Volkswagen Workshop Service and Repair Manuals

Removing   Note To improve access (depending on engine version), additional components, e.g. engine cover must be removed → Engine; Rep. gr.10. –  Extract refrigerant, e.g. with air conditioner service station -VAS 6007A- before opening refrigerant circuit. Comply with notes → Chapter. –  Remove dash panel → General body repairs, interior; Rep. gr.70. –  Remove left and right rear footwell air ducts → Chapter.

–  Place drip tray -V.A.G 1306- beneath engine. –  Mark coolant hoses -1-.   WARNING Danger of scalding injuries. When the engine is warm, the coolant temperature may be above 100 °C. The cooling system is pressurised. If necessary, release pressure and reduce temperature before carrying out repairs.

–  Clamp off coolant hoses -1- with hose clamps up to 40 mm Ø -VAS 3093- and disconnect coolant hoses to heat exchanger. –  Push a piece of hose -A- onto upper union. –  Hold a container -B- under lower connection -C-. –  Carefully blow remaining coolant out through unions of heat exchanger using a compressed air pistol. Applies only to vehicles with a heat shield before the expansion valve.   Note On right-hand drive vehicles, lock washers are installed instead of a clip and a nut.

–  Unscrew nut -1- (6 ± 0.9 Nm). –  Release clips -2- and remove heat shield -3-.

Continuation for all vehicles   WARNING Danger of freezing injuries. If refrigerant circuit has not been evacuated, refrigerant will escape. Extract refrigerant before opening refrigerant circuit. If the refrigerant circuit is not opened within 10 minutes after it has been evacuated, pressure may develop in coolant circuit due to re-evaporation. Extract refrigerant again. –  Unscrew bolts (10 ± 1 Nm) -1- of refrigerant lines -2- from engine compartment. –  Take refrigerant lines out of expansion valve -3-.   Note t  Seal open connections. t  To seal open connections of expansion valve, use, for example, sealing cover from spare expansion valve. –  Cover carpet in interior of vehicle with a waterproof foil and water absorbing paper.

When removing, observe lengths and location of bolts to ensure they are reinstalled in the correct position.

1 -

Bolt

q	4.5 ± 0.7 Nm.

q	Lower right on cable retainer to heater and air conditioning unit, near plenum chamber bulkhead

2 -

Bolts

q	4.5 ± 0.7 Nm.

3 -	Cable retainer

4 -	Heater and air conditioning unit

q

Removing:

–	Take condensation water drainage hose off heater and air conditioner unit → Chapter.

–	Disconnect connectors from heater and air conditioner unit.

t	Install all cable ties and other fasteners for wiring harness at the same places from which they were detached or cut when air conditioner was removed.

t	The air conditioning wiring harness is removed along with the heater and air conditioning unit.

–	Unscrew 2 securing nuts from convenience system central control unit -J393- and hang central control unit to side → Vehicle electrics; Rep. gr.97.

–	Remove bolts -6- and remove bracket -5-.

–	Unscrew bolts -8- and -10- and remove supports -9- and -11-.

–	Unscrew bolts -12- and -14- and remove bracket -13-.

–	Unscrew bolts -1- and -2- from cable retainer -3-.

t	To reach bolt -1-, pull heater and air conditioning unit on driver side slightly away from bulkhead.

t	When removing heater unit, observe both coolant pipes to heat exchanger so that they do not catch on opening to plenum chamber or noise insulation tray and become bent or damaged.

t	Also observe wiring harness. Pulling it too hard could damage individual connections.

–	Remove heater and air conditioning unit.

Installing:

Installation is carried out in the reverse order. When installing, note the following:

The aid of a second mechanic is required to install the heater unit.

–	Have second mechanic guide both coolant pipes to heat exchanger (from engine compartment) through seal when installing heater unit → Fig..

–	When installing, ensure that condensation water drainage hose is correctly seated → Chapter.

–	Fill with coolant → Engine; Rep. gr.19.

–	Refilling with refrigerant R134a and refrigerant oil → Chapter.

5 -

Bracket

6 -

Bolts

q

8 Nm.

7 -	Assembly carrier

8 -

Bolts

q	9 ± 1.3 Nm.

9 -	Right support

10 -

Bolts

q	20 ± 3 Nm.

11 -	Left support

12 -

Bolts

q	9 ± 1.3 Nm.

13 -

Bracket

14 -

Bolts

q	9 ± 1.3 Nm.

Note First tighten bolts -8- when installing supports -9- and -11-.

Heater and air conditioning unit/engine compartment seal   Note Note installation position of seal -A- during assembly.