's universal joint on the lower steering shaft.
Install a new screw and tighten with 30 Nm.
Install the cable casing on the steering column.
Installing the floor lighting
Install the floor lighting and plug in the connector.
Installing cable for key interlock
Note! Applies to cars with automatic transmission.
Set the gear selector lever to P position.
Move the ignition key to position I.
Press the cable into the ignition switch and feel to see that it sits correctly.
Remove the ignition key and check that the gear selector lever is blocked in P position.
Installing the steering wheel lock module
Remove the ignition key.
Install the connector and the module for steering wheel lock.
Plug in the connectors.
Installing lever module
See Gear selector assembly and steering wheel module Gear Selector Assembly and Steering Wheel Module.
Connect the lever module's connectors.
Installing steering column covers
Install the steering wheel casings according to: Combined instrument panel surround Combined Instrument Panel Surround.
Resetting contact roller
Reset the contact roller according to: Contact reel driver airbag module, resetting Adjustments.
Installing steering wheel and checking steering wheel position
Note! Check that the front wheels are pointing straight ahead.
Pull the connectors from the contact roller through the steering wheel.
Install the steering wheel carefully so that the contact roller's two catches fit in the steering wheel hub's both slots.
Install the steering wheel screw. Use a new screw. Tighten with fingers.
Caution! Do not turn the steering wheel when it is on the steering shaft. Since the contact reel is locked, it will be damaged beyond repair if the wheel is turned in this situation.
Loosen the lock screw that holds the contact roller.
Install it in the parking hole on the steering wheel.
Connect tools (2 pcs.): 951 1506 Test dummy 951 1506 Test Dummy to the contact roller's SRS-wiring.
Drive the car straight ahead and check that the steering wheel stands in position "straight ahead".
If the steering wheel position is incorrect, repeat the adjustment.
Tighten the screw in the center of the steering wheel.
Remove the tools (2 pcs.): 951 1506 Test dummy 951 1506 Test Dummy.
Tighten the steering wheel screw with 40 Nm.
Check that the SRS-light goes out, that is, that no diagnostic trouble codes remain.
Installing driver's airbag module
Install the driver's airbag module according to: Airbag driver and passenger (SRS), replacing Airbag Driver and Passenger (SRS), Replacing.
Finishing
Checking function on steering column
Ensure that the steering wheel turns easily and that the steering lock functions.
Check that no diagnostic trouble codes have been stored during the repairs.
Start the engine and the heating system.
Fill coolant in the cooling system.
Check that the pipe connections do not leak.
Install the soundproofing panel. See: Soundproofing panel, replacing Soundproofing Panel, Replacing.