Volkswagen ID.3: Air conditioner. Front heater and air conditioning unit

• Assembly overview - heater and air conditioning unit
• Assembly overview - evaporator housing
• Assembly overview - air intake box of heater and air conditioning unit
• Removing and installing heater and air conditioning unit
• Removing and installing evaporator
• Dismantling and assembling heater and air conditioning unit
• Removing and installing dust and pollen filter
• Removing and installing fresh air blower control unit [J126]
• Removing and installing evaporator temperature sensor [G308]
• Removing and installing condensation drain
• Checking condensation drain
• Removing and installing air intake box of heater and air conditioning unit
• Removing and installing air intake cowling
• Removing and installing high voltage heater (PTC) [ZX17]

Assembly overview - heater and air conditioning unit

Assembly overview - heater and air conditioning unit

1 - Cover for high-voltage heater (PTC) -ZX17-

2 - High-voltage heater (PTC) -ZX17-

❏ → Rep. gr.87; Removing and installing high-voltage heater (PTC) ZX17

3 - Condensation drain

❏ → Rep. gr.87; Checking condensation drain

❏ → Rep. gr.87; Removing and installing condensation drain

4 - Potential equalisation line

❏ → Electric drive motor; Rep. gr.93; Potential equalisation lines; Overview of fitting locations - potential equalisation lines

5 - Nut

❏ 8 Nm

6 - Bolt

❏ 4x

❏ 1.2 Nm

7 - Bolt

❏ 3x

❏ 1.2 Nm

Assembly overview - evaporator housing

Assembly overview - evaporator housing

1 - Heater and air conditioning unit

❏ → Rep. gr.87; Assembly overview - heater and air conditioning unit

❏ → Rep. gr.87; Removing and installing heater and air conditioning unit

2 - Spacer

❏ Renew after removing

3 - Foam

❏ Renew after removing

4 - Bolt

❏ 2x

❏ 4.5 Nm

5 - Expansion valve

❏ → Rep. gr.87; Removing and installing expansion valve

6 - Seal

❏ 2x

❏ Renew after removing

7 - Bolt

❏ 4x

❏ 1.2 Nm

8 - Cover

9 - Condensation drain

❏ → Rep. gr.87; Checking condensation drain

❏ → Rep. gr.87; Removing and installing condensation drain

10 - Evaporator

❏ → Rep. gr.87; Removing and installing evaporator

Assembly overview - air intake box of heater and air conditioning unit

Assembly overview - air intake box of heater and air conditioning unit

1 - Cover for fresh air intake

2 - Fresh air intake

❏ → Rep. gr.87; Removing and installing fresh air intake

3 - Bolt

❏ Observe tightening sequence → Rep. gr.87; Removing and installing air intake cowling

❏ 3x

❏ 8 Nm

4 - Air intake cowling

❏ See: “Mounting on air intake cowling for right-hand drive vehicles”

❏ → Rep. gr.87; Removing and installing air intake cowling

5 - Nut

❏ Observe tightening sequence → Rep. gr.87; Removing and installing air intake cowling

❏ 7x

❏ 8 Nm

6 - Bolt

❏ 4x

❏ 1.2 Nm

7 - Cover

8 - Bolt

❏ 3x

❏ 1.2 Nm

9 - Fresh air blower control unit -J126-

❏ → Rep. gr.87; Removing and installing fresh air blower control unit J126

10 - Air intake box of heater and air conditioning unit

❏ → Rep. gr.87; Removing and installing air intake box of heater and air conditioning unit

11 - Nut

❏ 5x

❏ 3.5 Nm

12 - Bolt

❏ → Rep. gr.87; Assembly overview - control motors

13 - Control motor for fresh air and air recirculation flap -VX96-

❏ With fresh air/air recirculation, air flow flap control motor -V425-

❏ With potentiometer for fresh air/air recirculation, air flow flap control motor -G644-

❏ → Rep. gr.87; Removing and installing control motor for fresh air and air recirculation flap VX96

14 - Noise insulation

15 - Dust and pollen filter

❏ → Rep. gr.87; Removing and installing dust and pollen filter

16 - Dust and pollen filter

❏ Depending on equipment/vehicle version

❏ → Rep. gr.87; Removing and installing dust and pollen filter

17 - Cover

18 - Bolt

❏ Depending on equipment/vehicle version

❏ 2 Nm

19 - Noise insulation

20 - Gasket

21 - Gasket

Mounting on air intake cowling for right-hand drive vehicles

ComponentTightening torqueBolt -3- 8 Nm

Removing and installing heater and air conditioning unit

Removing and installing heater and air conditioning unit

Special tools and workshop equipment required

♦ engine bung set -VAS 6122-

Removing

Immediately seal open lines and connections with clean plugs from engine bung set -VAS 6122-.

