Volkswagen Golf Service & Repair Manual: Removing and installing heater and air conditioning unit
| Special tools and workshop equipment
required |
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| Torque wrench -V.A.G 1331/- (5…50 Nm) |
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| Hose clamps up to 25 mm -3094- |
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| Drip tray for workshop hoist -VAS 6208- |
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| Engine bung set -VAS 6122- |
| Air conditioner service station |
| Commercially available compressed-air gun |
 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. |
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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.
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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. |
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| – |
Disconnect connector -3- from
fresh air blower control unit -J126-. |
| – |
Pull connector -5- off airbag
control unit -J234- (on tunnel) -2-. |
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| – |
Cover floor covering and airbag control unit -J234- in
interior of vehicle with impermeable sheeting and absorbent
paper. |
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| – |
Carefully pull condensation drain hose
-2- off heater and air conditioning unit
-1-. |
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| – |
Pull heater and air conditioning unit
-1- off retainers on plenum chamber bulkhead. |
| – |
Lay wiring harness -2- on
mountings -4- to one side
-arrows-. |
| – |
Remove heater and air conditioning unit to the side. |
| 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. |
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| – |
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. |
| → 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. |
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Note
The illustration shows a left-hand drive vehicle.
View from front
Note
-Arrow-&nbs ...
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:
Luggage net
Fig. 101 In the luggage compartment: luggage
net fitted flat
Fig. 102 In the luggage compartment: fastening
rings ① and hooks ③ for fixing the luggage net
First read and observe the introductory information
and safety warnings The luggage net stops light items of luggage from sliding ...
General description
Caution
If excessive force is exerted on sockets without
illumination, the retaining sleeve may be damaged.
Only illuminated sockets (cigarette lighter) can be
removed with the pull ...
Assembly overview - fuel delivery unit/fuel gauge sender, vehicles with
front-wheel drive
1 -
Fuel delivery unit
With fuel system pressurisation pump -G6-.
With integrated fuel filter; cannot be renewed individually.
With integrated pressure limiting valve; cannot be renewed
individually.
C ...
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Assembly overview - flaps and partitions in air distribution housing
Dismantling and assembling heater and air conditioning unit