Heating And A/C Unit (CLIMATRONIC): Notes

Special tools and workshop equipment required 

• Hose Clamps - Up To 40mm 3093
• Robinair A/C Service Unit ROB 134APF
• Shop Crane - Drip Tray VAS6208

Removing 

-- Extract refrigerant using Robinair A/C Service Unit ROB 134APF, only then open the refrigerant circuit. 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 Shop Crane - Drip Tray VAS6208 under the engine.

Fig 1: Identifying Coolant Hoses At Heater Core

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Mark the coolant hoses -1-.

-- Clamp off the coolant hoses -1- using the Hose Clamps - Up To 40mm 3093 and remove the coolant hoses from the heater core.

Fig 2: Identifying Hose, Container, And Heater Core

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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.

Fig 3: Identifying Refrigerant Lines, Bolts And Expansion Valve

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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.

Fig 4: Heating And A/C Unit Remove/Install Components

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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 -item 6-  .Screws from the bracket -item 5-  .Bracket.

     -- Remove the support -item 8-  .Right Support.

     -- Remove the bolts -item 10-  .Screws and nuts -item 12-  .Nuts and the bracket -item 11-  .Bracket.

     -- Remove the bolts -item 2-  .Screws and -item 1-  .Screw from the cable bracket -item 3-  .Cable Bracket.

     NOTE:

     To be able to reach the bolt -item 1-  .Screw, 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.

     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) 02E, 02Q] [For engine(s) CJAA] General Information or [For transmission(s) 02E, 02Q] [For engine(s) CCTA, CBFA] General Information or [For transmission(s) 0A4, 09G] [For engine(s) CBTA, CBUA] General Information .

     -- For capacities, refer to Maintenance, Diagnosis .

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