Volkswagen Passat B6 2005 - > (B6)

Manual A/C system - Climatic

Heating and A/C system - interior, component overview

Note : Disconnect battery before removing components marked with **

Repair Manual, Electrical Equipment, Repair Group 27,

A data plate indicates the refrigerant used and capacity.

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Instrument panel ** Center Outlet Temperature Sensor G191 Removing and installing 87-2, Center Outlet Temperature Sensor G191 , removing and installing Center vents Removing and installing 80-1, Center vents, removing and installing Right side vent Controls for heating and A/C system, Climatic With Fresh Air/Recirculating Flap Switch E159 Also with Immediate Heating Button E537 in vehicles with auxiliary heater With Rear Window Defogger Switch E230 With Fresh Air Blower Switch E9 Also with Drivers Heated Seat Adjuster E94 and Front Passengers Heated Seat Adjuster E95 in vehicles with auxiliary heater With A/C Control Module J301 Removing and installing 87-2, Heating and A/C system controls - Climatic, removing and installing Fresh/Recirculating Air Door Motor V154 Checking: Vehicle Diagnosis, Testing Info. System

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VAS5051B Removing and installing 80-1, Fresh/Recirculating Air Door Motor V154 , removing and installing Replacing: Initiate Basic Setting using Vehicle Diagnosis, Testing Info. System VAS5051B 87-3, Components, checking and adjusting . Right footwell vent Removing and installing 80-1, Right footwell vent, removing and installing Fresh Air Blower V2 Removing and installing 80-1, Fresh Air Blower V2 , removing Fresh Air Blower Series Resistor With Fuse N24 Removing and installing 80-1, Fresh Air Blower Series Resistor With Fuse N24 , removing and installing Evaporator Vent Temperature Sensor G263 Removing and installing 87-3, Evaporator Vent Temperature Sensor G263 , removing Heating unit partition Removing 80-1, Removing heating unit partition Dust and pollen filter With activated charcoal filter

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Removing and installing 80-1, Dust and pollen filter element, removing and installing Connection For rear vent air duct To remove, center console must be removed

Repair Manual, Body Interior, Repair Group 68, Rear vent air duct Removing and installing 80-1, Air duct for rear vents, removing and installing Rear vent Removing and installing 80-1, Rear vents, removing and installing Rear channel for right footwell Removing and installing 80-1, Rear footwell channel, removing and installing Rear channel for left footwell Removing and installing 80-1, Rear footwell channel, removing and installing Mounting bolt 8x Adapter for controls Auxiliary Air Heater Heating

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Element Z35 Not applicable to US/CDN Left footwell vent Removing and installing 80-1, Left footwell vent, removing and installing Heater core Removing and installing 80-1, Heater core, removing and installing Footwell Outlet Temperature Sensor G192 Removing and installing 87-2, Footwell Outlet Temperature Sensor G192 , removing and installing Temperature Regulator Flap Motor V68 Checking: Vehicle Diagnosis, Testing Info. System VAS5051B Removing and installing 87-2, Temperature Regulator Flap Motor V68 , removing and installing Replacing: Initiate Basic Setting using Vehicle Diagnosis, Testing Info. System VAS5051B 87-3, Components, checking and adjusting . Flexible shaft Removing and installing 80-1, Flexible shaft for air distribution, removing and installing

Manual A/C system - Climatic

Volkswagen, Skoda, Seat, Audi

. 6 17

Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru Heating and A/C unit Removing and installing 87-3, Heating and A/C unit, removing and installing Disassembling and assembling 87-2, Heating and A/C unit - Climatic, assembly

Heating and A/C unit - Climatic, assembly

Temperature Regulator Flap Motor V68 Removing and installing 87-2, Temperature Regulator Flap Motor V68 , removing and installing

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Bracket Bolts Bolts must be unscrewed to separate air distributor and evaporator housing. Cover Fresh/Recirculating Air Door Motor V154 Removing and installing 80-1, Fresh/Recirculating Air Door Motor V154 , removing and installing Housing for air entry With recirculating air flap Upper section of evaporator housing Disassembling and assembling evaporator housing 87-3, Evaporator housing, assembly Lower section of evaporator housing Disassembling and assembling evaporator housing 87-3, Evaporator housing, assembly Evaporator Removing and installing 87-5, Evaporator, removing and installing Evaporator Vent Temperature Sensor G263 Removing and installing 87-3, Evaporator Vent

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Temperature Sensor G263 , removing Connection for glove compartment cooling Cooling hose for glove compartment cooling Fresh Air Blower Series Resistor With Fuse N24 Removing and installing 80-1, Fresh Air Blower Series Resistor With Fuse N24 , removing and installing Fresh Air Blower V2 Removing and installing 80-1, Fresh Air Blower V2 , removing Dust and pollen filter With activated charcoal filter Removing and installing 80-1, Dust and pollen filter element, removing and installing Cover For dust and pollen filter Heater core Removing and installing 80-1, Heater core, removing and installing Heater core trim Auxiliary Air Heater Heating Element Z35 Not applicable to US/CDN Distribution housing

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Heating and A/C system controls - Climatic, removing and installing

Removing Note: The controls consist of two separable housings. Before removing controls, bring rotary buttons into the following position: Heater control to "cold" Blower to "0" Air flow direction to "footwell" - Remove center instrument panel trim

Repair Manual, Body Interior, Repair Group 68, .

- Unscrew bolts - 2 - (4.2 x 45) and - 3 - (4.2 x 16) and remove controls - 1 - from center console.

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- Disengage harness connector release catch - A - by pulling in direction or arrow - 1 - . - Disengage harness connector release catch - B - to connector - arrow 2 - and disconnect connector - C - . - Disengage harness connector release catch - D - and disconnect connector - D - . Installing Installation is performed in reverse order of removal, make sure when doing so that the rotary buttons have the same position as when removing.
Heating and A/C system controls - Climatic, electrical connections

Special tools, testers and auxiliary items required

Test Box 105 Pin VAG1598/42 Test Adapter VAG1598/47 Template V.A.G 1598/47-2

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Heating and A/C system controls - Climatic, multi-pin connector assignments

20-pin harness connector, T20b 3 - Center Outlet Temperature Sensor G191 5 - High Pressure Sensor G65 7 - CAN Low 8 - CAN-High 12 - Right seat heater (optional) 13 - Left seat heater (optional) 15 - Terminal 75 seat heater (optional) 16 - A/C Compressor Regulator Valve N280 18 - Center Outlet Temperature Sensor G191 19 - Terminal 30A 20 - Terminal 31

16-pin harness connector, T16j 1 - Temperature Regulator Flap Motor V68 , warm 2 - Evaporator Vent Temperature Sensor G263 4 - Footwell Outlet Temperature Sensor G192

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5 - Left Temperature Flap Potentiometer/Actuator G220 7 - + 5 V for Left Temperature Flap Potentiometer/Actuator G220 8 - Ground (GND) for Footwell Outlet Temperature Sensor G192 , Left Temperature Flap Potentiometer/Actuator G220 and Evaporator Vent Temperature Sensor G263 9 - Fresh/Recirculating Air Door Motor V154 , open 10 - Fresh/Recirculating Air Door Motor V154 , close 11 - Temperature Regulator Flap Motor V68 , cold

5-pin harness connector, T5r 1 - 3rd blower speed 2 - 2nd blower speed 3 - 1st blower speed 4 - 4th blower speed 5 - Terminal X
Flexible shaft, removing and installing

Removing - Remove glove compartment

Repair Manual, Body Interior, Repair Group 68, . - Bring flexible shaft into the following position:

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- Rotate rotary switch for air distribution - 1 - long enough until locking mechanism of shaft - 2 - is visible in step-up gearing - 3 - . - Remove controls for heating and A/C system, Climatic 87-2, Heating and A/C system controls - Climatic, removing and installing .

- Reach into center console and release retaining tab - 1 by pressing - in direction of arrow - . - Pull flexible shaft out of adapter - 2 - . Note: When installing flexible shaft, adapter and rotary switches on controls for hot air and fresh air must have a specific position to each other, otherwise it will malfunction 87-2, Flexible shaft, checking .

