SEAT Workshop Service and Repair Manuals

Fitting Installation is carried out in the reverse order of removing, noting the following:

–  Check seals -A- and -B- attached to heat exchanger. Only install heat exchangers with intact seals.   Note t  A seal that is not correctly fitted may roll up during introduction of the heat exchanger. t  If the seal is damaged or not correctly fitted, cold air may pass into the heat exchanger.

t  From model year 2005 the heat exchanger -B- has extra strips of foam -A-stuck to the corners. These strips of foam -A- should prevent some noises that may occur in Diesel engines, place these strips on all heat exchangers (eg. self-adhesive foam, part number 191 819 069 → Parts catalogue)

–  With heat exchanger removed, check climate control (heating) for contamination (via the cavity -A-). –  Remove any dirt or remnants of escaped coolant from air conditioner (heating) unit (e.g. after removing leaking heat exchanger). –  Fit heat exchanger into the air conditioning (heater).

–  Remove the old clips -B- form the two coolant tubes -C-. –  Attach new clips -A- (included with delivery of new heat exchanger) to both heat exchanger coolant pipes as shown. –  Lightly wet the new seals -A- (included with delivery of new heat exchanger) using coolant. –  Fit the new seals -A- to the connections of the heat exchanger -D-. –  Insert the two coolant tubes -C- into the connections on the heat exchanger -D-. –  Re-check position of seals -A- between coolant pipes -C- and heat exchanger connections -D-.

–  Attach the two coolant pipes -C- and -D- with clips -C- to heat exchanger. –  Tighten bolts in the clamps -A- to 2.5 Nm.

–  Check position of both clips -B- after tightening the bolts -A-; they must completely surround flange at heat exchanger and coolant pipe and not make contact with other components.

–  Fit the bolt -A- of the connection flange -B- (ensure that the bolt is tightened on the attachment point designed for this).

–  Check the correct positioning of the grommet -C- in the transverse panel. –  Seal the flanges for the coolant hoses to the heat exchanger -A- and the pressure release valve (to evaporator) -B- in the openings of the grommet -C-, for example using silicon sealing paste (so that it is water tight).

–  Connect the flexible tubes for the liquid coolant correctly to the heat exchanger. Note the markings: A -  Cylinder head feed B -  Return tube to the water pump –  Re-install components removed in reverse order with the exception of the heat exchanger connection cover and the driver side lower covering. –  Bleed the coolant circuit of air → Engine, mechanics; Rep. Gr.19.   Note t  The seal of the coolant circuit can be checked in the following manner, for example: t  Bleed coolant circuit. t  Carefully open cap at coolant expansion tank (heed relevant safety precautions) → Engine, mechanics; Rep. Gr.19. t  Increase the pressure in the coolant circuit, for example using the cooling tester -SAT 1274- (and the adaptors). t  When purging the coolant circuit, ensure that the heat exchanger is completely purged. If there are still air bubbles in the heat exchanger, the client may complain of low heating power in the winter or different air vent temperatures for the same setting on the control → Chapter.

–  Check coolant circuit for leaks, paying particular attention to connection between coolant pipes and heat exchanger, → Engine, mechanics; Rep. Gr.19. –  Re-install the heat exchanger connection cover and the driver side lower covering and all other removed components.