Replacement of heat exchanger
|
|
Replacement of heat exchanger
|
|
1.
|
Drape protective covers over the wings and drain off the coolant.
|
|
2.
|
Remove the rubber duct for the mass air flow sensor.
|
|
3.
|
Remove the engine covers.
|
|
4.
|
Remove the intake manifold and lift it up. Plug the holes with paper. Then disconnect:
|
|
|
•
|
the hose from the fuel pressure regulator
|
|
|
•
|
the secondary air injection vacuum hose (where fitted).
|
|
|
•
|
the IAC valve connector
|
|
|
•
|
the TCS throttle body connector
|
|
|
•
|
the coolant hoses to the throttle body
|
|
|
•
|
the hose from the EVAP canister purge valve Lift away the intake manifold.
|
|
5.
|
Disconnect the fuel lines and plug the connectors.
|
|
6.
|
Remove the bolts securing the centre intake manifold complete with fuel rail and place it to one side.
|
|
7.
|
Remove the gasket to obtain access to all the retaining bolts for the lower section of the intake manifold. Remove the lower section and plug with paper.
|
|
8.
|
Unplug the electrical connectors, the coolant hose and remove the coolant bridge.
|
|
9.
|
Remove the ignition coil and disconnect the HT leads. Remove the bracket for the ignition coil, camshaft position sensor and oxygen sensor connector. Lay the bracket aside.
|
|
10.
|
Raise the car and remove the oil filter.
|
|
11.
|
Undo the oil lines at the oil filter.
|
|
12.
|
Lower the car to the floor and remove the pipes at the heat exchanger.
|
|
13.
|
Remove the two heat exchanger retaining nuts.
|
|
14.
|
Remove the cover and lift out the heat exchanger.
|
|
1.
|
Fit new O-rings in place on the two pipe connections and fit the heat exchanger in place.
|
|
2.
|
Clean the heat exchanger cover with benzine and place silicone flange sealant 87 81 841 in the groove. Fit the cover, using a new gasket. Tighten the bolts clockwise, starting in the middle.
Tightening torque 20 Nm (15 lbf ft).
|
|
3.
|
Fit the two heat exchanger retaining nuts and connect the oil line.
Turning torque 30 Nm (22 lbf ft).
|
|
4.
|
Fit the oil lines to the cylinder block and attach the fixing between the oil lines.
Turning torque 30 Nm (22 lbf ft).
|
|
5.
|
Fit the oil filter.
Turning torque 10 Nm (7.4 lbf ft).
|
|
6.
|
Fit the ignition coil bracket, the camshaft position sensor connector, the ignition coil and the oxygen sensor in its holder.
|
|
7.
|
Fit the coolant bridge with 74 96 284 on the bolts, coolant hose and electrical connectors.
Turning torque 30 Nm (22 lbf ft).
|
|
8.
|
Fit the lower section of the intake manifold using a new gasket. Lock the bolts with 74 96 268 and tighten them in a circular sequence.
Tightening torque 20 Nm (15 lbf ft).
|
|
9.
|
Fit the middle intake manifold using a new gasket and the fuel rail. Remove the protective tape. Lock the bolts with 74 96 268.
Tightening torque 20 Nm (15 lbf ft).
|
|
10.
|
Connect the fuel lines.
|
|
11.
|
Fit the intake manifold. First fit:
|
|
|
•
|
the hose from the EVAP canister purge valve
|
|
|
•
|
the coolant hoses to the throttle body
|
|
|
•
|
the TCS throttle body connector
|
|
|
•
|
the IAC valve connector
|
|
|
•
|
the secondary air injection vacuum hose (where fitted).
|
|
|
•
|
the hose to the fuel pressure regulator.
|
Important
|
|
Check that the pressure regulator's vacuum hoses is connected to the
front
nipple on the throttle body (ahead of the throttle valve).
|
|
|
Tighten all bolts at the mating surface. Begin with the bolts in the middle and continue alternately towards the ends.
Tightening torque 20 Nm (15 lbf ft).
|
|
12.
|
Fit the rubber ducts for the mass air flow sensor. Fit the engine covers.
|
|
13.
|
Top up with coolant and check the system for leaks.
|
|
14.
|
Check all oil and fluid levels and top up as necessary. Make sure that the engine bay is clean. Remove the wing covers.
Warning
|
|
The coolant is very hot and under high pressure. When the pressure cap is opened there is a danger of scalding. Take great care.
|
|
|
|
|
|
|
|
15.
|
Bleed the system as follows: Fill the system up to the MAX level, close the expansion tank's pressure cap, start the engine and warm it up, preferably at varying rpm, until the radiator fan starts.
Open the expansion tank's pressure cap and top up to the MAX level. Close the pressure cap and run the engine at varying throttle openings until the radiator fan has started three more times.
Switch off the engine and top up to the MAX level, if necessary.
|
Note
|
|
The A/C should be OFF.
|
|
|
16.
|
Raise the car and check for leakage of any kind.
|
|
17.
|
Drive the car on the road and check all functions.
|