Flexible shaft, checking

Flexible shaft for adjusting unit of air distribution flaps: - Let fresh air blower run on highest speed. If air flows out of defroster vents in the "Defrost" position and no air flows out of footwell vents, installation of flexible shaft is correct. If this is not the case, remove flexible shaft from adapter.

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Place controls for heating and A/C system, Climatic onto adapter and rotate rotary knob for air distribution 1 / 2 rotation (180 test. ). Then reconnect flexible shaft. Repeat

Condensation water hose on heating and A/C unit, checking

- Remove heating unit partition unit partition Note:

80-1, Removing heating

The condensation water hose - 1 - must be able to be connected to connection of heating and A/C unit without pre-tension. Condensation water hose must sit securely on connection for condensation water hose on heating and A/C unit.

Temperature Regulator Flap Motor V68 , removing and installing

Removing - Remove instrument cluster

Repair Manual, Body Interior, Repair Group 70, . - Remove left footwell vent removing and installing . 80-1, Left footwell vent,

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- Remove bolts - 1 - and - 3 - . - Remove bracket - 2 - .

- Mark connector - C - to actuator motor (danger of interchange with other connectors of same construction). - Disconnect harness connector - C - from Temperature Regulator Flap Motor V68 . - Remove cover - A - . - Unscrew securing bolts - D - and remove Temperature Regulator Flap Motor V68 - B - . - Disengage actuator motor lever - E - from connecting rod -F-. Installing Installation is performed in the reverse order of removal, noting the following: - Install the wiring harness so that it cannot come in contact with any moving parts (e.g. the actuating arm of the actuator motor). Note: After installing Temperature Regulator Flap Motor

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V68 , recirculating air door must be checked for function. - Checking: Vehicle Diagnosis, Testing Info. System VAS5051B . - Replacing: Initiate Basic Setting using Vehicle Diagnosis, Testing Info. System VAS5051B 87-3, Components, checking and adjusting .
Fresh/Recirculating Air Door Motor V154 , removing and installing

Removing - Remove Fresh/Recirculating Air Door Motor V154 801, Fresh/Recirculating Air Door Motor V154 , removing and installing .
Center Outlet Temperature Sensor G191 , removing and installing

Removing - Remove instrument cluster

Repair Manual, Electrical Equipment, Repair Group 90, .

- Disconnect connector - 2 - at Center Outlet Temperature Sensor G191 - 1 - . - Rotate Center Outlet Temperature Sensor G191 - 1 - 90 and remove from instrument panel. Installing Installation is performed in the reverse order of removal.

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Footwell Outlet Temperature Sensor G192 , removing and installing

Removing - Remove left footwell vent removing and installing . 80-1, Left footwell vent,

- Disconnect connector at Footwell Outlet Temperature Sensor G192 - 1 - . - Rotate Footwell Outlet Temperature Sensor G192 90 and remove from housing. Installing Installation is performed in the reverse order of removal.

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87 - 3

Automatic climate control system - Climatronic

Note: Pressing the button AUTO will reverse all settings which deviate from the automatic operation. Deviations from automatic operation operating instructions. respective

In "ECON" operation, the A/C compressor is set to almost zero delivery. The heating and ventilation operation continues to be controlled electronically. Auxiliary heater (optional) is also switched off.
Components, checking and adjusting

In Vehicle Diagnosis, Testing Info. System VAS5051B , select "Guided Fault Finding" . After all control modules have been checked: - Press "Go to" button - Select "Function/component selection" - Select "Body" - "Heating, ventilation, air conditioning (Repair Group 01; 80 87)" - Select "01 - On Board Diagnostic (OBD) capable systems" - Select "Climatronic" - Select "Functions" : - "Basic setting" - "Code control module for Climatronic" - "Check coolant output" - "Read measuring value block"
A/C Control Head E87 , function

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Display of selected interior temperature, left side Button for air recirculation Press button for recirculating air function to prevent polluted air from entering interior. Push button - center air distribution Push button - lower air distribution Push button - upper air distribution Display of selected interior temperature, right side Push button for defrosting

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windshield Push button for rear window defroster Rotary button for interior temperature, left side Blower regulator Rotate to change blower speeds. Interior temperature sensor Push button for A/C system off Push button AUTO By pressing the AUTO button, Climatronic maintains the selected vehicle interior temperature completely automatically. With this setting the vent air temperature, the blower speed and the air distribution are controlled automatically. Push button ECON By pressing the ECON button, A/C compressor is set to almost zero delivery. The heating and ventilation operation continues to be controlled electronically. Auxiliary heater (optional) is also switched off. Rotary button for interior temperature, right side
A/C Control Head E87 with Climatronic Control Module J255 , removing and installing

Note: The Climatronic Control Module J255 and the A/C Control Head E87 are one component that cannot be disassembled.

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Removing - Remove center instrument panel trim

Repair Manual, Body Interior, Repair Group 68, .

- Unscrew bolts - 2 - and remove A/C Control Head E87 with Climatronic Control Module J255 - 1 - from instrument panel. - Disconnect harness connectors from A/C Control Head E87 . Installing Installation is performed in the reverse order of removal.
Climatronic Control Module J255 , electrical connections
Climatronic Control Module J255 , electrical connections A, B C multi-pin connector assignments

Special tools, testers and auxiliary items required

Test Box 105 Pin VAG1598/42

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Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru

Volkswagen, Skoda, Seat, Audi

Test Adapter VAG1598/47 Template V.A.G 1598/47-2

20-pin harness connector, connector housing - A - , in wiring diagram T20c 1 - Sunlight PhotoSensor 2 G134 or Sunlight Photo Sensor G107 , signal 2 - High Pressure Sensor G65 3 - Sunlight PhotoSensor 2 G134 or Sunlight Photo Sensor G107 , signal 5 - CAN-High 6 - CAN Low 7 - Indirect Ventilation Flap Motor V213 8 - Indirect Ventilation Flap Motor V213 9 - + 5V for Sunlight PhotoSensor 2 G134 or Sunlight Photo Sensor G107 10 - Drivers Heated Seat Adjuster E94 (optional) 11 - Front Passengers Heated Seat Adjuster E95 (optional) 12 - Terminal 75 (optional) 13 - Left Vent Temperature Sensor G150 14 - Right Vent Temperature Sensor G151 15 - Indirect Ventilation Flap Motor Position Sensor G330 16 - Terminal 30a/ without auxiliary heater terminal 15 17 - Signal Ground (GND) for Sunlight Photo Sensor G107 , Sunlight PhotoSensor 2 G134 , Left Vent Temperature Sensor G150 , Right Vent Temperature Sensor G151 and Indirect Ventilation Flap Motor V213

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18 - A/C Compressor Regulator Valve N280 19 - Terminal 31 20 - Terminal 30a/ without auxiliary heater terminal 15

16-pin harness connector, connector housing - B - , in wiring diagram T16i 1 - + 5V for actuator motors 2 - Left Temperature Flap Potentiometer/Actuator G220 3 - Right Temperature Flap Potentiometer/Actuator G221 4 - Defroster Flap Motor Position Sensor G135 5 - Central Flap Motor Position Sensor G112 6 - Recirculation Flap Motor Position Sensor G143 7 - Back Pressure Flap Motor Position Sensor G113 8 - Left Footwell Vent Temperature Sensor G261 9 - Right Footwell Vent Temperature Sensor G262 11 - Evaporator Vent Temperature Sensor G263 14 - Signal Ground (GND) potentiometer

16-pin harness connector, connector housing - C - , in wiring diagram T16h 1 - Left Temperature Flap Motor V158 , cold

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2 - Left Temperature Flap Motor V158 , warm 3 - Defroster Flap Motor V107 , closed 4 - Defroster Flap Motor V107 , open 5 - Central Air Flap Motor V70 , upper body vent 6 - Central Air Flap Motor V70 , footwell 7 - Recirculation Flap Motor V113 8 - Recirculation Flap Motor V113 9 - Air Flow Flap Motor V71 , open 10 - Air Flow Flap Motor V71 , close 11 - Right Temperature Flap Motor V159 , cold 12 - Right Temperature Flap Motor V159 , warm 15 - Fresh Air Blower Control Module J126 16 - Fresh Air Blower Control Module J126 , signal
Climatronic system - interior, component overview

Note: Disconnect battery before removing components marked with **

Repair Manual, Electrical Equipment, Repair Group 27, . A data plate indicates the refrigerant used and capacity.

