HVAC Unit Removal

WARNING: This page is about a different car, the 2016 Volkswagen Beetle, 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, 2013 Volkswagen Beetle, and 2012 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Shop Crane - Drip Tray VAS 6208
Hose Clamps - Up To 40 mm 3093
A/C Service Station VAS 6007A or newer model
Torque Wrench 5-50 Nm V.A.G 1331
Engine Bung Set VAS 6122
Compressed air gun, commercially available

NOTE:

Extract the refrigerant in advance with the A/C Service Station VAS 6007A (or succeeding models) on vehicles with an A/C system.

Environmentally hazardous draining of refrigerant is an offense punishable by law.

See notes. Refer to 00 TECHNICAL DATA .

Note the safety precautions on vehicles with a start-stop system. Refer to VEHICLES WITH START/STOP SYSTEM .

Depending on engine and vehicle version, it may be necessary to loosen or to remove the following components: upper engine cover, pressurized air pipe to throttle valve part and, depending on engine, the intake manifold, etc. .

-- Turn off the ignition.

-- Disconnect the battery. Refer to [For transmission(s) 0A4,02E,09G,02Q] Removal and Installation .

-- Cover the driver seat and front passenger seat with seat covers.

-- Cover the carpet in the right and left front footwell with a fluid resistant foil and absorbent paper.

NOTE:

Bleed the coolant circuit after it has been opened. Refer to BATTERY, DISCONNECTING AND CONNECTING .

The refrigerant system is under pressure when the engine is warm. Reduce the pressure before repairing, if necessary (for example, carefully open the reservoir).

-- Place Shop Crane - Drip Tray VAS 6208 under the engine.

-- Drain the coolant circuit. Refer to COOLANT, DRAINING AND FILLING .

WARNING:

Contact with hot engine coolant can cause severe scalding.

Coolant temperature can be above 100°C with a warm engine. The coolant system is under pressure.

If necessary, reduce pressure and temperature before repairs.

If equipped, remove the heat shield

-- Remove nut -1- (10 Nm).

-- Remove the lock washer -2- and the clip -3-.

-- Remove the heat shield for the expansion valve -4- from the bulkhead.

Fig 1: Identifying Nut, Lock Washer And Clip

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

All vehicles

-- Label the coolant hoses -2- to the heater and A/C unit.

-- Clamp off the coolant hoses to the heater core -2- with the Hose Clamps - Up To 40 mm 3093.

-- Release the locking clips -1- and remove the coolant hoses -2-.

Fig 2: Identifying Locking Clips And Coolant Hoses

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the hose -A- onto the upper connection on the heater core.

-- Hold the container -B- under the lower connection for the heater core -C-.

-- Using a compressed-air gun, carefully blow the remaining coolant out of the heater core via the hose -A- and into the container -B-.

Fig 3: Identifying Container

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Vehicles with an A/C system

-- Drain the refrigerant circuit, for example, using the A/C Service Station VAS 6008. .

-- Remove the bolts -1- for the refrigerant lines -2- and -4- (10 Nm).

-- Carefully remove the refrigerant lines -2- and -4- from the expansion valve -3-.

Fig 4: Identifying Refrigerant Lines And Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Seal the refrigerant lines and the expansion valve with suitable tools, for example, with the Engine Bung Set VAS 6122.

-- Remove the condensation water drain. Refer to CONDENSATION WATER DRAIN .

All vehicles

-- Remove the driver footwell vent. Refer to DRIVER SIDE FOOTWELL VENT .

-- Remove the footwell vent on the front passenger side. Refer to FRONT PASSENGER SIDE FOOTWELL VENT .

-- Remove the rear vent air guide channels. Refer to REAR VENT AIR GUIDE CHANNEL .

-- Remove the instrument panel. Refer to INSTRUMENT PANEL

-- Remove the nuts -1- and -2- (9 Nm).

-- Remove the instrument panel crossmember (module carrier) -3-. Refer to INSTRUMENT PANEL CENTRAL TUBE .

Fig 5: Identifying Instrument Panel Crossmember

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect all connectors and wiring harnesses from the heater and A/C unit.

NOTE:

All cable ties opened or cut during removal must be reinstalled at the same locations during installation.

It is helpful to make a sketch or to take a photo to ensure the installation of components in their original locations.

When removing the heater and A/C unit, make sure that both coolant pipes to the heater core do not get caught on the plenum chamber or noise insulation, bent or damaged.

-- The heater and A/C unit -2- from the bulkhead -1- with help from a second technician and take it out of the vehicle.

-- Drain the remaining coolant above the Shop Crane - Drip Tray VAS 6208.

Fig 6: Identifying Heater And A/C Unit

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.