VW Golf manuals

Volkswagen Golf Service & Repair Manual: Removing and installing heater and air conditioning unit

Special tools and workshop equipment required
   
Torque wrench -V.A.G 1331/- (5…50 Nm)
 

Removing and installing heater and air conditioning unit

Hose clamps up to 25 mm -3094-
 

Removing and installing heater and air conditioning unit

Drip tray for workshop hoist -VAS 6208-
 

Removing and installing heater and air conditioning unit

Engine bung set -VAS 6122-
Air conditioner service station
Commercially available compressed-air gun
Removing
  Note
Removal and installation for a left-hand drive vehicle is described; the procedure for a right-hand drive vehicle is analogous.
Depending on engine version, additional components, e.g. the engine cover panel or the air filter housing, must be removed to improve access → Rep. gr.10 or → Rep. gr.23.
–  Heed the safety precautions → Chapter „Safety instructions“.
–  Vehicles with air conditioning system: extract refrigerant, e.g. with air conditioner service station. Only then open refrigerant circuit. Comply with notes → Chapter.
–  Vehicles with air conditioning system: Disconnect refrigerant line with internal heat exchanger on expansion valve → Chapter.
 

Removing and installing heater and air conditioning unit

–  Place drip tray -VAS 6208- beneath engine.
–  Mark coolant hoses -1- and -4-.
  Note
The heat exchanger is designed for a particular direction of flow of the coolant. Therefore, the coolant hoses must not be interchanged when connecting them.
–  Clamp off coolant hoses -1- and -4- using hose clamps, up to 25 mm -3094-.
When the engine is warm, the cooling system is under pressure. Danger of scalding due to steam and hot coolant. There is a risk of injury to the skin and parts of the body due to scalding.Always wear safety gloves.Always wear safety goggles.Proceed as follows to release the pressure: cover the cap of the coolant expansion tank with a cloth, and open it carefully.
 

Removing and installing heater and air conditioning unit

–  Lift retaining clips -2- and -3-.
–  Disconnect coolant hoses -1- and -4- from heat exchanger for heater.
–  Push a piece of hose -A- onto upper union.
–  Insert compressed air gun into end of hose.
–  Hold drip tray -B- under connection -C- and carefully blow coolant out of heat exchanger using compressed air gun.
–  Seal off open lines and connections with clean plugs from engine bung set -VAS 6122-.
  Note
To seal open connections of expansion valve, use, for example, sealing cover from spare expansion valve.
–  Remove dash panel central tube → General body repairs, interior; Rep. gr.70.
–  Remove air duct leading to rear vent (depending on vehicle) → Chapter.
–  Lift rear footwell vents under front seats and pull them towards rear to ease removal of footwell vents from heater and air conditioning unit.
–  Remove rear footwell vents from heater and air conditioning unit.
 

Removing and installing heater and air conditioning unit

–  Disconnect connector -3- from fresh air blower control unit -J126-.
–  Pull connector -5- off airbag control unit -J234- (on tunnel) -2-.
 

Removing and installing heater and air conditioning unit

–  Cover floor covering and airbag control unit -J234- in interior of vehicle with impermeable sheeting and absorbent paper.
 

Removing and installing heater and air conditioning unit

–  Carefully pull condensation drain hose -2- off heater and air conditioning unit -1-.
 

Removing and installing heater and air conditioning unit

–  Pull heater and air conditioning unit -1- off retainers on plenum chamber bulkhead.
–  Lay bare the duct -3-.
–  Lay wiring harness -2- on mountings -4- to one side -arrows-.
–  Remove heater and air conditioning unit to the side.
Installing
Installation is carried out in the reverse order. When installing, note the following:
  Note
The aid of a second mechanic is required to install the heater and air conditioner unit.
 

Removing and installing heater and air conditioning unit

–  When installing, ensure that condensation drainage hose -3- is properly seated.
–  Lug -arrow- on connecting piece of heater and air conditioning unit -1- must engage in guide -2-.
–  If a commercially available cable tie was installed to retain the condensation drain -3-, then renew it.
–  The condensation drain hose must be routed below the wiring harness of the airbag control unit -J234--4- in the figure.
–  Fill with coolant → Rep. gr.19.
–  Refilling with refrigerant R134a and refrigerant oil → Chapter.
–  As a final step, check operation of the heater/air conditioner.
Specified torque
→ Chapter „Assembly overview - heater and air conditioning unit“
→ Chapter „System overview - refrigerant circuit“
Dash panel central tube; Assembly overview - dash panel central tube → General body repairs, interior; Rep. gr.70.
Engine cover panel → Rep. gr.10.
Air filter housing → Rep. gr.23.
 

Removing and installing heater and air conditioning unit

Assembly overview - flaps and partitions in air distribution housing
  Note The illustration shows a left-hand drive vehicle.     View from front   Note -Arrow-&nbs ...

Dismantling and assembling heater and air conditioning unit
  Note There are different designs and makes of heater and air conditioning unit. The individual components of the various heaters and air conditio ...

Other materials:

Removing and installing wheel bearing unit, torsion beam axle
Special tools and workshop equipment required Fitting sleeve -3241/4- Hub grease cap puller -VW 637/2- Torque wrench -V.A.G 1332- Tool insert -T10162 A- Torque wrench -V.A.G 1410-   ...

Physical basics
The four known physical states of water also apply to air conditioning refrigerants. 1 -  Gas (invisible) 2 -  Vapour 3 -  Liquid 4&nbs ...

Silicone remover
Designation: Aqueous silicone remover -LSW 019 000 A5- Silicone remover -LVM 020 000 A5- Slow-drying silicone remover -LVM 020 100 A5- Issued 02.2012 ...

© 2016-2019 Copyright www.vwgolf.org