Removing and installing heat exchanger for high voltage battery VX63 — VW

Removing and installing
heat exchanger for high voltage battery
VX63
Special tools and workshop equipment required
Drip tray for workshop hoist
VAS 6208
Engine bung set
VAS 6122
Torque wrench
V.A.G 1410/
Hose clip pliers
V.A.G 1921
Pliers for spring-type clips
VAS 5024A
Vehicle diagnostic tester
Removing
Observe instructions when working on refrigerant circuit
Chapter
.
Observe general warning instructions for work on high voltage system
Chapter
.
Note
Bleed the coolant circuit if it has been opened. Information about bleeding the coolant circuit is available from the E-field service team.
If the drive motor is warm, then the cooling system is pressurised. If necessary, release pressure before carrying out repairs.
Note
The refrigerant must be extracted beforehand, with the
air conditioning service station
.
The previously used air conditioner service stations can still be used ⇒ Volkswagen Workshop Equipment catalogue.
To prevent the intrusion of moisture, all components of the refrigerant circuit which have been opened must be sealed with suitable plugs.
Clamp off coolant hoses using
hose clamps up to 40 mm
3093
.
CAUTION
When the engine is warm, the cooling system is under pressure. Danger of scalding due to steam and hot coolant.
There is a risk of injury to the skin and parts of the body due to scalding.
Always wear safety gloves.
Always wear safety goggles.
Proceed as follows to release the pressure: cover the cap of the coolant expansion tank with a cloth, and open it carefully.
Detach clips
1
and pull off coolant hoses from
heat exchanger for high voltage battery
VX63
2
.
CAUTION
Escaping pressurised refrigerant can cause freezing.
Skin and other parts of the body may be frozen.
Always wear safety gloves.
Always wear safety goggles.
Extract refrigerant, and open the refrigerant circuit immediately afterwards.
If more than 10 minutes have passed since the refrigerant was extracted, repeat the extraction process before opening the refrigerant circuit. Continued evaporation will cause pressure to develop again in the refrigerant circuit.
Remove bolts
4
.
Pull out refrigerant lines
5
from
heat exchanger for high voltage battery
VX63
2
.
Unscrew bolts
3
(3 ± 0.3 Nm) and remove
heat exchanger for high voltage battery
VX63
2
.
Installing
Installation is carried out in the reverse order. When installing, note the following:
Note
After installing
heat exchanger for high voltage battery
VX63
, bleed coolant circuit. Information about bleeding the coolant circuit is available from the E-field service team.
Always renew O-rings and moisten them with refrigerant oil.
Note
Refrigerant shutoff valve for air conditioning system
N541
and
refrigerant shutoff valve for heat exchanger of high voltage battery
N542
must be open for filling and extraction of refrigerant.
When filling and extracting refrigerant, a voltage of 12V must be applied to the shutoff valves.