Volkswagen ID.4: Front heater and air conditioning unit, R744

• Assembly overview - heater and air conditioning unit
• Assembly overview - air intake box of heater and air conditioning unit
• Removing and installing heater and air conditioning unit
• Removing and installing dust and pollen filter
• Removing and installing fresh air blower control unit [J126]
• Removing and installing 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

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

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. Evaporator

• ⇒ Rep. gr. 87 ; Removing and installing evaporator

4. Foam

• Renew after removing

5. Bolt

• 2x
• 1.2 Nm

6. Cover for evaporator housing
7. Condensation drain

•  ⇒ Rep. gr. 87 ; Checking condensation drain
• ⇒ Rep. gr. 87 ; Removing and installing condensation drain

8.  Cover
9. Cover
10. Bolt

• 2x
• 1.2 Nm

11. Heat condenser

• With seal
• ⇒ Rep. gr. 87 ; Removing and installing heat condenser

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 righthand 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

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- .

If heater and air conditioning unit, evaporator or heat condenser has been renewed:

• Observe procedure for renewing components in refrigerant circuit ⇒ General information - air conditioning systems with refrigerant R744; Rep. gr. 87 ; Renewing components .

Continued

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 .
• Carry out function "Open electrically actuated valves to drain, evacuate or charge refrigerant circuit" using ⇒ Vehicle diagnostic tester ⇒ Rep. gr. 00 ; Access to diagnoses .
• ⇒ Air conditioning systems with refrigerant R744 - General notes; Rep. gr. 87 ; Working with air conditioner service station; Draining refrigerant circuit .
• 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 .

CAUTION

Risk of frostbite from escaping pressurised refrigerant Risk of frostbite on skin and other parts of the body

• Put on protective gloves.
• Put on safety goggles.
• Extract/drain refrigerant and then immediately open up refrigerant circuit.
• Extract/drain refrigerant again if more than 10 minutes have passed since initial extraction and refrigerant circuit has not been opened up. Renewed evaporation has created pressure in the refrigerant circuit.

• Unscrew bolts -1- through -4-.
• Pull off refrigerant lines.

• 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.
• Place a cloth underneath condensation drain -1- to catch escaping condensate.
• 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-, and 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:

If components of refrigerant circuit have been renewed:

• Carry out adaption routine for refrigerant oil capacity in refrigerant circuit ⇒ General information - air conditioning systems with refrigerant R744; Rep. gr. 87 ; Renewing components .

Continued

•  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 seals and captive fasteners free of oil.
• 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 .
• Carry out function "Open electrically actuated valves to drain, evacuate or charge refrigerant circuit" using ⇒ Vehicle diagnostic tester ⇒ Rep. gr. 00 ; Access to diagnoses .
• ⇒ Air conditioning systems with refrigerant R744 - General notes; 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

• Evaporator is not available as a separate part ⇒ Electronic parts catalogue (ETKA) .

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

Depending on the country, 2 dust and pollen filters -A- and -Bor 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

• 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

• 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

• 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

• 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

• Remove fresh air intake ⇒ Rep. gr. 87 ; Removing and installing fresh air intake .
• Remove vibration isolation strut ⇒ General body repairs, exterior; Rep. gr. 50 ; Lock carrier; Removing and installing vibration isolation strut .
• Release locking devices -3-.
• Remove cover -2-.
• Remove cover -1- from guide.

Vehicles with all-wheel drive

• Detach gearbox breather.

All vehicles (continued)

• 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:

Tightening torques

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

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

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 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 ; Trims, interior; 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-.
• Release retaining clip -5-.
• Unscrew nut -8-.
• Detach potential equalisation line.
• Unscrew bolts -2-, -3-, -4-, -6- and -9- from cover -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 the reverse sequence of removal, observing the following:

Important

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

• Check screw connections 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