| Disassembly and Assembly Disassembly Vehicles with non programmable fuel fired booster heater | | -
Remove the water cooling jacket cover. | | | -
Remove the combustion air blower motor cover. | Vehicles with programmable fuel fired booster heater | | -
Remove the fuel metering pump cover. | | | -
Detach the auxiliary coolant flow pump from the booster heater. | | | -
Remove the auxiliary coolant flow pump. - Disconnect the electrical connector.
| | | -
Disconnect the fuel metering pump electrical connectors. - Pull back the wiring harness grommets.
| | | -
CAUTION:Cap the fuel lines to prevent dirt ingress. Disconnect the fuel metering pump hose. | | | -
Remove the fuel metering pump. | | | -
Remove the combustion air blower motor cover. | All vehicles | | -
Detach the overheat sensor and the temperature sensor from the water cooling jacket. - Discard the O-ring seals.
| | | -
Remove the fuel fired booster heater module retaining bolts. | | | -
Remove the combustion air blower motor cover. | | | -
Remove the fuel fired booster heater module. - Disconnect the internal electrical connector.
| Vehicles built up to 08/2004 | | -
Disconnect the glow plug wire from the glow plug. | Vehicles built 08/2004 onwards | | -
Disconnect the cables from the fuel fired booster heater electrical connector (glow plug shown removed for clarity). | All vehicles | | -
Disconnect the cables from the fuel fired booster heater electrical connector (flame sensor shown removed for clarity). | | | -
Remove the combustion air blower motor. | | | -
Remove the combustion chamber. | | | -
Using a suitable screwdriver, remove the heat exchanger. | Assembly | | -
NOTE:Install new O-ring seals and gaskets. NOTE:Coat the O-ring seals in coolant prior to installation. To assemble, reverse the disassembly procedure. | | 
