CAUTION: Be careful not to get burned by hot liquid. The coolant temperature of a warm engine can exceed 100°C. The liquid in the cooling system is under pressure. Wait until the pressure and temperature of the coolant have dropped before starting repair work.
Clamp the coolant hoses "1" using clamps for hoses up to 40 mm in diameter "3093" and remove the hoses from the heat exchanger. Put the short hose "A" on the upper nipple of the heat exchanger. Place a container "B" under the lower nipple "C".
Using a blow gun, carefully blow the coolant out of the heat exchanger into vessel "B". Loosen the (do not twist) bolt located between the fittings on the heat exchanger flange.
Instructions: When unscrewing bolt "1", the tension of the coolant pipes is released and it is easier to remove the heat exchanger.
Remove the driver's side footwell trim. Remove the left footwell air duct. Loosen screws "A" and remove cover "B".
Instructions: There are several versions of the cover "B". The figure shows the version with an additional air heater "Z35". The drive lever "C" of the temperature control flap may be positioned so that access to the bolt "A" is blocked. In this case, you should change the position of the temperature control flap using the temperature control knob, and in cars with an air conditioning system using the display and control panel, for example, towards increasing the temperature ("Hi").
Spread waterproof film and absorbent paper on the fabric floor covering of the car under the heat exchanger. Disconnect clamps "A" and remove the hoses from the heat exchanger. Remove the heat exchanger from the heater module.
Installation is carried out in the reverse order. Check the condition of the heat exchanger seals "A" and "B"; install the heat exchanger only with undamaged seals.
Instructions: If the seal is not glued correctly, it may twist when inserting the heat exchanger into the heater. If the seal is damaged or incorrectly installed, cold air may pass by the heat exchanger.
With the heat exchanger removed, inspect the heater (through cavity "A" for the heat exchanger) for contamination. If necessary, remove dirt and coolant residues from the heater, such as those left after removing a leaky heat exchanger. Insert the heat exchanger into the heater.
Before installation, wet the sealing rings "1" in the coolant. Insert the sealing rings "1" into the heat exchanger fittings.
Instructions: Make sure that the rings are installed in the correct direction. Deformed clamps must be replaced.
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Connect the cooling system hoses to the heat exchanger. When installing, clamps "A" should be slightly twisted around the hoses. Position clamps "A" as shown in the figure. Tighten clamps "A" to a torque of 2 Nm. After tightening the screws, check the position of both clamps "A". They should completely cover the place where the hose connects to the heat exchanger and not touch other parts. Tighten bolt "1" on the flange between the heat exchanger fittings to a torque of 2 Nm.
Check that the sealing cuff "C" is installed correctly in the partition. To prevent moisture penetration, seal the edges of the heat exchanger pipes "A" and the expansion valve for the evaporator (only for cars with air conditioning) "B" in places where it passes through the cuff "C" using silicone sealant.
Instructions: The sealing rings must be replaced. After replacing the heat exchanger, the coolant must be completely replaced. Check the tightness of the cooling circuit, paying particular attention to the connections of the cooling system hoses to the heat exchanger.
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