VW Sharan 1996 Heating Air Conditioning Eng

Service
Workshop Manual
Sharan 1996 ➤
Heating, air conditioning
Edition 09.2015
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
01 - Self-diagnosis
80 - Heating
87 - Air conditioning system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Sharan 1996 ➤
Heating, air conditioning - Edition 09.2015
Contents
01 - Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Self-diagnosis of Climatronic, vehicles: ► 05.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Connecting vehicle diagnosis, testing and information system VAS 5051 . . . . . . . . . . . . 1
1.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Overview - available functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Read control unit version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Reading and clearing fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.6 Fault table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.7 Final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.8 Coding Climatronic control unit J255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.9 Read measured value block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
80 - Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1 Repairing heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.1 Removing and installing vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2 Removing and installing air duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.3 Removing and installing dust and pollen filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.4 Checking air extraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2 Removing and installing heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3 Dismantling and assembling heated air and fresh air controls . . . . . . . . . . . . . . . . . . . . . . 25
4 Dismantling and assembling heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5 Vacuum hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6 Repairing heating and ventilation for passenger compartment . . . . . . . . . . . . . . . . . . . . . . 28
87 - Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1 Notes on repair work to vehicles with air conditioning and on handling refrigerant . . . . . . 29
2 Air conditioning system with manual controls, vehicles ► 05.00 . . . . . . . . . . . . . . . . . . . . 30
2.1 Repairing air conditioning and heating - passenger compartment . . . . . . . . . . . . . . . . . . . . 30
2.2 Dismantling and assembling air conditioning system controls . . . . . . . . . . . . . . . . . . . . . . 32
2.3 Repairing air conditioning and heating - engine compartment . . . . . . . . . . . . . . . . . . . . . . 33
3 Air conditioning system with manual controls, vehicles 06.00 ► . . . . . . . . . . . . . . . . . . . . 36
3.1 Repairing air conditioning and heating - passenger compartment . . . . . . . . . . . . . . . . . . . . 36
3.2 Removing vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.3 Removing and installing glove box cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.4 Removing and installing air conditioning system control unit J301 . . . . . . . . . . . . . . . . . . 40
3.5 Dismantling and assembling air conditioning system control unit J301 . . . . . . . . . . . . . . 41
3.6 Repairing air conditioning system with manual controls - additional heat exchanger . . . . 42
3.7 Repairing air conditioning and heating - engine compartment . . . . . . . . . . . . . . . . . . . . . . 45
4 Climatronic air conditioning system with automatic regulation, vehicles ► 05.00 . . . . . . . . 48
4.1 Operation and function of displays and control buttons on Climatronic control unit J255 . . 49
4.2 Repairing Climatronic - dash panel area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.3 Removing and installing operating and display unit for Climatronic air conditioning system
E87 with Climatronic control unit J255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.4 Repairing Climatronic - additional heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.5 Repairing Climatronic - 2nd evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.6 Repairing Climatronic - engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.7 Checking excess pressure relief valve on air conditioner compressor . . . . . . . . . . . . . . . . 61
4.8 Coolant hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.9 Vacuum hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5 Climatronic air conditioning system with automatic regulation, vehicles 06.00 ► . . . . . . . . 65
5.1 Procedure for checking and adjusting components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.2 Operation and function of displays and control buttons on Climatronic control unit J255 . . 66
Contents i
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5.3 Repairing Climatronic - dash panel area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

5.4 Removing and installing operating and display unit for Climatronic air conditioning system
E87 with Climatronic control unit J255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5.5 Repairing Climatronic - additional heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.6 Repairing Climatronic - 2nd evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.7 Repairing Climatronic - engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.8 Coolant hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6 Removing and installing air conditioner compressor and/or ancillary bracket . . . . . . . . . . 82
6.1 Engine code ADY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
6.2 Engine codes AAA and AMY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
6.3 Engine code AYL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
6.4 Engine codes 1Z, AFN, AHU and AVG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.5 Engine codes AJH, ATM and AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
6.6 Engine codes ANU, AJM, ASZ, AUY, BRT, BTB, BVH and BVK . . . . . . . . . . . . . . . . . . . . 92
7 Repair work on refrigerant circuit which may be performed only in suitable workshops by
specially trained mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
7.1 Repairing Sanden air conditioning system magnetic clutch N25 with air conditioner
compressor removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
7.2 Running-in procedure for air conditioner compressor and temperature measurement . . . . 100
8 Repair work on refrigerant circuit which may be carried out only in suitable workshops by
specially trained mechanics, vehicles ► 05.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
8.2 Repairing components in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
8.3 Overview - components in the refrigerant circuits for front and rear seats . . . . . . . . . . . . . . 105
8.4 Removing evacuating and charging valve, low-pressure side . . . . . . . . . . . . . . . . . . . . . . 111
8.5 Removing evacuation and charging valve, high-pressure side . . . . . . . . . . . . . . . . . . . . . . 113
8.6 Checking excess pressure relief valve on air conditioner compressor . . . . . . . . . . . . . . . . 115
8.7 Repairing refrigerant circuit for rear seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
8.8 Removing expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
8.9 Removing and installing condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
8.10 Removing and installing receiver with dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
8.11 Removing and installing air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
8.12 Removing and installing heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . 123
8.13 Dismantling and assembling heater and air conditioning unit for front and rear seats . . . . 125
9 Repair work on refrigerant circuit which may be carried out only in suitable workshops by
specially trained mechanics, vehicles 06.00 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
9.1 Repairing components in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
9.2 Overview - components in the refrigerant circuits for front and rear seats . . . . . . . . . . . . . . 131
9.3 Removing expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
9.4 Removing and installing condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
9.5 2nd evaporator housing for rear seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
9.6 Remove dryer cartridge in receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
9.7 Removing and installing air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
9.8 Removing and installing heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . 150
9.9 Dismantling and assembling heater and air conditioning unit for front and rear seats . . . . 152
10 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
10.1 Refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
10.2 Refrigerant oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
10.3 Oil distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
ii Contents
Sharan 1996 ➤
01 – Self-diagnosis
1 Self-diagnosis of Climatronic, vehi‐
cles: ► 05.00
(VRL008438; Edition 09.2015)
Note
♦ Guided fault finding for vehicles 06.00 ► ⇒ Vehicle diagnostic

tester or later model in “Guided fault finding” function or “Gui‐
ded functions” including Read measured value block.
♦ Some components and functions of the air conditioning sys‐
tem are not monitored by the self-diagnosis. If no fault has
been found after the fault memory has been read even though
there is a specific complaint, carry out further complaint related
checks.
1.1 Connecting vehicle diagnosis, testing

and information system - VAS 5051-
Special tools and workshop equipment required
♦ Vehicle diagnosis, testing and information system - VAS 5051-
or later model.
♦ Diagnosis cable, 3 m with voltage supply - VAS 5051/1- or
diagnosis cable, 5 m without voltage supply - VAS 5051/3-
1.1.1 Test prerequisites:

♦ All fuses according to current flow diagram OK.
♦ The battery voltage must be at least 11.5 V.
1.1.2 Procedure
This description refers to the procedure with vehicle diagnosis,
testing and information system - VAS 5051- .
– Connect vehicle diagnosis testing and information system -
VAS 5051- as follows:
1. Self-diagnosis of Climatronic, vehicles: ► 05.00 1

Sharan 1996 ➤
– Open ash tray -3-.

– Press flap -1-on both sides slightly in direction of arrow. Ash
tray insert -2- will spring forwards slightly and can be removed.
– Pull opened ash tray housing out of centre console.
– Join connector of diagnosis cable, 3 m with voltage supply -
VAS 5051/1- or diagnosis cable, 5 m without voltage supply -
VAS 5051/3- to diagnosis connection.
– Switch ignition on.
1.1.3 Selecting operating mode

– Press “vehicle self-diagnosis” button on display.
1.1.4 Selecting vehicle system

– Press “08 - Air conditioning/heating electronics” button on dis‐
play.
The control unit identification and the Climatronic control unit -
J255- code appear on the display.
1.1.5 Selecting diagnosis function

All diagnosis functions which can be performed are shown on the
display.
– Press button on display for required function.
Note
The display fields of the functions 04 Basic setting and 08 Read

measured value block are displayed from top to bottom.
1.2 Function
The Climatronic control unit - J255- receives information from
electrical and electronic components (information transmitters).
This information is processed by the control unit in accordance
with specifications. The output signals of the control unit then
control the electrical components (final controls).
The Climatronic control unit - J255- is located in the dash panel
insert in one component together with air conditioning system/
Climatronic operating and display unit - E87- . To enable quick
detection of a fault when a component fails or there is an open
circuit, the control unit is equipped with a fault memory which can
be read using vehicle diagnosis testing and information system -
VAS 5051- .
Should a fault be detected in one of the monitored sensors or
components, it is stored in the fault memory.
If a fault has been stored, the Climatronic will be switched off ei‐
ther partially or entirely depending on the severity of the fault.
1.3 Overview - available functions

01 - Read control unit version ⇒ page 3
02 - Read fault memory ⇒ page 3
03 - Final control diagnosis ⇒ page 10
05 - Erase fault memory ⇒ page 3 .
06 - End output
2 Rep. gr.01 - Self-diagnosis

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07 - Code control unit ⇒ page 12

08 - Read measured value block ⇒ page 13
Only the functions listed can presently be used for self diagnosis.
1.4 Read control unit version

VAS 5051- ⇒ page 1 .
Press the “08 - Air conditioning/heating electronics” button on the
display. The control unit identification and the Climatronic control
unit - J255- code will be displayed.
e.g.
7M0 907 040 K CLIMATRONIC VXX Code 00012
or
7M0 907 040 L CLIMATRONIC VXX Code 00021
♦ 7M0 907 040 K = Part no. of the control unit (for latest control
unit version see Electronic parts catalogue)
♦ 7M0 907 040 L = Part no. of the control unit in vehicles with
2nd evaporator (for latest control unit version see Electronics
parts catalogue)
♦ CLIMATRONIC = System name
♦ VXX = Version
♦ Code
♦ WSC = Workshop code
If code differs from vehicle version:
Check control unit code ⇒ page 12 ; code Climatronic control
unit - J255- .
1.5 Reading and clearing fault memory

VAS 5051- ⇒ page 1 .
– Press “02 - Read fault memory” button on display.
– If no faults are stored in the Climatronic control unit - J255- ,
the display will show “0 faults detected”.
– If faults are stored in the Climatronic control unit - J255- , they
will be listed one after the other on the display.
– Press the ← key.
– Press “05 - Clear fault memory” button on display.
– Press “06 - End output” button on display.
– Rectify faults using fault table ⇒ page 4 .
Note
If no faults are detected although there is a complaint about the

Climatronic, conduct “Read measured value block” ⇒ page 13
function. If necessary, perform complaint-related fault finding
without self-diagnosis.

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1.6 Fault table
Note
♦ The following table lists all the faults, with the corresponding
5-digit fault codes, that can be detected by the Climatronic
control unit - J255- and read from the vehicle diagnosis, testing
and information system - VAS 5051- .
♦ If faults occur only sporadically or if the fault memory is not
cleared after a fault is rectified, these faults will be displayed
as “sporadic faults”.
♦ The fault table may also include the type of fault.
♦ When the repair has been completed, the fault memory must
always be read again with the vehicle diagnosis, testing and
information system - VAS 5051- and cleared.
♦ If no faults are detected although there is a complaint about
the Climatronic, conduct “Read measured value block”
⇒ page 13 function. If necessary, perform complaint-related
fault finding without self-diagnosis:
Display on -VAS 5051- Possible cause of fault Rectifying fault

0 faults detected If “0 faults detected” appears after repairs are completed, the self-diagnosis is
ended.
00532
Voltage supply
Signal too large1) Alternator defective – Check supply voltage using “Read meas‐
ured value block” ⇒ page 13
Signal too small1) Wiring or connectors to Clima‐ – Check wiring and connectors to control
tronic control unit - J255- unit using circuit diagram ⇒ Current flow
diagrams, Electrical fault finding and Fit‐
ting locations
– Check alternator ⇒ Current flow dia‐

grams, Electrical fault finding and Fitting
locations
1) One of these texts will be displayed in addition to relevant component.

00605
Two-way valve for fresh air
and air recirculation flap -
N63-
Open circuit/short to positive Short circuit or open circuit in wir‐ – Check wiring and connectors using cur‐
2)
ing or connectors to two-way rent flow diagram ⇒ Current flow dia‐
valve for fresh air and air recircu‐ grams, Electrical fault finding and Fitting
lation flap - N63- locations
Short to earth 2)
Two-way valve for fresh air and – Replace two-way valve for fresh air and
air recirculation flap - N63- defec‐ air recirculation flap - N63- ⇒ page 50
tive

00657

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Centre vent control motor -
V102- 3)
Short circuit or open circuit in wir‐ – Check wiring and connectors using cur‐
ing or connectors to centre vent rent flow diagram ⇒ Current flow dia‐
control motor - V102- grams, Electrical fault finding and Fitting
locations
– Check function of control motor
⇒ page 10 Functional test of the control
motors
Central vent control motor - – Replace centre vent control motor -
V102- defective V102- ⇒ page 50
3) Fault is recognized after 30 seconds at earliest.

