Volkswagen Golf Service & Repair Manual: Removing and installing Valeo heat exchanger, LHD 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. |
| 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. |
| – |
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 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 coolant hose connections in plenum
chamber with, e.g., impermeable sheeting and absorbent paper. |
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| – |
Lift locking element -6-,
remove clip -5- and pull coolant
line -4- off heat exchanger. |
| – |
Remove screw-type clip -2- and
pull coolant line -1- off heat
exchanger. |
| – |
Seal off open lines and connections with clean plugs from
engine bung set -VAS 6122-. |
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| – |
Unscrew bolts -1-,
-3- and -5-. |
| – |
Release the retainer tabs -4--arrows-
and detach the cover -2-. |
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| – |
If noise insulation cannot be pulled out, cut open tabs on
cover -arrows-. |
| – |
Take out the heat exchanger to the left. |
| 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 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. |
| Cold air may flow past the heat exchanger if the foam seal
is damaged or not properly fitted. |
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| – |
Check connection -3- of the
heat exchanger and connection -2-
of the coolant pipes for damage or contamination. |
| – |
Clean and smoothen sealing surface for seals. |
| – |
Moisten new seals -4- with
coolant (or lubricate lightly with silicone grease) and fit them
to coolant pipe -1-. |
| – |
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. |
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| – |
Fit new clip -5- or screw-type
clip -2- onto joint of coolant pipe
and heat exchanger. |
| – |
Tighten bolt -3-
→ 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. |
| → 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. |
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Removing
–
Remove centre console
→ General body repairs, interior; Rep. gr.68.
–
R ...
Special tools and workshop equipment
required
Drip tray for workshop hoist -VAS 6208-
& ...
Other materials:
Safety precautions when working in the vicinity of high-voltage components
Danger to life due to high voltage
The high-voltage system is under high voltage. If high-voltage
components are damaged, there is a risk of severe or fatal injury due to
electric shock.
–
Perform visual check of high-voltage components and high-v ...
Retrofitting a towing bracket
Fig. 108 Dimensions and attachment points
for retrofitting a towing bracket
First read and observe the introductory information
and safety warnings Volkswagen recommends having the towing bracket retrofitted
by a qualified workshop. The cooling system may need to be modified or heat shield ...
Repairs and technical modifications
First read and observe the introductory information
and safety warnings Repairs and modifications must always be carried
out according to Volkswagen specifications .
Unauthorised modifications to the electronic components or software in the vehicle
may cause faults. As the electronic co ...
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Removing and installing auxiliary air heater element - Z35- with auxiliary
air heater control unit - J604-, RHD vehicles
Removing and installing Valeo heat exchanger, RHD vehicles