Heater And A/C Unit, Removing And Installing: Removing
- When removing the bolts, make note of the lengths and allocation.
- All cable ties and other wiring harness fasteners released or cut open when removing the heater and A/C units are to be re-attached in same position on installation.
- Seal open line connections at the connection point with clean plugs, for example from the Engine Bung Set:VAS6122 .
-- Initiate the basic setting of the A/C system using the Thermal Management Control Module -J1024- and open the electric valves using the routine "Refrigerant Circuit, Extract, Evacuate and Fill" in the Vehicle Diagnostic Tester .
-- Switch the ignition off.
-- Discharge the refrigerant circuit. Refer to Refrigerant Circuit or A/C SERVICE STATION, USING .
-- Remove the plenum chamber cover. Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .
-- Remove the Battery -A-. Refer to BATTERY, REMOVING AND INSTALLING .
The cooling system is under pressure when the engine is warm. There is a risk of scalding due to hot steam and hot coolant.
Scalding the skin and other parts of the body is possible.
- Wear safety gloves.
- Wear protective eyewear.
- Reduce the pressure by covering the coolant expansion tank cap with a cloth and carefully opening it.
-- Release all the residual pressure in the cooling system, for this, cut the seal tab -3- and open the cap -1-.
-- Label the layout of the coolant hoses on the connections to the heat exchanger -B- (supply) and -A- (return to engine).
-- Clamp off the coolant hoses -A and B- using the Hose Clamps - Up To 25mm:3094 .
-- Cover the area under the connections for coolant hoses -A and B- in the plenum chamber, for example with absorbent paper.
-- Place a small container under the connections for coolant hoses -A- (to the heater core).
-- Remove the coolant hoses -A and B- from the connections to the heater and A/C unit heater core.
-- Insert one section each of hose -A and B- on to both connections to heater core.
-- Place the container -B- under the other end of the hose -C-.
-- Using a compressed air gun -D-, carefully blow coolant out of the heater core against the normal flow direction of the coolant) via the hose -A- into a container -B-.
-- Disconnect the refrigerant lines from the front expansion valve and move to the side (do not remove). Refer to EXPANSION VALVE, REMOVING AND INSTALLING .
-- Loosen the grommet -A- with the support ring -B- from the plenum chamber rear panel toward the passenger compartment (it is removed and installed with the heater and A/C unit).
-- Remove the instrument panel crossmember. Refer to INSTRUMENT PANEL CROSSMEMBER, REMOVING AND INSTALLING .
-- Remove the rear air duct. Refer to REAR AIR DUCT, REMOVING AND INSTALLING .
-- Remove the condensation water drain hose -A- from the left and right connection -B- on the heater and A/C unit.
-- Cover the floor covering in the area of the center tunnel with a sturdy mat.
-- Loosen the grommet -E- for the coolant pipes to the heater core and loosen the grommet -D- for the expansion valve/connection from the openings in the plenum chamber rear panel.
-- Loosen the heater and A/C unit -C- carefully from the vehicle (so that no components are damaged by any connections not yet loosened) and remove toward the front passenger footwell.