Repairing second heat exchanger — VW

VW
LT
1997
Heating, ventilation, air conditioning
Heating, air conditioning
Edition
04.2005
Repairing second heat exchanger
WARNING
Always disconnect the battery earth strap before working on the electrical system.
Note
Obtain radio anti-theft code before disconnecting battery.
When the battery is reconnected, check the vehicle equipment (radio, clock) according to workshop manual and/or owner's manual.
2-way valve for coolant shut-off valve
N147
Removing
Fig.
Bolts
Remove bolts from both sides
Air distribution housing
Heat exchanger
Seals must be bonded free of gaps all around
Removing
Chapter
Warm air blower switch
E100
Removing
Fig.
Rear warm air blower
V47
Removing
Chapter
Clips
Clips must be loosened all around 2nd heat exchanger
Air distribution housing cover
Continued coolant circulation pump
V51
Checking
Rep. Gr.
19
Installation position
Fig.
Warm air blower relay
J14
Removing
Fig.
Warm air blower relay 2
J164
Removing
Fig.
Series resistor for warm air blower
N72
Checking
Chapter
Note
Always renew coolant.
Removing second heat exchanger
Connector
Bolts
Air distribution housing - second heat exchanger
Special tools and workshop equipment required
Hose clamps up to 40 mm Ø
3093
Pull off connector
1
.
Clamp off connecting hoses at
2-way valve for coolant shut-off valve
N147
of second heat exchanger using
hose clamps to 40 mm Ø
3093
and pull off.
Remove bolts
2
and remove air distribution housing from floor of luggage compartment.
Removing
warm air blower switch
E100
Warm air blower switch
E100
Remove radio
Rep. Gr.
91
.
Relay for
rear warm air blower
V47
Warm air blower relay
J14
Warm air blower relay 2
J164
Pull out relays 1 and 2 upwards.
Remove two-way valve for coolant shut-off valve
N147
Hose clamp
2-way valve for coolant shut-off valve
N147
Connector
Rubber mounting
Separate connector
3
.
Loosen hose clip
1
.
Press rubber mounting
4
out of
two-way valve for coolant shut-off valve
N147
in
direction of arrow
.
Remove
two-way valve for coolant shut-off valve
N147
upwards.
Removing
continued coolant circulation pump
V51
Connector
Continued coolant circulation pump
V51
Coolant return hose
Coolant supply hose
Bracket for additional coolant pump
Rubber mounting
Note
The
continued coolant circulation pump
V51
is located on left (in direction of travel) of engine block.
Separate connector
1
.
WARNING
Danger of scalding injuries.
The cooling system is pressurised. When the engine is warm, the coolant temperature may be above 100° C.
If necessary, release pressure before carrying out repairs.
Clamp off coolant hoses 3 and 4 using
hose clamps to 40 mm Ø
3093
and separate.
Unclip rubber mounting
6
from continued coolant circulation pump
2
from bracket
5
.
Installation positions of coolant hoses
Note
Figure shows
continued coolant circulation pump
V51
.
Ensure proper installation positions of coolant hoses. The marks must align
arrows
.
Hose connection for supply to 2nd heat exchanger
Supply hose
1
with identification
V
on hose must be connected as shown in figure.
The wire
2
must be secured to bracket with a cable tie. It must not be able to come in contact with the coolant pipes.