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Volkswagen Golf Service & Repair Manual: Removing and installing heat exchanger for high-voltage battery

Volkswagen Golf Service & Repair Manual / Heating, air conditioning / Air conditioner / Refrigerant circuit / Removing and installing heat exchanger for high-voltage battery

Special tools and workshop equipment required
Hose clamps, up to 25 mm -3094-
Engine bung set -VAS 6122-
Pliers for spring-type clips -VAS 5024A-
Cooling system tester -V.A.G 1274 B-
Removing
–  Observe safety precautions → Chapter „Safety precautions when handling refrigerants“.
–  Comply with notes → Chapter „Working on refrigerant circuit“.
–  Observe safety precautions → Chapter „Safety precautions when working on the cooling system“.
–  Observe safety precautions when working in the vicinity of high-voltage components → Chapter „Safety precautions when working in the vicinity of high-voltage components“.
–  Observe the risk category of the high-voltage system → Rep. gr.00.
–  Extract refrigerant using air conditioner service station before opening refrigerant circuit.
  Note
To prevent the intrusion of moisture, all components of the refrigerant circuit which have been opened must be sealed with suitable plugs.
–  Switch off ignition.
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.
–  Open filler cap on coolant expansion tank for high-voltage system → Rep. gr.19.
–  Detach coolant expansion tank for coolant circuit of engine from vehicle, and slightly tilt it to the side → Rep. gr.19.
   
–  Clamp off coolant hoses -A- and -B- using hose clamps -3094-.
  Note
The heat exchanger is designed for a particular direction of flow of the coolant. Therefore, the coolant hoses must not be interchanged when connecting them.
–  Cover area beneath connections for coolant hoses on heat exchanger -E- with absorbent paper.
–  Disconnect coolant hoses -A- and -B- from connections on heat exchanger -E-.
–  Seal open connections for coolant hoses on heat exchanger -E- with clean plugs from engine bung set -VAS 6122-.
–  Remove bolts -F- on refrigerant lines to heat exchanger -E-.
–  Remove bolts -D-.
 

Removing and installing heat exchanger for high-voltage battery

–  Detach heat exchanger -C- from refrigerant lines -B- and -C-, and remove it together with bracket -F-.
–  Seal open connections for coolant hoses on heat exchanger -E- and refrigerant lines -B- and -C- with clean plugs from engine bung set -VAS 6122-.
  Note
Bracket -F- is secured to the heat exchanger -E- with two bolts -G-.
Installing
Installation is carried out in the reverse order. When installing, note the following:
–  Renew seals -D-; for correct version refer to → Electronic Parts Catalogue.
–  Check connections of refrigerant lines (-B- and -C-) and on heat exchanger -E- for soiling and damage.
 

Removing and installing heat exchanger for high-voltage battery

–  Insert seal -3- into groove -arrow- on connection of refrigerant line -1-.
  Note
If fitted, check that dowel pin -4- is not damaged and is seated correctly.
Moisten seals with refrigerant oil before installing → Chapter.
Make sure seals are seated correctly in groove of corresponding refrigerant line.
 

Removing and installing heat exchanger for high-voltage battery

–  Bracket -F- is secured to the heat exchanger -E- with two bolts -G-. If the bolts -G- have been loosened, insert them, but do not tighten them yet.
–  Install refrigerant lines -B- and -C- to heat exchanger -E-, and secure them with bolts -A- (do not tighten bolts -A- yet).
 

Removing and installing heat exchanger for high-voltage battery

–  Align heat exchanger -E- free of stress, and insert bolts -D-.
–  Tighten bolts -G- (specified torque 8 Nm).
–  Tighten bolts -D- (specified torque 8 Nm).
–  Tighten bolts -F- (specified torque 8 Nm).
–  Connect coolant hoses -A- and -B- to connections on heat exchanger -E-.
–  Fill coolant in coolant expansion tank for high-voltage system → Rep. gr.19.
–  Slightly increase pressure in coolant expansion tank for high-voltage system using e.g. cooling system tester -V.A.G 1274 B- → Rep. gr.19.
–  Carefully open bleeder valve -C-.
–  Carefully open hose clamp -3094- on coolant hose -A-, and let coolant flow into heat exchanger -E-.
–  As soon as coolant escapes from bleeder valve -C-, close bleeder valve -C-.
  Note
If the heat exchanger for high-voltage battery -E- has been removed and installed as described above, there should not be any air in the coolant circuit of the high-voltage system. If, however, there is still air in the coolant circuit, bleed coolant circuit → Rep. gr.19.
–  If necessary, fill coolant in coolant expansion tank for high-voltage system → Rep. gr.19.
–  Remove hose clamp -3094-, and reinstall all components which have been removed or detached.
–  The remaining steps for installation are carried out in reverse order.
–  As a final step, read event memory, and clear any entries displayed using cooling system tester in “Guided fault finding” mode.
 

Removing and installing heat exchanger for high-voltage battery

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