00766
Front vent temperature
sender - G152-
Open circuit/short to positive Short circuit or open circuit in wir‐ – Check front vent temperature sender -
4)
ing or connectors to front vent G152- using “Read measured value
temperature sender - G152- block” ⇒ page 13
– If faults are detected in ambient temper‐

ature sensor - G17- , sunlight penetration
photosensor - G107- or air conditioning
system coolant temperature sender -
G110- , first check wiring from control unit
to connection -L56- (sender) in wiring
harness for Climatronic.
Short to earth4) Front vent temperature sender - – Check wiring and connectors using cur‐
G152- defective rent flow diagram ⇒ Current flow dia‐
locations
– Replace front vent temperature sender -
G152- ⇒ page 50

00779
Ambient temperature sensor
- G17-
– “- -” will appear in the ambient tempera‐
ture display if ambient temperature sen‐
sor - G17- fails.
Open circuit/short to positive Short circuit or open circuit in wir‐ – Check ambient temperature sensor -
5)
ing or connectors to ambient tem‐ G17- using “Read measured value block”
perature sensor - G17- ⇒ page 13
– If faults are also detected in sunlight pen‐

etration photosensor - G107- , front vent
temperature sender - G152- or air condi‐
tioning system coolant temperature
sender - G110- , first check wiring from
control unit to connection L56 (sender) in
wiring loom for Climatronic.
Volkswagen Technical Site: http://vwts.ru http://vwts.info

Sharan 1996 ➤

Short to earth 5)
Ambient temperature sensor - – Check wiring and connectors using cur‐
locations
– Renew ambient temperature sensor -
G17- ⇒ page 58

00792
Air conditioning system
pressure switch - F129- 6)
ing or connectors to air condition‐ rent flow diagram ⇒ Current flow dia‐
ing system pressure switch - grams, Electrical fault finding and Fitting
F129- locations
Coolant pressure too high or too – Check air conditioning system pressure
low due to: incorrect charging of switch - F129- using “Read measured
refrigerant circuit or inadequate value block 08” ⇒ page 13 .
coolant cooling
Air conditioning system pressure – Renew air conditioning system pressure
switch - F129- defective switch - F129- ⇒ page 58
6) This fault cannot be detected if ambient temperature is below 12° C or ambient

temperature sensor - G17- malfunctions simultaneously.

00797
Sunlight penetration photo‐
sensor - G107-
Open circuit/short to positive Open circuit or short circuit in wir‐ – Check sunlight penetration photosensor
ing or connectors to sunlight pen‐ - G107- using “Read measured value
etration photosensor - G107- block” ⇒ page 13
– If faults are detected in ambient temper‐

ature sensor - G17- , front vent tempera‐
ture sender - G152- or air conditioning
system coolant temperature sender -
G110- , first check wiring from control unit
to connection -L56 (sender) in wiring har‐
ness for Climatronic.
Sunlight penetration photosen‐ – Check wiring and connectors using cur‐
sor - G107- defective rent flow diagram ⇒ Current flow dia‐
locations
– Renew sunlight penetration photosensor
- G107- ⇒ page 50 .

00799
Air conditioning system cool‐
ant temperature sender -
G110-

Sharan 1996 ➤

Open circuit/short to positive Open circuit or short circuit in – Check air conditioning system coolant
7)
wires or connectors to air condi‐ temperature sender - G110- using “Read
tioning system coolant tempera‐ measured value block” ⇒ page 13
ture sender - G110-
– If faults are also detected in ambient tem‐
perature sensor - G17- , front vent tem‐
perature sender - G152- and sunlight
penetration photosensor - G107- , first
check wiring from control unit to connec‐
tion -L56 (sender) in wiring harness for
Climatronic.
Short to earth7) Air conditioning system coolant – Check wiring and connectors using cur‐
temperature sender - G110- de‐ rent flow diagram ⇒ Current flow dia‐
fective grams, Electrical fault finding and Fitting
locations
– Renew air conditioning system coolant
temperature sender - G110-
⇒ page 58

01086
Speedometer sender - G22- Short circuit or open circuit in wir‐ – Check signal from speedometer sender -
8)
ing or connectors from dash pan‐ G22- using “Read measured value block”
el insert -K- to Climatronic control ⇒ page 13
unit - J255-
– Check wiring and connectors using cur‐
rent flow diagram ⇒ Current flow dia‐
locations
Speedometer sender - G22- on – Renew speedometer sender - G22-
gearbox defective (only if speed‐
ometer - G21- is also not func‐
tioning)
8) A fault in speedometer sender - G22- has been detected The fault will be
detected only if no speed signal is measured in 5 driving cycles within 2 minutes
after the engine is started.

01184
Rear vent temperature send‐
er - G174-
Open circuit/short to positive Short circuit or open circuit in wir‐ – Check rear vent temperature sender -
9)
ing or connectors to rear vent G174- using “Read measured value
temperature sender - G174- block” ⇒ page 13
Short to earth 9)
Rear vent temperature sender - – Check wiring and connectors using cur‐
locations
– Renew rear vent temperature sender -
G174- ⇒ page 57 .

01185

Sharan 1996 ➤

Rear fresh air blower - V80-
ing or connectors to rear fresh air rent flow diagram ⇒ Current flow dia‐
blower - V80- grams, Electrical fault finding and Fitting
locations
– Check voltage at rear fresh air blower -
V80- using “Read measured value block”
⇒ page 13
Rear fresh air blower control unit – Renew rear fresh air blower control unit -
- J391- defective J391- .
Rear fresh air blower - V80- de‐ – Renew rear fresh air blower - V80-
fective ⇒ page 57

01186
Rear air distribution servo‐
motor - V136- 10)
ing or connectors to rear air dis‐ rent flow diagram ⇒ Current flow dia‐
tribution control motor - V136- grams, Electrical fault finding and Fitting
locations
– Check function of rear air distribution
control motor - V136- ⇒ page 10 Func‐
tional test of control motors.
Rear air distribution control motor – Renew rear air distribution control motor
- V136- defective - V136- ⇒ page 57
10) Only on vehicles with 2nd evaporator

01187
Rear temperature flap con‐
trol motor - V137-
ing or connectors to rear temper‐ rent flow diagram ⇒ Current flow dia‐
ature flap control motor - V137- grams, Electrical fault finding and Fitting
locations
– Check function of rear temperature flap
Rear temperature flap control – Renew rear temperature flap control mo‐
motor - V137- defective tor - V137- ⇒ page 57

01188
Electrical connection for
magnetic clutch control unit
Open circuit/short to positive Short circuit or open circuit in wir‐ – Check wiring and connectors using cur‐
11)
ing or connectors from Climatron‐ rent flow diagram ⇒ Current flow dia‐
ic control unit - J255- to air grams, Electrical fault finding and Fitting
conditioning system magnetic locations
clutch - N25-

Sharan 1996 ➤

Short to earth 11)
In vehicles with VR 6 engine: – Renew magnetic clutch relay - J44- or ra‐
magnetic clutch relay - J44- de‐ diator fan control unit - J293-
fective In vehicles with all other ⇒ page 58
engines: radiator fan control unit
- J293- defective

01189
Centre flap control motor -
V70- is displayed in the ve‐
hicle diagnosis, testing and
information system - VAS
5051/- although front air dis‐
tribution control motor -
V145- is installed
ing or connectors to front air dis‐ rent flow diagram ⇒ Current flow dia‐
tribution control motor - V145- grams, Electrical fault finding and Fitting
locations
– Check function of front air distribution
Front air distribution control mo‐ – Replace front air distribution control mo‐
tor - V145- defective tor - V145- ⇒ page 50

01271
Temperature flap control
motor - V68- 12)
ing or connectors to temperature rent flow diagram ⇒ Current flow dia‐
flap control motor - V68- grams, Electrical fault finding and Fitting
locations
– Check function of temperature flap con‐
trol motor - V68- ⇒ page 10 Functional
test of control motors
Temperature flap control motor - – Renew temperature flap control motor -
V68- defective V68- ⇒ page 50
12) Fault is recognized after 2 seconds at earliest.

01273
Fresh air blower - V2-
ing or connectors to fresh air rent flow diagram ⇒ Current flow dia‐
blower - V2- grams, Electrical fault finding and Fitting
locations
– Check voltage at fresh air blower - V2-
using “Read measured value block”
⇒ page 13
Fresh air blower control unit - – Renew fresh air blower control unit -
J126- defective J126- .

Sharan 1996 ➤

Fresh air blower - V2- defective – Renew fresh air blower - V2-
⇒ page 50

65535
Control unit faulty Electrical interference caused by – Check wiring and connectors to Clima‐
outside sources, poor earth con‐ tronic control unit - J255- using current
nections or positive connections flow diagram ⇒ Current flow diagrams,
to Climatronic control unit - J255- Electrical fault finding and Fitting loca‐
tions
Dash panel temperature sensor - – Check dash panel temperature sensor -
G56- defective. Temperature G56- using “Read measured value block”
sensor blower - V42- defective ⇒ page 13
Climatronic control unit - J255- – Renew Climatronic control unit - J255- if
defective necessary ⇒ page 50
1.7 Final control diagnosis
Note
♦ Final control diagnosis can be carried out with the engine run‐
ning or stopped.
♦ The final control diagnosis is cancelled when the vehicle
speed reaches > 10 km/h or the ignition is switched off.
♦ The diagnosis takes approx. 2 minutes.
♦ During the final control diagnosis, radiator fan - V7- and right
radiator fan - V35- are activated with different voltage. The
control motors are first moved left to stop then right to stop.
They are returned to their initial position at the end of the di‐
agnosis.
♦ Climatronic is not regulated during final control diagnosis.
♦ If necessary, final control diagnosis can be repeated several
times.
1.7.1 Initiating final control diagnosis

VAS 5051- ⇒ page 1 .
– Press “03 - Final control diagnosis” button on the display.
The following tests will be carried out:
♦ Indication of display of operating and display unit for Clima‐
tronic air conditioning system - E87- ⇒ page 11 .
♦ Functional test of the 4 control motors ⇒ page 11
♦ The current paths to the following blower motors are tested:
fresh air blower - V2- , rear evaporator blower - V20- and rear
warm air blower - V47-
♦ The current path to air conditioning system magnetic clutch -
N25-

Sharan 1996 ➤
1.7.2 Control motor test using control buttons

The position of the flaps can be altered by pressing the corre‐
sponding control buttons:
♦ Temperature flap control motor - V68-
– Press control button -3- or -6- until the “Hi” or “Lo” display on
the display field of Climatronic control unit - J255- appears.
This will cause the temperature flap servomotor - V68- to move
once through its entire range.
♦ Front air distribution control motor - V145-
– Press control button -1- or -7-.
The control motor is now moved once through its entire range.
♦ Centre vent control motor - V102-
– Press control button -2-.
The control motor is now moved once through its entire range.
♦ Rear temperature flap control motor - V137-
Only on vehicles with 2nd evaporator
– Press control button -4- or -5- until “Hi” or “Lo” appears in dis‐
play field of Climatronic control unit - J255- .
This will cause the rear temperature flap servomotor - V137- to
move once through its entire range.
♦ Rear air distribution servomotor - V136-
Only on vehicles with 2nd evaporator
The actuation of the rear air distribution control motor - V136- is
map controlled. The function can be checked as follows using the
control buttons:
– Press control button -4- until “Hi” appears in display field of
Climatronic control unit - J255- .
In the “Hi” setting, air is sent only to the footwell vent.
– Press control button -5- until “Lo” appears in display field of
Climatronic control unit - J255- .
In the “Lo” setting, air is sent only to the footwell vent and to the
roof vents.
1.7.3 Checking displays of Climatronic control

unit - J255- using control buttons
Vehicles without 2nd evaporator:
Pressing control keys -1-, -2- and -3- at the same time switches
on all segments.

Sharan 1996 ➤
Check the display of Climatronic control unit - J255- .
Note
All segments should appear on the display; if they do not, replace

control unit.
Vehicles with 2nd evaporator:
Pressing control keys -1-, -2- and -3- at the same time switches
on all segments.
Check the display of Climatronic control unit - J255- .
Note
All segments should appear on the display; if they do not, replace

control unit.
1.8 Coding Climatronic control unit - J255-

If the appropriate code for the vehicle is not displayed or if the
Climatronic control unit - J255- has been renewed, the control unit
must be coded as follows:
The replacement Climatronic control unit - J255- is supplied with
coding 00000. This number must be changed according to the
following instructions to match the vehicle.
The Climatronic control unit - J255- will keep its previous code if
illogical numbers are entered.
1.8.1 Procedure
VAS 5051- ⇒ page 1 .
– Press “07 - Coding control unit” button on display.
– Enter appropriate code number for this vehicle and confirm
your entry by pressing Q key.

Sharan 1996 ➤
Codes Climatronic Climatronic and additional Climatronic and 2nd

heat exchanger evaporator
All petrol engines except 00001 00011 00021
for VR 6
VR 6 00002 00012 00022
Diesel engine 00003 00013 00023
“Coding performed in vehicle system” appears on the vehicle di‐

agnosis, testing and information system - VAS 5051- display.
– Press the ← key.
– Press “06 - End output” function.
Note
♦ The code entered and shown on the display will not be used
by the Climatronic control unit until the ignition has been
switched off once.
♦ An incorrect code leads to incorrect blower output.
1.9 Read measured value block
Note
♦ During the function “Read measured value block”, the Clima‐

tronic regulation is in operation.
♦ A 2nd mechanic is required to read the measured values dur‐
ing a road test.

