Air Conditioning (Hatchback): Other Volkswagen Beetle A4

SAFETY PRECAUTIONS

The subassemblies and lines of the air conditioner are filled with Tetrafluoroethane also known as refrigerant R-134a.

A label on the lock carrier in the engine compartment indicates the refrigerant type and capacity.

A/C REFRIGERANT R-134A, PROPERTIES

For information on A/C Refrigerant R-134a, refer to REFRIGERANT R134A

A/C REFRIGERANT SYSTEM

Replacement A/C compressors, evaporators and condensers supplied by the Parts Dept. are filled with Nitrogen. If gas (Nitrogen) does not escape when component is first opened, the component may be faulty (leaking), do not install.

Replacement A/C compressors are filled with the total refrigerant oil quantity needed for the entire refrigerant system.

Always replace the receiver drier whenever the refrigerant system has been left open. Install immediately after opening to prevent moisture contamination of drier desiccant. Moreover, keep refrigerant system and other replacement components sealed for as long as possible to minimize the chance of dirt and moisture contamination.

Always plug open refrigerant line connections to prevent dirt and moisture contamination.

If the system has been discharged due to a damaged or leaking component (refrigerant hose/line, compressor, evaporator, condenser, etc.), flush the refrigerant system first with compressed air, then with nitrogen (available locally) and collect the oil that runs out. This will remove the refrigerant oil which may be saturated with moisture.

If the compressor is not replaced after flushing the system, fill compressor with the correct type and quantity of refrigerant oil as specified under A/C system capacities A/C REFRIGERANT SYSTEM CAPACITIES . Fill compressor with the total system oil capacity.

If the compressor is replaced, do not add any additional oil as the total amount of oil required is already in the compressor.

Dispose of contaminated refrigerant oil following laws governing hazardous waste disposal. Do not combine any refrigerant oil with any other old oils such as engine oil or transmission fluid.

Follow all applicable Warnings and Cautions when working on the A/C system.

A/C REFRIGERANT SYSTEM, DISCHARGING

Note. Refer to safety measures starting on SAFETY PRECAUTIONS prior to discharging or charging A/C refrigerant system. Make sure that initial set-up of the refrigerant recovery/recycling/recharging unit has been completed before discharging the A/C system.

Connect red high-pressure hose of refrigerant recovery/recycling/recharging unit to high pressure service valve on vehicle (where applicable).

Connect blue low-pressure hose of refrigerant recovery/recycling/recharging unit to low pressure service valve.

Following refrigerant recovery/recycling/recharging unit manufacturer's instructions, discharge A/C system into refrigerant recovery/recycling/recharging unit.

Disconnect power supply from A/C Clutch to prevent accidental compressor operation with A/C system discharged.

A/C REFRIGERANT SYSTEM, EVACUATING AND RECHARGING

Note. Refer to R-134a safety measures prior to discharging or charging A/C refrigerant system SAFETY PRECAUTIONS . Follow refrigerant recovery/recycling/recharging unit manufacturer's instructions for evacuating and recharging A/C system. Evacuate refrigerant system for a minimum of 30 minutes. When recharging A/C system, add correct amount of refrigerant and PAG oil to system A/C REFRIGERANT SYSTEM CAPACITIES . After system recharge, manually rotate A/C compressor approximately 10 turns before starting engine. Start engine with A/C OFF. After idle speed has stabilized, switch A/C ON and let engine idle (compressor running) for a minimum of two minutes before raising engine speed.

SIGHT GLASS

If system is equipped with a sight glass, a properly charged A/C system can be confirmed when, with the A/C Clutch engaged and engine running at 1, 500 RPM, the sight glass remains clear and bubble free.

Note. The mixture of R-134a refrigerant and refrigerant (PAG) oil may appear milky in the sight glass.

Scheme 57

The expansion valve restricts and controls refrigerant flow to the evaporator. This lowers the refrigerant temperature, pressure and initiates refrigerant change of state from fluid to vapor prior to the evaporator.

Note. The R-134a expansion valve may be identified with a green label.

Scheme 58

Liquid refrigerant entering the evaporator absorbs heat from air passing through the evaporator fins and cools the air. As the refrigerant absorbs heat it turns to vapor and then is suctioned by the compressor.

Scheme 59

O-rings seal connections between A/C system components.

Note. Always use correct size O-rings (dimensions -a- and -b-). Do not reuse O-rings, always replace. Use only new O-rings that are compatible with R-134a refrigerant and refrigerant (PAG) oil on R-134a systems. O-rings for use only on R-134a systems may be color coded: red, green, violet or black. Lubricate O-rings with the appropriate refrigerant oil before installing (only use PAG oil).

