Plenum chamber (air conditioning) - remove and install — VW

🧭 Before you start

Fits: platform codes 6A1, 6A5

• Opens: coolant

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• Seal all hose connections.The spare expansion valve closing cover can be used to seal expansion valve connections, for example.
• The seal (2) must be first installed on the plenum chamber (1).
• Ensure proper sealing seating (2) on the front wall (1) .The condensation water drain nozzle must not be covered by the sealant (2) .

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Disconnect the earth wire of the BatteryAElectrical devices27Starter motor, alternator, battery.
2. ⚠ Risk of pressurized effluent refrigerant!Risk of freezing the skin and other body parts.Remove the refrigerant via suction and open the refrigerant circuit.If suction was carried out over 10 minutes and the refrigerant circuit is still not opened, repeat the refrigerant suction process. Re-evaporation creates pressure in the refrigerant circuit. — Remove the dash panel General body repairs, interior70Lining / insulation.
3. Protect the front floor lining.
4. ⚠ The cooling system is under pressure while the engine is hot!Risk of burns by hot steam and hot coolant.Reduce overpressure, covering the coolant compensation reservoir cover with a cloth and opening it carefully. — Remove the air filter Engine24Supply system - fuel injection-
5. Identify the cooling system hoses in the engine compartment and seal them using the Clamps (diameter 40 mm)3093 and remove the heat exchanger.

6. Install the hoses (A) and (B) in both heat exchanger connections.
7. Hold a recipient (C) underneath the lower connection hose (B) .
8. Use a compressed air gun (D) to drain the coolant from the heat exchanger through the hose (A) into the recipient (C).
9. Aspirate the refrigerant using the service station for air conditioningVAS 6007A or newer model, for example.
10. ⚠ Risk of pressurized effluent refrigerant!Risk of freezing the skin and other body parts.Remove the refrigerant via suction and open the refrigerant circuit.If suction was carried out over 10 minutes and the refrigerant circuit is still not opened, repeat the refrigerant suction process. Re-evaporation creates pressure in the refrigerant circuit. — Remove the bolts (2) (12 Nm) from the refrigerant line (3) in the engine compartment. — 12 Nm (8.9 lb-ft)
11. Remove the refrigerant lines (3) from the expansion valve (1) . [Note: Seal all hose connections.The spare expansion valve closing cover can be used to seal expansion valve connections, for example.]
12. Protect the front vehicle floor lining with a waterproof film and liquid absorbing paper.
13. Remove the plenum chamber connections.
14. Remove and install the intermediate part for the demisting baffle .
15. Remove and install the intermediate part for central air vent . [Note: All cable clamps and other electric harness fastening items, either loose or cut during the air conditioner's removal, must be reinstalled in the same areas.The "Air conditioning system" electric harness is removed along with the heater and air conditioner.]
16. Remove the screws (2) and (3) .
17. Remove the dashboard transverse support (1) . Body - Internal assembly works70Lining / insulation.
18. Remove the plenum chamber.
19. Installation is performed in reverse sequence to the removal, considering the following:
20. The seal (2) must be first installed on the plenum chamber (1).
21. Move the seal (2) to the engine compartment, through the front wall (1) . [Note: Ensure proper sealing seating (2) on the front wall (1) .The condensation water drain nozzle must not be covered by the sealant (2) .]
22. Fill the coolant system after installing Engine19Cooling system.
23. Supply the system with refrigerant.

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