Volkswagen Workshop Service and Repair Manuals

Installing

Install in reverse order. Note the following when doing this: –  Check seals attached to heat exchanger -A- and -B-. Only install heat exchangers with intact seals.   Note t  An improperly bonded seal can roll up when heat exchanger is pushed into heater unit. t  If seal is damaged or improperly attached, cold air can flow past heat exchanger.

–  With heat exchanger removed, check heater is not soiled (via heat exchanger shaft -A-). –  If necessary, remove dirt or residue of leaked coolant from heater unit, e.g. after removing a leaking heat exchanger.

–  Slide heat exchanger into heater unit.   Note Seals -1- must always be renewed. –  Moisten seals -1- with coolant before installing.   Note Renew deformed pipe clamps. –  Connect coolant pipes to heat exchanger. –  During assembly, pipe clamps -A- must turn easily on coolant pipes.

–  Pipe clamps -A- must be installed as shown in diagram. –  Tighten pipe clamps -A- to 2 Nm.

–  Check seating of both clips -A- after tightening screws. They must fully enclose the flange on the heat exchanger and the coolant pipe and they must not contact other components. –  Tighten bolt -1- from flange between heat exchanger connections to 2 Nm.

–  After installing, check that grommet -C- is properly seated in plenum chamber bulkhead. –  If necessary, seal flanges for coolant pipes to heat exchanger -A- and for expansion valve to evaporator -B- at apertures in grommet -C- with silicone adhesive to prevent ingress of moisture.   Note t  Seals must be replaced. t  After replacement of the heat exchanger, a complete coolant change must be carried out → Rep. gr.19. t  Check coolant circuit for leaks. In particular, inspect connections between coolant pipes and heat exchanger.