VAS 5051- ⇒ page 1 .
– Press “08 - Read measured value block” button on display.
– Enter desired display group and confirm entry by pressing Q
key.
Note
The key to the values in the individual display fields is presented

on the following pages.
1.9.1 Table of available display group num‐

bers
Note
Check the values for measurements specified in the following ta‐

bles using the applicable current flow diagram for Climatronic.
Display Display Designation

group zone
1 1 -G17- (-XX to +XXX° C)
Ambient temperature sensor

Sharan 1996 ➤

group zone
2 -G152- (-XX to +XXX° C)
Front vent temperature sender
3 -G174- (-XX to +XXX° C)

Rear vent temperature sender
4 -G110- (XX to +XXX° C)

Coolant temperature sender

group zone
2 1 -G22- (0 to XXX)
Speedometer sender
2 -G107- (0 to XX%)
Sunlight penetration photosensor
3 -G56- (-XX to +XXX° C)

Dash panel temperature sensor
4 Supply voltage (tl. 30)

group zone
3 1 -V2- (0.0 to XX.X V)
Fresh air blower
2 -V80- (0.0 to XX.X V)

Rear fresh air blower
3 No value on display
4 No value on display

group zone
4 1 -F129-
Air conditioning system pressure switch:
Value: 10
2/32 bar “on”; 16 bar “off”
Value: 11
2/32 bar “on”; 16 bar “on”
Value: 00
2/32 bar “off”; 16 bar “off”
Value: 01
2/32 bar “off”; 16 bar “on”
2 Air conditioning system ready/engine
start
Value: 10
ACS ready “on”; engine “off”
Value: 11
ACS ready “on”; engine “on”

Sharan 1996 ➤

group zone
Value: 01
ACS ready “off”; engine “on”
Value: 00
ACS ready “off”; engine “off”
3 -F8-
Kick-down switch
Value: 1 “on”
Value: 0 “off”

group zone
5 1 Auxiliary coolant heater
Value: “on”; “off”
2 Terminal 58
3 X terminal

group zone
6 1 Front temperature flap position
Value (0 to XXX %)
2 Front air distribution flap position
Value (0 to XXX %)
3 Centre vent flap position
Value (0 to XXX %)
4 Fresh air and air recirculation flap posi‐
tion
Value (0 to XXX %)

group zone
7 1 Rear temperature flap position
Value (0 to XXX %)
213) Rear air distribution flap position
Value (0 to XXX %)
13) For code 00010 (air conditioning in front only), the rear air distribution flap
motor does not exist.

group zone
8 1 Actual value for air conditioner compres‐
sor
2 Specification for air conditioner compres‐
sor requirement
3 Code for air conditioner compressor
“OFF”
Value (0 to 1614))
14) The number displayed on vehicle diagnostic tester is explained in the following
table.

Sharan 1996 ➤
Switch-off Meaning Remark

code
0 None Function OK
115) High-pressure event Druck > 32 bar
2/32 bar “off”, 16 bar “on”
2 Blower defective and
currentactual 3 V
315) Low-pressure event Pressure < 2 bar
> 2/32 bar “off”, 16 bar
“on”
5 4 seconds after en‐ No engine start detected
gine start with terminal 15 on.
v=0 km/h and no flank
change (no voltage indica‐
ted) from terminal 15.
6 ECON mode AC function not activated
7 Air conditioning OFF Blower switch in position 0
8 Function of ambient Ambient temperature < =
temperature +3 °C
10 Low voltage see TL 80101 Point 2.2
1115) Engine temperature Engine temperature
> 118° C
13 Excess voltage see TL 80101 Point 2.2
16 Air conditioner com‐ Due to fault source in ac‐
pressor actuation tuation path
⇒radiator fan control unit
switch-off
⇒engine control unit
switch-off
⇒gearbox control unit
switch-off
⇒magnetic clutch control
unit switch-off
etc.
15) If engine code 1 is selected in code table (0), the above-named codes for air
conditioner compressor “OFF” are not applicable because the air conditioning
system pressure switch - F129- is not installed. If the air conditioner switches off
in spite of a demand signal, a "16" will appear in the fourth position of display group
8.

group zone
9 1 Windscreen heater
2 Windscreen heating “on” remaining time
in seconds
XXX.X 0 -s 16)/ -17)
3 Windscreen wiper signal
16) Display range from maximum 240 seconds (minimum setting 60 seconds) to
0 seconds. This time display will only be activated or deactivated with the de-
frost function button. If the ambient temperature is greater than 10° C, the
windscreen heating cannot be activated using the defrost function button.
17) It will be indicated whether the windscreen heating was not switched on by
the Climatronic or the windscreen heating is switched off.

Sharan 1996 ➤
80 – Heating
1 Repairing heating system
1 - Dash panel
❑ Removing and installing
⇒ Rep. gr. 70
2 - Left and right side vents
⇒ page 18
3 - Centre vents
⇒ page 19
4 - Left and right vents
⇒ page 19
5 - Dust and pollen filter
❑ Fitting location: in ple‐
num chamber
⇒ page 20
6 - Filter housing
❑ Fitting location: in ple‐
num chamber
❑ Replacing ⇒ page 20 .
7 - Vacuum unit for fresh air
and air recirculation flap
❑ Ventilated: fresh air op‐
eration
❑ Vacuum hose connec‐
tion diagram
⇒ page 27
❑ Removing: ⇒ page 52
8 - Non-return valve
❑ Permits air flow in direc‐
tion of vacuum, blocked
in opposite direction
❑ Removing: first remove dash panel -1-, cross member and heating.
9 - Connection housing for vacuum hoses
❑ With interchange protection
❑ In fresh air and air recirculation switch - E184-
❑ Vacuum hose connection diagram ⇒ page 27
10 - Direction of vacuum
❑ To brake servo or to vacuum pump
11 - Fresh air blower - V2-
❑ To renew: remove stowage compartment on the front passenger side ⇒ Rep. gr. 68 .
❑ Removing: ⇒ page 70
12 - Controls for fresh and heated air
❑ Cables adjust themselves automatically after knobs are turned from stop to stop.
❑ Dismantling and assembling ⇒ page 25 .
1. Repairing heating system 17

Sharan 1996 ➤
13 - Centre section of dash panel

14 - Heater trim
15 - Rear duct
❑ Removing and installing ⇒ page 39
16 - Rear duct vent
17 - Cable for air distribution housing
❑ Identification: a black retaining clip on sheath
18 - Temperature flap cable
❑ Identification: a brown retaining clip on sheath
19 - Heater unit
❑ With temperature flap
❑ With centre flap
❑ With footwell/defroster flap
❑ Removing and installing heater unit ⇒ page 22
❑ Dismantling and assembling heater unit ⇒ page 26
Note
Always renew coolant.
20 - Heat exchanger
❑ Seals must be bonded free of gaps all around
❑ After removal, completely renew coolant ⇒ Rep. gr. 19 .
21 - Fresh air blower series resistor with overheating fuse - N24-
1.1 Removing and installing vents
1.1.1 Removing and installing right and left

side vents
Removing:
– Using a screwdriver with a pad underneath, lever out from side
facing passenger compartment.
Installing:
– Press in until vent engages.
18 Rep. gr.80 - Heating

Sharan 1996 ➤
1.1.2 Removing and installing centre vent

Removing:
– Lever out using a screwdriver with a pad underneath.
Installing:
1.1.3 Removing and installing right and left

vents
Removing:
Installing:
1.2 Removing and installing air duct
Note
For vehicles 06.00 ►, the air duct under the dash panel must also
be removed.
1.2.1 Removing
– Remove dash panel ⇒ Rep. gr. 70 .
– Removing wiper frame ⇒ Rep. gr. 92 .
– Remove dust and pollen filter ⇒ page 20 .
– Remove dust and pollen filter housing ⇒ page 21 .

Sharan 1996 ➤
– Remove bolts -2- (4.5 ± 0.7 Nm) and -3- (1.4 ± 0.2 Nm) and
remove air duct -1-.
1.2.2 Installing
Install in reverse order.
1.3 Removing and installing dust and pollen

filter
1.3.1 Removing
– Depending on year of construction, additional parts (air ducts,
battery cover or windscreen wiper linkage ⇒ Rep. gr. 92 )
must be removed.
– Disengage retaining clip -1- on right side. Pull dust and pollen
filter to right out of guide.

Sharan 1996 ➤
1.3.2 Installing
– Insert pin into guide -arrow- and engage retaining tab.
1.3.3 Replacing filter housing

1- Filter housing
2- Plastic nut M5, 2 Nm (other two nuts are M6)
3- Dust and pollen filter
1.4 Checking air extraction
Note
♦ The stale air escapes via ventilation openings in the luggage

compartment trim.
♦ If the ventilation is to function properly, the exhaust openings
must not be covered.
♦ The exhaust vents can be found on the lower rear cross panel,
under rear bumper.
1.4.1 Checking
– The sealing lips -1- in the ventilation frame -2- must move
freely and close by themselves.

Sharan 1996 ➤
2 Removing and installing heater unit

♦ Socket set - V.A.G 1835-
♦ Hose clamps up to 40 mm Ø - VAS 3093-
♦ Drip tray - V.A.G 1306-
Removing
First carry out the following work:
Note
If the vehicle is equipped with an air conditioning system, the re‐

frigerant must be extracted prior to work.
Note
For vehicles 06.00 ►, the air duct under the dash panel must also
be removed.

Sharan 1996 ➤
– Remove air duct ⇒ page 19 .

– Clamp off coolant hoses in engine compartment to heat ex‐
changer using hose clamps up to 40 mm Ø - VAS 3093- .
WARNING
Risk of scalding.
When the engine is warm, the coolant temperature may be
above 100 °C. The cooling system is pressurised.
If necessary, release pressure and reduce temperature before
carrying out repairs.
– Pull coolant hoses off heat exchanger.

– Seal heat exchanger to prevent coolant from leaking out.
– Remove dust and pollen filter with filter housing ⇒ page 20 .
– Remove mounting plate ⇒ Rep. gr. 70 .
1 - Hexagon nut
❑ Qty. 4.
❑ 4 Nm
❑ Under protective film
2 - Plenum chamber bulkhead
3 - Heater unit
❑ Dismantling and assem‐
bling heater unit
⇒ page 26
2. Removing and installing heater unit 23

Sharan 1996 ➤
Installing:
– Guide heater unit to plenum chamber bulkhead and push
studs through intended holes.
– Screw hexagon nuts -1- onto plenum chamber bulkhead in
engine compartment and tighten them.
– Connect coolant hoses to heat exchanger.
– Check coolant level and top up. ⇒ Rep. gr. 19

Sharan 1996 ➤
3 Dismantling and assembling heated air and fresh air controls
1 - Controls
2 - Fresh air regulator illumina‐
tion bulb - L16-
3 - Fresh air and air recircula‐
tion switch - E184-
❑ Do not dismantle further
4 - Rotary knob for flap setting
5 - Rotary knob for tempera‐
ture setting
6 - Rotary knob for air recircu‐
lation and blower speed
3. Dismantling and assembling heated air and fresh air controls 25

Sharan 1996 ➤
4 Dismantling and assembling heater

unit
– Remove heater unit ⇒ page 22 .
– Assemble dismantled heater unit using clips.
1 - Air intake connecting pipe

2 - Fresh air blower housing
3 - Air duct
4 - Heat exchanger housing
5 - Footwell vent
6 - Insulation matting
7 - Clip

Sharan 1996 ➤
5 Vacuum hose connection diagram
Note
♦ Insert vacuum hose into vacuum tank 30 mm

♦ Push vacuum hoses onto plastic tube to stop (approx. 15 mm)

Note
Vacuum unit for fresh air and air re‐

circulation flap are located next to
intake connecting pipes.
2 - Connection housing for vac‐

uum hoses
tion switch - E184-
4 - To brake servo or to vac‐
uum pump
5. Vacuum hose connection diagram 27

Sharan 1996 ➤
6 Repairing heating and ventilation for

passenger compartment
Note
First remove rear side wall trim. ⇒ Rep. gr. 70
1 - Switch for heating, temper‐

ature control and timer - E13-
2 - Warm air blower switch -
E100-
3 - Housing for heating and
ventilation for rear seats, in‐
take side
❑ Assemble with clips
4 - Temperature flap for pas‐
senger compartment
5 - Heat exchanger for rear
seats
ventilation for passenger com‐
partment, vent side
7 - Series resistor for warm air
blower - N72-
8 - Rear warm air blower - V47-
9 - Rear temperature flap con‐
trol motor - V137-
10 - Coolant hoses
❑ Bleed coolant circuit af‐
ter working on it
❑ Bleeding ⇒ Rep. gr. 19

Sharan 1996 ➤
87 – Air conditioning system

1 Notes on repair work to vehicles with
air conditioning and on handling re‐
frigerant
Note
♦ Notes on repairs to vehicles with air conditioning and on han‐

dling refrigerant can be found in ELSA under ⇒ Air condition‐
ing system with refrigerant R134a; Rep. gr. 00 ; General
information for air conditioning system, Safety precautions for
when working on vehicles with air conditioning and when han‐
dling refrigerant R134a .
♦ Notes on testers and tools for repairs to vehicles with air con‐
ditioning can be found in ELSA under ⇒ Air conditioning
system with refrigerant R134a; Rep. gr. 00 ; Testing equip‐
ment and tools .
♦ Notes on working with air conditioner service station can be
found in ELSA under ⇒ Air conditioning system with refriger‐
ant R134a; Rep. gr. 00 ; Working with air conditioner service
station .
Caution
Do not kink or severely bend refrigerant hoses.

