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#1
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W109 4.5 Need advise to remove heater core
I am doing this big job right now on my 4.5. I have the AC out for renovation anyhow and I need to rebuild the ventilation before I bring the AC back. I saw that all foam seals for the vents are gone and the heater fan is questionable. So it is time to tacke this.
Now I have everything disconnected/removed around and the heater box is lose. I can pull the heater box back as far as possible but barely get the 2 copper pipes through the fire wall, only with force. I am afraid I'll damage something. There is just not enough slack that I could free up that box through the fire wall. One unknown to me is what happens with the heater fan. Is this fan connected to the heater box? Does it come out with the heater box or is this an independent unit that stays in place while the heater core is removed. Main question is how to get the heater box out there. Thanks for any hints. Martin |
#2
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on my least favorite job list. It will come out remove everything in the way. I think I removed the wiring harness wire tie to get just a little more room I saw a mechanic get mad and beat the trans hump. Good Luck.
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#3
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The heater core is on the right side and is a separate unit. the main fan box is in the middle of the car. The heater core just keep wiggling and pushing things out of the way.
Your mechanic is correct, you need to beat the right side of hump down about 1/2 inch to slide the monster out on the right side. These were installed in the factory from the left side before the pedals and steering column were in place. |
#4
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Beat the trans hump- haha
Thanks both of you. I removed the AC duct with the 2 switches and vents in the center (I forgot to remove it). But removing the wire harness was finally it! I removed the U-brackets that hold the harness in place and this gave a bit of space...it was enough so I could move the unit. The entire unit comes out with the fan (fan is attached on the left side of the heater core) I am scared about all the cables inside. Hope I'll get every thing together again. I need to find all new rubber grommets for the connections through the fire wall. And that fat rubber around the heater fan. Attached a few pictures, one with the AC duct in front still in place.... not a good idea, needs to be removed. I'll start renovating that heater core, make all the flaps work again, pressure test the heater core and check the fan, see if the brushes and all are working well. Best, Martin |
#5
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Questions for my shopping list heater box renovation:
What rubber parts? What MB number is the rubber gasket/seal for the heater fan? How can I judge on the fan motor to be kept or to be replaced? I found 2 pieces of a bigger rubber grommet? in the floor after the battle yesterday but I have no idea where it is from. Where was this rubber? I'll post pictures. Any ideas of what I will need to get the heater box in good shape again? What was the foam stuff on the flaps (it is all crumbled by now). How to replace? Martin |
#6
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I think the rubber grommet at the top of the motor is 000 835 06 98. Mercedes refers to it as an 'elastic ring'.
Try to save it if you can. They run almost $100. |
#7
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congrats my body is sore thinking about it
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#8
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I understand. Too many bad memories coming back
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#9
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Quote:
You are correct....very expensive. Mine was installed incorrectly-probably 50 years ago- and one lip was folded over, see picture. Any remedy how to save it? I can try and iron it out Best, Martin |
#10
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Update on heater box.
Box with Flaps : I spent hours disassembling, cleaning and renovating all the flaps. What is that foam on the flaps for? 2 side flaps had front and back with foam pads. 2 Center flaps only on the inside. The single plastic flap was broken, no pads here. I removed all old foam crumbles and glued new rubber foam on. Heater Core: both valves renovated with new rubber and new 18mm circlips. I did not understand why there are 2 valves at one line. Any ideas? The rubber pads at the sides of the core were very much cooked, I needed to patch them with new rubber strips. New rubber is not available. I performed a pressure test and core tested well. Motor: I cleaned the motor and wheel. Disassembled the motor as much as needed. Brushes look good, almost no wear. First I thought the motor was replaced but I don't think the wheel ever came off that motor. Motor runs nicely when tested I'll probably use the motor as it is unless you think otherwise. I'll start assembly of the heater box soon. Waiting for the grommets in fire wall for the heater tubes. Martin |
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