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Instrument panel ** Removing and installing

Repair Manual, Body Interior, Repair Group 70, Sunlight Photo Sensor G107 or Sunlight PhotoSensor 2 G134 Checking: Vehicle Diagnosis, Testing Info. System VAS5051B Function: controls temperature flap and fresh air blow depending on light intensity Emergency running during

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failure: Climatronic Control Module J255 utilizes a fixed value Removing and installing 87-3, Sunlight Photo Sensor G107 or Sunlight PhotoSensor 2 G134 , removing Left Vent Temperature Sensor G150 Checking: Vehicle Diagnosis, Testing Info. System VAS5051B Removing 87-3, Left Vent Temperature Sensor G150 , removing Vent for indirect ventilation Center vents Removing and installing 80-1, Center vents, removing and installing Right Vent Temperature Sensor G151 Checking: Vehicle Diagnosis, Testing Info. System VAS5051B Removing and installing 87-3, Right Vent Temperature Sensor G151 , removing Air vent Removing and installing 80-1, Driver or front passenger side vent, removing A/C Control Head E87 with Climatronic Control Module J255 The Climatronic Control

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Module J255 and the A/C Control Head E87 are one component that cannot be disassembled. Checking: Vehicle Diagnosis, Testing Info. System VAS5051B Removing and installing 87-3, A/C Control Head E87 with Climatronic Control Module J255 , removing and installing Replacing: Initiate Basic Setting using Vehicle Diagnosis, Testing Info. System VAS5051B 87-3, Components, checking and adjusting . Air Flow Flap Motor V71 Checking: Vehicle Diagnosis, Testing Info. System VAS5051B Removing and installing 87-3, Air Flow Flap Motor V71 with Back Pressure Flap Motor Position Sensor G113 , removing and installing Replacing: Initiate Basic Setting using Vehicle Diagnosis, Testing Info. System VAS5051B 87-3, Components, checking and adjusting . Recirculation Flap Motor V113 Checking: Vehicle Diagnosis, Testing Info. System VAS5051B Removing and installing 87-3, Recirculation Flap Motor V113 , removing and installing Replacing: Initiate Basic Setting using Vehicle Diagnosis, Testing Info.

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System VAS5051B 87-3, Components, checking and adjusting . Right footwell vent Removing and installing 80-1, Right footwell vent, removing and installing Fresh Air Blower V2 with Fresh Air Blower Control Module J126 Note : Fresh Air Blower Control Module J126 and Fresh Air Blower V2 are located in one housing and therefore cannot be replaced individually. Checking: Vehicle Diagnosis, Testing Info. System VAS5051B Removing 87-3, Fresh Air Blower V2 with Fresh Air Blower Control Module J126 , removing Harness connector Evaporator Vent Temperature Sensor G263 Checking: Vehicle Diagnosis, Testing Info. System VAS5051B Removing and installing 87-3, Evaporator Vent Temperature Sensor G263 , removing Heating unit partition Removing 80-1, Removing heating unit partition Dust and pollen filter With activated charcoal filter

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Removing and installing 80-1, Dust and pollen filter element, removing and installing Connection For rear vent air duct To remove, center console must be removed

Repair Manual, Body Interior, Repair Group 68, Rear vent air duct Removing and installing 80-1, Air duct for rear vents, removing and installing Rear vent Removing and installing 80-1, Rear vents, removing and installing Rear channel for right footwell Removing and installing 80-1, Rear footwell channel, removing and installing Rear channel for left footwell Removing and installing 80-1, Rear footwell channel, removing and installing Right Temperature Flap Motor V159 Checking: Vehicle Diagnosis, Testing Info. System VAS5051B Removing and installing

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87-3, Right Temperature Flap Motor V159 , removing and installing Replacing: Initiate Basic Setting using Vehicle Diagnosis, Testing Info. System VAS5051B 87-3, Components, checking and adjusting . Right Footwell Vent Temperature Sensor G262 Checking: Vehicle Diagnosis, Testing Info. System VAS5051B Removing 87-3, Right Footwell Vent Temperature Sensor G262 , removing Auxiliary Air Heater Heating Element Z35 Not applicable to US/CDN Left footwell vent Removing and installing 80-1, Left footwell vent, removing and installing Heater core Removing and installing 80-1, Heater core, removing and installing Left Footwell Vent Temperature Sensor G261 Checking: Vehicle Diagnosis, Testing Info. System VAS5051B Removing 87-3, Left Footwell Vent Temperature Sensor G261 , removing

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Defroster Flap Motor V107 Checking: Vehicle Diagnosis, Testing Info. System VAS5051B Removing and installing 87-3, Defroster Flap Motor V107 , removing and installing Replacing: Initiate Basic Setting using Vehicle Diagnosis, Testing Info. System VAS5051B 87-3, Components, checking and adjusting . Left Temperature Flap Motor V158 Checking: Vehicle Diagnosis, Testing Info. System VAS5051B Removing and installing 87-3, Left Temperature Flap Motor V158 , removing and installing Replacing: Initiate Basic Setting using Vehicle Diagnosis, Testing Info. System VAS5051B 87-3, Components, checking and adjusting . Central Air Flap Motor V70 Checking: Vehicle Diagnosis, Testing Info. System VAS5051B Removing and installing 87-3, Central Air Flap Motor V70 , removing and installing Replacing: Initiate Basic Setting using Vehicle Diagnosis, Testing Info. System VAS5051B 87-3, Components, checking and adjusting .

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Heating and A/C unit Removing and installing 87-3, Heating and A/C unit, removing and installing Disassembling and assembling 87-3, Heating and A/C unit, assembly Indirect Ventilation Flap Motor V213 Checking: Vehicle Diagnosis, Testing Info. System VAS5051B Removing 87-3, Indirect Ventilation Flap Motor V213 , removing and installing Replacing: Initiate Basic Setting using Vehicle Diagnosis, Testing Info. System VAS5051B 87-3, Components, checking and adjusting .

Heating and A/C unit, removing and installing

Special tools, testers and auxiliary items required

Refrigerant recycling/recovery unit Kent-Moore ACR4 (or UL approved equivalent) A/C service station VAS 6007A illustrated for reference only

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Drip Tray For VAS6100 VAS6208

Hose Clamps, Up to 40 mm. 3093 Compressed air gun, standard Removing Note: To improve accessibility, additional components e.g. engine cover must be removed (depending on engine version)

Repair Manual, 2.0 Liter 4-Cyl. 4V Turbo Engine Mechanical, Fuel Injection Ignition, Engine Code(s): BPY, Repair Group 10, . - Extract refrigerant e.g. using Refrigerant

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recycling/recovery unit Kent-Moore ACR4 (or UL approved equivalent), only then open the refrigerant circuit. Observe notes 87-5, A/C refrigerant system, servicing . - Remove instrument cluster

Repair Manual, Body Interior, Repair Group 70, . - Remove rear channels for right and left footwells Rear footwell channel, removing and installing . 80-1,

- Place Drip Tray For VAS6100 VAS6208 under the engine.

- Mark coolant hoses - 1 - to prevent interchanging the coolant hoses. Warning! There is a danger of scalding. Coolant temperature can be above 100 C with a warm engine. Cooling system is under pressure. If necessary, reduce pressure and temperature before repairs. - Clamp off coolant hoses - 1 - using Hose Clamps, Up to 40 mm. 3093 and disconnect coolant hoses to heater core.