There is a film in the refrigerant hoses which can be destroyed.
Refrigerant hoses must not be bent to a radius less than r =
100 mm.
Additional information:
♦ ⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations
1. Notes on repair work to vehicles with air conditioning and on handling refrigerant 29
Sharan 1996 ➤
2 Air conditioning system with manual

controls, vehicles ► 05.00
2.1 Repairing air conditioning and heating -

passenger compartment
Note
♦ Parts marked with * can be repaired only by specially trained

mechanics in suitable workshops since the refrigerant must be
extracted beforehand.
♦ A label on the lock carrier indicates the type and quantity of
refrigerant used.
1 - Dash panel
⇒ Rep. gr. 70
air ducts and vents
⇒ page 17 , Repairing
heating
⇒ page 20
3 - Filter housing
⇒ page 20
Note
Vacuum unit for fresh air and air re‐

circulation flap are located next to
intake connecting pipes.
eration
tion diagram ⇒ page 27
❑ Removing ⇒ page 52
5 - Air intake duct*
❑ With fresh air and air re‐
circulation flap
❑ To renew: remove stow‐
age compartment on the
front passenger side ⇒ Rep. gr. 68 .
30 Rep. gr.87 - Air conditioning system

Sharan 1996 ➤
8 - Trim for air conditioning system controls

9 - Evaporator housing*
❑ With evaporator
10 - Air conditioning system controls
❑ With built-in air conditioning system switch - E30-
❑ Installing and adjusting cables ⇒ page 17
11 - Heater and air conditioning unit*
❑ With evaporator
❑ With centre flap
12 - Water drain pipe*
13 - Seal*
14 - Connection housing for vacuum hoses
❑ With interchange protection
❑ In fresh air and air recirculation switch - E184-
❑ Vacuum hose connection diagram ⇒ page 27
15 - Arrow points in direction of vacuum
16 - Non-return valve*
❑ Permits air flow in direction of vacuum, blocked in opposite direction
❑ Removing: first remove dash panel -1-, cross member and heating.
17 - Cable for air distribution housing
❑ Identification: a black retaining clip on sheath
18 - Temperature flap cable
❑ Identification: a brown retaining clip on sheath
19 - Heat exchanger*
❑ If tabs do not engage when inserted or if they have broken off, bolt on heat exchanger.
❑ After removal, completely renew coolant ⇒ Rep. gr. 19 .
20 - Relay carrier
❑ With air conditioning system delay relay - J70- ; control number 168; in brown slot; delays the engaging
of air conditioning system magnetic clutch - N25- for 8 seconds to make starting the engine easier.
❑ With air conditioning system switch-off relay - J365- ; control number 147; in yellow slot; disengages air
conditioning system magnetic clutch - N25- for kick-down or at full load.
❑ With cut-out relay for air conditioning system magnetic clutch - J246- ; control number 94; in yellow slot.
The engine control unit switches off the air conditioning system magnetic clutch - N25- via the relay for
8 seconds when vehicle pulls away from start or under powerful acceleration.
❑ With radiator fan control unit - J293- (note part number)
2. Air conditioning system with manual controls, vehicles ► 05.00 31

Sharan 1996 ➤
2.2 Dismantling and assembling air conditioning system controls

controls
switch - E30-
3 - Fresh air regulator illumina‐
tion bulb - L16-
4 - Flap setting button
5 - Temperature setting button
6 - Blower and air recirculation
setting button
tion switch - E184-
8 - Wheel
❑ When assembling, align
holes in wheel and con‐
trol.

Sharan 1996 ➤
2.3 Repairing air conditioning and heating - engine compartment
Note
Parts marked with * can be repaired only by specially trained mechanics in suitable workshops ⇒ page 29 since
the refrigerant must be extracted beforehand.
1 - Evaporator*
❑ In passenger compart‐
ment
2 - Vacuum hose
tion diagram ⇒ page 27
❑ To brake servo or to
vacuum pump
3 - Water drain pipe
❑ Checking: water drain
4 - Thermal switch for air con‐
ditioning system shut-off -
F163- and thermal switch for
radiator fan third speed - F165-
❑ Thermal switch for radi‐
ator fan third speed -
F165- switches radiator
fan to third speed as
coolant temperature
rises (on at 112 °C and
off at 108 °C).
❑ Thermal switch for air
conditioning system
shut-off - F163-
switches air condition‐
ing system magnetic
clutch - N25- off when
the refrigerant tempera‐
ture is too high (off at
119° C, on at 112° C)
⇒ page 35
5 - Connector*
❑ Rotating
6 - Evacuating and charging
valve* Volkswagen Technical Site: http://vwts.ru http://vwts.info
❑ High-pressure side.
7 - Condenser*
8 - Bolt*
❑ 30 ± 4.5 Nm

Sharan 1996 ➤
9 - Hose protection
10 - Excess pressure relief valve*
WARNING
Danger of freezing inju‐
ries.
When the pressure in the
refrigerant circuit is too
high (e.g. due to overfill‐
ing), refrigerant leaks out
of excess pressure relief
valve.
Wear protective goggles
and suitable clothing.
❑ Checking ⇒ page 115

11 - Air conditioner compressor*
❑ Self-regulating
Running-in procedures ⇒ page 100 .
12 - Air conditioning system magnetic clutch - N25-

13 - Connector*
❑ Rotating
14 - Receiver with dryer*
Note
Under certain conditions, it is not

necessary to renew the receiver
with dryer every time that the refrig‐
erant circuit is opened. Refer to EL‐
SA under Heating, ventilation, air
conditioning system; Air condition‐
ing system with refrigerant R134a ⇒
Air conditioning system with refrig‐
erant R134a; Rep. gr. 00 ; Renew‐
ing components .
15 - Ambient temperature switch - F38-
❑ Switches off air conditioning system magnetic clutch - N25- if the ambient temperature is too low (off at
-1 °C, on at 7 °C).
16 - Connector*
❑ Rotating
17 - Evacuating and charging valve*
❑ Low-pressure side.
18 - Air conditioning system pressure switch - F129-
❑ 8 Nm
❑ Renew O-ring (note part number).

Sharan 1996 ➤
19 - Expansion valve*
20 - Insulator
Removing and installing thermal switch for air conditioning sys‐

tem shut-off - F163- and thermal switch for radiator fan third speed
- F165-
Note
♦ Cooling system is pressurized when engine is warm. If nec‐

essary, release pressure before carrying out repairs.
♦ Refill with coolant after installing thermal switch.
♦ This illustration shows a vehicle with engine code AAA
1- Clip
2- Thermostat housing
3- O-ring
4- Thermal switch for air conditioning system shut-off - F163- /
thermal switch for radiator fan third speed - F165-
5- Coolant temperature display sender - G2- / thermal switch
for fan run-on - F87-
6- Coolant temperature sender - G62-

Sharan 1996 ➤
3 Air conditioning system with manual

controls, vehicles 06.00 ►
3.1 Repairing air conditioning and heating - passenger compartment
Note
1 - Left side window vent

⇒ page 39
2 - Dash panel
⇒ Rep. gr. 70
air ducts and vents
⇒ page 38 ; Repairing
heating
3 - Right side window vent
⇒ page 39
tion flap control motor - V154-
❑ Checking: ⇒ Vehicle di‐
agnostic tester
5 - Temperature flap control
motor - V68-
agnostic tester
⇒ page 72
6 - Right vent
⇒ page 38
7 - Centre vents
⇒ page 38
⇒ page 20
9 - Filter housing
❑ With fresh air and air recirculation flap
11 - Rubber hose for glove box cooling (optional)

Sharan 1996 ➤

❑ max.300 W rating
15 - Trim for air conditioning system controls
16 - Rear duct vent
17 - Rear duct
❑ With evaporator
19 - Air conditioning system control unit - J301-
❑ With built-in air conditioning system switch - E30-
❑ With fresh air blower switch - E9- .
❑ With fresh air and air recirculation flap switch - E159- .
❑ With built-in additional heat exchanger and rear control switch - E271-
20 - Heater and air conditioning unit for front seats*
❑ With evaporator
❑ With air distribution flap for air distribution
21 - Wiring harness for front air distribution control motor - V145-
23 - Front air distribution control motor - V145-
❑ Checking: ⇒ Vehicle diagnostic tester
24 - Wiring harness for temperature flap control motor - V68-
❑ After removal, completely renew coolant.
26 - Left vent
27 - Radiator fan control unit - J293-
❑ The control unit in conjunction with the engine control unit and gearbox control unit (automatic gearbox)
controls air conditioning system magnetic clutch - N25-
❑ Switches off air conditioning system magnetic clutch - N25- for a limited time for kick-down or at full load.
❑ Controls the first radiator fan speed
❑ Controls the radiator run-on phase
❑ Controls coolant circulation pump - V50-
3. Air conditioning system with manual controls, vehicles 06.00 ► 37

Sharan 1996 ➤
❑ Delays engaging air conditioning system magnetic clutch - N25- for 8 seconds via the engine control unit
to make it easier to start the engine.
❑ Location: on relay carrier
28 - Radiator fan 2nd speed relay - J101-
❑ Switches on the 2nd blower speed when the ignition is off (radiator fan run-on phase)
❑ Location: on relay carrier
3.2 Removing vents

Removing and installing centre vent
Removing:
Note
Centre compartment -1- is secured in vent housing -3- with steel

clips -2-. The two steel clips must be released in order to remove
compartment without damage.
– Open compartment.
– Insert a flat-blade screwdriver into openings along front edge
of compartment -1- and release the two steel clips -2- in di‐
rection of arrow.
– Pull compartment when doing this to prevent released steel

clip from re-engaging.
– Remove bolts -1- (1.4 + 0.2 Nm).
– Lift front of vent housing -2- -arrow A-.
– Then carefully lift vent housing -2- off dash panel in direction
of -arrow B-.
– Disconnect connectors depending on equipment fitted in ve‐
hicle.
Installing:
– Installation is carried out in reverse order of removal.
Removing and installing right and left vents

Removing:
Installing:

Sharan 1996 ➤
Removing and installing rear vents

– Release locking lugs -arrows- using a screwdriver.
– Pull out upper part of rear vent upwards in direction of
-arrow-.
– Remove securing nuts (2 ± 0.3 Nm) -in direction of arrow-.

– Remove lower part of rear vent.
Removing and installing rear air duct

– Remove front seats ⇒ Rep. gr. 72 .
– Raise front floor covering.
– Unscrew securing nuts -1- (2 ± 0.3 Nm) and remove rear foot‐
well air duct.
Removing and installing side window vents

Only the left side window vent removal is described. The right side
window vent is removed in the same manner.
– Remove corresponding speaker trim from dash panel ⇒ Rep.
gr. 91 .
– Use a screwdriver to lever out the side window vent.
– Remove side window vent in -direction of arrow-.

Sharan 1996 ➤
– Pull out air duct for side window vent in direction of -arrow-.
3.3 Removing and installing glove box cool‐

ing
– Pull cover flap -2- in glove box downwards out of fasteners and
separate rubber hose -1-.
– Remove lower right dash panel trim ⇒ Rep. gr. 70 .
Note
♦ It is permitted to use a small amount of soap to aid in installa‐

tion.
♦ Fix rubber hose -1- in place using a cable tie.
3.4 Removing and installing air conditioning

system control unit - J301-
Note
The air conditioning system control unit - J301- cannot be dis‐

mantled except for the fresh air blower switch - E9- .
3.4.1 Before beginning repair work, perform

the following steps:
– Switch off all electrical consumers.
– Switch off ignition.
– Pull out ignition key.

Sharan 1996 ➤
3.4.2 Removing
– Using a screwdriver and a pad, carefully unclip trim for air
conditioning system control unit - J301- -arrows-.
– Remove bolts -arrows- from instrument trim.

– Pull air conditioning system control unit - J301- forwards.
– Pull off connectors.
– Pull out air conditioning system control unit - J301- .
3.4.3 Installing and adjusting
Note
The replacement air conditioning system control unit - J301- must

not be coded.
3.5 Dismantling and assembling air conditioning system control unit - J301-

Sharan 1996 ➤
1 - Bolt
2 - Fresh air blower switch -
E9-
control unit - J301-
❑ With built-in air condi‐
tioning system switch -
E30-
❑ With fresh air and air re‐
circulation flap switch -
E159- .
❑ With fresh air blower
switch - E9- .
❑ With built-in additional
heat exchanger and
rear control switch -
E271-
4 - Rotary knob
❑ For blower speed
5 - Rotary knob
❑ For air distribution
6 - Trim
7 - Rotary knob
❑ For interior temperature
3.6 Repairing air conditioning system with

manual controls - additional heat ex‐
changer
Note
First remove rear left side wall trim. ⇒ Rep. gr. 70

Sharan 1996 ➤
1 - Additional heat exchanger

and rear control button - E312-
2 - Rear heated air control
❑ Left side in moulded
headlining close to B-
pillar
❑ With warm air blower
switch - E100-
❑ With interior rear tem‐
perature potentiometer -
G275-
take side
senger compartment
seats
partment, vent side
7 - Series resistor for warm air
blower - N72-
8 - Rear warm air blower - V47-
agnostic tester
❑ Removing: first remove moulded trim for rear left side wall ⇒ Rep. gr. 70
9 - Rear temperature flap control motor - V137-
10 - Coolant hoses
❑ Bleed coolant circuit after working on it

Sharan 1996 ➤
Removing additional heat exchanger

– Remove rear left side wall trim ⇒ Rep. gr. 70 .
– Pull connector off rear warm air blower - V47- , rear tempera‐
ture flap control motor - V137- and series resistance for warm
air blower - N72- .
– Clamp off connecting hoses close to heat exchanger with hose
clips and then pull off connecting hoses.
– Unscrew the four bolts -arrows-.
– If the vehicle is equipped with a 2nd evaporator ⇒ page 57 .
Note
Cooling system is pressurized when engine is warm. If necessary,

release pressure before carrying out repairs.
Removing and installing rear temperature flap control motor -

V137-
– Separate connector -1- and remove bolts -2-.
– Pull out rear temperature flap control motor - V137- -3-.
Replacing series resistor for warm air blower - N72-

– Separate connector -1- and remove bolt -2-.
3.6.1 Removing rear heated air control
Note
Rear heated air controls may be installed with or without a retain‐

ing clip. Controls with retaining clips will destroyed when re‐
moved. Since this retaining clip is not visible, first try the method
for removing the control without a retaining clip.
Removing rear heated air control without a retaining clip:

Sharan 1996 ➤
– Use a screwdriver to lever control out from underneath and

pull control out downwards.
– Pull off connector.
Removing rear heated air control with a retaining clip:
– Use a pair of pliers to pull rotary knob -1- off rear heated air
control.
– Remove securing bolt -2- for retaining clip -1-.

