Heating and A/C Unit
Heating and A/C Unit
Special tools, testers and auxiliary items required
• Drip Tray For Shop Crane (VAS 6208)
• Hose Clamps Up To 40 mm Diameter (3093)
• Robinair A/C Service Unit (ROB 134APF) or succeeding model.
• Torque Wrench (V.A.G 1331)
• Compressed air gun, commercially available
Removing
• Extract the refrigerant using the (ROB 134APF) (or succeeding model).
• Environmentally hazardous draining of refrigerant is an offense punishable by law.
• To improve accessibility, additional components such as the engine cover must be removed (depending on engine version).
- Extract refrigerant using (ROB 134APF) , only then open the refrigerant circuit. See notes, refer to => [ Servicing Refrigerant Circuit ] Servicing Refrigerant Circuit.
- Remove the instrument panel.
- Loosen the clips- 2 - and remove the intermediate defrost piece - 1 - from heater and A/C unit.
- Remove the intermediate piece - 3 - from the heater and A/C unit.
- Remove the subframe.
- Remove the rear channels from the right and left footwells. Refer to => [ Rear Footwell Channel ] Rear Footwell Channel.
- Place (VAS 6208) under the engine.
- Mark the coolant hoses - 1 -.
Contact with hot engine coolant can cause severe scalding.
Coolant temperature can be above 100 °C (212° F) with a warm engine. The cooling system is under pressure.
If necessary, reduce pressure and temperature before repairs.
- Clamp the coolant hoses - 1 - using the (VAS 3093) and remove the coolant hoses from the heater core.
- Connect a section of hose - A - to the upper connection.
- Hold a container - B - under the lower connection - C -.
- Using a compressed air gun, carefully blow residual coolant out of heater core at heater core connection.
Only for vehicles with a heat shield in front of the expansion valve
- Remove the nut - 1 - (6 Nm).
- Remove the clamps - 2 - and the heat shield - 3 -.
All vehicles
There is a danger of ice-up.
Refrigerant leaks out if refrigerant circuit is not discharged.
Refrigerant must be extracted before opening the refrigerant circuit. If refrigerant circuit is not opened within 10 minutes of extraction, pressure may form in refrigerant circuit due to evaporation. Extract refrigerant once more.
- From inside the engine compartment, remove the bolts (10 +/- 1 Nm), - 1 - from the refrigerant pipes - 2 -.
- Remove the refrigerant pipes from the expansion valve - 3 -.
• Seal the open connections.
• To seal off all open connections on expansion valve, sealing caps from a replacement expansion valve can be used (preventing dirt and moisture from entering the system).
- Cover the carpet inside the passenger compartment with waterproof foil and water absorbing paper.
• When removing the bolts, make note of the lengths and allocation.
1 Screw
• 4.5 ± 0.7 Nm
2 Screws
• Quantity: 2
• 4.5 ± 0.7 Nm
3 Cable Bracket
4 Heating and A/C unit
• Removing
- Remove the condensation water hose from the heater and air conditioner. Refer to => [ Condensation Water Drain Hose on Heating and A/C Unit, Checking ] Testing and Inspection.
- Disconnect the connectors from the heater and air conditioner.
• All cable ties and other wiring harness fasteners released or cut open on removing air conditioner unit are to be re-attached in same position on installation.
• The air conditioning wiring harness is removed with the heater and air conditioner.
• The tunnel braces - 8 - and - 9 - are welded to the assembly carrier - 7 -.
- Remove the subframe.
- Remove the bolts - 5 - and - 6 - from the bracket.
- Remove the bolts - 10 - and nuts - 12 - and bracket - 11 -.
- Remove the bolts - 2 - and - 1 - from the cable bracket - 3 -.
• To be able to reach the bolt - 1 -, heating and A/C unit on driver side must be pulled out slightly from facing wall.
• When removing heat unit, make sure the two coolant pipes of the heater core do not get caught and bent or damaged on plenum chamber or noise insulation pan.
• Observe wiring harness, individual electrical wiring connections may get damaged when pulling on harness.
- Remove heating and A/C unit.
Installing
Installation is carried out in the reverse order while noting the following:
• A second technician is necessary to install the heater.
- When inserting heater, have the second technician guide both coolant pipes to heater core through the seal (from engine compartment). Refer to => [ Seal For Heating And A/C Unit / Engine Compartment ].
- Make sure the condensation water hose fits correctly. Refer to => [ Condensation Water Drain Hose on Heating and A/C Unit, Checking ] Testing and Inspection.
- Fill the coolant.
5 Bracket
6 Screws
• 8 Nm
7 Subframe
8 Right Support
9 Left Support
10 Screws
• Quantity: 2
• 9 ± 1.3 Nm
11 Bracket
12 Nut
• Quantity: 2
• 9 ± 1.3 Nm
Seal For Heating And A/C Unit / Engine Compartment
• Make sure the seal - A - is installed correctly.