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Heat Exchanger, Remove and Install
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 Remove
Remove coolant bridge – see operation "Coolant Bridge,
Remove and Install".
Loosen upper heat shield for exhaust manifold 2-4-6 (3 bolts
from above, 1 bolt from below).
Detach oil feed line (1) and oil return line (2) from heat
exchanger.
Remove front exhaust pipe for cylinders 2-4-6. Remove oil filter
or oil filter housing (as of MY '99) – see operation "Engine
Oil with Oil Filter Change" or "Oil Filter Housing, Remove and
Install (as of MY '99)". Remove crankshaft pulse pick-up. Detach
oil feed line (3) and oil return line (4) from cylinder block. Open
fastening clamp for oil lines. Push oil lines away towards
rear.
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Remove fastening nuts (1) from heat exchanger.
Remove fastening bolts (2) from heat exchanger cover. Remove
heat exchanger from cylinder block – detach seal ring from
heat exchanger.
For version with fluid seal: detach heat exchanger cover from
cylinder block with wide spatula.
 Clean
Clean sealing surfaces and remove gasket remnants.
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Install
Connect new seal rings (1) to heat exchanger. Insert heat
exchanger in cylinder block.
Note: The previous
seal ring for the heat exchanger cover is now replaced by a bead of
silicon sealing compound (light grey).
Apply an approx. 2 mm (dimension I) thick bead of silicon
sealing compound (light grey) in groove of heat exchanger cover and
install immediately while wet.
Install heat exchanger cover on heat exchanger –
tightening torque 30 Nm / 22 lbf. ft.
Attach heat exchanger cover to cylinder block – tightening
torque 20 Nm / 15 lbf. ft.
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Install
Attach oil feed line and oil return line with new seal rings to
heat exchanger – tightening torque 30 Nm / 22 lbf. ft. +
30° + 15°.
Fasten upper heat shield for exhaust manifold 2-4-6 (3 bolts
from above, 1 bolt from below).
Close fastening clamp for oil lines.
Attach oil feed line and oil return line to cylinder block
– 30 Nm / 22 lbf. ft. Install crankshaft pulse pick-up.
Coat seal ring of new oil filter with engine oil and attach to
cylinder block with KM-726-A (up to MY '99) – tightening
torque 15 Nm / 11.1 lbf. ft. – or install oil filter housing
with new oil filter insert (as of MY '99) – see operation
"Oil Filter Housing, Remove and Install (as of MY '99)".
Install front exhaust pipe for cylinders 2-4-6.
Install coolant bridge – see operation "Coolant Bridge,
Remove and Install".
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