– Pull out control -3-.
– Pull off connector.
– Remove retaining clip.
3.7 Repairing air conditioning and heating -

engine compartment
Note
Parts marked with * can be repaired only by specially trained me‐

chanics in suitable workshops ⇒ page 29 since the refrigerant
must be extracted beforehand.

Sharan 1996 ➤
1 - Evaporator*
ment
2 - Radiator fan thermal switch
- F18-
❑ Switches the radiator
fan to first and second
speed as the coolant
temperature increases
(on at 102° C, off at
95° C).
3 - Radiator fan relay - J26-
❑ Note part number.
❑ Initiates the first and
second blower speeds.
For the coolant temper‐
ature and refrigerant
pressure range.
❑ Close to battery
5 - Coolant temperature send‐
er - G62-
❑ Sends information to the
engine control unit or ra‐
diator fan control unit -
J293- by means of
which the air condition‐
ing system magnetic
clutch - N25- switches
off if the coolant temper‐
ature is too high (off at
119 °C, on at 112 °C).
6 - Condenser*
⇒ page 142
WARNING
ries.
valve.

❑ Self-regulating

Sharan 1996 ➤
10 - Refrigerant line*
12 - Receiver with dryer cartridge
❑ Removing dryer cartridge ⇒ page 145
Note

necessary to renew the dryer car‐
tridge every time that the refrigerant
circuit is opened. Refer to ELSA un‐
der Heating, ventilation, air condi‐
tioning system; Air conditioning sys‐
tem with refrigerant R134a ⇒ Air
conditioning system with refrigerant
R134a; Rep. gr. 00 ; Renewing
components .
13 - Air conditioning system pressure switch - F129-

❑ Removing and installing:
❑ 8 Nm
❑ Controls the second blower speed
14 - Ambient temperature switch - F38-
❑ Switches off air conditioning system magnetic clutch - N25- if the ambient temperature is too low (off at
-1 °C, on at 7 °C).
15 - Connector*
❑ Rotating

Sharan 1996 ➤
4 Climatronic air conditioning system

with automatic regulation, vehicles
► 05.00

Sharan 1996 ➤
4.1 Operation and function of displays and

control buttons on Climatronic control
unit - J255-
Note
The illustration is an example for vehicles with a 2nd evaporator.
Climatronic control unit - J255-

1- Dash panel temperature sensor - G56-
2- Display “AUTO” (automatic operation) or “ECON” (air con‐
ditioner compressor off)
3- Blower speed display for front seats
4- Ambient temperature display
5- Display for windscreen defrosting
6- Air recirculation display
7- Display for air flow direction
8- Display for selected interior temperature in driver's com‐
partment
9- Celsius/Fahrenheit selection button
10 - Blower speed display for rear seats
11 - Display for selected interior temperature in passenger com‐
partment
12 - Button for automatic mode
13 - “Blower speed faster” button for front seats
14 - “Blower speed slower” button for front seats (this button also
switches system off)
15 - Air recirculation button
16 - Windscreen defroster button
17 - Button for “air flow to footwell”
18 - Button for “air flow to upper body”
19 - “Colder” button for front seats
20 - “Warmer” button for front seats
21 - “Blower speed slower” button for rear seats
22 - “Blower speed faster” button for rear seats
23 - “Colder” button for rear seats
24 - “Warmer” button for rear seats
25 - “ECON” (compressor off) button
Note
♦ The automatic control of the system can be influenced with

buttons 13 to 18, 21 and 22.
♦ In ECON mode, the air conditioner compressor is switched off;
heating and ventilation continue to be controlled electronically.
4. Climatronic air conditioning system with automatic regulation, vehicles ► 05.00 49

Sharan 1996 ➤
4.2 Repairing Climatronic - dash panel area
Note
Parts marked with * can be repaired only by specially trained me‐

chanics in suitable workshops ⇒ page 29 since the refrigerant
must be extracted beforehand.
1 - Dash panel
⇒ Rep. gr. 70
air ducts and vents
heating
2 - Sunlight penetration photo‐
sensor - G107-
❑ Function: controls tem‐
perature flap and fresh
air blower depending on
light intensity
❑ Emergency running in
event of failure: Clima‐
tronic control unit -
J255- assumes fixed
value.
❑ Checking: read and
clear fault memory via
self-diagnosis ⇒ page 3
❑ Lever out using a screw‐
driver with a pad under‐
neath
⇒ page 20
eration
tion diagram
⇒ page 64
⇒ page 52
5 - Temperature flap control motor - V68-
❑ Checking: read and clear fault memory via self-diagnosis ⇒ page 3
6 - Two-way valve for fresh air and air recirculation flap - N63-
8 - Filter housing

Sharan 1996 ➤
9 - Blower relay - J323-
❑ For fresh air blower and blower for 2nd evaporator
❑ Behind dash panel on right
❑ Control number 114
10 - Fresh air blower control unit - J126-
❑ Task: continuously variable control of fresh air blower speed depending on voltage
12 - Climatronic control unit - J255-
❑ The Climatronic control unit - J255- , the operating and display unit for Climatronic air conditioning system
- E87- and the dash panel temperature sensor - G56- with temperature sensor blower - V42- are com‐
bined in one unit which cannot be dismantled.
❑ After installing a new control unit, check the control unit code ⇒ page 12 .
13 - Operating and display unit for Climatronic air conditioning system - E87- with Climatronic control unit -
J255-
❑ Checking: ⇒ page 10 , final control diagnosis
14 - Dash panel temperature sensor - G56- with temperature sensor blower - V42-
❑ Integrated in Climatronic control unit - J255-
❑ Function: temperature sensor controls temperature flap and fresh air blower, depending on temperature
❑ Emergency running in event of failure of dash panel temperature sensor - G56- : continued operation
assuming value of +24 °C
❑ With evaporator
❑ With evaporator
❑ With air distribution flap
19 - Front vent temperature sender - G152-
❑ Emergency running in event of failure of front vent temperature sender - G152- : continued operation
assuming value of +42 °C.

Sharan 1996 ➤
21 - Lip valve
22 - Centre vent control motor - V102-
❑ If tabs do not engage when inserted or if they have broken off, bolt on heat exchanger.
24 - Front Climatronic fuse - S140-
❑ Above relay plate
25 - Rear Climatronic fuse - S141-
❑ Above relay plate
26 - Magnetic clutch relay - J44-
❑ On relay carrier
❑ Only on vehicles with engine code AAA
❑ Control number 186
❑ In engine compartment, front left ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
❑ Installed to model year 1998, not on vehicles with engine code AAA
Removing and installing vacuum unit for fresh air and air recircu‐
lation flap
Removing:
– Pull off hose connection.
– Remove cross-head screws -arrows-.
– Twist and lift vacuum unit off lever.
Installing:
Removing and installing fresh air blower control unit - J126-

Removing:
– Removing glove box or passenger side airbag unit ⇒ Rep. gr.
69
– Pull off connector -2- and remove bolt -3-.
– Seal area between fresh air blower control unit - J126- -1- and
air duct with AMV 176 000 05 before fitting.
Installing:

Sharan 1996 ➤
Removing and installing two-way valve for fresh air and air recir‐
culation flap - N63-
Removing:
– Removing glove box or passenger side airbag unit ⇒ Rep. gr.
69
– Pull connector off.
– Pull off hose connections and remove bolts -arrows-.
Installing:
Removing and installing centre vent control motor - V102-

Removing:
– Remove driver side dash panel cover ⇒ Rep. gr. 68 .
– Pull off connector -1- and remove bolts -2-.
– Pull out centre vent control motor - V102- -3-.
Installing:
Removing and installing front air distribution control motor - V145-

Removing:
Installing:
Install in reverse order. Note the following when doing this:
The markings -arrows- must align with one another when the
centre flap is correctly adjusted.
Removing and installing temperature flap control motor - V68-

Removing:
– Remove air duct behind dash panel.
Installing:
temperature flap is correctly adjusted.

Sharan 1996 ➤
Removing and installing front vent temperature sender - G152-

Removing:
– Pull connector off front vent temperature sender - G152- .
– Turn front vent temperature sender - G152- 90° and remove.
Installing:
4.3 Removing and installing operating and

display unit for Climatronic air condition‐
ing system - E87- with Climatronic con‐
trol unit - J255-
Note
The Climatronic control unit - J255- and the operating and display
unit for Climatronic air conditioning system - E87- are a single
component which cannot be dismantled.

4.3.2 Removing
– Remove radio ⇒ Rep. gr. 91 .
– Press retaining spring upwards and pull out operating and dis‐
play unit for Climatronic air conditioning system - E87- .
– Separate connector.
4.3.3 Installing
– Press operating and display unit for Climatronic air condition‐
ing system - E87- into dash panel until retaining spring en‐
gages.
– After installing a new operating and display unit for Climatronic
air conditioning system - E87- , check control unit code
⇒ page 12 .

Sharan 1996 ➤
4.4 Repairing Climatronic - additional heat

exchanger
Note
First remove rear side wall trim. ⇒ Rep. gr. 70
1 - Operating and display unit

for Climatronic air conditioning
system - E87- with Climatronic
control unit - J255-
take side
senger compartment
seats
partment, vent side
6 - Rear fresh air blower control
unit - J391-
7 - Rear fresh air blower - V80-
trol motor - V137-
9 - Coolant hoses
10 - Rear vent temperature sender - G174-

Sharan 1996 ➤
Removing air distribution housing

– Remove left side wall trim ⇒ Rep. gr. 70 .
– Pull connectors off rear fresh air blower - V80- , rear temper‐
ature flap control motor - V137- and rear fresh air blower
control unit - J391- .
– Clamp off connecting hoses close to heat exchanger using
hose clamps and pull off hoses.
– Remove four bolts -arrows-.
– If vehicle has 2nd evaporator ⇒ page 57
Note

Removing rear temperature flap control motor - V137-

– Pull out temperature flap control motor -3-.
Renewing rear fresh air blower control unit - J391-

Removing rear vent temperature sender - G174-

– Remove cover -2-.
– Pull connector off rear vent temperature sender - G174- -1-.
– Turn rear vent temperature sender - G174- -1- 90° and re‐
move.

Sharan 1996 ➤
4.5 Repairing Climatronic - 2nd evaporator
Note

mechanics in suitable workshops ⇒ page 29 since the refrig‐
erant must be extracted beforehand.
♦ There is an opening in the rear side wall trim for searching for
leaks on the 2nd evaporator ⇒ page 58
1 - 2nd evaporator*
unit - J391-
❑ Removing: first remove
moulded trim for rear
side wall ⇒ Rep. gr. 70
4 - Expansion valve for rear
evaporator*
trol motor - V137-
7 - Lip valve
8 - Rear vent temperature
sender - G174-
event of failure of front
vent temperature send‐
er - G152- : continued
operation assuming val‐
ue of +42 °C.
9 - Rear air distribution control motor - V136-
10 - Air duct
❑ Removing: first remove left D-pillar trim ⇒ Rep. gr. 70

Sharan 1996 ➤
Removing rear air distribution control motor - V136-

– Remove rear side wall trim ⇒ Rep. gr. 70 .
– Pull out rear air distribution control motor - V136- -3-.
Opening in rear side wall trim for leak detection
4.6 Repairing Climatronic - engine compartment
Note

Sharan 1996 ➤
1 - Evaporator*
ment
2 - Vacuum hose
tion diagram
⇒ page 64
❑ To brake servo or to
vacuum pump
4 - Thermal switch for air con‐
ditioning system shut-off -
F163- and thermal switch for
radiator fan third speed - F165-
❑ Thermal switch for radi‐
ator fan third speed -
F165- switches radiator
fan to third speed as
coolant temperature
rises (on at 112 °C and
off at 108 °C).
❑ Thermal switch for air
conditioning system
shut-off - F163-
switches air condition‐
ing system magnetic
clutch - N25- off when
the refrigerant tempera‐
ture is too high (off at
119° C, on at 112° C)
on vehicles with engine
code AAA ⇒ page 61
coolant temperature sender -
G110-
❑ Task: the air conditioning system coolant temperature sender - G110- controls the defroster function/
footwell air distribution and fresh air blower output depending on coolant temperature.
6 - Ambient temperature sensor - G17-
❑ Function: ambient temperature sensor - G17- controls temperature flap and fresh air blower, depending
on temperature.
7 - Connector*
❑ Rotating
9 - Condenser*
10 - Hose protection

Sharan 1996 ➤
Note
Depending on the engine version,

the evacuating and charging valve
may be fitted near the receiver with
dryer.
WARNING
ries.
valve.

15 - Connector*
❑ Rotating
16 - Receiver with dryer*
Note

ing components .
17 - Connector*
❑ Rotating
18 - Air conditioning system pressure switch - F129- or high-pressure sender - G65-
❑ Checking air conditioning system pressure switch - F129- ⇒ page 110
❑ Torque setting 8 Nm
❑ Checking high-pressure sender - G65- : ⇒ Vehicle diagnostic tester
Function:
❑ Switches radiator fan - V7- to next higher speed when pressure increases in refrigerant circuit.

Sharan 1996 ➤
❑ Switches off the air conditioner when the pressure is too high (for example, insufficient engine cooling).
❑ Switches off the air conditioner when the pressure is too low (for example, loss of refrigerant).
20 - Insulator
Checking water drain pipe with lip valve
Note
If water drain pipe -1- has to be replaced, transfer the vehicle to

a suitable workshop ⇒ page 29 .
1- Water drain pipe

2- The lip valve is only pushed on; it must not be bonded.
Removing and installing thermal switch for air conditioning sys‐

tem shut-off - F163- and thermal switch for radiator fan third speed
- F165- on vehicles with engine code AAA
Note

♦ Refill with coolant after installing thermal switch ⇒ Rep. gr.
19 .
1- Clip
2- Thermostat housing
3- O-ring
4- Thermal switch for air conditioning system shut-off - F163- /
thermal switch for radiator fan third speed - F165-
5- Coolant temperature display sender - G2- / thermal switch
for fan run-on - F87-
6- Coolant temperature sender - G62-
4.7 Checking excess pressure relief valve

on air conditioner compressor
WARNING
Danger of freezing injuries.

