Heater Core: Service and Repair

Heat exchanger

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





Draining coolant and removing the engine splash guard.

Remove:
- the cover for the expansion tank and raise the vehicle
- the engine splash guard.
Attach a hose on the nipple at the radiator and lower the hose to a container.
Open the nipple and drain off the coolant.





Lower the vehicle.
Detach the radiator hoses from the engine compartment.
Turn the radiator hose connection counter-clockwise to the end position and then pull off the radiator hose.

Removal


Remove:
- the center console. Refer to: Floor console Floor Console.
- the glove compartment. Refer to: Glove compartment Glove Compartment.
Detach the central electrical unit from its bracket but allow it to hang from the wiring. Refer to: Control module relay box passenger compartment Service and Repair.






Remove:
- the brackets on both sides of the climate control unit and the screws, 3 per bracket
- the air duct
- the 8 x screws for the cover.
Pull the cover at angle downwards/backwards.

Vehicles with split pipes. Refer to: Heat exchanger.






Note! The heat exchanger has pipes that are factory integrated. These pipes must be cut in order to remove the unit. The heat exchanger in the service kit has separate pipes, however.

Place some paper below the pipe couplings to collect any spilled coolant.
Cut or saw off the pipes.
Press the pipes towards the firewall so that they protrude into the engine compartment.

Hint: To facilitate, also route the pipes from the engine compartment.






Remove:
- the 2 x screws and the lead-in's right half, see image
- the section that holds the heat exchanger and evaporator pipes apart.
Pull the heat exchanger pipes through the seal.





Seal the pipes to the heat exchanger so that the remaining coolant cannot run out.
Angle the heat exchanger up at the rear edge. Lift out the heat exchanger towards the passenger side.

Note! Note how the seal is located on the heat exchanger.

Installation


Note! Install a new seal carefully using the removed evaporator as a template.

Install:
- the heat exchanger
- the heat exchanger pipes through the seal.

Hint: To facilitate assembling the pipes, lubricate the ends with a little oil.

Note! Use new O-rings for the pipe ends.

Install the pipes at the connection to the heat exchanger pipes.





Install the clips so that they lock securely. A click must be heard.

Note! The clips only fit one way in the pipe connection.






Install:
- the 8 x screws for the cover. Tighten
- the air duct
- the brackets on both sides of the climate control unit and the screws, 3 per bracket. Tighten.

Finishing


Install:
- the central electrical unit in its bracket. Refer to: Control module relay box passenger compartment Service and Repair
- the center console. Refer to: Floor console Floor Console.

Checking the function and leak tracing
Install the radiator hoses in the connections by the firewall.
Tighten the drain nipple on the radiator.
Fill with coolant and warm up the engine until the thermostat opens. Top up the coolant if necessary.
Check that the pipe coupling does not leak.

Install the glove compartment. Refer to: Glove compartment Glove Compartment.