Scheme 60

The pressure relief valve is mounted on the compressor or compressor inlet/outlet manifold. At pressures above 40 bar (580 psi), the pressure relief valve opens to vent excessive pressure. When the system pressure is reduced, the valve closes to prevent total refrigerant loss.

On some models, a cap on the pressure relief valve will pop out if the valve has opened.

Scheme 61

Note. Depending on engine type, refrigerant systems have either an A/C Pressure Switch -F129- or High Pressure Sensor -- -G65- installed. Refer to appropriate wiring diagram.

A/C Pressure Switch -F129- has three functions

1. Switches the A/C Clutch -N25- off when excessive refrigerant circuit pressure is present (e.g.: insufficient air flow over condenser or when overcharged).
2. Switches the A/C Clutch -N25- off when insufficient refrigerant circuit pressure is present (e.g.: when refrigerant has leaked out)
3. Switches on the second speed Coolant Fan -V7- when refrigerant circuit pressure increases.

Scheme 62

Note. Depending on engine type, refrigerant systems have either an A/C Pressure Switch -F129- or High Pressure Sensor -G65- installed. Refer to appropriate wiring diagram.

High Pressure Sensor -G65- -B-, transmits a square wave signal to Coolant Fan Control (FC) Control Module -J293- at a rate which varies according to the refrigerant system pressure. The signal is processed as follows

Based on the signal transmitted by High Pressure Sensor -G65-, Coolant Fan Control (FC) Control Module -J293- determines the A/C refrigerant system pressure and controls A/C Clutch -N25- and Coolant Fan functions accordingly. For example

1. Switches the Coolant Fan -V7- to the next higher speed when pressure in the refrigerant circuit increase.
2. Switches off A/C Clutch -N25- when pressure is excessive (for example when engine cooling is insufficient).
3. Switches off A/C Clutch -N25- off when pressure is too low (for example with low/no refrigerant).

The High Pressure Sensor -G65- signal is also input to the Motronic Engine Control Module (ECM). As the amount of torque needed to drive the A/C compressor varies according to refrigerant system pressure, the ECM processes this signal in order to enhance engine performance.

High Pressure Sensor -G65- signal, checking HIGH PRESSURE SENSOR, FUNCTION .

Scheme 63

On A/C compressors without A/C Clutch -N25-, the A/C Compressor Regulator Valve -N280- is integrated with the A/C compressor. Its function is controlled by the Motronic Engine Control Module (ECM) -J220- in accordance with engine loads, speed and engine coolant temperature. The valve regulates the low pressure (suction) side of the A/C compressor, thus controlling the evaporator temperature.

A/C SYSTEM HOSES AND LINES

The mixture of refrigerant oil (PAG oil) and refrigerant R-134a attacks some metals and alloys (for example, copper) and breaks down certain hose material. Use only hoses and lines that are identified with a green mark (stripe) or the lettering "R-134a".

Hoses and lines are fastened together with threaded couplings/fittings and are retained (to bodywork or components) with specially isolated hose clamps.

Note. During servicing, all couplings, fittings and related fasteners must be torqued to specifications A/C REFRIGERANT SYSTEM COMPONENT OVERVIEW . Ensure that only special tools (as specified) are used while servicing.

Scheme 64

1. Evaporator
2. Expansion Valve
3. High Pressure Service Valve
4. Receiver Drier
5. Condenser
6. Compressor

Note. Arrows indicate direction of refrigerant flow.

Ribbed Belt, Routing

Note. When installing the belt ensure it is correctly seated in the pulley.

A/C REFRIGERANT SYSTEM COMPONENTS

A/C COMPRESSORS

REFRIGERANT OIL R134A, DISTRIBUTION

The total refrigerant oil quantity is distributed in the refrigerant circuit as follows

Compressor approximately 50%

Condenser approximately 10%

Suction pipe approximately 10%

Discharge pipe

Evaporator approximately 20%

Receiver drier approximately 10%

Note. When replacing refrigerant circuit components, fill an appropriate amount of refrigerant oil (as indicated above) into the new part before installation.

A/C PRESSURE SWITCH, CHECKING

Visual check: Ensure that O-ring (color: red) 10.8mm x 1.8mm is seated in groove.