The excess pressure relief valve releases refrigerant when the
engine is running and the pressure in the refrigerant circuit is
too high.
Switch off engine.

Sharan 1996 ➤
Task: protects the refrigerant circuit against excessive pressure.

The excess pressure relief valve indicates whether the valve has
been opened. An attached adhesive plate -arrow- is pushed out.
In this case, hand over the vehicle to a suitable workshop.
4.8 Coolant hose connection diagram
Note
Complete hose routing ⇒ Rep. gr. 19

Sharan 1996 ➤
1 - Auxiliary heat exchanger

2 - Coolant hose, return
❑ From additional heat ex‐
changer to coolant pipe
3 - Coolant hose, supply
❑ From coolant pipe to ad‐
ditional heat exchanger
4 - Coolant pipe
❑ From coolant pipe to ad‐
ditional heat exchanger
valve
❑ From T-piece to coolant
pipe
❑ From T-piece to T-piece
8 - T-piece
❑ From T-piece to T-piece
10 - T-piece
❑ From T-piece to coolant
shut-off valve
12 - Coolant shut-off valve
13 - Coolant circulation pump -
V50-
❑ From coolant shut-off
valve to engine Volkswagen Technical Site: http://vwts.ru http://vwts.info
❑ From engine to coolant circulation pump
❑ From engine to T-piece
17 - Engine
❑ From additional heat exchanger valve to engine
19 - Additional heat exchanger valve - N172- or 2nd heat exchanger switch-off valve - N317-
Note
Installation depends on vehicle

identification number

❑ From T-piece to front heat exchanger
❑ From front heat exchanger to additional heat exchanger valve

Sharan 1996 ➤
22 - Heat exchanger for front heater

23 - T-piece
4.9 Vacuum hose connection diagram
Note
♦ Push vacuum hoses onto plastic tube to stop (approx. 15 mm)

♦ This illustration shows a vehicle with engine code AAA

2 - Vacuum hose
❑ From two-way valve for
fresh air and air recircu‐
lation flap - N63- to vac‐
uum unit for fresh air
3 - Two-way valve for fresh air
and air recirculation flap - N63-
❑ No current, no through-
flow
4 - Vacuum hose
5 - To brake servo
6 - Vacuum hose
7 - To intake manifold
❑ Arrow points in direction
of suction.

Sharan 1996 ➤
5 Climatronic air conditioning system

with automatic regulation, vehicles
06.00 ►
5.1 Procedure for checking and adjusting

components
Select “Guided Fault Finding” function or “Guided Functions” in
the vehicle diagnosis, testing and information system - VAS 5051-
(or later model).
After all control units have been read:
– Press “GoTo” 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”
– “Coding Climatronic control unit”.
– “Checking cooling output”.
– “Read measured value block”
5. Climatronic air conditioning system with automatic regulation, vehicles 06.00 ► 65

Sharan 1996 ➤
5.2 Operation and function of displays and

control buttons on Climatronic control
unit - J255-
1- Dash panel temperature sensor - G56-
2- Windscreen defroster button (also switches on the wind‐
screen heater at ambient temperature < 10° C). The maxi‐
mal operating time of the windscreen heater is 4 minutes.
3- Blower speed display for front seats. Display is dynamic in
automatic mode.
4- Display “AUTO” (automatic mode), “ECON” (air conditioner
compressor off) or “OFF” (entire system off).
5- Ambient temperature display. Ambient temperature is
measured by ambient temperature sensor - G17- . In the
event of failure “- - -” appears in display. If road speed drops
below 15 km/h and the coolant temperature is above 70 °C,
the value displayed will not change. The actual measured
value is not displayed because at slow speeds it will be in‐
fluenced by the heat build-up in the engine. When the igni‐
tion is switched off, the last displayed ambient temperature
is stored for 2 hours. When the ignition is on, the parked time
is < 2 hours and the speed is < 15 km/h, the last displayed
ambient temperature is retained unless it is colder than the
last stored temperature. When the ignition is on, the parked
time is < 2 hours and the speed is > 15 km/h, after a specified
time, the displayed ambient temperature is corrected up‐
wards to a higher temperature (higher than the last dis‐
played temperature). When the ignition is on and parked
time is > 2 hours, the current ambient temperature is dis‐
played immediately.
6- Display for windscreen defrosting (also appears when elec‐
tric windscreen heating is switched on)
7- Display for fresh and air recirculation
8- Display for air flow direction
9- Display for selected interior temperature in driver's com‐
partment
10 - Blower speed display for rear seats (is dynamic in automatic
mode)
11 - Display for selected interior temperature in passenger com‐
partment
12 - Button for automatic mode
13 - Trim grille
14 - Air recirculation button
15 - “Blower speed faster” button for front seats
16 - “Blower speed slower” button for front seats (this button also
switches system off)
17 - Button for “air flow to upper body”
18 - Button for “air flow to footwell”
19 - “Colder” button for front seats
20 - “Warmer” button for front seats
21 - “Blower speed slower” button for rear seats (this button also
switches off the system for the rear seats)
22 - “Blower speed faster” button for rear seats

Sharan 1996 ➤
23 - “Colder” button for rear seats

24 - “Warmer” button for rear seats
25 - “ECON” (compressor off) button
Note
♦ The automatic regulation of the system can be influenced with

buttons -2-, -14-, -15-, -16-, -17-, -18-, -21- and -22-.
♦ Climatronic can be completely switched off only with button
-16-. To do this, press the button until “OFF” appears in the
display. Because the flaps remain in the last position set when
this function is used, this manner of selection should only be
used in special circumstances e.g. when there is a malfunc‐
tion.
♦ The rear system can be shut off for the rear seats via button
-21- for “blower speed slower”. To do this, press the button
until no blower speed appears in the display for passenger
compartment.
♦ A temperature deviation of ±3° C for the rear seats compared
to the selected interior temperature for the front seats is pos‐
sible via buttons -24- for “warmer” and button -23- for “colder”.
♦ Pressing button -2- also switches on the windscreen heater,
providing the windscreen heater has not already been activa‐
ted by the windscreen button. The maximal operating time is
4 minutes.
♦ In ECON mode, only the air conditioner compressor is switch‐
ed off; heating and ventilation continue to be controlled elec‐
tronically.
♦ Pressing the “AUTO” button -12- cancels all settings which
deviate from automatic operation.
♦ Pressing and holding the “ECON” button -25- at the same time
as pressing the “AUTO” button -12- changes the display from
degrees Celsius to Fahrenheit and vice versa. The corre‐
sponding temperature unit appears in the display.
5.3 Repairing Climatronic - dash panel area
Note

Sharan 1996 ➤
1 - Left side window vent

2 - Dash panel
⇒ Rep. gr. 70
air ducts and vents
heating
3 - Sunlight penetration photo‐
sensor - G107-
❑ Function: controls tem‐
perature flap and fresh
air blower depending on
light intensity
event of failure: Clima‐
tronic control unit -
J255- assumes fixed
value.
agnostic tester
4 - Right side window vent
5 - Right vent
⇒ page 38
6 - Centre vents
⇒ page 38
⇒ page 20
8 - Filter housing
9 - Fresh air blower control unit - J126-
❑ Task: continuously variable control of fresh air blower speed depending on voltage
❑ Max. 300 W rating
❑ Checking ⇒ Vehicle diagnostic tester
❑ After installing a new control unit, check the control unit code ⇒ Vehicle diagnostic tester; in the function
“guided fault finding”
13 - Operating and display unit for Climatronic air conditioning system - E87-

Sharan 1996 ➤
❑ Checking ⇒ Vehicle diagnostic tester; in the function “final control diagnosis”
14 - Rear duct vent

15 - Trim for operating and display unit for Climatronic air conditioning system - E87-
16 - Rear duct
17 - Dash panel temperature sensor - G56- with temperature sensor blower - V42-
❑ Function: temperature sensor controls temperature flap and fresh air blower, depending on temperature
❑ Emergency running in event of failure of dash panel temperature sensor - G56- : continued operation
assuming value of +24 °C
❑ With evaporator
❑ With air distribution flap
❑ With centre vent flap
21 - Front vent temperature sender - G152-
❑ Emergency running in event of failure of front vent temperature sender - G152- : continued operation
assuming value of +42 °C.
23 - Centre vent control motor - V102-
25 - Left vent
❑ The radiator fan control unit - J293- in conjunction with the engine control unit and the gearbox control
unit (automatic gearbox) controls the air conditioning system magnetic clutch - N25- .
❑ Switches off air conditioning system magnetic clutch - N25- for a limited time for kick-down or at full load.
❑ Controls the first radiator fan speed
❑ Controls the radiator run-on phase
❑ Controls coolant circulation pump - V50-
❑ Delays the switching on of the air conditioning system magnetic clutch - N25- for 8 seconds to make
starting the engine easier

Sharan 1996 ➤
27 - Radiator fan 2nd speed relay - J101-
❑ Switches on the 2nd blower speed when the ignition is off (radiator fan run-on phase)
28 - Fresh air and air recirculation flap control motor - V154-
29 - Temperature flap control motor - V68-
31 - Rubber hose for glove box cooling (optional)
Removing fresh air blower - V2-

1- Heater and air conditioning unit
2- Fresh air blower - V2-
3- Locking lug
4- Connector
– Remove glove box ⇒ Rep. gr. 68 or passenger side airbag
unit ⇒ Rep. gr. 69 .
– Pull connector -4- off fresh air blower.
– Using a screwdriver, raise locking lug carefully and turn fresh
air blower - V2- in direction of arrow.
– Pull out fresh air blower - V2- .
Removing sunlight penetration photosensor - G107-

– Using a screwdriver, unclip sunlight penetration photosensor
- G107- -1- on side.
– Pull connector off.

Sharan 1996 ➤
Removing fresh air and air recirculation flap control motor - V154-
– Pull connector -1- off control motor.

– Remove bolts -2-.
– Pull out fresh air and air recirculation flap control motor - V154-
-3- sideways.
Renewing fresh air blower control unit - J126-

– Remove glove box or passenger side airbag unit.
– Seal area between fresh air blower control unit - J126- -1- and
air duct with AMV 176 000 05 before fitting.
Remove centre vent control motor - V102- .

– Remove driver side dash panel cover.
– Pull out centre vent control motor - V102- -3-.

Sharan 1996 ➤
Removing and installing front air distribution control motor - V145-

Removing:
– Remove driver side dash panel cover.
– Pull out front air distribution control motor - V145- -3-.
Installing:
The markings -arrows- must align with one another when the air
distribution flap is correctly adjusted.
Removing and installing temperature flap control motor - V68-

Removing:

– Pull out temperature flap control motor - V68- -3-.
Installing:
temperature flap is correctly adjusted.
Removing front vent temperature sender - G152-

– Remove front left footwell trim.
– Pull connector -1- off front vent temperature sender - G152- .
– Turn front vent temperature sender - G152- 90° and remove.

Sharan 1996 ➤
5.4 Removing and installing operating and

display unit for Climatronic air condition‐
ing system - E87- with Climatronic con‐
trol unit - J255-
Note
The Climatronic control unit - J255- and the operating and display
unit for Climatronic air conditioning system - E87- are a single
component which cannot be dismantled.

5.4.2 Removing
– Use a screwdriver to unclip trim panel for operating and display
unit for Climatronic air conditioning system - E87- -arrows-.
– Remove bolts -arrows- from instrument trim.

– Pull out operating and display unit for Climatronic air condi‐
tioning system - E87- .
– Pull off connectors.
5.4.3 Installing
– After installing a new operating and display unit for Climatronic
air conditioning system - E87- , check control unit code ⇒ Ve‐
hicle diagnostic tester; in function “Guided Fault Finding” .

Sharan 1996 ➤
5.5 Repairing Climatronic - additional heat

exchanger
Note
First remove rear left side wall trim. ⇒ Rep. gr. 70
1 - Climatronic control unit -

J255-
take side
⇒ page 75
senger compartment
seats
partment, vent side
⇒ page 75
unit - J391-
agnostic tester
trol motor - V137-
❑ Checking ⇒ vehicle di‐
agnosis, testing and in‐
formation system
VAS 5051 in the func‐
tion "guided fault find‐
ing".
9 - Coolant hoses
10 - Rear vent temperature sender - G174-

Sharan 1996 ➤
Removing additional heat exchanger

– Pull connectors off rear fresh air blower - V80- , rear temper‐
ature flap control motor - V137- and rear fresh air blower
control unit - J391- .
– Clamp off connecting hoses close to heat exchanger using
hose clamps and pull off hoses.
– Remove four bolts -arrows-.
– If vehicle has 2nd evaporator, see ⇒ page 76 .
Note

Removing rear temperature flap control motor - V137-

– Pull out rear temperature flap control motor - V137- -3-.
Renewing rear fresh air blower control unit - J391-

Removing rear vent temperature sender - G174-

– Remove cover -2-.
– Pull connector -1- off rear vent temperature sender - G174- .
– Turn rear vent temperature sender - G174- 90° and remove.

