Removing and installing Valeo heat exchanger, RHD vehicles

Special tools and workshop equipment required

Drip tray for workshop hoist -VAS 6208-

Hose clamps up to 25 mm -3094-

Compressed air gun, commercially available

Engine bung set -VAS 6122-

Removing

• Heed the safety precautions → Chapter „Safety instructions“.

Vehicles with TDI engine:

• Press release buttons on crankcase breather hose -1- and detach hose from cylinder head cover.
• Detach vacuum hoses from air pipe -arrows- to permit access.
• Loosen hose clip -3-.
• Remove bolt -2-, swivel air pipe with connection rearwards and detach from turbocharger.

Continuation for all vehicles:

• Mark installation position of coolant hoses -1- and -4-.

Note

• Clamp off coolant hoses -1- and -4- using hose clamps, up to 25 mm -3094-.
• Lift retaining clips -2- and -3-.
• Disconnect coolant hoses -1- and -4- from heat exchanger for heater.

• Push a piece of hose -A- onto upper connection.

Insert compressed air gun into end of hose.

• Hold drip tray -B- under connection -C- and carefully blow coolant out of heat exchanger using compressed air gun.
• Seal off open lines and connections with clean plugs from engine bung set -VAS 6122-.
• Remove baffle plate → Chapter.
• Remove glove compartment → General body repairs, interior; Rep. gr.68.
• Removing footwell vent on front passenger side → Chapter.
• Remove centre console trim in footwell → General body repairs, interior; Rep. gr.68.
• Vehicles with auxiliary air heater: Remove auxiliary air heater element -Z35- with auxiliary air heater control unit -J604- → Chapter.
• Cover area beneath coolant hose connections in plenum chamber with, e.g., impermeable sheeting and absorbent paper.

• Lift locking element -6-, remove clip -5- and pull coolant line -4- off heat exchanger.

The illustration shows a left-hand drive vehicle.

• Remove bolt -3-.
• Remove screw-type clip -2- and pull coolant line -1- off heat exchanger.
• Seal off open lines and connections with clean plugs from engine bung set -VAS 6122-.

• Unscrew bolts -1-, -3- and -5-.

The illustration shows a left-hand drive vehicle.

• Release retainer tabs -4--arrows- and detach cover -2-.

• If noise insulation cannot be pulled out, cut open tabs on cover -arrows-.
• Remove heat exchanger to left.

Installing

Renew seals.

• Check heater slot for dirt with heat exchanger removed.
• If necessary, remove any dirt and coolant residue.
• Vehicles with TDI engine: With auxiliary air heater element removed, check heating element slot for dirt and clean if necessary.

• Check foam seals -2- attached to heat exchanger -1- for damage and replace if necessary.

• Check connection -3- of heat exchanger and connection -2- of coolant pipes for damage or soiling.
• Clean and smoothen sealing surface for seals.
• Moisten new seals -4- with coolant (or lubricate lightly with silicone grease) and fit them to coolant pipe -1-.
• Carefully slide heat exchanger into heater and air conditioning unit to stop.

• Push coolant pipes into heat exchanger to stop.

• Fit new clip -5- or screw-type clip -2- onto joint of coolant pipe and heat exchanger.
• Tighten bolt -3- → Chapter „Assembly overview - heater and air conditioning unit“.
• Check clip and screw-type clip for proper seating on connections of heat exchanger and check coolant pipes. The coolant pipes must not contact air distribution housing or any other components.
• Fill with coolant → Rep. gr.19.
• Read event memory, and clear any entries displayed vehicle diagnostic tester in “Guided fault finding” mode.
• As a final step, check operation of heater and air conditioner.

Specified torques:

→ Chapter „Assembly overview - heater and air conditioning unit“

Turbocharger; Assembly overview - turbocharger → Rep. gr.21.