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Subject: Re: Heater Core repair - VI. Re-assembly Author: davidsoine : member since September, 2004 : 870 posts Posted on: 2004-09-06 20:46:54

Again, the overview:

1. Remove the console
2. Remove the steering column
3. Remove the left support structure
4. Remove the HVAC front cover
5. disconnect heater hoses & blow out lines
6. Remove pipes & replace O-rings
7. reconnect heater hoses, top off coolant, pressure test if possible
8. assemble interior (reverse order)
9. bleed cooling system
10. test drive, check everything, reset radio stations, etc

7. Tips: Re-Assembly

Getting the HVAC cover back on is a pain. Be patient. I found the bellows attachements to the underseat ducts especially challenging.

Getting the actuator motors back in can be a bit tricky. There is a clip on one side and a peg on the other, I found that inserting the clip side first worked a bit better...but make sure that the peg gets fully seated on the other side. The actuator will have some play when fully installed - if there is no play, then the peg is probably not fully seated.

Here is a shot of with the peg not quite fully seated:



The rest of the installation will go "by the book" in basically reverse order of dis-assembly. Refer to the pics if you have them for the wiring, etc. Amazingly, everything will go back together, and if you are reasonably carefull you'll get most of the fasteners back in their places.

I spent time cleaning some console parts. Water and a rag takes off all that spilled soda, coffee, etc. I used a little tuner cleaner on the Auto/Manual switch by the shifter and now it moves freely.

That's it for now,

best,

Dave
97 740iL
Liberty, MO

• Heater Core repair - I. general info (pic) - davidsoine 2004-09-06 14:57:36 (15134 views)
  • More followup info (url) - DavidC 2005-04-09 02:43:33 (1230 views)
  • you are one brave man. good work. (nt) - LA-Sean 2004-09-07 01:59:26 (759 views)
    • Indeed, the photos are very graphic. Serious surgery. (nt) - islandbeef 2004-09-07 14:19:00 (883 views)
  • Phenomenal!! Thanks! What was your symptoms that lead to the heater core? (nt) - silber98 2004-09-06 22:31:13 (1073 views)
    • Symptom: Coolant smell when the heat cycled on, esp. Defrost (m) - davidsoine 2004-09-07 10:08:39 (1140 views)
  • Re: Heater Core repair - II. Removing the console (pic) - davidsoine 2004-09-06 19:22:13 (3062 views)
    • Re: Heater Core repair - III. Removing the steering column (pic) - davidsoine 2004-09-06 20:00:05 (2069 views)
      • Re: Heater Core repair - IV. Removing the 'left support' (pic) - davidsoine 2004-09-06 20:14:43 (1761 views)
        • Re: Heater Core repair - V. HVAC cover, heater hoses & pipes (pic) - davidsoine 2004-09-06 20:30:44 (2367 views)
          • Bravo! This is a perfect example of how to document a project - DavidC 2004-09-06 21:49:02 (859 views)
            • The leaking joints were... (m) - davidsoine 2004-09-07 10:18:02 (1011 views)
          • Re: Heater Core repair - VI. Re-assembly (pic) - davidsoine 2004-09-06 20:46:54 (2147 views)
            • Absolutely Beautiful, Well done - thanks!! (nt) - WTH 2004-09-06 21:04:46 (682 views)
              • My goodness, very impressive! - M.Wong 2004-09-07 00:29:23 (670 views)
  • This is great information David. - farnarkler 2004-09-06 18:56:45 (594 views)