Volkswagen Workshop Service and Repair Manuals

Removal   Note It is not necessary to remove the dash panel and the plenum chamber in order to remove and install the heat exchanger.

–  Close the coolant hoses in engine compartment by using the Clamps (diam. 25 mm) -3094- –  Release the clamps -arrows- with the Standard-type clamp pliers -VW 5162 (VWB) - ou - VAS 5024A- and remove the hoses. –  Install a compressed air hose on one of the heat exchanger outlets. At the other outlet, place a container to collect coolant. –  Use a compressed air pistol to remove the coolant from the heat exchanger.

–  Remove fastening screw -2- and flange -1-. –  Remove lower console → General body repairs, interior; Rep. gr.68

–  Remove the lower part of the right support for the panel bracket -arrow- → Body - Internal assembly works; Rep. gr.70.

–  Remove coupling for rear air duct -arrow-. –  Set aside the carpet and the noise insulation.

–  Remove the side locks -arrows- (right and left) on the heat exchanger housing.

–  Release front locks and remove carefully lower part of plenum chamber to the right, as indicated.

–  Remove the lower part of the plenum chamber -1-. –  Remove heat exchanger -3-.   Note The Auxiliary heating resistance -Z35--2- only exists for certain models. Removal and installation → Chapter.