Climatic Heating and A/C Unit
Climatic Heating and A/C Unit
Preparation
Special tools, testers and auxiliary items required
• Drip tray for VAS 6100 (VAS 6208)
• Hose clamps, up to 40 mm. (3093)
• Compressed air gun, commercially available
CAUTION!
• Switch off all electrical consumers.
• Switch ignition off and remove ignition key.
• To improve accessibility, additional components e.g., engine cover must be removed (depending on engine version).
- Evacuate refrigerant circuit using refrigerant recycling/recovery unit Kent-Moore ACR4 (or UL approved equivalent) Observe notes --> [ A/C Refrigerant System ] A/C Refrigerant System.
Removing
- Remove instrument panel
- Remove facing wall in plenum chamber.
- Remove rear footwell air ducts --> [ Rear Footwell Air Ducts ] Instrument Panel Vents
- Place Drip tray for VAS6100 (VAS 6208) under engine.
- Mark coolant hoses - 1 -
CAUTION!
• Scalding danger!
• The cooling system is pressurized when the engine is warm. Wear gloves and other protection and carefully release system pressure if necessary before performing repairs.
- Clamp off coolant hoses - 1 - using Hose clamps, up to 40 mm. (3093) and disconnect coolant hoses to heater core.
- Connect a section of hose - A - onto upper connection.
- Hold suitable container - B - under lower connection - C -.
- Using a compressed air gun, carefully blow residual coolant from heater core at heater core connection.
CAUTION!
• Frostbite danger!
• High pressure refrigerant may leak out if refrigerant circuit is not discharged.
• Always evacuate refrigerant prior to opening refrigerant circuit.
- From engine compartment, remove bolts (12 Nm) - 1 - for refrigerant lines - 2 -.
- Disconnect refrigerant lines from expansion valve - 3 -.
CAUTION!
• Always plug open refrigerant line connections to prevent dirt and moisture contamination.
• Where applicable, use sealing caps from replacement expansion valve.
- Cover floor carpet in vehicle interior with leak-proof foil and absorbent paper.
• Observe screw position, length and orientation during removal.
1 Screw
• 4 Nm
2 Screw
• Qty. 2
• 4 Nm
3 Cable bracket
4 Heating and A/C unit
Removing
- Disconnect condensation water drain hose from heating and A/C unit --> [ Heating and A/C Unit Condensation Water Drain Hose, Checking ] Testing and Inspection.
- Disconnect electrical connections from heating and A/C unit.
• All cable ties opened or cut during air conditioner removal must be reinstalled at the same locations during installation.
• The wiring harness "air conditioner" is removed together with the air conditioner unit.
- Remove screws --> [ 6 Screws ] from bracket--> [ 5 Bracket ].
- Remove supports --> [ 8 Right support ] and --> [ 9 Left support ].
- Remove screws --> [ (item 10) Screws ] and --> [ 12 Screws ] and remove bracket --> [ 11 Bracket ].
- Remove screws --> [ 2 Screw ] and --> [ 1 Screw ] from cable bracket --> [ 3 Cable bracket ].
• To be able to reach bolt --> [ 1 Screw ] , heating and A/C unit on driver side must be pulled out slightly from facing wall.
• When removing heat unit, ensure the two coolant pipes of the heater core do not get caught and bent or damaged on plenum chamber or sound 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, noting the following:
• The assistance of a second mechanic is necessary to install the heating and ventilation unit.
- When inserting heating and ventilation unit, have the second mechanic guide both coolant pipes to heater core through the seal (from engine compartment)--> [ Heating and A/C unit seal at bulkhead, installation
position ].
- When installing, ensure condensation water drain hose is seated correctly --> [ Heating and A/C Unit Condensation Water Drain Hose, Checking ] Testing and Inspection
- After installing heater core, replace engine coolant completely
5 Bracket
6 Screws
• 8 Nm
7 Assembly carrier
8 Right support
9 Left support
10 Screws
• Qty. 2
• 8 Nm
11 Bracket
12 Screws
• Qty. 2
• 8 Nm
Heating and A/C unit seal at bulkhead, installation position
• Note installation position of seal - A - during assembly.