Switch function between contacts -T4a/1- and -T4a/2- (at connector housing) switches A/C Clutch -N25- off whenever

1. excessive refrigerant circuit pressure is present (e.g.: insufficient air flow over condenser or if system is overcharged)
2. insufficient refrigerant circuit pressure is present (e.g.: when refrigerant has leaked out).

Switch function between contacts -T4a/3- and -T4a/4- (at connector housing) switches Coolant Fan -V7- to 2nd speed when refrigerant pressure rises.

Switching conditions

Scheme 65

1. Contacts -1- and -2- open below 1.2 bar (17.4 psi) and closed above 2.4 bar (34.8 psi) switching threshold
2. Contacts -1- and -2- open above 32 bar (464 psi) and closed below 24 bar (348 psi) switching threshold
3. Contacts -3- and -4- closed above 16 bar (232 psi) and open below 12.5 bar (181.2 psi) switching threshold

Switch function, checking

Bridge contacts -1- and -2- with engine running. If A/C Clutch -N25- switches on, refrigerant system may be empty A/C REFRIGERANT SYSTEM, TESTING WITH PRESSURE GAUGES .

HIGH PRESSURE SENSOR, FUNCTION

Where equipped, the High Pressure Sensor -G65- transmits a square wave signal to Coolant Fan Control (FC) Module -J293- at a rate which varies according to the refrigerant system pressure.

The signal from High Pressure Sensor -G65- is processed as follows

Based on the pulse rate transmitted by the High Pressure Sensor -G65-, the Coolant Fan Control (FC) Module -J293- determines the A/C refrigerant system pressure and controls the function of the A/C Clutch -N25- and Coolant Fans accordingly. For example

1. Switches the Coolant Fan -V7- to the next higher speed when pressure in the refrigerant circuit increases.
2. Switches off A/C Clutch -N25- when pressure is excessive (for example when engine cooling is insufficient).
3. Switches off A/C Clutch -N25- off when pressure is too low (for example with low/no refrigerant).

The signal generated by High Pressure Sensor -G65- is also provided as an input to the Motronic Engine Control Module (ECM). As the amount of torque needed to drive the A/C compressor varies according to the refrigerant system pressure, the ECM processes this signal in order to enhance engine performance.

Scheme 66

1. Contact 1: Ground (GND)
2. Contact 2: Square wave signal (output) to Coolant Fan Control (FC) Module -J293- and Motronic Engine Control Module (ECM) -J220
3. Contact 3: Terminal 15 (ignition on)

Note. A/C Clutch -N25- is switched off when connector -B- is disconnected

A/C REFRIGERANT SYSTEM PRESSURES AND TEMPERATURES, CHECKING

The pressures and temperatures in the A/C system will vary depending on engine speed (RPM), Coolant Fan speed, engine coolant temperature, A/C Clutch engagement, outside temperature, humidity, etc.

Pressure and temperature specifications are based on the following

1. Engine speed (RPM) at 1500
2. Fresh air blower on high speed
3. A/C adjusted to Max. cooling

A = Low Pressure

B = High Pressure

Scheme 67

1. Evaporator
2. Compressor, low pressure side -A
3. Compressor, high pressure side -B
4. Condenser
5. Receiver drier
6. High pressure service valve
7. Expansion valve
8. Low pressure service valve

REQUIREMENTS

1. Electrical systems OK
2. Air flow distribution systems (controls and cables) OK

Correct and repair as necessary before proceeding.

If any one of the following system conditions exists, check A/C refrigerant system pressures A/C REFRIGERANT SYSTEM PRESSURES, CHECKING .

1. A/C does not cool (cooling has stopped completely)
2. Insufficient cooling during all driving speeds or engine speeds (RPM)
3. No cooling or insufficient cooling after a period of driving

INSTRUMENT PANEL VENTS SPRAYING WATER

Check evaporator drain pipe for proper routing (should not be kinked or pinched).

Check evaporator water drain valve.

1. Must not be plugged with wax, dirt or undercoating (clean if necessary)
2. Valve door must open/close properly

Check plenum tray.

1. Must be properly installed and not damaged

A/C REFRIGERANT SYSTEM PRESSURES, CHECKING

Check A/C refrigerant system pressures using these three tests

1 - Air temperature drop from center instrument panel outlet (A/C system cooling performance)

2 - A/C system high pressure

3 - A/C system low pressure

The combined results of all three steps determine which part of the A/C system is causing the problem, see table SPECIFIED RESULT .

