Kansas City Tdi & CoolAirVw Repair
01M Valve Body Removal and Reinstalation
Folks
seem very intimidated, by the thought of removing and reinstalling their valve
body. I built this page to help.
First
remove the skid plate pan and filter as shown in 01M filter change.
The
most difficult part is unplugging the solenoid harness without breaking the
ends off. If your ends break off you could end up with a solenoid code
immediately or your connector could wiggle loose over time and give you a
solenoid code later. Here’s what the
broken connectors look like.
Vw makes a special tool for this #3373. Here’s a pic of the special tool. I put a tape measure with it so you could
make one if you wanted. I have a plastic
version available for $10.00 + shipping.
So
if you’re pulling your valve body or changing a solenoid then carefully pry the
solenoid with the special tool as in the pic. .
Notice
how this cocks the connector in the solenoid.
This is what you want to a certain extent because it make the teeth move
to the left to disengage the window that they lock in.
Be
careful though wiggle gently. And watch
as your doing it.
Sometimes
when it’s stubborn you might have to pry in here with a very small pick. This is a little counter productive though
because it pulls the plastic away from the solenoid at the top but I think the
bottom of it moves opposite and hinders the teeth from releasing. Do this carefully.
Here’s
what happens if you get too aggressive trying to release teeth with a
pick. This solenoid is ok and reusable
but if your break that piece out then you’ll need to replace the solenoid to
keep the connector plugged in to it.
Here’s
an alternate method you might try with a screwdriver if you don’t have the
special tool. It makes the same motion
and I had good luck doing it this way back when. Notice it cocks the connector the same way to
pull the teeth out of the “window” that they latch into.
At
this loosen the bolt that holds the manual valve linkage. Do take it out of the threads, but do not
take the bolt all the way out of the linkage.
If it falls apart it can be a little confusing on how it goes back
together.
Just
leave it like it is in the pic. The
manual valve will probably pull out with the link. If so just set it aside till your ready to
reinstall the manual valve linkage.
At
this point pull the torx bolts out of the valve body. There are two little T20’s and a bunch of
large T30’s. Just pull the T30’s
out. Don’t pull out the t20’s. The t20’s hold the valve body together and if
you separate them you might loose checkballs and springs. Some fluid will run out when you remove the
valve body.
Up
above the valve body there is a reverse feed pipe. I’ve never had one fall out
on me but it is possible. If it does
fall out put it back. Here is where it
goes.
Enough
for now. I’ll finish reinstallation
later.