Volkswagen Golf Service & Repair Manual: Removing and installing Denso heat exchanger, RHD vehicles
| Special tools and workshop equipment
required |
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| Drip tray for workshop hoist -VAS 6208- |
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| Hose clamps up to 25 mm -3094- |
| Compressed air gun, commercially available |
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| Engine bung set -VAS 6122- |
| – |
Heed the safety precautions
→ Chapter „Safety instructions“. |
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| 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. |
| – |
Remove bolt -2-, swivel air
pipe with connection rearwards and detach from turbocharger. |
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| 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. |
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| – |
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 baffle plate
→ Chapter. |
| – |
Remove glove compartment
→ General body repairs, interior; Rep. gr.68. |
| – |
Removing footwell vent on front passenger side
→ Chapter. |
| – |
Remove 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. |
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| – |
Remove bolts -2- and detach
screw-type clamps -3-. |
| – |
Separate 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 cut coolant pipes -4-
and -7- of heat exchanger off
coolant pipes -1- and
-11- leading to the engine. |
| – |
Remove bolt -10- and detach
heat exchanger bracket-9-. |
| – |
Pull out heat exchanger -6- to
left. |
| – |
Seal off open lines and connections with clean plugs from
engine bung set -VAS 6122-. |
| Installation is carried out in the reverse order. When
installing, note the following: |
Note
| – |
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. |
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| – |
Check foam seals -2- attached
to 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. |
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| – |
Check connection -3- of heat
exchanger and connection of coolant pipe
-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 to stop. |
Note
| When sliding in the heat exchanger, make sure not to damage
the connections and coolant pipes. |
| – |
Push coolant pipes into heat exchanger to 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. |
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Fit heat exchanger bracket -3-
on air distribution housing and tighten bolt
-4- to specified torque. |
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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. |
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As a final step, check operation of heater and air
conditioner. |
| → 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 |
| Compartments/covers; Assembly overview - glove compartment
→ General body repairs, interior; Rep. gr.68. |
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Special tools and workshop equipment
required
Drip tray for workshop hoist -VAS 6208-
& ...
Note
There are different designs and makes of heater and air
conditioning unit. The individual components of the various
heaters and air conditioning u ...
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Removing and installing Denso heat exchanger, LHD vehicles
Removing and installing coolant pipes at heat exchanger (Valeo)