Test Conditions

1. A/C refrigerant system fully charged; discharge, evacuate and recharge system if necessary
2. Condenser and radiator clean and free of obstructions (spray clean if necessary)
3. Air distribution can be adjusted correctly using control knobs (all air distribution doors reach end positions)
4. Wiring OK per wiring diagram
5. Outside (ambient) air temperature between 20-30°C (68-86°F)
6. Drive belts for A/C compressor and Generator in good condition and properly tensioned

Test 1 - Checking A/C Cooling Performance

Start engine.

Set temperature control to maximum "cold".

Press "A/C" button and select second blower speed.

Adjust air distribution to instrument panel outlets.

Insert thermometer into center instrument panel outlet and raise engine speed to approximately 1500 RPM.

Specified result

With humidity normal and outside (ambient) temperature between 20-25°C (68-77°F), system is cooling satisfactorily if air temperature from center instrument panel vent drops below 10°C (50°F) within 1 minute.

For higher ambient temperatures and/or higher humidity, specified air temperature from center instrument panel vent can be slightly higher.

If specified reading is not obtained, perform tests 2 and 3, then compare results of all three tests --> table, SPECIFIED RESULT .

Test 2 - A/C System High Pressure, Checking

Connect high- and low-pressure hoses of refrigerant recovery/ recycling/recharging unit Kent-Moore ACR 4 or equivalent, to high- and low-pressure service valves.

Disconnect electrical connector from Coolant Fan.

Start engine.

Set temperature control to maximum "hot".

Press "A/C" button and select highest blower speed.

Adjust air distribution to footwell outlets.

Raise engine speed to approximately 1500 RPM.

Specified result

System high pressure is normal if high-pressure gauge reads 232 psi (16 bar) within 30 seconds.

If specified reading is not obtained, also perform test 3 and compare results of all three tests --> table, SPECIFIED RESULT .

Test 3 - A/C System Low Pressure, Checking

Connect high- and low-pressure hoses of refrigerant recovery/recycling/recharging unit Kent-Moore ACR 4 , or equivalent, to high- and low-pressure service valves.

Start engine.

Set temperature control to maximum "cold".

Press "A/C" button and select first blower speed.

Adjust air distribution to instrument panel outlets.

Raise engine speed to 1500 RPM.

SPECIFIED RESULT

System low pressure is normal if low-pressure gauge reads 22-36 psi (1.5-2.5 bar) within 30 seconds.

If specified reading is not obtained, compare results of all three tests --> table, A/C REFRIGERANT SYSTEM PRESSURES, CHECKING .

A/C REFRIGERANT SYSTEM, CHECKING COOLING PERFORMANCE

Note. A/C Evaporator Temperature Switch -E33- (if equipped) switches A/C compressor OFF only in special instances so evaporator does not ice up; variable displacement A/C compressor maintains temperature of 0°C (32°F) in evaporator.

Test Conditions

1. A/C refrigerant system fully charged
2. A/C Clutch -N25- and compressor function OK
3. Condenser and radiator clean and free of obstructions
4. Air distribution can be adjusted properly
5. Wiring OK as per wiring diagram
6. Outside (ambient) temperature 20°C-30°C (68°F-86°F)

Checking

Start engine.

Set temperature control to maximum "cold".

Press A/C button and select second blower speed.

Adjust air distribution to instrument panel outlets.

Insert thermometer into center instrument panel outlet.

Raise engine speed to approximately 1500 RPM.

Specified Result

With normal humidity and outside (ambient) temperature between 20°-25°C (68°-77°F), system is sufficiently charged if air temperature from center instrument panel vent drops below 10°C (50°F) within one minute.

For higher ambient temperatures and/or higher humidity, specified air temperature from center instrument panel vent can be slightly higher.

Scheme 68

Use halogen leak detector, Hitec HI400A-TEL or equivalent, to check for refrigerant leaks, following the leak detector manufacturer's instructions.

Refrigerant gas dissipates very quickly. To make the job easier, avoid drafty or windy areas when checking for leaks.

If the refrigerant system is discharged (empty), recharge the system with approximately 100 g (3.5 oz.) of refrigerant in order to check for leaks.

Scheme 69

Fold cover -1- in bulkhead insulation mat -3- upwards.

Remove drain valve -2- from opening in bulkhead -4-.

Check water drain valve as follows to ensure correct function

1. The water drain valve must not be stuck together.
2. Insulation mat must not be deformed or damaged in the area of water drain valve.
3. The opening in the sealing cap of the water drain valve must point downwards.

