Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Heating And A/C Unit
Special tools and workshop equipment required
- Drip Tray For Shop Crane VAS 6208
- Hose Clamps Up To 40 mm Diameter 3093
- A/C Service Station ROB 134APF
- Rinsing Device For Refrigerant Circuits VAS6337/1
- Torque Wrench V.A.G 1331
- Compressed air gun, commercially available
Removal
Extract the refrigerant using the ROB 134APF.
Environmentally hazardous draining of refrigerant is an offense punishable by law.
To improve accessibility, additional components, such as the engine cover must be removed (depending on engine version). Refer to REMOVAL AND INSTALLATION for Engine(s): BUB, REMOVAL AND INSTALLATION for Engine(s): BPY or REMOVAL AND INSTALLATION for Engine(s): CCTA, CBFA .
-- Extract refrigerant using, for example, ROB 134APF, only then open the refrigerant circuit. Refer to SPECIALIZED REFRIGERANT CIRCUIT REPAIRS .
-- Remove the instrument panel. Refer to Removal and Installation .
-- If the vehicle has a steel subframe, then remove the subframe. Refer to Removal and Installation . The tunnel support is welded to the steel tube on these vehicles.
-- Remove the right and left footwell channels (on vehicles where it is not necessary to remove the subframe). Refer to REAR FOOTWELL CHANNEL .
-- Place VAS 6208 under the engine.
-- Mark the coolant hoses -1-.
There is a danger of ice-up.
Refrigerant leaks out if refrigerant circuit is not discharged.
Refrigerant must be extracted before opening the refrigerant circuit. If refrigerant circuit is not opened within 10 minutes after extracting, pressure may build up in refrigerant circuit by renewed evaporation. Extract refrigerant once more.
-- Clamp the coolant hoses -1- using the VAS 3093 and remove the coolant hoses from the heater core.
-- Connect a section of hose -A- to the upper connection.
-- Hold a container -B- under the lower connection -C-.
-- Using a compressed air gun, carefully blow residual coolant out of heater core at heater core connection.
Only for vehicles with a heat shield in front of the expansion valve
-- Remove the nut -1- (6 ± 0.9 Nm).
-- Remove the clamps -2- and the heat shield -3-.
-- From inside the engine compartment, remove the bolts -1- from the refrigerant pipes -2-.
-- Remove the refrigerant pipes from the expansion valve -3-.
Seal the open connections.
To seal off all open connections on expansion valve, sealing caps from a replacement expansion valve can be used (preventing dirt and moisture from entering the system).
-- Cover the carpet inside the passenger compartment with waterproof foil and water absorbing paper.
When removing the bolts, make note of the lengths and allocation.
NO RELATED
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.