Removing and Installing

Heating And A/C Unit (with Heater Core And Evaporator), Removing And Installing

- Discharge refrigerant circuit.
- Remove dust and pollen filter.
- Switch ignition on.
- Press "recirculated air" button on A/C control head -E87-.







- Wait until air flow flap -A- closes (fresh/recirculated air flap moves to "recirculated air" position).
- Switch off ignition with the air flow flap closed.


CAUTION!
Before beginning repairs on the electrical system:
- Obtain the anti-theft radio security code.
- On vehicles with electrically adjustable seats, move seats back as far as possible before disconnecting battery.
- Ignition OFF!
- Disconnect battery Ground (GND strap).


NOTE: When the battery is reconnected, reset and check operation electrical equipment (radio, clock, convenience system if applicable etc.).


- Disconnect battery.
- Release pressure in cooling system by opening cap on coolant expansion tank.


WARNING! The cooling system is pressurized when the engine is warm. Wear gloves, safety glasses and other protection, and carefully release system pressure prior to proceeding with repairs.







- Using tools 3094, clamp off both coolant hoses for heater core at a point between the engine and connections -A-.
- Remove spring clamps -B- and detach coolant hoses.


NOTE:
- Coolant hoses must not be interchanged when installing.
- Coolant hose -C- = supply hose from cylinder head (marked with letter "V")
- Coolant hose -D- = return hose to water pump (marked with letter "R")







- Place suitable container under connection -B- and carefully expel coolant from heater core (using compressed air) through connection - A-.
- Remove expansion valve.







- Seal off refrigerant pipes and open connections -A- and -B- on evaporator.
- Remove hex nuts with washers -C-, tightening torque 15 Nm (11 ft lb).


NOTE: Washers for hex nuts should be fitted with seals.







- Fold back pre-punched flaps -A- on insulation mat and remove hex nuts and washers -B- underneath, tightening torque 15 Nm (11 ft lb).
- Remove glove box.
- Remove storage compartment on driver's side, dash panel center section and instrument panel.
- Remove center console (complete).
- Remove footwell vent.







- Remove air duct -A- (leading to defroster vent).
- Remove front passenger's airbag unit (complete) together with lefthand bracket for instrument panel cross member.
- Disconnect Ground (GND) connection between heating and A/C unit and ground connection at bottom of right A-pillar.
- Cover all exposed connectors and the A/C air ducts (protection from drilling remains).







- Drill two 7 mm holes in instrument panel support, one at each of the welding points marked -A- (drill through both layers).
- Saw through support at -B- (e.g. using body saw V.A.G 1523 A or equivalent).


CAUTION! Do not saw through section -C- (reinforcement) or the instrument panel support.







- Bend section -A- of support to one side in direction of -arrow- (or break off completely) along break line -B-.


WARNING!
- Remove any burrs and sharp edges from the holes made in section -C- and -D- of the support.
- Cover all resulting sharp edges (e.g. with adhesive tape).


- Unplug all electrical wiring connections between vehicle systems and the heating and A/C unit.







- Remove unit towards passenger side -arrow-.


Notes on installation:
- Before installing, check all gaskets and seals on the heating and A/C unit for damage and replace if necessary.
- When installing, check seal at intake housing. Seal must face body side.







- Replace seal -A- and ensure it is properly seated against contact surface -C-.
- After assembling, all cable ties which were removed in order to take out the air conditioner must be refitted in their original positions.
- Replace both O-rings for refrigerant pipes and expansion valve.
- Install refrigerant pipes free of stress.
- Ensure evaporator drain pipe and valve are properly seated.







- Replace gasket and ensure it is properly seated on the evaporator connecting flange.

After installing the heating and A/C unit, proceed as follows:







- Bend section -A- of the instrument panel support back into position.
- Bolt section -B- (which is welded to section -A-) to section -C- of the support with two bolts -D- (for example, M6 x 10 bolts) and two combi nuts -E-.


NOTE: When inserting bolts -D-, make sure they do not contact the bracket for the airbag unit.