Auxiliary Cabin Heater: Service and Repair
Removing And Installing Water Tubes For Additional Heating
Tools
Preliminary work
Preliminary work - line to distribution valve and second heat exchanger
1. Remove heater completely.
Preliminary work - line from front heat exchanger to heater
1. Remove intake muffler along with suction line.
Removing water tubes for additional heating
Removing line to distribution valve and second heat exchanger
1. Unclip the fuel line -arrows-.
2. Pull the electric wire with the holder off the water line -arrow A-.
3. Undo the fastening screw -1- and remove the line holder -arrow B-.
4. Release the two spring band clamps using circlip pliers for spring band clamps, Cayenne hose connections NR.72-1 (-arrows A-) and slide them off the connections -arrows B-.
5. Remove the line along with the hoses -arrow C-.
Removing line from front heat exchanger to heater
1. Release spring band clamp using circlip pliers for spring band clamps, Cayenne hose connections NR.72-1-arrows A- and slide it off the flange -arrow B-.
2. Lift the line up and out -arrows C-.
Removing line to rear heat exchanger
1. Unscrew fastening nut -arrow 2-.
2. Undo the fastening screw -arrow 3- and remove the line -arrow-.
Removing lines from check valve to circulation pump and engine
1. Release spring band clamp using circlip pliers for spring band clamps, Cayenne hose connections NR.72-1-arrows A- and slide it off the flange -arrow B-.
2. Pull hose off the line -arrow C-.
3. Undo the fastening screw -arrow 1- and turn up the line holder around the inner water line -arrow-.
4. Release the two spring band clamps using circlip pliers for spring band clamps, Cayenne hose connections NR.72-1 (-arrows A-) and slide them off the flange -arrow B-.
5. Pull the moulded hose off the two flanges -arrow C-.
6. Release the connector -arrow A- and pull it off -arrow B-.
7. Release the clamp -arrows A-, turn it towards the plug connection -arrows B- and remove it.
8. Release spring band clamp using circlip pliers for spring band clamps, Cayenne hose connections NR.72-1-arrows A- and slide it off the flange -arrow B-.
9. Pull the circulation pump out of the hose -arrow C-.
10. Unscrew fastening nut -arrow 2-.
11. Turn the line outwards -arrow A- and remove it -arrows B-.
12. Release spring band clamp using circlip pliers for spring band clamps, Cayenne hose connections NR.72-1-arrows A- and slide it off the flange -arrow B-.
13. Pull the hose down off the flange -arrow C-.
14. Release the two lines -a and b- from the threaded pin -arrow D- and remove them.
Installing water tubes for additional heating
Installing line from check valve to circulation pump and engine
1. Attach the two lines -a and b- to the threaded pin -arrow A- and screw on the fastening nut -2-, but do not tighten.
2. Connect the hose to connection 2 on the distribution valve -arrow B- and align with the marking.
3. Use circlip pliers for spring band clamps, Cayenne hose connections NR.72-1 to slide the spring band clamp on to the connection -arrow C- and align with the marking on the hose.
4. Relieve spring band clamp -arrows D- and secure the hose.
5. Insert the line -arrows A- and move it into fastening position -arrow B-.
6. Screw in the fastening nut -arrow 2- but do not tighten until the circulation pump is secured. Tightening torque 6 ftlb.
7. Connect the circulation pump to the hose -arrow A- and align at the markings.
8. Use circlip pliers for spring band clamps, Cayenne hose connections NR.72-1 to slide the spring band clamp on to the connection -arrow B- and align with the marking on the hose.
9. Relieve spring band clamp -arrows C- and secure the hose.
10. Align the pump parallel to the holder -arrows A-.
11. Connect the clamp via the plug contact -arrow B- and secure the circulation pump with the clamp at the holder -arrows C-.
12. Connect the connector -arrow A- until the locking tab -arrow B- is felt to engage.
13. Push the moulded hose onto the line and the heater -arrows A-.
14. Use circlip pliers for spring band clamps, Cayenne hose connections NR.72-1 to slide the spring band clamps on to the connections -arrow B- and align with the marking on the hose.
15. Relieve spring band clamps -arrows C- and secure the moulded hose.
16. Turn the line holder back -arrow- and press on the outer line until it engages audibly.
17. Secure the line holder with the fastening screw -arrow 1-. Tightening torque 2.5 ftlb.
18. Push the moulded hose onto the line -arrow A-.
19. Use circlip pliers for spring band clamps, Cayenne hose connections NR.72-1 to slide the spring band clamp on to the connection -arrow B- and align with the marking on the hose.
20. Relieve spring band clamp -arrows C- and secure the hose.
Installing line to rear heat exchanger
1. Unscrew fastening nut -2-.
2. Connect the line with the holder at the threaded pin and screw in the fastening nut -2- but do not tighten.
3. Secure the lead with the fastening screw -3-.
4. Tighten the fastening nut -2-. Tightening torque 6 ftlb.
Installing line from front heat exchanger to heater
1. Position the line in installation position -arrows A- and connect to the heater -arrow B-.
2. Use circlip pliers for spring band clamps, Cayenne hose connections NR.72-1 to slide the spring band clamp on to the connection -arrow C- and align with the marking on the hose.
3. Relieve spring band clamp -arrows D- and secure the hose.
Installing line to distribution valve and second heat exchanger
1. Attach the line to the distribution valve -a- and to the line to the second heat exchanger -b- (-arrow A-).
2. Use circlip pliers for spring band clamps, Cayenne hose connections NR.72-1 to slide the spring band clamps on to the connections -arrow B- and align with the markings.
3. Relieve the spring band clamps -arrows C- and secure the hoses.
4. Connect the line holder to both lines -arrow A- until the lines are felt to engage in the line holder.
5. Secure the line holder with the fastening screw -1-. Tightening torque 2.5 ftlb.
6. Connect the electric wire with the holder to the water line -arrow B- until the holder clicks into place.
7. Clip in the fuel line -arrows-.