Removal and Replacement
Heater and A/C Unit
Special tools, testers and auxiliary items required
• Hose Clamps up to 40 mm (3093)
• A/C Service Station (ROB134APF) or succeeding model
• Drip Tray For Shop Hoist (VAS 6208)
Removing
• To improve accessibility, additional components must be removed, for example the engine cover (depending on engine version).
There is a danger of ice-up.
Refrigerant leaks out if refrigerant circuit is not discharged.
Refrigerant must be extracted before opening the refrigerant circuit. If refrigerant circuit is not opened within 10 minutes of extraction, pressure may form in refrigerant circuit due to evaporation. Extract refrigerant once more.
- Extract refrigerant using (ROB134APF) , only then open the refrigerant circuit. See notes, refer to => [ Refrigerant Circuit, Specialized Repairs ] Procedures.
- Remove the instrument panel.
- Remove the bulkhead in the plenum chamber.
- Remove the rear channels from the right and left footwells. Refer to => [ Rear Footwell Channel ] Rear Footwell Channel.
- Place (VAS 6208) under the engine.
- Mark the coolant hoses - 1 -.
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.
- Clamp the coolant hoses - 1 - using the (3093) and remove the coolant hoses from the heater core.
- 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.
- From inside the engine compartment, remove the bolts - 1 - from the refrigerant pipes - 2 -.
- Remove the refrigerant pipes from the expansion valve - 3 -.
• 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 the carpet inside the passenger compartment with waterproof foil and water absorbing paper.
• On removal, note bolt lengths and assignment for installation later.
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 Drain Hose ] Service and Repair.
- Disconnect the connectors from the heater and air conditioner.
• 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 nuts item 6 => [ (Item 6) Nuts ] from the bracket item 5=> [ (Item 5) Bracket ].
- Remove the support item 8=> [ (Item 8) Right Support ].
- Remove the bolts item 10 => [ (Item 10) Screws ] and nuts item 12 => [ (Item 12) Nuts ] and the bracket item 11=> [ (Item 11) Bracket ].
- Remove the bolts item 2 => [ (Item 2) Screws ] and item 1 => [ (Item 1) Screw ] from the cable bracket item 3=> [ (Item 3) Cable Bracket ].
• To be able to reach the bolt item 1 => [ (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 => [ Seal For Heating And A/C Unit / Engine
Compartment ].
- Make sure the condensation water hose fits correctly. Refer to => [ Condensation Drain Hose ] Service and Repair.
- Add coolant.
5 Bracket
6 Nuts
• 9 Nm
• Quantity: 2
7 Subframe
8 Right Support
9 Left Support
10 Screws
• 9 Nm
• Quantity: 2
11 Bracket
12 Nuts
• 9 Nm
• Quantity: 2
Seal For Heating And A/C Unit / Engine Compartment
• Note installation position of seal - A - during assembly.