Instructions. Factory heat exchanger due to limited space with front panel installed (and installed air conditioner) due to the presence of brackets -B-and-C- cannot be reinstalled or can be installed, but with insufficient reliability. If it is necessary to reinstall the factory heat exchanger (original part) it is necessary to remove the front panel and the air duct to the deflector to "defrosting". Install O-rings, lightly lubricated with coolant (as described for installing the heat exchanger), onto coolant pipes -D- and -E- and press coolant pipes -D- and -E- (with O-rings) from above in the heat exchanger connection -. Hold coolant pipes -D- and -E- in the heat exchanger and install clamps -B- and -C-. Further assembly is similar to the description for the spare heat exchanger.
Make preparations for removing the heat exchanger. Relieve pressure in the coolant circuit by opening the expansion cap. cooling system reservoir. Mark the location of the coolant hoses -A- (pre-feed line from the cylinder head) and -B- (return line to water pump). The heat exchanger is positioned according to a specific coolant flow direction, so the coolant hoses must be connected correctly on all sides. Clamp coolant hoses -A- and -B- using hose clamps. Cover the areas under the coolant hose connections -A- and -B- in the plenum chamber, for example with suction paper. Remove coolant hoses -A- and -B- from the connections on the air conditioner heat exchanger.
Attach a piece of hose (-A- and -C-) on both connections to the heat exchanger. Place a container -B- under the other end of the hose -C-. Using an air gun -D-, carefully blow coolant out of the heat exchanger through hose -A- (into container -B-).
Remove clamps -B- and -C- from heat exchanger connections -A-. Disconnect both coolant pipes -D- and -E- from heat exchanger connections -A-. Remove heat exchanger -A- in direction of arrow -arrow-. The figure shows a heat exchanger with factory connections. If the heat exchanger has already been replaced once, both coolant pipes in the installed replacement heat exchanger are held in place by fastening -A-. Remove bolt -B- from this heat exchanger. Then screw in the longer bolt -C- (M5 thread), according to the figure, all the way and unscrew the fastening -A- from the connection with this bolt.
Installation
Installation is in the reverse order, in this case the following instructions must be observed: cover the installed heat exchanger, according to the climate, installation and vehicle version, with the foam seals included in the delivery set -A- and -D-.
1. Heat exchanger for vehicles with climate control, installation version "Basis"; 2. Heat exchanger for vehicles with climate control, installation version "Komfort"; 3. Heat exchanger for vehicles with climate control, installation version "Komfort" with right-hand drive.
Check the heat exchanger seals; only use heat exchangers with seals that are intact and firmly adhered. On vehicles with climate control, installation version "Komfort" it is possible to set different temperatures for the right and left sides, as well as behind the rear seats; seals -C- and -D- separate the air ducts in the air conditioner for the left and right sides. The heat exchanger has a color marking on which the seal -C- must be glued. Stick the seal -D-, according to the illustration, centrally on the heat exchanger. The seal -C- has different lengths (short version as shown in the figure, or long version along the entire length of the heat exchanger). If the heat exchanger is supplied with a long strip of sealant -C-, stick it around the perimeter of the heat exchanger. An incorrectly glued seal may become dislodged during installation. If the seal is damaged or incorrectly installed, cold air may enter the heat exchanger, on vehicles with climate control, installation version "Komfort" Clean insulation may not be provided by various areas. With heat exchanger -A- removed (through the heat exchanger shaft) Check the air conditioner and evaporator -F- for contamination. Remove any dirt or leaked coolant from the air conditioner (for example, after removing a leaking heat exchanger). Check the cleanliness and integrity of both connections -A- and -B- of the heat exchanger -C-. Lightly coat both connections -A- and -B- of heat exchanger -C- with silicone grease.
Silicone grease is available as a spare part, for example with the number G 000 405 A2. Lightly moisten new seals -D- (supplied with heat exchanger) coolant (or lightly lubricate with silicone lubricant). Place new seals -D- on both coolant pipes -E- and -F- to the heat exchanger.
Insert heat exchanger -A- into the air conditioner. Support the heat exchanger -A-, for example, with a plastic wedge -B- against the central tunnel -C- so that it does not fall down when inserting the coolant pipes.
Screw in the long bolt -G- (with M5 thread), according to the figure, into the mount -C- until it stops. Insert both coolant pipes -E- and -F- with seal -D- into the heat exchanger connections on the connecting flange -H- and press them in as far as they will go. When inserting coolant pipes -D- and -E- into the heat exchanger pipes, do not distort them. Check the seating of the seals -C- between the coolant pipes -D- and -E- and the connections on the connecting flange -B- of the heat exchanger -A-. Incorrectly installed or pinched seals -C- will lead to leaks. The seals -C- in both connections must be completely inserted with the coolant pipes -D- and -E- into the connections on the connecting flange -B-. Secure both coolant pipes -E- and -F- with bracket -C- to the connecting flange of the heat exchanger -H-.
The bolt -G- is required to facilitate installation; it must be removed after installing the bracket. Insert bolt -A- with washer -B- and tighten bolt -A-. The tightening torque for bolt -A- is 2.5 Nm. Remove bolt -G-. Check the position of the trim -H- in the engine bulkhead. compartment Correctly connect the coolant hoses to the heat exchanger, observing the markings: A - Direct supply from the cylinder head. B - Return line to the coolant pump. Place coolant hose -A- onto coolant pipe to heat exchanger (observe the markings) and secure it with a clamp -D-. Place the coolant hose -B- onto the coolant pipe -F- to the heat exchanger, without blocking the air hole -G-. Remove hose clamp from coolant hose -A-. Pour coolant into the expansion tank. tank. Carefully pump, for example using the hand pump of the cooling system tester -VAG 1274/-, coolant from the expansion tank. tank into the heat exchanger. After the coolant begins to flow out of the air. holes -G-, place the coolant hose -B- on the coolant pipe -F- as marked. Secure coolant hose -B- with clamp -E- to the marked location. Remove hose clamp from coolant hose -B-. If necessary, add coolant to the expansion tank. tank.
Instructions. The cooling system is now fully bled. If for some other reason there is air left in the cooling system, it is necessary to bleed it again after installing all the elements.
Check the heat exchanger connections for tightness: Carefully increase the pressure in the cooling circuit using, for example, the hand pump of the cooling system tester -VAG 1274/-. Check the tightness of the coolant circuit, especially the connection between the pipes and the heat exchanger. When bleeding the coolant circuit, it is necessary to completely remove air from the heat exchanger. If air pockets still remain in the heat exchanger, customers may complain of insufficient heating output in winter or different air temperatures at the outlet of the baffles despite the same adjustment in normal operation. Depending on the equipment of the vehicle and the engine, thermal insulation is installed on the coolant hoses; they must not be damaged, and after completion of the work they must be reinstalled. Install all removed elements in reverse order (preliminary work before removing the heat exchanger). Connect the battery ground cable -A-, following the instructions for connecting the battery. Perform basic setup and diagnostics of climate control actuators and settings.
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