Volkswagen Workshop Service and Repair Manuals > Golf Mk5 > Heating, ventilation, air conditioning system | Heating, air conditioning | Heating | Repairing heating system | Removing and installing heat exchanger

Removing

–	Place drip tray -V.A.G 1306- beneath engine.

WARNING

Danger of scalding injuries.

When the engine is warm, the coolant temperature may be above 100 °C. The cooling system is pressurised.

If necessary, release pressure and reduce temperature before carrying out repairs.

–	Clamp off coolant hoses -1- with hose clamps up to 40 mm Ø -VAS 3093- and disconnect coolant hoses to heat exchanger.

–	Push a piece of hose -A- onto upper union of heat exchanger.

–	Hold a container -B- under lower connection -C-.

–	Using a compressed air pistol, carefully blow coolant out of heat exchanger into container -B-.

Depending on the engine type, some parts must be removed additionally, e.g. the charge air pipe.

–	Loosen bolt (6 mm hexagon socket head) -1- on flange between heat exchanger connections slightly.

Note

t	Do not unscrew bolt -1-.

t	Loosening the bolt -1- loosens the coolant pipe which eases the removal of the heat exchanger.

–	Remove footwell trim on driver side → General body repairs, interior; Rep. gr.68.

–	Remove left footwell vent → Chapter.

–	Remove screws -A- and take off cover -B-.

Note

t	There are two different versions of cover -B-.

t	The figure shows the version with auxiliary air heater element -Z35-.

t	If the lever -C- to temperature flap is positioned so that the upper bolt -A- is not accessible. Change the position of the temperature flap at the heater and fresh air controls. On vehicles with Climatronic, at the control and display unit (e.g. the setting „Hi“).

–	Cover carpet in area under heat exchanger with waterproof foil and water absorbing paper.

–	Open pipe clamps -A- and pull coolant pipes out of heat exchanger.

–	Take heat exchanger out of heater unit.

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