Heating And A/C Unit

Special tools and workshop equipment required 

• Robinair A/C Service Unit -ROB 134APF-
• 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, for example -ROB 134APF-, only then open the refrigerant circuit. See notes, refer to REFRIGERANT CIRCUIT REPAIRS .

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

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

-- Place -VAS 6208- under the engine.

Only for vehicles with a heat shield in front of the expansion valve

-- Remove the nut -1- (4.5 Nm) and bolt -4- (2.5 Nm).

Fig 1: Identifying Nuts, Bolts, Clips And Heat Shield

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

All vehicles 

Fig 2: Identifying Coolant Hoses At Heater Core

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Mark the coolant hoses -1- to prevent interchanging them.

-- Clamp 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.

Fig 3: Identifying Section Of Hose, Suitable Container And Lower Connection

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- 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.

Fig 4: Identifying Refrigerant Lines, Bolts And Expansion Valve

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- 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-.

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

Fig 5: Identifying Heating And A/C Unit Remove/Install Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1. Screw 
   • 4 Nm
2. Screws 
   • Quantity: 2
   • 4 Nm
3. Cable Bracket 
4. Heating and A/C Unit 

   Removal 

   -- 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 opened or cut during removal must be reinstalled at the same locations during installation.

   -- Remove the bolts -9- and -5-.

   -- Remove the supports -7- and -8-.

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

   -- 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 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.

   Observe wiring harness, individual electrical wiring connections may get damaged when pulling on harness.

   -- Remove heating and A/C unit.

   Installation 

   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.

   -- When installing the heater and A/C unit, have the second technician guide the coolant pipes to heater core through the seal (from engine compartment), refer to Seal for Heating and A/C Unit / Engine Compartment .

   -- Fill with coolant. Refer to [For transmission(s) 09M] [For engine(s) BLV] DRAINING AND FILLING and refer to [For transmission(s) 02E, 02Q, 09M] [For engine(s) CCTA, CBFA] DRAINING AND FILLING .

5. Bracket 
6. Subframe 
7. Right Support 
8. Left Support 
9. Screws 
   • 9 +/- 1.3 Nm
10. Screws 
    • 9 +/- 1.3 Nm
    • Quantity: 2
11. Bracket 
12. Screws 
    • 9 +/- 1.3 Nm
    • Quantity: 2