Removing and installing right heat exchanger: VW Phaeton

🧭 Before you start

Remove the dash panel and wiper system, drain the coolant and blow the rest out of the pump-valve unit and heat exchangers. Loosen and remove the pipe retainer in the plenum chamber, remove the footwell vent and cover the carpet. Lubricate the pipes at the grommet, remove the clips, release the pipes, push them toward the plenum chamber and remove the bracket and heat exchanger. Clean the condensation drain holes, fit new O-rings moistened with coolant, refit with original-type clips, leak test before the dash goes back, check the grommet and fill the system with the ignition off.

Fits: VW Phaeton (3D)

• Opens: coolant
• Renewed: o-ring

Don't miss

• Always renew the O-rings, moistened lightly with coolant.
• Fill the cooling system with the ignition switched off, or the pump-valve unit valves are damaged.
• Do not run circulation pump V50 dry; it is destroyed.
• Check and clean the condensation drain holes; the drain valve must open and close freely.
• Leak test the cooling system before refitting the dash panel.

Written for this job from the workshop steps below · TorqFix editorial.

📋 Procedure

1. Remove dash panel 70.
2. Remove windscreen wiper system 92.
3. Place drip trayVAS 6208 beneath engine.
4. Drain cooling system 19.
5. Hold coolant hose (B) into container.

6. Using compressed air gun, carefully blow remaining coolant out of pump-valve unit and heat exchangers via coolant hose (A). [Note: To ensure that the coolant is blown out of both heat exchangers, alternately clamp off the upper coolant hose to each of the heat exchangers.]
7. Loosen bolt (A) for cooling system pipe retainer (in plenum chamber) approx. 2 turns.
8. Remove cooling system pipe retainer.
9. Remove footwell vent.
10. Cover carpet in area under heat exchanger with waterproof foil and water absorbing paper.
11. Slightly moisten contact surface of both coolant pipes (A) and (B) on grommet (C) with silicon lubricant. In this way the pipes are easier to move and it is not necessary to change the position of the grommet.
12. Remove clips (D).
13. Release coolant pipes (A) from heat exchanger.
14. Push both coolant pipes towards "“plenum chamber”".
15. Remove bracket (B).
16. Pull heat exchanger (C) out of heater and air conditioning unit.
17. Before installing heat exchanger, check condensation drain holes (A) and (B) for soiling. Clean if necessary. [Note: The function of the condensation drain valve should not be impaired by conservation wax or underseal. The valve must open and close properly.In the figure the drain holes are shown with the fresh air blower installed.]
18. Heat exchanger removed: check both drain holes through heat exchanger aperture using illuminated inspection mirror. Clean drain holes, e.g. with wire.
19. Heat exchanger installed: with condensation drain hose removed, clean drain holes from exterior using, for example, wire.
20. Secure all connections using clips corresponding to original equipment Parts catalogue.
21. Check coolant pipe (B) and heat exchanger connection (C) for soiling or damage. [Note: Always renew O-ring.]
22. Moisten O-Ring (A) lightly with coolant and position it on coolant pipe (B).
23. Proceed in same manner to install second coolant pipe.
24. Before installing dash panel, check cooling system for leaks 19.
25. Before installing dash panel and plenum chamber cover, check position of grommet in opening for coolant pipes to plenum chamber. [Note: Running cooling system circulation pump V50 dry will destroy it.The coolant circulation pump V50 and the pump-valve unit may only be operated when the cooling system has been filled and bled.Do not switch ignition on.The valves of the pump-valve-unit may be damaged when the cooling system is being filled.The valves of the pump-valve-unit are closed when ignition is "“on”" and temperature preselection is "“cold”". If ignition is "“on”" and temperature preselection is "“warm”", the valves will be damaged when the system is filled.The ignition must always be switched off when filling the cooling system.]
26. Fill cooling system 19.

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