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Heating And A/C Unit, CLIMATRONIC

Special tools and workshop equipment required 

Removing 

NOTE:

To improve accessibility, additional components engine cover must be removed depending on engine version. Refer to [For transmission(s) 0A6, 09M] [For engine(s) CCTA] Removal and Installation .

-- Extract refrigerant using A/C Service Station VAS 6007A, only then open the refrigerant circuit. Observe notes, refer to REFRIGERANT CIRCUIT COMPONENTS .

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

-- Loosen the clips -2- and remove the defroster intermediate piece -1- from the heating and A/C unit.

Fig 1: Loosening Clips And Remove Defroster Intermediate Piece
GWWN80-10212Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the intermediate piece -3- from the heating and A/C unit.

-- Remove rear channels for right and left footwells. Refer to REAR VENT .

-- Place Drip Tray For Shop Crane VAS 6208 under the engine.

Fig 2: Identifying Coolant Hoses At Heater Core
GWWN80-10016Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Mark coolant hoses -1-.

WARNING:

Contact with hot engine coolant can cause severe scalding.

Coolant temperature can be above 100 °C with a warm engine. The cooling system is under pressure.

If necessary, reduce pressure and temperature before repairs.

-- Clamp off coolant hoses -1- using Hose Clamps Up To Ø 40 Mm VAS 3093 and disconnect coolant hoses to heater core.

Fig 3: Identifying Hose, Container, And Heater Core
GWWA87-0675Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect a section of hose -A- onto 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 nuts -1- (6 Nm).

Fig 4: Identifying Heat Shield
GWWN87-10474Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the heat shield -2-.

All vehicles 

Fig 5: Identifying Refrigerant Lines, Bolts And Expansion Valve
GWWN87-10018Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
WARNING:

There is a danger of ice-up.

Refrigerant leaks out if refrigerant circuit is not discharged.

Refrigerant must be extracted before opening 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 the engine compartment, unscrew bolts -1- for refrigerant lines -2-.

-- Disconnect refrigerant lines from expansion valve -3-.

NOTE:
  • Seal open pipe 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 floor carpet in vehicle interior with leak-proof foil and absorbent paper.

NOTE:

On removal, note down bolt lengths and assignment for installation later.

Fig 6: Identifying Heating And A/C Unit Overview
GWWN87-10475Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
  1. Screw
    • 4, 5 ± 0.7 Nm
  2. Screws
    • Quantity: 2
    • 4, 5 ± 0.7 Nm
  3. Cable Bracket
  4. Heater Unit

    Removing 

    -- Disconnect the condensation water hose from heating and A/C unit. Refer to CONDENSATION WATER DRAIN HOSE ON HEATING AND A/C UNIT, CHECKING .

    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.
    • The tunnel braces -8- and -9- are welded to the assembly carrier -7-.

    -- Remove the assembly carrier. Refer to Removal and Installation .

    -- Disconnect the connectors from the heater.

    -- Remove bolts -6- from bracket -5-.

    -- Remove the bolts -10- and nuts -12- and the bracket -11-.

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

    NOTE:
    • To be able to reach the bolt -1-, heater 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.
    • Also pay attention to wiring harness, individual wiring connections may get damaged when pulling too forcefully on wiring harness.

    -- Remove the heater.

    Installing 

    Installation is carried out in the reverse order, when doing this note 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). Fig 7

    Fig 7: Heating And Ventilation Unit Seal At Bulkhead, Installation Position
    GWWN80-10012Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

    -- Fill with coolant, refer to[For transmission(s) 0A6, 09M] [For engine(s) CCTA] Removal and Installation .

  5. Bracket
  6. Screws
    • 8 Nm
  7. Assembly Carrier
  8. Right Support
    • Attached to the assembly carrier
  9. Left Support
    • Attached to the assembly carrier
  10. Screws
    • Quantity: 2
    • 9 ± 1.3 Nm
  11. Bracket
  12. Nut
    • Quantity: 2
    • 9 ± 1.3 Nm
NOTE:

Note installation position of seal -A- during assembly.

Fig 8: Heating And A/C Unit Seal At Bulkhead, Installation Position
GWWN87-10012Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
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