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- Connect a section of hose - A - onto upper connection. - Hold a container - B - under the lower connection - C - . - Using a compressed air gun, carefully blow residual coolant out of heater core at heater core connection. Warning! There is a danger of ice-up. Refrigerant may leak out if refrigerant circuit is not discharged. Refrigerant must be extracted before opening refrigerant circuit. - From the engine compartment, unscrew bolts - 1 - for refrigerant lines - 2 - .

- Disconnect refrigerant lines from expansion valve - 3 - . Note: Seal all open connections. To seal off all open connections on expansion valve, sealing caps from a replacement expansion valve can be used (preventing dirt and moisture from entering

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the system). - Cover floor carpet in vehicle interior with leak-proof foil and absorbent paper. Note : Take note during removal of the length and assignment of bolts for reinstallation

Bolt 4 Nm Bolts 2x 4 Nm

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Cable bracket Heating and A/C unit Removing: - Disconnect condensation water hose from heating and A/C unit 87-3, Condensation water hose at hHeating and A/C unit condensation water hose, checking . - Disconnect harness connectors from heating and A/C unit. Note : All cable ties opened or cut during removal must be reinstalled at the same locations during installation. - Remove bolts Item - 9 from bracket Item - 5 - . - Remove supports Item - 7 - and Item - 8 - . - Unscrew bolts Item 10 - and Item - 12 - and remove bracket Item 11 - . - Remove bolts Item - 1 and Item - 2 - from cable bracket Item - 3 - . Note : To be able to reach the bolt Item - 1 - , heating and A/C unit on driver side must be pulled out slightly from facing wall. When removing heating and A/C unit, make sure the two coolant pipes of the heater core do not get caught and bent or damaged on plenum chamber or sound insulation pan. Also pay attention to wiring harness, individual wiring connections may get damaged when pulling too

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forcefully on wiring harness. - Remove heating and A/C unit. Installing: Installation is performed in the reverse order of removal, noting the following: Note : The assistance of a second mechanic is necessary to install the heating and A/C unit. - When inserting heating and A/C unit, have the second mechanic guide both coolant pipes to heater core through the seal (from engine compartment) 87-3, Seal for heating and A/C unit / engine compartment . - Fill with coolant

Repair Manual, 2.0 Liter 4-Cyl. 4V Turbo Engine Mechanical, Fuel Injection Ignition, Engine Code(s): BPY, Repair Group 19,

Bracket Assembly carrier Right support Left support Bolts 9 Bolts 2x 1.3 Nm

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9 Bracket Bolts 2x 9

1.3 Nm

1.3 Nm

Seal for heating and A/C unit / engine compartment

Note: Note installation position of seal - A - during assembly.

Heating and A/C unit, assembly

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Volkswagen, Skoda, Seat, Audi

. 23 47

Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru

Central Air Flap Motor V70 Removing and installing 87-3, Central Air Flap Motor V70 , removing and installing Left Temperature Flap Motor V158 Removing and installing 87-3, Left Temperature Flap Motor V158 , removing and installing Defroster Flap Motor V107 Removing and installing 87-3, Defroster Flap Motor V107 , removing and installing

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Indirect Ventilation Flap Motor V213 Removing and installing 87-3, Indirect Ventilation Flap Motor V213 , removing and installing Intermediate piece for indirect ventilation Bracket Bolts Bolts must be unscrewed to separate air distributor and evaporator housing. Cover Recirculation Flap Motor V113 Removing and installing 87-3, Recirculation Flap Motor V113 , removing and installing Air Flow Flap Motor V71 Removing and installing 87-3, Air Flow Flap Motor V71 with Back Pressure Flap Motor Position Sensor G113 , removing and installing Housing for air entry With fresh/recirculating air door With air flow flap (Climatronic) Upper section of evaporator housing Disassembling and assembling evaporator housing 87-3, Evaporator housing, assembly

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Evaporator Removing and installing 87-5, Evaporator, removing and installing Lower section of evaporator housing Disassembling and assembling evaporator housing 87-3, Evaporator housing, assembly Evaporator Vent Temperature Sensor G263 Removing and installing 87-3, Evaporator Vent Temperature Sensor G263 , removing Connection for glove compartment cooling Fresh Air Blower V2 with Fresh Air Blower Control Module J126 Cannot be replaced individually The Fresh Air Blower Control Module J126 and the Fresh Air Blower V2 are combined into one assembly. Removing 87-3, Fresh Air Blower V2 with Fresh Air Blower Control Module J126 , removing Dust and pollen filter With activated charcoal filter Removing and installing 80-1, Dust and pollen filter element, removing and installing

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Cover For dust and pollen filter Cooling hose for glove compartment cooling Heater core Removing and installing 80-1, Heater core, removing and installing Heater core trim Auxiliary Air Heater Heating Element Z35 Not applicable to US/CDN Right Temperature Flap Motor V159 Removing and installing 87-3, Right Temperature Flap Motor V159 , removing and installing Distribution housing
Evaporator housing, assembly

- Separate evaporator housing from heating and A/C unit 87-3, Heating and A/C unit, assembly . - Disconnect harness connectors from heating and A/C unit.

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Lower section of evaporator housing Evaporator Check insulation, it must be completely present Removing and installing 87-5, Evaporator, removing and installing Clip Upper section of evaporator housing Bolt Seal / insulation Heat insulation for expansion

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valve Removing and installing 87-5, Evaporator, removing and installing Bracket Removing and installing 87-5, Evaporator, removing and installing

Fresh Air Blower V2 with Fresh Air Blower Control Module J126 , removing

Fresh Air Blower V2 with Fresh Air Blower Control Module J126 is accessible from footwell on front passenger side. Note: Fresh Air Blower Control Module J126 and Fresh Air Blower V2 are located in one housing and therefore cannot be replaced individually. - Remove heating unit partition unit partition 80-1, Removing heating

- Disconnect harness connector from Fresh Air Blower V2 with Fresh Air Blower Control Module J126 - 1 - . - Release locking mechanism - 2 - and rotate Fresh Air Blower V2 with Fresh Air Blower Control Module J126 - in direction of arrow - and remove.
Outside Air Temperature Sensor G17 removing and installing

Removing

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- Remove noise insulation

Repair Manual, Body Exterior, Repair Group 50, .

- Unclip Outside Air Temperature Sensor G17 - 1 - and disconnect harness connector. Installing Installation is performed in the reverse order of removal.
Sunlight Photo Sensor G107 or Sunlight PhotoSensor 2 G134 , removing

Removing Special tools, testers and auxiliary items required

Trim Removal Wedge 3409

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- Using adhesive tape, mark dimensions "a and b" on instrument panel. a = 115 mm b = 15 mm Caution! Panel for indirect ventilation could be damaged. Panel is secured by a bolt under Sunlight Photo Sensor G107 . Lift panel max. 15 mm. - Unclip panel at markings on right and left sides from instrument panel using Trim Removal Wedge 3409 .

- Guide a screwdriver - 3 - with a long blade in direction of Sunlight Photo Sensor G107 - 2 - . - Use e.g. a wooden block - 1 - as a support underneath. - Press screwdriver - in direction of arrow - and unclip Sunlight Photo Sensor G107 . - Disconnect harness connector from Sunlight Photo Sensor G107 .

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Installing - Connect connector to Sunlight Photo Sensor G107 and engage it in instrument panel.
Left Vent Temperature Sensor G150 , removing

- Remove instrument cluster

Repair Manual, Electrical Equipment, Repair Group 90, .

- Disconnect connector - 2 - at Left Vent Temperature Sensor G150 . - Rotate Left Vent Temperature Sensor G150 - 1 - 90 and remove from instrument panel.
Right Vent Temperature Sensor G151 , removing

- Remove glove compartment

Repair Manual, Body Interior, Repair Group 68, .

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- Disconnect connector - 1 - from Right Vent Temperature Sensor G151 . - Rotate Right Vent Temperature Sensor G151 - 2 - 90 and remove from air channel.
Left Footwell Vent Temperature Sensor G261 , removing

- Remove left footwell vent removing and installing .

