Heater and A/C Unit, through 30 October 2008
Heater and A/C Unit, through 30 October 2008
Special tools, testers and auxiliary items required
• A/C Service Station (ROB 134APF)
• Drip Tray For Shop Crane (VAS 6208)
• Hose Clamps up to 40 mm (VAS 3093)
• Compressed air gun, commercially available
Removing
• To improve accessibility, additional components must be removed, for example, the engine cover (depending on engine version).
- Extract refrigerant using (ROB 134APF) , only then open the refrigerant circuit. See notes, refer to => [ Refrigerant Circuit, Specialized Repairs ] Refrigerant Circuit, Specialized Repairs.
- Remove the instrument panel.
- Remove the rear channels from the right and left footwells. Refer to => [ Rear Channel, Footwell ] Rear Channel, Footwell.
- Place (VAS 6208) under the engine.
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
- Make a marking on the coolant hoses - 1 - to prevent interchanging them.
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 (VAS 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.
Danger due to refrigerant coming out under pressure.
Danger of frost bite to skin and other parts of the body.
• Extract the refrigerant and immediately open the refrigerant circuit after that.
• If the refrigerant was extracted more than 10 minutes in the past and the refrigerant circuit was not opened, extract the refrigerant again. Pressure in the refrigerant circuit is caused by evaporation.
- From inside the engine compartment, remove the bolts (10 +/- 1 Nm), - 1 - from the refrigerant pipes - 2 -.
- Remove the refrigerant pipes from the expansion valve - 3 -.
• Seal the open 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.
• When removing the bolts, make note of the lengths and allocation.
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 opened or cut during removal must be reinstalled at the same locations during installation.
- Remove the bolts - 9 - and - 5 -.
- Remove the supports - 7 - and - 8 -.
- Remove the bolts - 10 - and - 12 - and bracket - 11 -.
- Remove the bolts - 1 - and - 2 - from the cable bracket - 3 -.
• To be able to reach the bolt - 1 -, heating and A/C unit on driver side must be pulled out slightly from facing wall.
• 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 heating and A/C unit.
Installing
Installation is carried out in the reverse order while noting the following:
• The assistance of a second technician is necessary to install the heating and A/C unit.
- When installing the heater and A/C unit, have the second technician guide the coolant pipes to heater core through the seal (from engine compartment)=> [ Seal for heating and A/C unit / engine
compartment ].
- Add coolant.
5 Bracket
6 Subframe
7 Right Support
8 Left Support
9 Screws
• 9 +/- 1.3 Nm
10 Screws
• Quantity: 2
• 9 +/- 1.3 Nm
11 Bracket
12 Screws
• Quantity: 2
• 9 +/- 1,3 Nm
Seal for heating and A/C unit / engine compartment
• Make sure the seal - A - is installed correctly.