Heater Unit

Heater Unit

Special tools, testers and auxiliary items required

• Drip Tray For Shop Crane (VAS 6208)

• Hose Clamps Up To 40 mm Diameter (3093)

• Torque Wrench (V.A.G 1331)

• Compressed air gun, commercially available

Removing

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

- Remove the instrument panel.

- Loosen the clips- 2 - and remove the intermediate defrost piece - 1 - from heater and A/C unit.






- Remove the intermediate piece - 3 - from the heater and A/C unit.

- Remove the subframe.

- 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 cooling 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 on the heater core.

- 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.

- Cover the carpet inside the passenger compartment with waterproof foil and water absorbing paper.

• When removing the bolts, make note of the lengths and allocation.








1 Screw

• 4.5 +/- 0.7 Nm

2 Screws

• Quantity: 2

• 4.5 +/- 0.7 Nm

3 Cable Bracket

4 Heater Unit

Removing

All cable ties opened or cut during removal of the A/C system must be reinstalled at the same locations during installation.

The heater wiring harness is removed with the heater.

The tunnel braces - 8 - and - 9 - are welded to the assembly carrier - 7 -.

- Remove the subframe.

- Disconnect the connectors from the heater.

- Remove the bolts - 6 - and - 5 -.

- Remove the bolts - 10 - and nuts - 12 - and bracket - 11 -.

- Remove the bolts - 1 - and - 2 - from the cable bracket - 3 -.

• All cable ties opened or cut during removal of the A/C system must be reinstalled at the same locations during installation.

• Pull the heater on the driver side slightly from the bulkhead in order to access the bolt - 1 -.

• 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.

• Observe wiring harness, individual electrical wiring connections may get damaged when pulling on harness.

- Remove the heater.

Installing

Installation is carried out in the reverse order while noting the following:

• A second technician is necessary to install the heater.

- When inserting heater unit, have the second technician guide the coolant pipes to heater core through the seal (from engine compartment). Refer to => [ Seal Between Heater and Engine Compartment ].

- Fill the coolant.

5 Bracket

6 Screws

• 8 Nm

7 Subframe

8 Right Support

• Secure it to the subframe.

9 Left Support

• Secure it to the subframe.

10 Screws

• Quantity: 2

• 9 +/- 1.3 Nm

11 Bracket

12 Nut

• Quantity: 2

• 9 +/- 1.3 Nm

Seal Between Heater and Engine Compartment





• Make sure the seal - A - is installed correctly.

Installing

- Install in reverse order of removal.