DANGER

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock or electric arcs.

– Have a high-voltage technician (HVT) or a high-voltage expert (HVE) de-energise the high-voltage system.

– → Rep. gr.93; De-energise high-voltage system.

– → General information, air conditioning systems with refrigerant R134a/R1234yf; Rep. gr.87; Working with air conditioner service station; Draining refrigerant circuit.

– Detach refrigerant line from expansion valve → Rep. gr.87; Detaching/attaching refrigerant line from/to expansion valve.

– Remove dash panel cross member → General body repairs, interior; Rep. gr.70; Dash panel cross member; Removing and installing dash panel cross member.

– Remove rear footwell vent → Rep. gr.87; Removing and installing rear footwell vent.

– Detach air duct for rear centre console vent from heater and air conditioning unit → Rep. gr.87; Removing and installing air duct for rear centre console vent.

– Disconnect electrical connectors and electrical wire from heater and air conditioning unit.

NOTICE

Risk of damage to airbag control unit. Electrical connectors corrode when exposed to moisture.

– After unplugging connectors for control unit, cover them or seal them off to prevent moisture from entering.

– To collect escaping condensate, place cleaning cloth under condensation drain -1-.

– Pull condensation drain -2- off connection of heater and air conditioning unit -1- -arrow A-.

– Disconnect electrical connector -7-.

– Release retaining clip -5-.

– Unscrew nut -8-.

– Detach potential equalisation line.

Important

● The aid of an additional person is required for the subsequent work steps.

– Remove heater and air conditioning unit -1-.

Installing

– Install in reverse order of removal, observing the following:

– Make sure that the condensation drain is properly seated → Rep. gr.87; Removing and installing condensation drain.

– Check screw connections of potential equalisation line, and clean them if necessary → Electrical system; Rep. gr.97; Cleaning contact surfaces.

Important

● Contact surfaces must be free of dirt, rust and grease.

– Connect potential equalisation line, and tighten nut -8-.

– Connect electrical connectors.

– Install air intake box of heater and air conditioning unit → Rep. gr.87; Removing and installing air intake unit of heater and air conditioning unit.

– → General information, air conditioning systems with refrigerant R134a/R1234yf; Rep. gr.87; Working with air conditioner service station; Charging refrigerant circuit.

WARNING

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock or electric arcs.

– Have a high-voltage technician (HVT) or a high-voltage expert (HVE) re-energise the high-voltage system.

– → Rep. gr.93; Re-energising high-voltage system.

Tightening torques

♦ → Rep. gr.87; Assembly overview - refrigerant lines

♦ → Rep. gr.87; Assembly overview - heater and air conditioning unit

♦ → Rep. gr.87; Assembly overview - evaporator housing

Removing and installing evaporator

Removing and installing evaporator

Special tools and workshop equipment required

♦ engine bung set -VAS 6122-

Removing

Immediately seal open lines and connections with clean plugs from engine bung set -VAS 6122-.

– → General information, air conditioning systems with refrigerant R134a/R1234yf; Rep. gr.87; Working with air conditioner service station; Draining refrigerant circuit.

– Remove heater and air conditioning unit → Rep. gr.87; Removing and installing heater and air conditioning unit.

– Unscrew bolts -2-.

– Remove evaporator housing cover -1-.

– Pull evaporator -1- out of evaporator housing.

– Remove expansion valve -3- → Rep. gr.87; Removing and installing expansion valve.

– Remove spacer -2-.

– Remove gasket -4-.

Installing

Install in the reverse sequence of removal, observing the following:

– Before inserting, clean evaporator housing and evaporator.

– Before inserting evaporator, check and clean condensation drain → Rep. gr.87; Checking condensation drain.

– Check tongue-and-groove joint between upper and lower sections of evaporator housing for damage and proper seating.

If evaporator is been renewed:

– Carry out adaption routine for refrigerant oil capacity → General information – air conditioning systems with refrigerant R134a/R1234yf; Rep. gr.87; Renewing components; Renewing components.

Continued

– → General information, air conditioning systems with refrigerant R134a/R1234yf; Rep. gr.87; Working with air conditioner service station; Charging refrigerant circuit.

Tightening torques

♦ → Rep. gr.87; Assembly overview - refrigerant lines

♦ → Rep. gr.87; Assembly overview - heater and air conditioning unit

Dismantling and assembling heater and air conditioning unit

Dismantling and assembling heater and air conditioning unit

Heater and air conditioning unit must not be disassembled and reassembled separately → Electronic parts catalogue.

