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Dismantling and assembling heater unit > < Checking ventilation

Polo Mk5

Removing and installing heater unit
   
Removing and installing heater unit
1 - Dash panel cross member
q   Removing and installing → Rep. gr.70.
2 - Hexagon combi-bolt
q   Qty. 2
q   5 Nm
3 - Heater unit
Removing:
First carry out the following work:
–  Disconnect battery → Electrical system; Rep. gr.27.
–  Remove dash panel → Rep. gr.70.
–  Remove dash panel cross member → Rep. gr.70.
–  Cover floor carpeting at front.
  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.
–  Seal coolant hoses in engine compartment and remove from heat exchanger. → Fig.
–  Unbolt coolant pipes from heat exchanger in engine compartment. → Fig.
–  Carefully blow compressed air through heat exchanger.
Installing:
–  Install in reverse order. When doing this, ensure bolt -5- is tightened before bolts -4-.
–  Replenish coolant on completion of installation → Rep. gr.19.
4 - Hexagon combi-bolt
q   Qty. 2
q   5 Nm
q   Observe tightening sequence.
5 - Hexagon combi-bolt
q   5 Nm
q   Observe tightening sequence.
6 - Gasket between heat exchanger and plenum chamber bulkhead
q   Note installation position → Fig..

   
Clamp off coolant hoses using hose clamps up to 25 mm -3094-.
  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.
–  Release spring-type clips and pull water hoses off.
  N80-0373
Unscrew coolant pipes (9 ± 1.3 Nm) -arrow- and renew seals.
  N80-0365
Installation position of gasket between heat exchanger and plenum chamber bulkhead
–  Fit gasket -1- first on heat exchanger flange -2- and then insert in plenum chamber bulkhead. Ensure that seal sits correctly in groove -arrows-.
–  Connect coolant hoses (do not interchange).
–  Supply -3-.
–  Return -4-.
  Note
If heat exchanger is renewed, renew entire coolant.
–  Check coolant level and top up if necessary.
  N80-0367

Dismantling and assembling heater unit > < Checking ventilation