Heat Exchanger, Installing

Heat Exchanger, Installing

Installing
- With heater core removed, check for contamination of air conditioner (by way of heater core duct).
- Remove any dirt or remnants of escaped coolant from air conditioner (e.g. after removing leaking heater core).







- Check seals - A -, - B - and - C - installed to heater core. Only fit heater core with intact seals.







- Moisten new seals - A - slightly with coolant.
- Insert new seals - A - (included in scope of delivery of heater core) in connections of heater core - B
- Slide heater core - C - into air conditioner.







- Remove old clips - A - from both coolant lines - B - and - C -.
- Install new clips - A - (included in scope of delivery of heater core) to both heater core coolant lines as shown.
- Press both coolant lines - B - and - C - into connections of heater core - D -.
- Re-check position of seals between coolant lines and heater core.







- Install the two coolant lines - B - and - C - with clips - A - to the heater core.
- Check position of both clips - A -. They must completely surround the flange at the heater core and coolant line and not make contact with other components.
- Tighten bolts at clips - A - to 2.5 Nm.
- Make sure coolant hoses are properly connected to heater core. observe markings:

A. Supply hose from cylinder head
B. Return hose to water pump

- Reinstall components removed (with the exception of drivers storage compartment) in reverse order.
- Bleed coolant circuit.

NOTE:
- The arrangement of the coolant lines to the heater core of the air conditioner is such that the heater core must also be bled. Proceed as follows:
- Bleed coolant circuit.
- Switch off ignition.
- Carefully open cap at coolant reservoir (observe safety precautions for opening cap).







- Loosen clip at coolant hose - B -.
- Slide back hose - B - until hole in hose is no longer sealed off by line.
- Use cooling system tester V.A.G 1274/hand pump for example to increase pressure in coolant circuit.
- Bleed heater core by way of hose - B - until there are no bubbles in coolant emerging.
- Install coolant hose - B - and secure with clip.
- Replenish coolant if necessary.







- Check coolant circuit for leaks, paying particular attention to connection between coolant lines and heater core.
- Reinstall drivers storage compartment and remaining components removed.