Removing and installing dust and pollen filter

Removing and installing dust and pollen filter

Depending on the country, 2 dust and pollen filters -A- and -B- or 1 dust and pollen filter -B- may be installed.

Removing

– Unscrew bolt -1-.

– Release cover -2- -arrow-, and remove it.

– Remove dust and pollen filter -1-.

Installing

– Install in reverse order of removal, observing the following:

– Observe installation position of dust and pollen filter.

Removing and installing fresh air blower control unit [J126]

Removing and installing fresh air blower control unit [J126]

Removing

– Remove air intake box of heater and air conditioning unit → Rep. gr.87; Removing and installing air intake unit of heater and air conditioning unit.

– Unscrew bolts -2-.

– Remove cover -1- in direction of -arrow-.

– Disconnect electrical connector -3-.

– Unscrew bolts -2-.

CAUTION

Danger of burns due to hot cooling surface on fresh air blower control unit

Take care not to burn your hands.

– Put on protective gloves.

NOTICE

Risk of damage to fresh air blower if handled incorrectly.

Risk of imbalance and operating problems.

– Avoid any force or strain on fan wheel.

– Do not move balancing weights on fan wheel.

– Do not set fresh air blower down on fan wheel.

– Remove fresh air blower control unit -J126- -1-.

Installing

Install in reverse order of removal, observing the following:

Tightening torques

♦ → Rep. gr.87; Assembly overview – air intake box of heater and air conditioning unit

Removing and installing evaporator temperature sensor [G308]

Removing and installing evaporator temperature sensor [G308]

Removing

– Remove tunnel support cover → General body repairs, interior; Rep. gr.70; Dash panel; Removing and installing tunnel support cover.

– Disconnect electrical connector -2-.

– Remove evaporator temperature sensor -G308- -1- using commercially available plastic wedge -3-.

Installing

Install in reverse order of removal.

Removing and installing condensation drain

Removing and installing condensation drain

Removing

– Remove floor covering → General body repairs, interior; Rep. gr.70; Passenger compartment trim panels; Removing and installing floor covering.

NOTICE

Risk of damage to airbag control unit. Electrical connectors corrode when exposed to moisture.

– After unplugging connectors for control unit, cover them or seal them off to prevent moisture from entering.

– Place a cleaning cloth under connection for condensation drain -1- to catch escaping condensation.

– Carefully pull condensation drain -2- off connection on heater and air conditioning unit -1-.

– Take condensation drain -2- out of body opening -3-.

Installing

Installation is carried out in reverse order; note the following:

Important

● It must be possible to push condensation drain -2- onto connection of heater and air conditioning unit -1- without applying tension. Pay attention to retaining hook -arrow A-.

● Sealing lip -4- must sit firmly on body opening -3- -arrow B-.

– Fit condensation drain -2-, making sure to keep it straight.

– Make sure that floor covering does not compress condensation drain -2-.

Checking condensation drain

Checking condensation drain

– Remove floor covering → General body repairs, interior; Rep. gr.70; Interior trim; Removing and installing floor covering.

NOTICE

Risk of damage to airbag control unit. Electrical connectors corrode when exposed to moisture.

– After unplugging connectors for control unit, cover them or seal them off to prevent moisture from entering.

– Check the condensation drain.

Important

● Locking device -arrow A- must be engaged in connection on heater and air conditioning unit -1-.

● Gasket -4- must sit firmly on body aperture -3- -arrow B-.

● Condensation drain -2- must not be twisted or pinched.

– Remove condensation drain -2- → Rep. gr.87; Removing and installing condensation drain.

– Check condensation drain -2- for bottleneck/blockage.

Installing

Install in reverse order.

Removing and installing air intake box of heater and air conditioning unit

Removing and installing air intake box of heater and air conditioning unit

Removing

– Remove fresh air intake → Rep. gr.87; Removing and installing fresh air intake.

– Release retaining tab -3-.

– Remove cover for high-voltage connection on vehicle front end -2-.

– Remove cover for high-voltage connection on vehicle front end -1- from guide.

– Disconnect electrical connectors -1-.

– Release clamps -2-.

– Lay electrical connector -3- to one side without disconnecting it.

– Unscrew fasteners -1-.

– Remove adapter plate -2-.

– Unscrew nuts -2- from air intake box of heater and air conditioning unit -1-.

– Unscrew nuts -2- from air intake box of heater and air conditioning unit -1-.