Note. When cover -1- is closed it must be flush with the insulation matting. If cover -1- is pushed in too far, the water drain valve sealing cap -2- can become jammed.

Scheme 70

Note. Design of new evaporator drain valve from 06.00 is essentially maintenance free.

A/C PRESSURE SWITCH AND HIGH PRESSURE SENSOR

Removing

Note. Components can be removed without discharging refrigerant system.

Disconnect electrical connection to switch/sensor

Remove by turning switch/sensor -B- counterclockwise (switch/sensor threaded onto refrigerant pipe equipped with Schrader valve).

Installing

Install in reverse order of removal, noting the following.

Note. Always replace O-ring seal -A- (10.8; 1.8mm) Tightening torque 5 Nm.

CONDENSER

First do the following

Discharge refrigerant system A/C REFRIGERANT SYSTEM, DISCHARGING

Drain engine coolant [For engine(s) BDC, BEV, BGD, AVH, AZG, AEG] COOLING SYSTEM, DRAINING AND FILLING , or refer to [For engine(s) APH, BNU, AWP, AWV, BKF] COOLING SYSTEM, DRAINING AND FILLING , or refer to [For engine(s) ALH] COOLANT, DRAINING AND FILLING , or refer to [For engine(s) BPR, BPS] DRAINING AND FILLING , or refer to [For engine(s) BEW] COOLING SYSTEM, DRAINING AND FILLING .

Disconnect refrigerant pipes at condenser

Bring front end assembly (lock carrier) into service position. Description and Operation

Scheme 71

1. Radiator Always use new coolant after replacement
2. Condenser
3. Bolt 8 Nm
4. Lock carrier Bring into service position «Description and Operation»(ref-492713-S41482608822012080600000)

HEATING AND A/C CONTROLS

Removing

Remove center air outlet console CENTER AIR OUTLET CONSOLE

Scheme 72

Remove mounting screws -arrows-.

Lift out controls with cables from instrument panel in direction of -arrow A-.

Detach cables from controls.

Disconnect electrical connector.

With controls removed, check function of heating and ventilation cables as follows

Scheme 73

Move cables in and out several times -arrow-.

Replace damaged or stiff cables.

Installing

Note. Cable sleeves are color coded. All doors must audibly move onto stops when turning controls. Always check cables before installing. Replace tight or damaged cables.

Attach cable -1- to actuating arm -2- as indicated-arrow-.

Scheme 74

Press cable for footwell/defrost, cable for temperature door and cable for central door -1- into retainer -2- until it engages.

Scheme 75

Cable Color Codes

1. Footwell/defrost door cable: green
2. Central door cable: yellow
3. Temperature door cable: beige

Check and adjust cables HEATING AND A/C CABLES COMPONENT OVERVIEW .

Connect electrical connector

Fit controls into instrument panel opening and install mounting screws.

TEMPERATURE DOOR CABLE

Cable sleeve marking: Beige

Installing, prerequisites

1. Heating and A/C controls are installed.
2. Connecting duct removed «CONNECTING DUCT»(ref-492801-S07842865882012080600000)

Adjusting

Scheme 76

Turn temperature rotary control knob to left onto stop.

Attach center wire of cable -1- to the temperature door lever -2-.

Push temperature door lever -2- onto stop -arrow A- and secure outer cable -1- with clip -3-.

Turn temperature rotary control knob to left and right onto stops.

When turning the rotary control knob both end stops must be reached.

FOOTWELL/DEFROST DOOR CABLE

Cable sleeve marking: Green

Prerequisite

Heating and A/C controls are installed.

Installing and adjusting

Scheme 77

Turn air distribution rotary knob to left onto stop.

Attach end of cable -1- to the temperature door lever -3-, arrow -A-.

Press footwell/defrost door lever onto stop arrow -C- and attach outer cable -1- with clip -2-, arrow -B-.

Turn air distribution rotary control knob to left and right onto stops.

When turning the rotary control knob both end stops must be reached.

CENTRAL DOOR CABLE

Cable sleeve marking: Yellow

Prerequisites

1. Central door lever correctly adjusted «HEATER CORE BULKHEAD SEAL, INSTALLATION POSITION»(ref-492801-S24222096562012080600000) .
2. Heating and A/C controls are installed.
3. Connecting duct removed «CONNECTING DUCT»(ref-492801-S07842865882012080600000) .

Installing and adjusting

Scheme 78

Turn air distribution rotary control knob to left onto stop.

Attach center wire of cable -2- to the central door lever -1-.

