Heating And A/C Unit: Notes

Special tools and workshop equipment required 

• Robinair A/C Service Unit ROB 134APF with Rinsing Device For Refrigerant Circuits VAS6337/1A
• Drip Tray For Shop Crane VAS 6208
• Hose Clamps Up To Diameter 40 mm VAS 3093
• Compressed air gun, commercially available

Removing 

-- Extract refrigerant using ROB 134APF, only then open the refrigerant circuit. See notes, refer to REFRIGERANT CIRCUIT COMPONENTS OVERVIEW .

-- Remove the instrument panel. Refer to Removal and Installation .

-- Remove the rear channels from the right and left footwells. Refer to REAR FOOTWELL CHANNEL .

-- Place V.A.G 1306 under the engine.

-- Mark the coolant hoses -1-.

-- 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 +/- 0.9 Nm).

-- Remove the clamps -2- and the heat shield -3-.

All vehicles

-- From inside the engine compartment, remove the bolts (10 +/- 1 Nm), -2- from the refrigerant pipes -2-.

-- Remove the refrigerant pipes from the expansion valve -3-.

-- Cover the carpet inside the passenger compartment with waterproof foil and water absorbing paper.

1. Screw
   • 4.5 +/- 0.7 Nm
   • On the lower right side on the cable bracket for the heater and air conditioner near the plenum chamber bulkhead.
2. Screws
   • 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 .

     -- Disconnect the connectors from the heater and air conditioner.

     NOTE:

     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.

     -- Remove the two nuts from the comfort system central control module -J393- and hang the comfort system central control module to the side. Refer to COMFORT SYSTEM CENTRAL CONTROL MODULE -J393- .

     -- Remove the bolts -6- and the holder -5-.

     -- Remove the screws -8- and -10-, and the cover -9- and -11-.

     -- Remove the bolts -12- and -14- and bracket -13-.

     -- Remove the bolts -1- and -2- from the cable bracket -3-.

     NOTE:

     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:

     NOTE:

     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 .

     -- Fill with coolant. Refer to [For transmission(s) 02E, 09G, 02Q] [For engine(s) BPY] General Information , [For transmission(s) 0A4, 09G] [For engine(s) BGP, BGQ, CBTA, CBUA] General Information , or [For transmission(s) 02E, 09G, 02Q] [For engine(s) CCTA, CBFA] General Information .

     -- Fill with R134a refrigerant and refrigerant oil. Refer to SPECIFICATIONS .

5. Bracket
6. Screws
   • 8 Nm
7. Subframe
8. Screws
   • 9 +/- 1.3 Nm
9. Right Support
10. Screws
    • 20 +/- 3 Nm
11. Left Support
12. Screws
    • 9 +/- 1.3 Nm
13. Bracket
14. Screws
    • 9 +/- 1.3 Nm