80-1, Left footwell vent,

- Disconnect connector - 1 - from Left Footwell Vent Temperature Sensor G261 . - Rotate Left Footwell Vent Temperature Sensor G261 - 2 90 in direction of arrow and remove from housing.
Right Footwell Vent Temperature Sensor G262 , removing

- Remove right footwell vent removing and installing .

80-1, Right footwell vent,

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- Disconnect connector - 1 - at Right Footwell Vent Temperature Sensor G262 . - Rotate Right Footwell Vent Temperature Sensor G262 - 2 - 90 in direction of arrow and remove from housing.
Evaporator Vent Temperature Sensor G263 , removing

- Remove heating unit partition unit partition

80-1, Removing heating

- Disconnect connector - 2 - at Evaporator Vent Temperature Sensor G263 - 1 - . - Rotate Evaporator Vent Temperature Sensor G263 - 1 90 in direction of arrow and remove from housing.
Condensation water hose at hHeating and A/C unit condensation water hose, checking

- Remove heating unit partition unit partition Note:

80-1, Removing heating

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The condensation water hose - 1 - must be able to be connected to connection of heating and A/C unit without pre-tension. Condensation water hose must sit securely on connection for condensation water hose on heating and A/C unit.

Actuator motors for A/C system regulation - actuator motors, replacing

Special tools, testers and auxiliary items required

Vehicle Diagnosis, Testing Info. System VAS5051B First perform the following work: - Switch off all electrical consumers. - Switch ignition off. - Remove ignition key.
Central Air Flap Motor V70 , removing and installing

Removing

Automatic climate control system - Climatronic

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- Remove instrument cluster

Repair Manual, Body Interior, Repair Group 70, . - Disconnect harness connector from Central Air Flap Motor V70 .

- Unscrew securing bolts - 1 - and remove Central Air Flap Motor V70 . Installing Installation is performed in the reverse order of removal. Note: After installing Central Air Flap Motor V70 , central flap must be checked for function. Initiate "Basic Setting" function using Vehicle Diagnosis, Testing Info. System VAS5051B 87-3, Components, checking and adjusting .

Air Flow Flap Motor V71 with Back Pressure Flap Motor Position Sensor G113 , removing and installing

Note: Air Flow Flap Motor V71 can only be removed without difficulty in "fresh air mode stop" and installed only in this position. If motor remains standing in a different position and can no longer be moved electrically into "fresh air mode stop" position, it can only be pulled off and removed with difficulty.

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Position of fresh/recirculating air door must not be changed. Removing - If necessary, switch ignition on, select operating mode "Defrost" on A/C Control Head E87 (actuator motor is always set to "fresh air mode" position in this operating mode) and wait until actuator motor has reached its "fresh air mode" end position. - Switch ignition off. - Remove glove compartment

Repair Manual, Body Interior, Repair Group 68,

- Disengage catches - D - and - E - for bracket - A - on intake housing and remove bracket - A - . - Remove Recirculation Flap Motor V113 87-3, Recirculation Flap Motor V113 , removing and installing . - Mark connector to Recirculation Flap Motor V113 (to rule out an interchange with connector to Air Flow Flap Motor V71 ).

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- Remove actuator motor - A - from intake housing. Note: Connection between actuator motor toothed gears and air flow flap is designed so that actuator motor can be removed without difficulty only in the "fresh air mode" position. If motor is found in a different position and can no longer be moved, motor cannot be simply pulled off, rather it must be loosened first with great force from mounting points - B - , ensure that toothed gear - C is not damaged when doing this. Installing Note:

Motor as replacement part is delivered in the "fresh air mode" position, only when toothed gear - A contacts stop - B - can it then be connected onto toothed gear of fresh/recirculating air door. If a motor was removed in a different position or activated in the removed state, it cannot be installed. If toothed gear - A - of motor does not stand at stop B - "fresh air mode" , proceed as follows: - Connect motor to vehicle wiring harness. - Switch ignition on. - Wait until toothed gear - A - of motor reaches stop - B "fresh air mode" . - Switch ignition off.

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- Before installing actuator motor, check bearing of air flow flap in intake housing and of toothed gear - C - (air flow flap is opened, "fresh air mode" ). - Connect Air Flow Flap Motor V71 to vehicle wiring harness (make sure connectors are allocated correctly).

- Reach into intake opening for recirculating air mode and bring fresh/recirculating air door - A - into "fresh air mode" position (intake opening for recirculating air mode is closed).

- Insert motor - B - into mounts - C - in opposite direction of arrow and onto toothed gear - D - . Note:

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So that toothed gear on motor - A - can be slid on toothed gear of air flow flap, short tooth - C - of motor toothed gear must align with short tooth interval - D of toothed gear on shaft of air flow flap - B - .

- After assembling actuator motor, press toothed gear - 1 again on to shaft of air flow flap. - Install Recirculation Flap Motor V113 87-3, Recirculation Flap Motor V113 , removing and installing . - Install the wiring harness so that it cannot come in contact with any moving parts (e.g. the actuating arm of the actuator motor).

Automatic climate control system - Climatronic

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- Install bracket - A - , take special care when doing this, that bracket guide - B - is inserted correctly into intake housing mount - C - and bracket is engaged correctly in both catches - D - and - E - . Note: Position of Air Flow Flap Motor V71 and of Recirculation Flap Motor V113 (and corresponding flaps) is no longer visible with glove compartment installed, therefore it is advisable to check its function before installing glove compartment. When both toothed gears (on Air Flow Flap Motor V71 and air flow flap) are assembled in incorrect position, it can be detected as the air flow flap does not reach its two end positions or motor does not run cleanly and without hitching. - Install all removed components in reverse order. Note: After installing Air Flow Flap Motor V71 , air flow flap must be checked for function. - Checking: Vehicle Diagnosis, Testing Info. System VAS5051B . - Replacing: Initiate Basic Setting using Vehicle Diagnosis, Testing Info. System VAS5051B 87-3, Components, checking and adjusting .
Defroster Flap Motor V107 , removing and installing

Removing - Remove instrument cluster

Repair Manual, Body Interior, Repair Group 70, .

Automatic climate control system - Climatronic

. 41 47

- Remove bolts - 1 - and - 3 - . - Remove bracket - 2 - .

- Mark connector - C - to actuator motor (danger of interchange with other connectors of same construction). - Disconnect harness connector - C - at Defroster Flap Motor V107 . - Unscrew securing bolts - A - and remove Defroster Flap Motor V107 - B - . - Disengage actuator motor lever - E - from connecting rod -D-. Installing Installation is performed in the reverse order of removal. Note: After installing, function of defroster flap must be checked. Initiate "Basic Setting" function using Vehicle Diagnosis, Testing Info. System VAS5051B 87-3, Components, checking and adjusting .

Automatic climate control system - Climatronic

. 42 47

Recirculation Flap Motor V113 , removing and installing

Removing - Remove glove compartment

Repair Manual, Body Interior, Repair Group 68, .

- Mark connector - A - if necessary (to rule out an interchange in the event several connectors are disconnected at the same time). - Disconnect connector - A - .

- Disengage catches - C - and - D - for bracket - B - on intake housing and remove bracket - B - (toward rear). - Remove actuator motor - A - from intake housing. Installing

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- Check shaft of recirculation flap - C - before installing actuator motor - A - . - Set shaft - C - so that connecting element of actuator motor - D - can be inserted. - Insert actuator motor with connecting element - D - into shaft - C - and mounts at intake housing - B - .

- Install bracket - A - , take special care when doing this, that bracket guide - B - is inserted correctly into intake housing mount - C - and bracket is engaged correctly in both catches - D - and - E - . - Install all removed components in reverse order. Note: After installing, function of recirculation flap must be checked. Initiate "Basic Setting" function using Vehicle Diagnosis, Testing Info. System VAS5051B 87-3, Components, checking and adjusting .