Press footwell/defrost door lever onto stop arrow -A- and attach outer cable -2- with clip -3-.

Turn air distribution rotary control knob to left and right onto stops.

When turning the rotary control knob both end stops must be reached.

A/C CLUTCH

Special tools and workshop equipment required

1. Pin wench VAS 3212A (or equivalent)
2. Two arm puller
3. Three arm puller
4. Depth gauge
5. Torque wrench (5-50 Nm) or equivalent VAG 1331

Note. It is not necessary to discharge the refrigerant system to remove and install the A/C Clutch. If A/C Clutch is to be removed with compressor installed, first do the following: Remove ribbed belt. Refer to RIBBED BELT (1.8L, 2.0L, 2.5L), or [For engine(s) APH, BNU, AWP, AWV, BKF] RIBBED BELT or refer to [For engine(s) BPR, BPS] RIBBED BELT (1.9L TDI), or [For engine(s) BEW] Removal and Installation (1.9L TDI-PD) Remove intercooler (engine code ALH only). Refer to [For engine(s) ALH] Removal and Installation If A/C Clutch is to be removed with compressor removed, first discharge refrigerant system A/C REFRIGERANT SYSTEM, DISCHARGING .

Removing

Hex Nut

Scheme 79

Remove hex nut while counter-holding with 3213A or equivalent commercially available 2 hole pin wrench (with 4 mm pins).

1. Tightening torque: 15 Nm

Clutch Plate

Scheme 80

Carefully pry off clutch plate using two large screwdrivers -A-.

Use locally available 2 or 3 arm puller if plate is securely seated (difficult to remove).

Clutch Pulley

Scheme 81

Remove circlip A/C CLUTCH, SANDEN ASSEMBLY OVERVIEW , key - A/C CLUTCH, SANDEN ASSEMBLY OVERVIEW -.

Attach commercially available 2 arm puller -A- on shoulder -B- and pull off pulley.

Installing

Scheme 82

Install coil on compressor.

Locate locking pin on coil -A- into recess -C-.

Scheme 83

1. Gap: 0.4 - 0.8 mm (0.015 - 0.023 in)

Determine "Dimension 1"

Using depth gauge -1-, measure gap between top of clutch plate -3- and clutch pulley -2- at three equally spaced locations (measurement must not deviate).

Determine "Dimension 2"

If compressor is installed in vehicle, disconnect compressor electrical connector -4- from vehicle wiring harness.

Using a jumper wire, energize the clutch coil by applying 12V to connector -A- (battery terminal B+). If compressor is removed from vehicle, compressor must be grounded.

With clutch energized, measure gap between pulley -2- and clutch plate -3- with depth gauge -1-.

The allowable gap (0.4 - 0.8 mm / 0.015 - 0.023 in) is the difference between "Dimension 1" and "Dimension 2".

Note. Gap must be within tolerance around entire circumference. If gap is outside the permitted tolerance range, remove clutch plate and adjust gap by adding or removing shims A/C CLUTCH, SANDEN ASSEMBLY OVERVIEW Shims , key - A/C CLUTCH, SANDEN ASSEMBLY OVERVIEW -.

HEATER/EVAPORATOR UNIT

Removing

Discharge refrigerant system A/C REFRIGERANT SYSTEM, DISCHARGING

Drain engine coolant [For engine(s) BDC, BEV, BGD, AVH, AZG, AEG] COOLING SYSTEM, DRAINING AND FILLING , or refer to [For engine(s) APH, BNU, AWP, AWV, BKF] COOLING SYSTEM, DRAINING AND FILLING , or refer to [For engine(s) ALH] COOLANT, DRAINING AND FILLING , or refer to [For engine(s) BPR, BPS] DRAINING AND FILLING , or refer to [For engine(s) BEW] COOLING SYSTEM, DRAINING AND FILLING .

Disconnect refrigerant lines at condenser/expansion valve

Disconnect coolant hoses from heater core

Remove instrument panel Removal and Installation

Loosen instrument panel cross member INSTRUMENT PANEL CROSSMEMBER

Remove heater/evaporator unit

Scheme 84

1. Heater core Always use new coolant after replacement
2. Housing, upper part With fresh/recirculating air door
3. Evaporator seal
4. Evaporator
5. Housing, lower part

Evaporator Seal, Installing

Scheme 85

Glue seal -B- evenly to top and sides of the evaporator -A-.

Note. Evaporator water (condensation) must be able to drain from housing. Evaporator seal must NOT be installed on the bottom of the evaporator (see detail).