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VDORepair pixel repair specialists

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



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