Removing and installing heat exchanger — VW

🧭 Before you start

Fits: VW Passat B7 saloon (362, 2010–2014), VW Passat B7 Variant (365, 2010–2014)

• Special tools named: VAS 3093
• Renewed: deformed hose clips

Don't miss

• This makes it possible to move the coolant pipes in order to remove heat exchanger.
• An improperly bonded seal can roll up when heat exchanger is pushed into heater unit.If seal is damaged or improperly fitted, cold air can flow past heat exchanger.
• Renew deformed hose clips.
• During assembly, hose clips (A) must turn easily on coolant pipes.
• Hose clips (A) must be secured as shown in the diagram.

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Disconnect battery Electrical system27Battery; Disconnecting and connecting battery.
2. Place drip trayVAS 6208 beneath engine.
3. Clamp off coolant hoses (1) using hose clamps up to 40 mm VAS 3093 and disconnect coolant hoses to heat exchanger.
4. Push a piece of hose (A) and (B) onto both connections to heat exchanger.
5. Hold a container (C) under hose from lower connection (B).

6. Using a compressed air gun (D), carefully blow coolant out of heat exchanger into container (C) via hose (A).
7. Loosen bolt (6 mm hexagon socket head) (1) on flange between heat exchanger connections slightly (do not completely unscrew). [Note: This makes it possible to move the coolant pipes in order to remove heat exchanger.]
8. Remove driver side footwell trim General body repairs, interior68Compartments/covers; Overview of fitting locations - compartments/covers.
9. Remove footwell vent on driver side .
10. Remove bolts (1) (9 ± 1.3 Nm) and (3) (1.5 Nm). — 1.3 Nm (1.0 lb-ft)
11. Remove heat exchanger cover (2).
12. Cover carpet in area under heat exchanger with waterproof foil and water absorbing paper.
13. Open hose clips (A) (2 Nm) and pull coolant pipes out of heat exchanger. — 2 Nm (1.5 lb-ft)
14. Take heat exchanger out of heater unit.
15. Check seals attached to heat exchanger (A) and (B). Only install heat exchanger if seals are undamaged. [Note: An improperly bonded seal can roll up when heat exchanger is pushed into heater unit.If seal is damaged or improperly fitted, cold air can flow past heat exchanger.]
16. With heat exchanger removed, check heater is not soiled (via heat exchanger shaft (A)).
17. If necessary, remove dirt or coolant leakage residue from heater unit, e.g. following removal of a leaking heat exchanger.
18. Slide heat exchanger into heater unit.
19. Seals (1) must be renewed.
20. Before installing, moisten seals with coolant. [Note: Renew deformed hose clips.]
21. Connect coolant pipes to heat exchanger.
22. During assembly, hose clips (A) must turn easily on coolant pipes.
23. Hose clips (A) must be secured as shown in the diagram.
24. Tighten hose clips (A) to 2.0 Nm. — 2.0 Nm (1.5 lb-ft)
25. Check seating of both clips (A) after tightening screws. They must fully enclose the flange on the heat exchanger and the coolant pipe and the must not contact other components.
26. Tighten bolt (1) of flange between heat exchanger connections to 2 Nm. — 2 Nm (1.5 lb-ft)
27. Check grommet (C) is seated correctly in plenum chamber bulkhead.
28. If necessary, seal flanges for coolant pipes to heat exchanger (A) and for expansion valve (to evaporator, only on vehicles with air conditioning system) (B) at apertures in grommet (C) with silicone adhesive sealant to prevent water ingress. [Note: Seals must be replaced.Renew deformed hose clips.After renewing heat exchanger, entire coolant must be renewed 19Cooling system, coolant; Draining and filling coolant.Check coolant circuit for leaks. In particular, inspect connections between coolant pipes and heat exchanger.]

Other VW procedures

• Removing engine · 41 torque figures
• Removing and installing camshaft – VW Golf Cabriolet · 47 torque figures
• Adjusting valve timing – VW Passat B5 · 83 torque figures
• Removing and installing camshafts – VW Passat B6 · 39 torque figures
• Removing and installing coolant pump · 53 torque figures