Sharan 1996 ➤
5.6 Repairing Climatronic - 2nd evaporator
Note

mechanics in suitable workshops ⇒ page 29 since the refrig‐
erant must be extracted beforehand.
♦ There is an opening in the rear side wall trim for searching for
leaks on the 2nd evaporator ⇒ page 58
1 - 2nd evaporator*
❑ Installing seal on evap‐
orator ⇒ page 77
unit - J391-
agnostic tester
rear left side wall trim ⇒
Rep. gr. 70
evaporator*
rear left side wall trim ⇒
Rep. gr. 70
❑ ⇒ page 140
trol motor - V137-
agnostic tester
7 - Lip valve
8 - Rear vent temperature
sender - G174-
event of failure of front
vent temperature send‐
er - G152- : continued
operation assuming val‐
ue of +42 °C.
10 - Air duct
❑ Removing: first remove left D-pillar trim ⇒ Rep. gr. 70

Sharan 1996 ➤
Removing rear air distribution control motor - V136-

– Remove rear left side wall trim ⇒ Rep. gr. 70
– Pull out rear air distribution control motor - V136- -3-.
Installing seal on evaporator

The evaporator must sealed against the housing using seal -1-.
5.7 Repairing Climatronic - engine compartment
Note

Sharan 1996 ➤
1 - Evaporator*
ment
coolant temperature sender -
G110-
3 - Radiator fan relay - J26-
❑ Initiates the first and
second blower speeds.
For the coolant temper‐
ature and refrigerant
pressure range.
4 - Ambient temperature sen‐
sor - G17-
❑ Task: ambient tempera‐
ture sensor - G17- re‐
cords the information
and sends it to the con‐
trol unit. For controlling
the temperature flap
and the fresh air blower
depending on the ambi‐
ent temperature.
agnostic tester
6 - Coolant temperature send‐
er - G62-
❑ Sends information to the
engine control unit or ra‐
diator fan control unit -
J293- by means of
which the air conditioning system magnetic clutch - N25- switches off if the coolant temperature is too
high (off at 119 °C, on at 112 °C).
7 - Condenser*
WARNING
ries.
valve.

Sharan 1996 ➤

11 - Refrigerant line*
Note

components .

❑ Check air conditioning system pressure switch - F129- ⇒ page 110
❑ Renew O-ring.
❑ 8 Nm
Note
In vehicles with engine code ASZ,

high-pressure sender - F129- is in‐
stalled instead of air conditioning
system pressure switch - G65- .
❑ Checking ⇒ Vehicle diagnostic tester in the function “guided fault finding”
❑ Renew O-ring.
❑ 8 Nm
15 - Connector*
❑ Release tools - VAS 6127-
❑ Rotating

Sharan 1996 ➤
Checking water drain pipe
Note
If water drain pipe -1- has to be replaced, transfer the vehicle to

a suitable workshop ⇒ page 29 to have the heater and air condi‐
tioning unit removed.
1- The water drain pipe is located approx. 10 cm below the

expansion valve and must not be blocked.
Checking excess pressure relief valve on air conditioner com‐

pressor
WARNING

too high.
Switch off engine.
♦ Task: protects refrigerant circuit against excessive pressure

♦ The excess pressure relief valve indicates whether the valve
has been opened. An attached adhesive plate -arrow- is push‐
ed out. In this case, hand over the vehicle to a suitable work‐
shop.
Removing air conditioning system coolant temperature sender -

G110-
Note

♦ Refill with coolant after installing thermal switch ⇒ Rep. gr.
19 .
Removing ⇒ Rep. gr. 92

1- Air conditioning system coolant temperature sender - G110-
2- O-ring
3- Clip
4- Coolant housing
5.8 Coolant hose connection diagram
Note
Complete hose routing ⇒ Rep. gr. 19

Sharan 1996 ➤
1 - Heat exchanger for heater

2 - Auxiliary heat exchanger
3 - Thermostat for the 2nd heat
exchanger
❑ Always in vehicles with‐
out supplementary
heater or auxiliary heat‐
er
❑ Begins to open at ap‐
prox. 55° C
❑ Fully opened at
approx. 65° C
4 - Expansion tank
5 - Continued coolant circula‐
tion pump - V51-
6 - Switch-off valve for supple‐
mentary heater
7 - ATF cooler
8 - Radiator
❑ a = Bottom
❑ b = Top
9 - Engine oil cooler
10 - Thermostat
11 - Coolant pump
12 - Cylinder head
13 - Throttle valve preheater
❑ Only 2.0 l and 2.8 l en‐
gines
Removing thermostat for 2nd heat exchanger
Note
♦ Opens the 2nd heat exchanger as the coolant temperature

rises. Starts opening at approx. 50° C, fully opened at approx.
65° C.
♦ The identification -V- on the picture indicates coolant supply
from engine to heat exchanger.
♦ Note the installation position. Collar -2- must point towards the
2nd heat exchanger.
♦ Refill with coolant after installing the thermostat ⇒ Rep. gr.
19 .
Removing:
– Unfasten hose clips.
– Remove thermostat -1- for 2nd heat exchanger.

Sharan 1996 ➤
6 Removing and installing air condi‐

tioner compressor and/or ancillary
bracket
6.1 Engine code ADY
Note
♦ The ancillary bracket for air conditioner compressor can be

removed and installed without the refrigerant circuit being
opened.
♦ Take the vehicle to a suitable workshop with specially trained
mechanics if the air conditioner compressor must be removed.

♦ Torque wrench - V.A.G 1331-

Sharan 1996 ➤
1 - Ancillary bracket for alter‐

nator and air conditioner com‐
pressor
❑ Part No. 037 903 139 L
– Remove alternator ⇒
Rep. gr. 27 .
2 - Tensioning element for ten‐

sioning roller
3 - Hexagon nut M8
❑ 30 Nm
4 - Threaded bush
5 - Refrigerant hose
❑ Between expansion
valve and air conditioner
compressor
❑ Bolt 22 Nm
6 - Refrigerant hose
❑ Between air conditioner
compressor and con‐
denser
❑ Bolt 22 Nm
7 - Air conditioner compressor
❑ Remove air conditioner
compressor
⇒ page 121 .
❑ Removing from ancillary
bracket:
❑ Remove poly V-belt ⇒
Rep. gr. 13 .
– Loosen hexagon bolts
-9- by a few turns and
drive back threaded
bush -4- on air conditioner compressor. Continue unscrewing hexagon bolts.
8 - Poly V-belt
❑ Removing and installing ⇒ Rep. gr. 13
❑ Poly V-belt routing ⇒ page 84
9 - Hexagon bolt M10×11
❑ 45 Nm
❑ 25 Nm
11 - Tensioning roller
6. Removing and installing air conditioner compressor and/or ancillary bracket 83

Sharan 1996 ➤
Poly V-belt routing
Note
When installing poly V-belt, ensure that it is correctly seated on

poly V-belt pulley.
6.2 Engine codes AAA and AMY
Note

opened.


Sharan 1996 ➤

nator, air conditioner compres‐
sor and power steering vane
pump
❑ Part No. 021 260 087
❑ Removing:
Rep. gr. 27 .
– Remove power steering

vane pump ⇒ Rep. gr.
48 .
– Remove air conditioner

compressor -8- from an‐
cillary bracket.
❑ Installing:
– First install fitted bolts
-3- and -12-.
2 - Washer 8.4x16x1.6
3 - Fitted bolt M8×28
❑ 25 Nm
4 - Socket head bolt with cap‐
tive washer M8×30
❑ 25 Nm
tive washer M8×30
❑ 25 Nm
tive washer M8×38
❑ 25 Nm
7 - Refrigerant hoses
❑ Bolts 22 Nm Volkswagen Technical Site: http://vwts.ru http://vwts.info
❑ Remove air conditioner compressor ⇒ page 121 .
❑ Removing from ancillary bracket:
– Remove front bumper. ⇒ Rep. gr. 63
– Separate lock carrier and pull it forwards.
– Remove headlight housing. ⇒ Rep. gr. 94
– Remove poly V-belt -9-.
– Remove alternator ⇒ Rep. gr. 27 .
– Loosen hexagon bolts -10- by a few turns and drive back spring pins on air conditioner compressor;
continue unscrewing hexagon bolts.
9 - Poly V-belt
❑ 45 Nm

Sharan 1996 ➤
11 - Socket head bolt with captive washer M8×30

❑ 25 Nm
❑ 25 Nm
13 - Washer 8.4x16x1.6
Poly V-belt routing
Note

poly V-belt pulley.
6.3 Engine code AYL
Note

opened.


Sharan 1996 ➤

pump
❑ Part No. 022 260 089
❑ To remove:
Rep. gr. 27 .

48 .

cillary bracket.
❑ Installing:
– Renew securing bolts.
– Observe securing bolts

tightening sequence.
First tighten fitted bolt
-3-, then fitted bolt -4-,
then socket head flange
bolts -2-.
2 - Socket head flange bolts

M8×30
❑ 25 Nm
❑ 25 Nm
❑ 25 Nm
❑ Bolts 22 Nm
– Remove front bumper ⇒ Rep. gr. 63 .
– Remove headlight housing ⇒ Rep. gr. 94

7 - Poly V-belt
❑ 45 Nm
❑ Qty. 2.

Sharan 1996 ➤
Poly V-belt routing
Note

poly V-belt pulley.
6.4 Engine codes 1Z, AFN, AHU and AVG
Note

opened.


Sharan 1996 ➤

❑ 25 Nm
nator and air conditioner com‐
pressor
❑ Part No. 028 903 139 T
❑ Removing:
❑ First remove alternator
⇒ Rep. gr. 27 .
cillary bracket.

❑ 25 Nm
4 - Alternator
⇒ Rep. gr. 27
5 - Tensioning element for ten‐
sioning roller
6 - Socket head bolt M8×22
❑ 25 Nm
❑ Qty. 3.
7 - Hexagon nut M8
❑ 30 Nm
❑ Qty. 4.
❑ 25 Nm
❑ Remove air conditioner
compressor
⇒ page 121 .
– Loosen hexagon bolts -11- by a few turns and drive back threaded bush on air conditioner compressor;
continue unscrewing hexagon bolts.
10 - Poly V-belt
❑ 45 Nm
❑ Qty. 2.
12 - Tensioning roller
❑ Removing:
– First loosen socket head screw M6 x 16 on tensioning element for tensioning roller and drive back ten‐
sioning roller using a rubber mallet.

Sharan 1996 ➤
Poly V-belt routing
Note

poly V-belt pulley.
6.5 Engine codes AJH, ATM and AWC
Note

opened.


Sharan 1996 ➤

pump
❑ Part No. 06A 903 143 P
❑ To remove:
Rep. gr. 27 .

48 .

cillary bracket.
❑ Installing:

First tighten fitted bolt
-2-, then fitted bolt -6-,
bolts -7-, -3-, -4- and
-5-.

❑ 45 Nm
3 - Socket head flange bolt
M10×45
❑ 45 Nm
M10×45
❑ 45 Nm
5 - Socket head flange bolt M10×45
❑ 45 Nm
❑ 45 Nm
❑ 45 Nm
❑ Bolts 22 Nm

❑ Remove air conditioner compressor from ancillary bracket and secure to body with suitable material (e.g.
welding wire) ⇒ page 92 .

Sharan 1996 ➤
10 - Poly V-belt
❑ 45 Nm
❑ Qty. 2.
12 - Bush
Securing air conditioner compressor to body

If compressor is removed without opening refrigerant circuit, it
should be secured to body using suitable material, for example,
welding wire.
When doing this, ensure refrigerant hoses on air conditioner com‐
pressor are not stressed.
Poly V-belt routing
Note

poly V-belt pulley.
6.6 Engine codes ANU, AJM, ASZ, AUY,

BRT, BTB, BVH and BVK
Note

opened.

Sharan 1996 ➤
1 - Dowel sleeve
pump
❑ Part No. 045 903 143 C
❑ To remove:
Rep. gr. 27 .

48 .

compressor -10- from
ancillary bracket.
❑ Installing:

First tighten socket
head flange bolt -6-,
bolt -5-, then socket
head flange bolts -8-,
-7-, -4- and -3-.

M10×45
❑ 45 Nm
M10×45
❑ 45 Nm
M10×45
❑ 45 Nm
❑ 45 Nm
❑ 45 Nm

Sharan 1996 ➤

❑ 45 Nm
❑ Bolts 22 Nm
❑ Remove from ancillary bracket

11 - Poly V-belt
❑ 45 Nm
❑ Qty. 2.
13 - Bush
Poly V-belt routing
Note

poly V-belt pulley.

Sharan 1996 ➤
7 Repair work on refrigerant circuit

which may be performed only in suit‐
able workshops by specially trained
mechanics
WARNING
Danger from escaping pressurised refrigerant!

