Heating And A/C Unit, CLIMATRONIC: Notes

Special tools and workshop equipment required 

• Hose Clamps Up To 40 mm 3093
• For example A/C Service Station VAS 6007A or ROB134APF
• Drip Tray For VAS 6100 VAS 6208

Removing 

-- Extract refrigerant e.g. using ROB134APF, only then open the refrigerant circuit. See notes, refer to SERVICING VEHICLES EQUIPPED WITH A/C .

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

-- Remove the bulkhead inside the plenum chamber. Refer to Description and Operation .

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

-- Place the VAS 6208 under the engine.

-- Mark the coolant hoses -1-.

-- Clamp off the coolant hoses -1- using the VAS 3093 and remove the coolant hoses from the heat exchanger.

-- 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.

-- From inside the engine compartment, remove the bolts -1- 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 Nm
2. Screws 
   • 4 Nm
   • Quantity: 2
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, 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 bolts from the bracket, see "Screws" in item:  6 and "Bracket" in item:  5.

     -- Remove the support, see "Right Support" in item:  8.

     -- Remove the bolts and the bracket, see "Screws" in item:  10, "Screws" in item:  12 and "Bracket" in item:  11.

     -- Remove the bolts from the cable bracket, see "Screws" in item:  2, "Screw" in item:  1 and "Cable Bracket" in item:  3.

     NOTE:

     To be able to reach the bolt, heating and A/C unit on driver side must be pulled out slightly from facing wall, see "Screws" in item:  1.

     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.

     Also pay attention to wiring harness, individual wiring connections may get damaged when pulling too forcefully on wiring harness.

     -- Remove heating and A/C unit.

     Installing 

     Install in reverse order of removal. When doing this, note the following:

     -- When installing, note installation position of seal for heating and A/C unit to 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, CHECKING .

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

5. Bracket 
6. Screws 
   • 8 Nm
7. Subframe 
8. Right Support 
9. Left Support 
10. Screws 
    • 8 Nm
    • Quantity: 2
11. Bracket 
12. Screws 
    • 8 Nm
    • Quantity: 2