Volkswagen Golf/Jetta 2 manual

Heat exchanger/fresh air box - removal and refitting
Cooling, heating and air conditioning systems / Heat exchanger/fresh air box - removal and refitting


Removal
1 Disconnect the battery earth lead.

2 Remove the centre console.

3 Remove the parcel shelf and insulator panel on the passenger side.

4 Drain the engine coolant (heater in ON position).

5 Disconnect the heater coolant hoses at the bulkhead on the engine compartment side (see illustration).

10.5 Bulkhead coolant hose connections
10.5 Bulkhead coolant hose connections

A Passenger compartment B Engine compartment
C Return hose
D Supply hose

6 Undo the retaining nuts and withdraw the outlet distributor from the air box, disconnecting the distributor from the left and right-hand air ducts as it is withdrawn.

Remove the gasket (see illustration).

10.6 Heater and ventilation system components
10.6 Heater and ventilation system components

7 Disconnect the control cables at the air box end.

8 Loosen the dash securing screws enough to enable the air box to be withdrawn and removed.

9 Release the clips and withdraw the heat exchanger unit from the air box. Allow for further coolant drainage from the inlet and outlet pipes.

10 The housing upper and lower housing halves can be separated by releasing the securing clips (see illustration). Once separated, the flap valves can be removed.

Take care not to split or crack the housings.

10.10 Upper-to-lower housing retaining clips (arrowed)
10.10 Upper-to-lower housing retaining clips (arrowed)

Refitting
11 Refitting is a reversal of the removal procedure. When engaging the control cable levers, align the index markings on the outer faces of the segments (see illustration).

Renew the heat exchanger cover gasket and ensure that the hose connections are securely made.

10.11 Align marks to set centre and side outlet flap positions
10.11 Align marks to set centre and side outlet flap positions

12 Before refitting the parcel shelf, top-up the cooling system and run the engine up to its normal operating temperature. Operate the heater and check for any sign of leakage from the heat exchanger hose connections. Check that the controls operate in a satisfactory manner.


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