Heating and Ventilation Unit

Heating and Ventilation 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).

- Remove instrument panel

- Remove facing wall in plenum chamber.

- Remove left and right rear footwell channels --> [ Rear Footwell Air Ducts ] Instrument Panel Vents

- Place Drip tray for VAS 6100 (VAS 6208) under the 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.

- Using a compressed air gun, carefully blow residual coolant from heater core at heater core connection.

- Cover floor carpet in vehicle interior with leak-proof foil and absorbent paper.

• Take note during removal of the length and assignment of screws for re-installation





1 Bolt

• 4 Nm

2 Screws

• Qty. 2

• 4 Nm

3 Cable bracket

4 Heating and ventilation unit

Removing

- Disconnect electrical connections from heating and ventilation unit.

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

- 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 --> [ 1 Bolt ] and --> [ 2 Screws ] from cable bracket --> [ 3 Cable bracket ].

• To be able to reach the bolt --> [ 1 Bolt ] , heating and ventilation 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 ventilation unit.

Installing

Install in reverse order of removal, noting the following:

• Assistance of a second mechanic is necessary to install heating and ventilation unit.

- When inserting heating and ventilation unit, have second mechanic guide both coolant pipes to heater core through the seal (from engine compartment)--> [ Heating and ventilation unit seal at bulkhead,
installation position ].

- Fill with coolant.

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 ventilation unit seal at bulkhead, installation position





- First install seal - A - on bulkhead , then engage on heater core.

• To prevent ingress of water into vehicle interior, note installation position.