Volkswagen Golf Service & Repair Manual: Removing and installing Denso heat exchanger, LHD vehicles

Volkswagen Golf Service & Repair Manual / Heating, air conditioning / Air conditioner / Front heater and air conditioning unit / Removing and installing Denso heat exchanger, LHD vehicles

Special tools and workshop equipment required

Drip tray for workshop hoist -VAS 6208-

Removing and installing Denso heat exchanger, LHD vehicles

Hose clamps up to 25 mm -3094-

Compressed air gun, commercially available

Removing and installing Denso heat exchanger, LHD vehicles

Engine bung set -VAS 6122-

Removing

–	Heed the safety precautions → Chapter „Safety instructions“.

Removing and installing Denso heat exchanger, LHD vehicles

Vehicles with TDI engine:

–	Press release buttons on crankcase breather hose -1- and detach hose from cylinder head cover.

–	Detach vacuum hoses from air pipe -arrows- to permit access.

–	Loosen hose clip -3-.

–	Remove bolt -2-, swivel air pipe with connection rearwards and detach from turbocharger.

Removing and installing Denso heat exchanger, LHD vehicles

Continuation for all vehicles:

–	Mark installation position of coolant hoses -1- and -4-.

Note

The heat exchanger is designed for a particular direction of flow of the coolant. Therefore, the coolant hoses must not be interchanged when connecting them.

–	Clamp off coolant hoses -1- and -4- using hose clamps, up to 25 mm -3094-.

–	Lift retaining clips -2- and -3-.

–	Disconnect coolant hoses -1- and -4- from heat exchanger for heater.

Removing and installing Denso heat exchanger, LHD vehicles

–	Push a piece of hose -A- onto upper connection.

Insert compressed air gun into end of hose.

–	Hold drip tray -B- under connection -C- and carefully blow coolant out of heat exchanger using compressed air gun.

–	Seal off open lines and connections with clean plugs from engine bung set -VAS 6122-.

–	Remove driver side knee airbag → General body repairs, interior; Rep. gr.69.

–	Remove left centre console trim in footwell → General body repairs, interior; Rep. gr.68.

–	Vehicles with auxiliary air heater: Remove auxiliary air heater element -Z35- with auxiliary air heater control unit -J604- → Chapter.

–	Cover area beneath connections for coolant hoses in plenum chamber as well as airbag control unit -J234- with, for example, impermeable sheeting and absorbent paper.

Removing and installing Denso heat exchanger, LHD vehicles

–	Screw out the bolts -2- and detach the screw-type clamps -3-.

–	Separate the coolant pipes.

Note

If the coolant pipes cannot be separated because the seals are gummed up, cut through them at the marked locations -arrows- using pliers -T40147-.

Pull the separated coolant pipes -4- and -7- of heat exchanger off coolant pipes -1- and -11- leading to the engine.

–	Screw out the bolt -10- and detach the heat exchanger holder -9-.

–	Pull out the heat exchanger -6- to the left.

–	Seal off open lines and connections with clean plugs from engine bung set -VAS 6122-.

Installing

Installation is carried out in the reverse order. When installing, note the following:

Note

Renew seals.

–	Check heater slot for dirt with heat exchanger removed.

–	If necessary, remove any dirt and coolant residue.

–	Vehicles with TDI engine: With auxiliary air heater element removed, check heating element slot for dirt and clean if necessary.

Removing and installing Denso heat exchanger, LHD vehicles

–	Check the foam seals -2- attached to the heat exchanger -1- for damage and replace if necessary.

Note

If the foam seal is not bonded in, it may roll up when the heat exchanger is fitted.

If the foam seal is damaged or improperly fitted, cold air can flow past the heat exchanger.

The illustration shows the heat exchanger for a “Valeo” heater and air conditioning unit.

Removing and installing Denso heat exchanger, LHD vehicles

–	Check connection -3- of the heat exchanger and the connection of the coolant pipes -1- for damage or dirt.

–	Clean and smoothen sealing surface for seals.

–	Moisten new seals -1- with coolant (or lubricate lightly with silicone grease) and fit them to coolant pipe.

–	Carefully slide heat exchanger into heater and air conditioning unit as far as stop.

Note

When sliding in the heat exchanger, make sure not to damage the connections and coolant pipes.

–	Push coolant pipes into heat exchanger as far as stop.

Risk of malfunction on heat exchanger due to defective seals and leaks.Never squeeze seals.Never cant coolant pipes.Slide on coolant pipes completely.

Removing and installing Denso heat exchanger, LHD vehicles

–	Fit heat exchanger bracket -3- on air distribution housing and tighten bolt -4- to specified torque.

–	Fit new clip -2- to joint between coolant pipe and heat exchanger.

–	Tighten bolt -1- → Chapter „Assembly overview - heater and air conditioning unit“.

–	Check clip and screw-type clip for proper seating on connections of heat exchanger and check coolant pipes. The coolant pipes must not contact air distribution housing or any other components.

–	Fill with coolant → Rep. gr.19.

–	Read event memory, and clear any entries displayed vehicle diagnostic tester in “Guided fault finding” mode.

–	As a final step, check operation of heater and air conditioner.

Specified torques:

→ Chapter „Assembly overview - heater and air conditioning unit“

Turbocharger; Assembly overview - turbocharger → Rep. gr.21.

Centre console; Assembly overview - centre console → General body repairs, interior; Rep. gr.68

Knee airbags; Assembly overview - knee airbag → General body repairs, interior; Rep. gr.69.

Removing and installing Denso heat exchanger, LHD vehicles

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