Left Temperature Flap Motor V158 , removing and installing

Removing

Automatic climate control system - Climatronic

. 44 47

- Remove instrument cluster

Repair Manual, Body Interior, Repair Group 70, . - Remove left footwell vent removing and installing . 80-1, Left footwell vent,

- Remove bolts - 1 - and - 3 - . - Remove bracket - 2 - .

- Mark connector - C - to actuator motor (danger of interchange with other connectors of same construction). - Disconnect harness connector - C - at Left Temperature Flap Motor V158 . - Remove cover for heater core - A - . - Unscrew securing bolts - D - and remove Left Temperature Flap Motor V158 - B - . - Disengage actuator motor lever - E - from connecting rod -F-. Installing

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Installation is performed in the reverse order of removal, noting the following: - Install the wiring harness so that it cannot come in contact with any moving parts (e.g. the actuating arm of the actuator motor). Note: After installing Left Temperature Flap Motor V158 , temperature flap must be checked for function. Initiate "Basic Setting" function using Vehicle Diagnosis, Testing Info. System VAS5051B 87-3, Components, checking and adjusting .

Right Temperature Flap Motor V159 , removing and installing

Removing - Remove glove compartment

Repair Manual, Body Interior, Repair Group 68, . - Remove right footwell vent removing and installing . 80-1, Right footwell vent,

- Disconnect harness connector from Right Temperature Flap Motor V159 .

- Unscrew securing bolts - 1 - and remove Right Temperature Flap Motor V159 . - Unhook brace - 2 - from Right Temperature Flap Motor V159 .

Automatic climate control system - Climatronic

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Installing Installation is performed in the reverse order of removal. Note: After installing Right Temperature Flap Motor V159 , temperature flap must be checked for function. Initiate "Basic Setting" function using Vehicle Diagnosis, Testing Info. System VAS5051B 87-3, Components, checking and adjusting .

Indirect Ventilation Flap Motor V213 , removing and installing

Removing - Remove instrument cluster

Repair Manual, Body Interior, Repair Group 70, .

- Disconnect harness connector from Indirect Ventilation Flap Motor V213 - 3 - . - Remove bolts - 1 - . - Disconnect Indirect Ventilation Flap Motor V213 - 3 - from intermediate piece for indirect ventilation flap - 2 - . Installing Installation is performed in the reverse order of removal. Note: After installing Indirect Ventilation Flap Motor V213 , it must be checked for function.

Automatic climate control system - Climatronic

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Initiate "Basic Setting" function using Vehicle Diagnosis, Testing Info. System VAS5051B 87-3, Components, checking and adjusting .

A/C compressor bracket

. 1 10

87 - 4

A/C compressor bracket

A/C compressor bracket - 4-cylinder engine, removing and installing

Special tools, testers and auxiliary items required

Torque Wrench 5-50Nm VAG1331 Note : The auxiliary component bracket for A/C compressor and ancillary parts can be removed and installed without opening the refrigerant circuit. To remove the ribbed belt:

Repair Manual, 2.0 Liter 4-Cyl. 4V Turbo Engine Mechanical, Fuel Injection Ignition, Engine Code(s): BPY, Repair Group 13,

A/C compressor bracket

Volkswagen, Skoda, Seat, Audi

. 2 10

Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru

Cylinder collar bolt M1045 Alignment bore 2.0L Turbo FSI-engine: 40 Nm Cylinder collar bolt M1045 2.0L Turbo FSI-engine: 40 Nm Cylinder collar bolt M1045 2.0L Turbo FSI-engine: 40 Nm Cylinder collar bolt M1045 2.0L Turbo FSI-engine: 40

A/C compressor bracket

. 3 10

Nm A/C compressor Removing and installing 87-5, A/C compressor, removing and installing Hex bolts M8100 3x 25 Nm Cylinder collar bolt M1045 Alignment bore 2.0L Turbo FSI-engine: 40 Nm Cylinder collar bolt M1045 2.0L Turbo FSI-engine: 40 Nm Dowel sleeves 2x Ensure proper seating between auxiliary component bracket and A/C compressor Auxiliary component bracket for A/C compressor No. on auxiliary component bracket 06F 903 143 E/F Removing - Remove generator

Repair Manual, Electrical Equipment, Repair Group 27, - Loosen A/C compressor, unscrew hex-bolts - 6 - .

A/C compressor bracket

. 4 10

Remove A/C compressor from auxiliary component bracket and secure to body with appropriate material (e.g. welding wire) 87-4, Securing A/C compressor to body - Unscrew bolts - 1 - to - 4 and - 7 - and - 8 - and remove auxiliary component bracket - 10 from cylinder block. Installing Always observe tightening torque of mounting bolts: - Tighten cylinder collar bolt, items - 1 - (alignment bore), - 7 - (alignment bore) , - 4 - , - 8 - , - 3 - and - 2 - in succession.

Securing A/C compressor to body

If A/C compressor is removed and refrigerant circuit not opened, A/C compressor must be secured to body using appropriate material, a welding wire for example. Make sure that coolant hoses remain on A/C compressor without tension for this. Note:

A/C compressor bracket

. 5 10

When installing the belt ensure it is correctly seated in the ribbed belt pulley. Last, install ribbed belt over ribbed belt pulley of A/C compressor.

Ribbed belt pulley, removing and installing

Ribbed belt pulley - Zexel, removing and installing

A/C compressor Zexel Clean flange before sliding ribbed belt pulley on Ribbed belt pulley

A/C compressor bracket

. 6 10

Removing

Topic 87-4

To loosen and tighten bolt, hold ribbed belt pulley firmly in place using a standard band wrench (with webbing). Circlip Replace Install on proper side, beveled insertion edge faces away from compressor (install flat side facing compressor) Overload safeguard Bolted to ribbed belt pulley Guarantees ribbed belt pulley will continue to turn if A/C compressor locks up To loosen and tighten bolts, hold ribbed belt pulley firmly in place using a standard band wrench (with webbing). Hex bolt Replace To loosen and tighten bolt, hold ribbed belt pulley firmly in place using a standard band wrench (with webbing). Before screwing in, clean off old bolt locking compound from thread on A/C compressor shaft. Insert bolt with locking fluid D 000 600 A2 . 20 Nm Socket head bolt 3x

A/C compressor bracket

. 7 10

5 Nm

Removing ribbed belt pulley Note: A/C compressor must not be removed to replace the ribbed belt pulley. To loosen and tighten bolts, hold ribbed belt pulley firmly in place using a standard band wrench (with webbing). - Remove ribbed belt

Repair Manual, 2.0 Liter 4-Cyl. 4V Turbo Engine Mechanical, Fuel Injection Ignition, Engine Code(s): BPY, Repair Group 13,

- Remove bolts - arrows - . - Remove bolt - 1 - .

A/C compressor bracket

. 8 10

- Remove circlip - 1 - . - Remove ribbed belt pulley - 2 - from A/C compressor. Installing Installation is performed in the reverse order of removal, noting the following: Before screwing in, clean off old bolt locking compound from thread on A/C compressor shaft. Clean A/C compressor flange before sliding ribbed belt pulley on. Install circlip on proper side, beveled insertion edge faces away from compressor (install flat side facing compressor) Hex bolt Item - 5 - must be replaced

Ribbed belt pulley - Sanden, removing and installing

Note : A/C compressor must not be removed to replace the ribbed belt pulley. To loosen and tighten bolts, hold ribbed belt pulley firmly in place using a standard band wrench (with webbing). Removing ribbed belt

Repair Manual, 2.0 Liter 4-Cyl. 4V Turbo Engine Mechanical, Fuel Injection Ignition, Engine Code(s): BPY, Repair Group 13,

A/C compressor bracket

. 9 10

Hex nut Replace To loosen and tighten hex nut, hold ribbed belt pulley firmly in place using a standard band wrench (with webbing). Insert hex nut with locking fluid D 000 600 A2 . 25 Nm Bolt To loosen and tighten hex nut, hold ribbed belt pulley firmly in place using a standard band wrench (with webbing).

