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- |
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Heed the safety precautions
→ Chapter „Safety instructions“. |
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Vehicles with TDI engine: |
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Press release buttons on crankcase breather hose
-1- and detach hose from cylinder
head cover. |
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Detach vacuum hoses from air pipe
-arrows- to permit access. |
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Remove bolt -2-, swivel air
pipe with connection rearwards and detach from turbocharger. |
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Continuation for all vehicles: |
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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. |
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Clamp off coolant hoses -1- and
-4- using hose clamps, up to 25 mm
-3094-. |
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Lift retaining clips -2- and
-3-. |
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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. |
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Hold drip tray -B- under
connection -C- and carefully blow
coolant out of heat exchanger using compressed air gun. |
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Seal off open lines and connections with clean plugs from
engine bung set -VAS 6122-. |
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Remove baffle plate
→ Chapter. |
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Remove glove compartment
→ General body repairs, interior; Rep. gr.68. |
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Removing footwell vent on front passenger side
→ Chapter. |
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Remove centre console trim in footwell
→ General body repairs, interior; Rep. gr.68. |
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Vehicles with auxiliary air heater: Remove auxiliary air
heater element -Z35- with auxiliary air heater control unit
-J604-
→ Chapter. |
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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-. |
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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. |
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Remove bolt -10- and detach
heat exchanger bracket-9-. |
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Pull out heat exchanger -6- to
left. |
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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
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Check heater slot for dirt with heat exchanger removed. |
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If necessary, remove any dirt and coolant residue. |
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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. |
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Clean and smoothen sealing surface for seals. |
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Moisten new seals -1- with
coolant (or lubricate lightly with silicone grease) and fit them
to coolant pipe. |
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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. |
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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. |
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Tighten bolt -1-
→ Chapter „Assembly overview - heater and air conditioning unit“. |
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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. |
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Fill with coolant
→ Rep. gr.19. |
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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 ...
Other materials:
Dangers when handling vehicle batteries
Recognition and avoidance of dangers
Batteries can be dangerous. These dangers can be avoided
when the warnings on the battery, in the operating manual and in
ELSA are observed.
WARNING
...
Removing and installing cover frame for through-loading aperture
Special tools and workshop equipment
required
Removal wedge -3409
Release lever -T10039
...
Displays
First read and observe the introductory information
and safety warnings
Display
Solution
ProActive occupant protection not available
Go to a qualified workshop and have the system checked.
ProActive occupant protection: function re ...
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