Heater And A/C Unit: Notes

Special tools and workshop equipment required

ROB 134 APF or succeeding model.
Drip tray for shop crane VAS 6208
Hose clamps up to 40 mm diameter 3093
Compressed air gun, commercially available

Removing

NOTE:

To improve accessibility, additional components e.g. engine cover must be removed (depending on engine version). Refer to [For transmission(s) 02E, 02Q] [For engine(s) CJAA] Removal and Installation or [For transmission(s) 0A4, 09G] [For engine(s) CBTA, CBUA] Removal and Installation .

-- Extract refrigerant e.g. using VAS 6007A, only then open the refrigerant circuit. Observe notes. Refer to REFRIGERANT CIRCUIT COMPONENTS .

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

-- Place VAS 6208 under the engine.

Fig 1: Identifying Coolant Hoses At Heater Core

Courtesy 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 the coolant hoses -1- using 3093 and disconnect the coolant hoses to the heater core.

Fig 2: Identifying Section Of Hose, Suitable Container And Lower Connection

Courtesy 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 nut -1- (6 ± 0.9 Nm).

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

Fig 3: Identifying Shielding Plate, Clips And Nuts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Loosen the clips -2- and remove the heat shield -3-.

All Vehicles

Fig 4: Identifying Refrigerant Lines, Bolts And Expansion Valve

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

WARNING:

Danger due to refrigerant coming out under pressure.

Danger of frost bite to skin and other parts of the body.

Extract the refrigerant and immediately open the refrigerant circuit after that.
If the refrigerant was extracted more than 10 minutes in the past and the refrigerant circuit was not opened, extract the refrigerant again. Pressure in the refrigerant circuit is caused by evaporation.

- 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-.

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 leakproof foil and absorbent paper.

NOTE:

Make a note of the screw lengths and their location.

Fig 5: Identifying Heater and A/C Unit Overview

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Bolt
- 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.
Bolts
- 4.5 ± 0.7 Nm
Cable Bracket
Heating and A/C Unit
Bracket
Bolts
- 8 ± 1 Nm
Subframe
NOTE:
There are two versions of the assembly carrier -7-. On the version made of steel, the supports are welded to the assembly carriers -8- and -10-. On the version made of aluminum, the supports are attached to the assembly carriers -8- and -10- with bolts.

The illustration shows the version made of steel.
Right Support
Bolts
- 20 ± 3 Nm
Left Support
Bolts
- 9 ± 1.3 Nm
Bracket
Bolts
- 9 ± 1.3 Nm

- Remove the condensation water hose from the heater and air conditioner. Refer to CONDENSATION WATER DRAIN HOSE ON HEATING AND A/C UNIT .

- Disconnect the connectors from the heater and air conditioner.

All cable ties opened or cut during the removal of the A/C system must be reinstalled at the same locations during installation.
The air conditioning wiring harness is removed with the heater and air conditioner.

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

- Remove screws -9-.

- Remove the bolts -11- and -13- and bracket -12-.

- Remove the subframe -7-.

NOTE: On the version made out of aluminum, only the supports -8- and -10- need to be removed. Tightening specification for the upper bolts on the support: 9 +/- 1.3 Nm.

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

To be able to reach the bolt -1-, the heating and A/C unit on the driver side must be pulled out slightly from the bulkhead.

When removing the heater and A/C unit, make sure the two coolant pipes on the heater core do not get caught and bent or damaged on plenum chamber or noise insulation pan.
Pay attention to the wiring harness. The individual wire connections could 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: The assistance of a second technician is necessary to install the heating and A/C unit.

NOTE: - Guide both heater core coolant pipes (from inside the engine compartment) through the seals with the help of a second technician when installing the heater and A/C unit. Refer to

- Make sure the condensation water hose fits correctly. Refer to CONDENSATION WATER DRAIN HOSE ON HEATING AND A/C UNIT .

- Add coolant.

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