– Remove air intake box of heater and air conditioning unit -1-.

Installing

Install in reverse order of removal, observing the following:

NOTICE

Risk of water ingress into the heater and air conditioning unit and the vehicle interior due to damaged gaskets.

– Make sure that the gaskets are correctly installed.

– Check gaskets for damage.

– Gaskets -1- and -2- must be seated properly on air intake box.

Tightening torques

♦ → Rep. gr.87; Assembly overview - air intake box of heater and air conditioning unit

Removing and installing air intake cowling

Removing and installing air intake cowling

Removing

– Remove air intake box → Rep. gr.87; Removing and installing air intake box of heater and air conditioning unit.

– Remove heater and air conditioning unit → Rep. gr.87; Removing and installing heater and air conditioning unit.

– Release fasteners -6- from grommet -5-.

– Guide high-voltage wire -7- out of cowling -4-.

– Unscrew bolts -1- to -3-.

– Remove nuts -1- to -7-.

– Detach air intake cowling -8-.

Installing

Installation is carried out in reverse order; note the following:

NOTICE

Water entering into heater and air conditioning unit and interior due to damaged gaskets/seals.

– Fit gaskets/seals correctly.

– Check gaskets/seals for damage.

– Check seal -9- for damage.

– Tighten nuts in sequence -1- to -7-.

– Tighten bolts in sequence -1- to -3-.

– Guide high-voltage wire -7- through opening in air intake cowling -4-, making sure it is routed correctly.

– Clip in fasteners -6- of grommet -5-.

Tightening torques

♦ → Rep. gr.87; Assembly overview - air intake box of heater and air conditioning unit

♦ → Rep. gr.87; Assembly overview - heater and air conditioning unit

Removing and installing high voltage heater (PTC) [ZX17]

Removing and installing high voltage heater (PTC) [ZX17]

Removing

DANGER

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock or electric arcs.

– Have a high-voltage technician (HVT) or a high-voltage expert (HVE) de-energise the high-voltage system.

– → Rep. gr.93; De-energise high-voltage system.

– Remove tunnel support cover → General body repairs, interior; Rep. gr.70; Dash panel; Removing and installing tunnel support cover.

Left-hand drive vehicles:

– Remove footwell vent on front passenger side → Rep. gr.87; Removing and installing footwell vent on front passenger side.

– Remove dash panel cover on front passenger side → General body repairs, interior; Rep. gr.68; Compartments/covers; Removing and installing dash panel cover on front passenger side.

– Remove accelerator pedal module → Engine; Rep. gr.93; Accelerator mechanism; Removing and installing accelerator pedal module [GX2].

All vehicles (continued)

Right-hand drive vehicles:

– Remove footwell vent on driver side → Rep. gr.87; Removing and installing footwell vent on driver side.

– Remove footrest → General body repairs, interior; Rep. gr.70; Passenger compartment trim panels; Removing and installing footrest.

All vehicles (continued)

– Disconnect electrical connector -4-.

– Unscrew bolts -2- and -3- from high-voltage heater (PTC) -ZX17- -1-.

– Disconnect electrical connector -7-, and loosen retaining clip -5-.

– Unscrew nut -8-.

– Detach potential equalisation line.

– Unscrew bolts -2-, -3-, -4-, -6- and -9- from cover of heat condenser -1- and high-voltage heater (PTC) -ZX17-.

– Pull high-voltage heater (PTC) -ZX17- -1- as far as possible downwards out heater and air conditioning unit -arrow A-.

– Loosen cover of heat condenser -2- in direction of -arrow B-, and remove it from upper holder towards side.

– Break off locking element -1- on heater and air conditioning unit.

– Press down floor covering as far as possible.

– Remove high-voltage heater (PTC) -ZX17- -2- in direction of -arrow-.

Installing

Install in reverse order of removal, observing the following:

Important

● Contact surfaces must be free of dirt, rust and grease.

– Check contact points of potential equalisation line, and clean them if soiled → Electrical system; Rep. gr.97; Cleaning contact surfaces.

– Fit potential equalisation line.

– Tighten nut -8-.

WARNING

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock or electric arcs.

– Have a high-voltage technician (HVT) or a high-voltage expert (HVE) re-energise the high-voltage system.

– → Rep. gr.93; Re-energising high-voltage system.

Tightening torques

♦ → Rep. gr.87; Assembly overview - heater and air conditioning unit

♦ → Rep. gr.87; Assembly overview – air ducts and air distribution in passenger compartment

Air conditioner. Control motorsAir conditioner. Air duct