Removing/Fixing Heat Exchanger in 2002 9-5 V6

2. Engine\Basic engine, V6 Adjustment/Replacement - Heat ...
Heat exchanger, to change
To remove
1. Drape the wing protectors over the wings and remove the engine cover.
2. Disconnect the negative cable from the battery.
3. Open the cap on the expansion tank and release the pressure.
4. Raise the car.
5.
Remove the lower spoiler sections.
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6. Drain the coolant from the radiator.
7. Lower the car.
8.
Unhook the throttle cable. Unplug the throttle's connector.
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9. Remove the vacuum hoses and unplug the pressure sensor's connector from the
upper intake manifold.
10. Detach the vacuum hose and the two water hoses from the throttle. Remove the
turbo pressure hose with charge air bypass pipe. Detach the venting-valve hose
from the underside of the throttle.
11. Unplug the connector for the injectors.
12.
Detach the fuel lines.
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13. Undo the upper intake manifold and move it aside.
14.
Remove the middle intake manifold.
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15. Remove the lower intake manifold. Plug the holes with paper or the like.
16. Undo the coolant bridge and move it aside. Mind the gaskets.
17. Undo the clamp holding the oil pipes.
18.
Raise the car. Remove the crankshaft position sensor.
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19. Detach the heat exchanger's oil pipes from the oil filter adapter and cylinder block.
20.
Lower the car and remove the heat exchanger oil pipes. Remove the two heat
exchanger retaining nuts.
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21. Remove the cover and lift out the heat exchanger.
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1. Fit new O-rings on the two pipe connections and mount the heat exchanger.
2. Clean the heat exchanger's cover with benzine and place part No. (10) 81 52 381 in
the groove. Position a new gasket and fit the cover in place. Tighten the bolts
clockwise, starting in the middle.
Tightening torque: 20 Nm (15 lbf ft)
3. Screw on the two heat exchanger retaining nuts. Position the heat exchanger's oil
pipes and connect them to the heat exchanger. Do not tighten the bolts.
4. Fit the clamp for the oil pipes.
5. Raise the car.
6.
Connect the oil pipes to the oil filter adapter and cylinder block.
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Tightening torque: 25 Nm (18.5 lbf ft).
7. Fit the crankshaft position sensor.
8. Lower the car.
9. Tighten the retaining nuts and the oil pipe to the heat exchanger.
Tightening torque, retaining nuts 35 Nm (26 lbf ft)
Tightening torque, oil pipe 30 Nm (22 lbf ft)
10.
Fit the coolant bridge. Coat the bolts with part No. (10) 74 96 284.
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Tightening torque: 30 Nm (22 lbf ft).
11. Fit the lower intake manifold with new gaskets.
12. Fit the middle intake manifold.
13.
Fit the upper intake manifold with a new gasket.
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14. Connect the fuel lines.
15. Plug in the connector for the injectors.
16.
Connect the vacuum hose and the two water hoses to the throttle. Fit the turbo
pressure hose with charge air bypass pipe. Connect the hose to the venting valve on
the underside of the throttle and plug in the throttle's connector.
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Tightening torque:
Bypass pipe 8 Nm (6 lbf ft)
17. Connect the vacuum hoses and plug in the pressure sensor's connector to the upper
intake manifold.
18. Refit the throttle cable.
19. Reconnect the negative cable to the battery.
20. Fill up with coolant. Do not forget to close the radiator drain cock first. Screw on the
expansion tank filler cap.
21. Bleed the cooling system as follows:
Fill the system up to the MAX level, close the expansion tank filler cap, start the
engine and warm it up (by running it at varying rpm) until the radiator fan starts.
Unscrew the expansion tank filler cap and top up again to the MAX level. Close the
filler cap and run the engine at varying rpm until the radiator fan starts three more
times. Switch off the engine and top up as necessary to the MAX level.
Note
The A/C should be OFF.
22. Raise the car.
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23. Check for leakage.
24. Fit the lower spoiler sections.
25. Lower the car.
26. Fit the engine cover and remove the wing protectors.
27. Reset the clock and the radio, if fitted.
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Removing/Fixing Heat Exchanger in 2002 9-5 V6

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Removing/Fixing Heat Exchanger in 2002 9-5 V6

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2. Engine\Basic engine, V6 Adjustment/Replacement - Heat ...

Heat exchanger, to change

2. Disconnect the negative cable from the battery.

4. Raise the car.

Remove the lower spoiler sections.

9-5 (9600) 2 2002 1

6. Drain the coolant from the radiator.

7. Lower the car.

Unhook the throttle cable. Unplug the throttle's connector.

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11. Unplug the connector for the injectors.

Detach the fuel lines.

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13. Undo the upper intake manifold and move it aside.

Remove the middle intake manifold.

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17. Undo the clamp holding the oil pipes.

Raise the car. Remove the crankshaft position sensor.

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Tightening torque: 20 Nm (15 lbf ft)

4. Fit the clamp for the oil pipes.

5. Raise the car.

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Tightening torque: 25 Nm (18.5 lbf ft).

7. Fit the crankshaft position sensor.

8. Lower the car.

Tightening torque, retaining nuts 35 Nm (26 lbf ft)

Tightening torque, oil pipe 30 Nm (22 lbf ft)

9-5 (9600) 2 2002 9

Tightening torque: 30 Nm (22 lbf ft).

11. Fit the lower intake manifold with new gaskets.

Tightening torque: 20 Nm (15 lbf ft)

12. Fit the middle intake manifold.

Tightening torque: 20 Nm (15 lbf ft)

Fit the upper intake manifold with a new gasket.

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Tightening torque: 20 Nm (15 lbf ft)

14. Connect the fuel lines.

15. Plug in the connector for the injectors.

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Bypass pipe 8 Nm (6 lbf ft)

18. Refit the throttle cable.

19. Reconnect the negative cable to the battery.

21. Bleed the cooling system as follows:

22. Raise the car.

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23. Check for leakage.

24. Fit the lower spoiler sections.

25. Lower the car.

27. Reset the clock and the radio, if fitted.

9-5 (9600) 2 2002 13

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