A/C compressor bracket

. 10 10

3x 4.5 Nm Overload safeguard Bolted to ribbed belt pulley. Guarantees ribbed belt pulley will continue to turn if A/C compressor locks up. To loosen and tighten bolts, hold ribbed belt pulley firmly in place using a standard band wrench (with webbing). Washer Circlip Replace Install on proper side, beveled insertion edge - A - faces away from A/C compressor (install flat side facing A/C compressor) Ribbed belt pulley Clean A/C compressor flange before sliding on pulley. A/C compressor Sanden Clean flange before sliding ribbed belt pulley on.

A/C refrigerant system, servicing

. 1 21

87 - 5

A/C refrigerant system, servicing

Special tools, testers and auxiliary items required Information for performing repair work on A/C refrigerant circuit and on handling refrigerant

Repair Manual, Refrigerant R134a - Servicing, Repair Group 00, . Information on tools for repairing A/C refrigerant circuit

Repair Manual, Refrigerant R134a - Servicing, Repair Group 00, . Note:

Refrigerant must be extracted beforehand using e.g. Refrigerant recycling/recovery unit Kent-Moore ACR4 (or UL approved equivalent). A/C service station VAS 6007A illustrated for reference only. The previously used service stations can still be used catalog V.A.G tools. To prevent the ingress of damp air, all components of

A/C refrigerant system, servicing

. 2 21

the refrigerant circuit which have been opened must be sealed with suitable plugs. The color coding of O-rings for the R134a refrigerant circuits has been discontinued. Colored and black Orings are used. Threaded connections of refrigerant circuit must be coated with polyethylene glycol (PEG) VW material no. 294440 before installing. Under certain conditions, the dryer cartridge must no longer be replaced after each time refrigerant circuit is opened

Repair Manual, Refrigerant R134a - Servicing, Repair Group 00, replacing components.
A/C refrigerant system components, replacing

Warning! There is a danger of ice-up. Refrigerant may leak out if refrigerant circuit is not discharged. Refrigerant must be extracted before opening refrigerant circuit.

A/C refrigerant system, servicing

. 3 21

A/C compressor Manufacturers identification for Sanden: PXE16 Manufacturers identification for Zexel: DSC17E Pay attention to notes for installing A/C compressor 87-5, A/C Compressor, installation notes Removing and installing 87-5, A/C compressor, removing and installing Condenser Removing and installing 87-5, Condenser, removing and installing

A/C refrigerant system, servicing

. 4 21

Fluid reservoir with dryer cartridge Note : Under certain conditions, the dryer cartridge must no longer be replaced after each time refrigerant circuit is opened

Repair Manual, Refrigerant R134a Servicing, Repair Group 00, replacing components. Fluid reservoir with dryer cartridge is installed on right or left side on condenser, depending on engine version. Removing and installing 87-5, Fluid reservoir with dryer cartridge, removing and installing High Pressure Sensor G65 Removing Bracket Evacuating and charging valve High pressure side Environmentally hazardous draining of refrigerant is an offense punishable by law. Capacities Retaining bracket Evacuating and charging valve Low pressure side Environmentally hazardous draining of refrigerant is an offense punishable by law. 87-6, Capacities 87-5, Removing

A/C refrigerant system, servicing

. 5 21

Capacities Expansion valve

87-6, Capacities

Function and removal 87-5, Expansion valve, removal and function Hex nut 20 Nm Bracket

Removing High Pressure Sensor G65

Note: For better depiction, right headlight is removed. - Disconnect harness connector from high pressure sensor -1-. - Unscrew High Pressure Sensor - 2 - from connection of refrigerant line. Note: Replace O-ring High Pressure Sensor G65 - 2 - may also be installed on a different side in the vicinity of the condenser, depending on the engine version.

A/C refrigerant system, servicing

. 6 21

Fluid reservoir with dryer cartridge, removing and installing

Note: Under certain conditions, the dryer cartridge must no longer be replaced after each time refrigerant circuit is opened

Repair Manual, Refrigerant R134a - Servicing, Repair Group 00, replacing components. Fluid reservoir with dryer cartridge is installed on right or left side on condenser, depending on engine version. Special tools, testers and auxiliary items required

Refrigerant recycling/recovery unit Kent-Moore ACR4 (or UL approved equivalent). A/C service station VAS 6007A illustrated for reference only. Not illustrated Seeger ring pliers (commercially available) Removing - Extract refrigerant e.g. using Refrigerant recycling/recovery unit Kent-Moore ACR4 (or UL approved equivalent), only then open the refrigerant circuit. Observe notes 87-5, A/C refrigerant system components, replacing . - Bring the lock carrier into service position

A/C refrigerant system, servicing

. 7 21

Repair Manual, Body Exterior, Repair Group 50, .

- Unscrew mounting bolts for cooler - arrows - .

- Push cooler in direction of engine until cover bolt - arrow is accessible. - Unscrew cover bolt 1.2 Nm 0.3 Nm

- Screw in one cylinder bolt (M5) into thread of sealing cap. Warning! There is a danger of ice-up. Refrigerant may leak out if refrigerant circuit is not discharged. Refrigerant must be extracted before opening refrigerant circuit. - Press sealing cap downward and remove Seeger ring.

A/C refrigerant system, servicing

. 8 21

- Using pliers on the cylinder bolt - 2 - , pull out sealing cap - 1 - straight in direction of arrow.

- Pull out dryer cartridge - 1 - in direction of arrow using needle-nose pliers. Installing Installation is performed in the reverse order of removal. Tightening torque of plastic nut on fluid reservoir with dryer cartridge is 1.2 Nm 0.3 Nm
A/C compressor, removing and installing

Special tools, testers and auxiliary items required

A/C refrigerant system, servicing

. 9 21

Refrigerant recycling/recovery unit Kent-Moore ACR4 (or UL approved equivalent). A/C service station VAS 6007A illustrated for reference only. Removing - Extract refrigerant e.g. using Refrigerant recycling/recovery unit Kent-Moore ACR4 (or UL approved equivalent), only then open the refrigerant circuit. Observe notes 87-5, A/C refrigerant system components, replacing . - Remove noise insulation beneath engine

Repair Manual, Body Exterior, Repair Group 50, . - Remove ribbed belt

Repair Manual, 2.0 Liter 4-Cyl. 4V Turbo Engine Mechanical, Fuel Injection Ignition, Engine Code(s): BPY, Repair Group 13, . - Disconnect harness connector to A/C Compressor Regulator Valve N280 - Unscrew bolts (22 Nm 1 Nm) - 1 from A/C compressor and disconnect refrigerant lines from A/C compressor.

A/C refrigerant system, servicing

. 10 21

- Unscrew hex bolts - 2 - and remove A/C compressor. Installing Note: Make sure alignment bushings - 3 - are seated correctly. Pay attention to notes for installing A/C compressor 87-5, A/C Compressor, installation notes .

Pressure relief valve on A/C compressor - pressure relief valve, checking

Function: protects refrigerant circuit against excessive pressures

A/C refrigerant system, servicing

. 11 21

Warning! There is a danger of ice-up. Pressure relief valve will drain refrigerant when engine is running and there is excessive pressure in refrigerant circuit. Turn engine off.

Checking pressure relief valve on A/C compressor (Sanden)

The pressure relief valve - arrow - has triggered when refrigerant oil is found in the immediate vicinity. In this case, refer to

Repair Manual, Refrigerant R134a - Servicing, Repair Group 00, . Warning! There is a danger of ice-up. Pressure relief valve will drain refrigerant when engine is running and there is excessive pressure in refrigerant circuit. Turn engine off.

A/C refrigerant system, servicing

. 12 21

Checking pressure relief valve on A/C compressor (Denso)

The pressure relief valve - arrow - has triggered when refrigerant oil is found in the immediate vicinity. In this case, refer to

Repair Manual, Refrigerant R134a - Servicing, Repair Group 00, .

