Heater and A/C Unit, from 03 November 2008

Heater and A/C Unit, from 03 November 2008

Special tools, testers and auxiliary items required

• Drip Tray for Workshop Hoist (VAS6208)

• Hose Clamps up to 40 mm (3093)

• A/C Service Station (ROB 134APF) or newer model

• Torque Wrench (V.A.G 1331)

• Compressed air gun, commercially available

• Extract the refrigerant using the (ROB 134APF) (or succeeding model).

• Environmentally hazardous draining of refrigerant is an offense punishable by law.

• See notes, refer to => [ A/C System Repairing and Handling Refrigerants ] Description and Operation.

• To improve accessibility, additional components must be removed, for example, the engine cover (depending on engine version).

Removing

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).






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

All vehicles

• Vent the coolant system after opening it.

• The refrigerant system is under pressure when the engine is warm. If necessary, release system pressure prior to repair work.

- Place (VAS 6208) under the engine.

- Drain the coolant system.

- Label the coolant hoses - 1 - to the heating and A/C unit.






Contact with hot engine coolant can cause severe scalding.

Coolant temperature can be above 100 °C (212 °F) with a warm engine. The coolant system is under pressure.

If necessary, reduce pressure and temperature before repairs.

- Disconnect the coolant hoses to the heater and A/C unit heater core - 1 - (for example, with (3094) ) and remove them.

- Insert one section of hose - A - and of - B - on to both connections to the heater core.






- Hold a container - C - under the hose of lower connection - B -.

- Using a compressed air gun - D -, carefully blow coolant out of the heater core (into container - C -) via hose - A -.

- Remove the bolts (10 Nm) - 1 - for the refrigerant pipes - 2 - from the expansion valve - 3 -.

- Pull the refrigerant pipes - 2 - carefully off the expansion valve - 3 -.






- Seal off the refrigerant pipes and expansion valve with suitable caps.

- Cover the carpet.

- Remove the instrument panel.

- Remove the air guide channels for the right and left passenger compartment footwell vents. Refer to => [ Rear Channel, Footwell ] Rear Channel, Footwell.

- Remove the bolts (9 Nm) - 2 - from the bracket - 5 - for the module carrier - 6 -.

- Remove the bolts (4 Nm) - 3 - from the cable guide - 4 - and then remove the module carrier - 6 -.






- Remove the lower bolts (9 Nm) - 9 - from the heater and A/C unit - 7 -.

- Disconnect all connectors from the heater and A/C unit - 1 -.

• All cable ties opened or cut during removal must be reinstalled at the same locations during installation.

- Remove the module carrier - 6 -..

• 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 the heater and A/C unit - 1 - with a second technician.

- Drain the remaining coolant above the (VAS 6208).

Installing

- Install the heater and A/C unit in reverse order of removal with a second technician. Note the following while installing it:

• Make sure the seal fits correctly - A -.






• Make sure all cables and wires are routed correctly and are not bent or caught.

- Fill the coolant and then vent the coolant system.