Expansion valve, removal and function

Special tools, testers and auxiliary items required

Refrigerant recycling/recovery unit Kent-Moore ACR4 (or UL approved equivalent). A/C service station VAS 6007A illustrated for reference only. Note:

A/C refrigerant system, servicing

Volkswagen, Skoda, Seat, Audi

. 13 21

Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru Refrigerant must be extracted beforehand using e.g. Refrigerant recycling/recovery unit Kent-Moore ACR4 (or UL approved equivalent). The previously used service stations can still be used catalog V.A.G tools. To prevent the ingress of damp air, all components of the refrigerant circuit which have been opened must be sealed with suitable plugs.

Bolts 10 2x Refrigerant lines on expansion valve 1 Nm

A/C refrigerant system, servicing

. 14 21

O-ring 13.7 mm; 2.5 mm Expansion valve Removing: - Extract refrigerant e.g. using Refrigerant recycling/recovery unit Kent-Moore ACR4 (or UL approved equivalent). - Remove bolts Item - 1 and disconnect refrigerant lines Item - 2 - from expansion valve. - Unscrew bolts Item - 8 - and remove expansion valve.

O-ring 14 mm; 1.82 mm Coat with refrigerant oil when installing O-ring 10.8 mm; 1.82 mm Coat with refrigerant oil when installing O-ring 9.5 mm; 2.5 mm Cylindrical combination bolt 5 Nm

Function

A/C refrigerant system, servicing

. 15 21

The expansion valve atomizes the streaming refrigerant and controls the flow quantity so that the vapor is gaseous only at the evaporator outlet, depending on the heat transmission.

Evaporator, removing and installing

- Remove A/C unit and installing .

87-3, Heating and A/C unit, removing

- Disassemble A/C unit 87-3, Heating and A/C unit, assembly , vehicles with Climatic 87-2, Heating and A/C unit - Climatic, assembly . - Disassemble evaporator housing housing, assembly . 87-3, Evaporator

- Remove evaporator - A - from lower section of evaporator housing. Note: Before inserting the evaporator, check condensation water drain and clean drain if necessary. Before inserting evaporator, clean evaporator housing and the evaporator if necessary. - When inserting evaporator - A - into lower section of evaporator housing and when assembling both housing halves, make sure the seal - F - is not damaged.

A/C refrigerant system, servicing

. 16 21

- Check seal - F - (it must be glued all around) before inserting evaporator. - Place bracket - C - and seal / insulation - B - onto connecting pipe of evaporator - D - and - E - . - Insert evaporator - A - into lower section of evaporator housing as shown in the illustration. Note: After assembling both housing halves, check seal / insulation -B- for correct seating at pass-through for both refrigerant lines -D- and -E-. Check seating of bracket - C - on both refrigerant lines - D - and - E - for correct seating. If heat protection insulation - B - is missing or not installed correctly, it can cause reduced performance of the A/C system (change of adjusted control characteristics of expansion valve due to radiant heat).

Condenser, removing and installing

Special tools, testers and auxiliary items required

A/C refrigerant system, servicing

. 17 21

Refrigerant recycling/recovery unit Kent-Moore ACR4 (or UL approved equivalent). A/C service station VAS 6007A illustrated for reference only. Note: Refrigerant must be extracted beforehand using e.g. Refrigerant recycling/recovery unit Kent-Moore ACR4 (or UL approved equivalent). The previously used service stations can still be used catalog V.A.G tools. To prevent the ingress of damp air, all components of the refrigerant circuit which have been opened must be sealed with suitable plugs. First perform the following work: - Switch off all electrical consumers. - Switch ignition off. - Remove ignition key. - Extract refrigerant e.g. using Refrigerant recycling/recovery unit Kent-Moore ACR4 (or UL approved equivalent). Note: Environmentally hazardous draining of refrigerant is an offense punishable by law. - Remove bumper

A/C refrigerant system, servicing

. 18 21

Repair Manual, Body Exterior, Repair Group 63, - Bring lock carrier into service position

Repair Manual, Body Exterior, Repair Group 50, - Disconnect refrigerant lines from condenser (12 and seal. 1 Nm)

Bolt 5 Nm 4x Air duct Clipped on to condenser

A/C refrigerant system, servicing

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Installation position: Fluid reservoir with dryer cartridge Note : Under certain conditions, the dryer cartridge must no longer be replaced after each time refrigerant circuit is opened

Repair Manual, Refrigerant R134a Servicing, Repair Group 00, replacing components. Fluid reservoir with dryer cartridge is installed on right or left side on condenser, depending on engine version. Removing and installing 87-5, Fluid reservoir with dryer cartridge, removing and installing Sealing strip Adhere upper sealing strips onto 3rd lamella row from top of condenser before installing. Adhere lower sealing strips onto 3rd lamella row from bottom of condenser before installing. Water cooler Mount for fan Bolts 4x 5 Nm Charge air cooler

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Condenser Secured to water cooler with 4 bolts.

A/C Compressor, installation notes

Installing

- Only start engine after refrigerant circuit has been assembled. - After installing a new A/C compressor or fresh refrigerant oil has been filled into compressor (e.g. after blowing through the A/C system), turn ribbed belt pulley of A/C compressor 10 rotations by hand before starting the engine. This prevents damage to the A/C compressor. - If possible, only start engine with refrigerant circuit recharged. Note: The A/C compressor is always driven by the ribbed belt pulley (no A/C clutch): If an A/C compressor locks-up the overload safeguard for the A/C compressor shaft is triggered. An indication that the A/C compressor has locked-up is deformations/bumps on the ribbed belt pulley, but these are not always easy to detect. Another indicator is abraded rubber material in the area of the ribbed belt pulley. The A/C compressor is equipped with a protected oil supply, this prevents A/C compressor damage in the event that the system is empty. This means that approx. 40 to 50 cm 3 of refrigerant oil remains in the A/C compressor. The engine should only be started when the refrigerant circuit is completely and properly installed. For example; if the refrigerant lines are not connected to A/C compressor, when the engine is running the A/C compressor may heat up (via internal heat generation) so much that the A/C compressor will be damaged.

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A/C Compressor Regulator Valve N280 is not activated when the refrigerant circuit is empty and the A/C compressor idles with the engine. If it is necessary to start the engine with a discharged refrigerant circuit: Refrigerant circuit must be fully assembled. At least 1/4 of the prescribed refrigerant oil must be in the A/C compressor. Engine speed should not increase above 2500 RPM. The engine should only run as long as absolutely necessary. Note the following when starting engine for first time after charging refrigerant circuit: - Start engine with A/C compressor switched off ( "ECON" mode) and wait until the idling speed stabilizes. - Open instrument panel vents. - Select temperature preset "Lo" on A/C Control Head E87 . - Now switch A/C compressor on ( "Auto" mode) and allow engine to run for 5 minutes at idling speed.

Capacities

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87 - 6

Capacities
Refrigerant R134a

A/C compressor PXE16 DSC17E

Refrigerant oil

Manufacturer Sanden Zexel

Total capacity 600 + 25 grams 600 + 25 grams

The special refrigerant oil (for use with refrigerant circuits R134a only) is no longer obtainable on the refrigerant/machine oil market. Refrigerant oil can be obtained using following part No.; for: PXE16- Sanden DSC17E- Zexel Model 1K0 820 803 G Sanden 1K0 820 803 L Zexel
1) This

G 052 154 A2 G 052 200 A2 Production As of 12.04 As of 12.04 Total capacity 1) 110 cm 3 120 cm 3 10 cm 3 15 cm 3

quantity of refrigerant oil is in a replacement compressor and equates to the total capacity. Important information:

The refrigerant oil is very hygroscopic, therefore opened containers must be closed immediately after use to stop ingress of moisture. Refrigerant oil, because of its chemical properties, must not be disposed of together with engine oils or transmission oils.
Oil distribution

The oil, which is located in the sump of the A/C compressor before initially switching on the air conditioner system, is distributed through the refrigerant circuit as follows: A/C compressor approx. 50% Condenser approx. 10% Suction hose approx. 10%

Capacities

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Evaporator approx. 20% Fluid reservoir approx. 10%