Freezing of skin and other body parts.
• Extract refrigerant and then immediately open refrigerant
circuit.
• If the refrigerant was extracted more than 10 minutes be‐
fore the opening of refrigerant circuit, the refrigerant must
be extracted again. The pressure in the circuit will increase
due to subsequent evaporation.
7.1 Repairing Sanden air conditioning system magnetic clutch - N25- with air
conditioner compressor removed
Special tools and workshop

equipment required
♦ Pin wrench - 3212-
♦ Thrust plate - VW 401-
♦ Thrust plate - VW 402-
♦ Press tool - VW 412-
♦ Press tool - VW 432-
♦ Base plate - VW 441-
7. Repair work on refrigerant circuit which may be performed only in suitable workshops by specially trained mechanics 95
Sharan 1996 ➤

♦ Counterhold - V.A.G 1616-
♦ Pulling device - V.A.G 1616/1-
♦ E.g. air conditioner service station - VAS 6007A- (or later

model)
♦ Commercially available two-arm puller e.g. Kukko 20-10 mm

with 100 mm long hooks

Sharan 1996 ➤
– Extract refrigerant, e.g. with air conditioner service station -

VAS 6007A- (or later model).
Note
Releasing refrigerant into the environment is a criminal offence.
– Unbolt air conditioner compressor from ancillary bracket

⇒ page 82
1 - Hexagon nut
❑ 20 Nm
❑ Self-locking
❑ Always renew
2 - Clutch disc
❑ Pulling off ⇒ page 98 ,
❑ Checking clearance
⇒ page 100 .
3 - Circlip
❑ Renew.
❑ Install correctly: flat side
faces air conditioner
compressor
❑ Ensure that it is seated
correctly in groove.
4 - Poly V-belt pulley
❑ Pulling off ⇒ page 99 ,
❑ Pressing on
⇒ page 99
5 - Ball bearing
❑ Pressing off
⇒ page 99
❑ Pressing in
⇒ page 99
6 - Circlip
❑ Renew.
❑ Install correctly: flat side
faces air conditioner
compressor
❑ Ensure that it is seated
correctly in groove.
7 - Circlip
❑ Renew.
❑ Install correctly: flat side faces air conditioner compressor
❑ Ensure that it is seated correctly in groove.
8 - Solenoid
❑ Locking with dowel pin
❑ Secured with circlip -7-.
Sharan 1996 ➤
Note
An overheating fuse is installed in

the solenoid. The overheating fuse
interrupts the solenoid as soon as
the magnetic clutch overheats (for
example if compressor turns with
difficulty).
9 - Spacers
❑ To adjust clearance between clutch disc and poly V-belt pulley.
❑ Checking clearance ⇒ page 100 .
10 - Woodruff key
7.1.1 Removing air conditioning system mag‐

netic clutch - N25- from and installing on
air conditioner compressor
Unscrewing hexagon nut
– Use pin wrench - 3212- or counterhold - V.A.G 1616- to un‐
screw hexagon nut.
Pulling off clutch disc
Note
If this version is the one without the 3 threads in the clutch disc,
lever out the clutch disc carefully using 2 screwdrivers as illustra‐
ted.
Note
The three hexagon bolts of puller - V.A.G 1616/1- have 1/4"

threads.

Sharan 1996 ➤
Pulling off poly V-belt pulley for magnetic clutch

– Place hooks -arrow- as shown in illustration.
Note
If hook is placed on lower edge of poly V-belt pulley, there is a

danger of damaging air conditioning system magnetic clutch -
N25- .
– Pull off poly V-belt pulley with a commercially available two-

arm puller, e.g. Kukko 20-10 with 100 mm long hooks.
Pressing off ball bearing
Pressing in ball bearing
Pressing on poly V-belt pulley for air conditioning system mag‐

netic clutch - N25-
Note
Set compressor in place flat, or there is a danger that poly V-belt

pulley could deformed when pressed on.
– Drive back threaded bush -1-.
Sharan 1996 ➤
Checking and adjusting clearance

– Measure clearance with a depth gauge while repeatedly
switching air conditioning system magnetic clutch - N25- on
and off (applying a 12 V current).
♦ Specification: 0.4 to 0.8 mm
– If necessary, use spacers to adjust clearance. Pull off clutch
disc to do this.
Note
♦ The clearance must lie within permitted tolerances over the

complete circumference.
♦ The clearance can also be measured when the air conditioner
compressor is installed.
♦ If the clearance is outside of the specifications, remove the
clutch disc and adjust the clearance by removing or adding
spacers.
7.2 Running-in procedure for air conditioner

compressor and temperature measure‐
ment
• After installing new air conditioner compressor, charge refrig‐
erant circuit with refrigerant R134a ⇒ page 154 and adjust
quantity of refrigerant oil.
– Start engine and stabilise idling speed (for approx. 5 seconds)
before taking further steps. Insert thermometer in centre dash
panel vent.
– b: “Open” all dash panel vents.
– c: Set 3rd blower speed or 75 % of maximum blower output.
In vehicles with 1st evaporator system and 2nd heater unit for
rear seats, switch off 2nd heater unit.
– d: Switch on air conditioning system and let run without inter‐
rupting engine speed. For one and two evaporator systems,
let run below 1,500 rpm for at least 3 minutes with temperature
setting “Cold” or “Low”. After minimum temperatures have
been reached, compare with diagram ⇒ page 101 .
– e: then switch off air conditioning system and check each con‐
nection for leaks for at least 3 seconds (permissible leakage
7 g/year).

Sharan 1996 ➤
♦ Manual air conditioning system: picture 1

♦ Climatronic: picture 2
♦ Air conditioning system with 1st evaporator: picture 1

♦ Air conditioning system with 2nd evaporator: picture 2
♦ a: Temperature on dash panel vent
♦ b: Ambient temperature
Sharan 1996 ➤

which may be carried out only in suit‐
mechanics, vehicles ► 05.00
WARNING

circuit.
Note
♦ The refrigerant circuit must be purged with refrigerant R134a:

♦ If dirt or other contamination is in the circuit.
♦ If during the evacuation of a leak-tight refrigerant circuit the
vacuum is not maintained at the gauge (there is moisture in
the refrigerant circuit and this generates vapour pressure).
♦ If the refrigerant circuit has been left open for longer than nor‐
mally required for repairs (e.g. following an accident).
♦ Pressure and temperature measurements in the refrigerant
circuit indicate that there is moisture in the refrigerant circuit.
♦ There is doubt about the amount of refrigerant oil in the refrig‐
erant circuit.
♦ The air conditioner compressor has to be exchanged because
of internal damage (e.g. noisy or lack of power).
♦ The procedure for purging with refrigerant R134a is described
in ELSA under ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00 ; Clearing refrigerant circuit of contami‐
nants; Purging (cleaning) refrigerant circuit with refrigerant
R134a .

Sharan 1996 ➤
8.1 Tools
Note

ment and tools .
station .

model)
♦ Release tools case - VAS 6127- with release tool - VAS

6127/1- , release tool - VAS 6127/2- and release tool - VAS
6127/3-
8. Repair work on refrigerant circuit which may be carried out only in suitable workshops by specially trained mechanics, vehicles
► 05.00 103
Sharan 1996 ➤
♦ Adapter set for service connections - T10364-
♦ Torque wrench - V.A.G 1783- adapter set for service connec‐

tions - T10364-
♦ Ratchet insert tool 1/4" - VAS 6234- for adapter set for service
connections - T10364-
8.2 Repairing components in refrigerant cir‐

cuit
WARNING

circuit.

Sharan 1996 ➤
Note
♦ The refrigerant must be extracted beforehand, e.g. with air

conditioner service station - VAS 6007A- (or later model).
♦ If refrigerant lines have been renewed, spray them with cavity
sealant after installing and checking connections for leaks. Al‐
so spray between the retaining clips and the refrigerant lines.
♦ Releasing refrigerant into the environment is a criminal of‐
fence.
♦ Observe the safety measures when working on an evacuated
refrigerant circuit ⇒ page 29 .
♦ To prevent the intrusion of moisture, all components of the re‐
frigerant circuit which have been opened must be sealed with
suitable plugs.
♦ The colour coding of O-rings for R134a refrigerant circuits has
been discontinued. Coloured and black O-rings are used.
♦ Under certain conditions, it is not necessary to renew the re‐
ceiver with dryer every time that the refrigerant circuit is
opened. Refer to ELSA under Heating, ventilation, air condi‐
tioning system; Air conditioning system with refrigerant R134a
⇒ Air conditioning system with refrigerant R134a; Rep. gr.
00 ; Renewing components .
ment and tools .
station .
8.3 Overview - components in the refrigerant circuits for front and rear seats
► 05.00 105
Sharan 1996 ➤
1 - Components in the refriger‐

ant circuit for front seats
❑ Repairing refrigerant
circuit for front seats
⇒ page 106
ant circuit for rear seats
circuit for rear seats
⇒ page 115
8.3.1 Repairing refrigerant circuit for front

seats
– Observe notes ⇒ page 104 .

Sharan 1996 ➤
1 - Front evaporator
❑ Removing ⇒ page 125 ,
Dismantling and assem‐
bling heater and air con‐
ditioning unit for front
and rear seats
2 - Seal
❑ Watertight
3 - Threaded plate
4 - O-ring
❑ 10.8 mm; 1.8 mm
5 - Bolt
❑ 7 ± 1.1 Nm
6 - Evacuating and charging
valve
❑ Releasing refrigerant in‐
to the environment is a
criminal offence.
⇒ page 113
❑ Capacities ⇒ page 154
7 - Bolts
❑ 4.5 ± 0.7 Nm
8 - O-ring
❑ 10.8 mm; 1.8 mm
9 - O-rings
❑ 11.1 mm; 1.8 mm
❑ Qty. 2.
10 - Excess pressure relief
valve
WARNING
ries.
valve.

11 - Condenser
12 - O-rings
❑ 20.4 mm; 1.8 mm
❑ Qty. 2.
► 05.00 107
Sharan 1996 ➤
Note
Before installing, moisten O-rings

with refrigerant oil and insert in air
conditioner compressor.
13 - O-ring
❑ 11.1 mm; 1.8 mm
14 - Socket head bolt M6
❑ 7 ± 1.1 Nm
15 - O-ring
❑ 8.13 mm; 1.78 mm
16 - 1/2" pipe
❑ Release connection using release tool ⇒ page 110
17 - Hexagon bolt
❑ 8.5 ± 1.3 Nm
18 - Bolt
❑ 30 ± 4.5 Nm
❑ With air conditioning system magnetic clutch - N25- .
❑ Running-in procedures ⇒ page 100 .
❑ Manufacturer: Sanden
❑ Repairs on air conditioning system magnetic clutch - N25- with air conditioner compressor still installed
should be performed only as an exception.
❑ Repairing air conditioning system magnetic clutch - N25- with the air conditioner compressor removed
⇒ page 95
21 - 3/8" pipe
22 - O-rings
❑ 8.13 mm; 1.78 mm
❑ Qty. 2.
23 - Nut
❑ 6 ± 0.9 Nm
24 - Stud
❑ 9.6 ± 1.5 Nm
25 - Receiver with dryer
❑ Functions ⇒ page 110 .
Note

ing components .

Sharan 1996 ➤
❑ Removing receiver with dryer cartridge ⇒ page 120 .
26 - O-rings
❑ 17.2 mm; 1.8 mm
❑ Qty. 2.
27 - Socket head bolt M6
❑ 7 + 1.1 Nm
28 - O-rings
❑ 8.13 mm; 1.78 mm
❑ Qty. 2.
29 - O-ring
❑ 10.8 mm; 1.8 mm
30 - Evacuating and charging valve
❑ Releasing refrigerant into the environment is a criminal offence.
31 - Protective cap*
❑ 8 Nm
❑ The pressure switch can be removed without extracting the refrigerant from the refrigerant circuit.
Function:
❑ Check high-pressure sender - G65- : ⇒ Vehicle diagnostic tester in the function “guided fault finding.”
❑ Renew O-ring.
33 - O-ring
❑ 10.8 mm; 1.8 mm
34 - 3/4" pipe
35 - Bolts
❑ 4 ± 0.5 Nm
36 - O-ring
❑ 11.1 mm; 1.8 mm
37 - O-ring
❑ 17.1 mm; 1.8 mm
38 - Expansion valve
❑ Aperture must be sealed against splashed water.
❑ Tasks: the expansion valve atomises the influent refrigerant and regulates the flow so that the vapour,
depending on heat transport, becomes a gas only upon reaching the outlet of the evaporator
❑ Identification: the expansion valves for R134a refrigerant circuits are marked with a green sticker.
► 05.00 109
Sharan 1996 ➤
39 - Insulating cap*
40 - O-ring
❑ 14 mm; 1.8 mm
Functions of receiver with dryer

The receiver collects the liquid droplets and directs them in a
continuous stream to the expansion valve. Moisture which has
entered the refrigerant circuit during assembly is collected by the
dryer in the receiver.
Note
Under certain conditions, it is not necessary to renew the receiver

with dryer every time that the refrigerant circuit is opened. Refer
to ELSA under Heating, ventilation, air conditioning system; Air
conditioning system with refrigerant R134a ⇒ Air conditioning
system with refrigerant R134a; Rep. gr. 00 ; Renewing compo‐
nents .
Release connector: release tools case - VAS 6127- with release

tool - VAS 6127/1- and release tool - VAS 6127/2- .
Note
♦ The flanges of the pipes are held together by spring pressure.

If the spring is stretched with the release tool it is possible to
pull the pipes apart.
♦ Release tools case - VAS 6127-
WARNING

circuit.
– Clamp release tool - VAS 6127/1- (blue/black) or release tool

- VAS 6127/2- (red/white) around connector flange, push in
direction of spring and then pull pipes apart.
8.3.2 Checking air conditioning system pres‐

sure switch - F129-
♦ The pressure switch can be removed without extracting the
refrigerant from the refrigerant circuit.

Sharan 1996 ➤
♦ Visual check: ensure that O-ring 10.8 mm x 1.8 mm is seated

in groove.
Switch unit between contact -T4d/1- and contact -T4d/2- in con‐
nector housing switches off air conditioning system magnetic
clutch - N25- when refrigerant circuit is insufficiently filled or pres‐
sure is too high:
Opens below 1.2 bar and closes again above 2.4 bar (switching
threshold).
Opens above 32 bar and closes again below 24 bar (switching
threshold).
8.3.3 Checking switch unit

– Briefly bridge circuit between chambers 1 and 2 with engine
running. The refrigerant circuit is empty if the air conditioner
magnetic clutch - N25- switches on.
Switch unit between contact -T4d/3- and contact -T4d/4- in con‐
nector housing switches radiator fan - V7- to 2nd speed when the
pressure in the refrigerant circuit rises.
Closes above 16 bar and opens below 12.5 bar (switching thresh‐
old).
8.3.4 Evaluating checks of air conditioning

system pressure switch - F129-
♦ The following tests are performed with component installed.
To assess the air conditioner's performance, perform and evalu‐
ate the following tests:
– Check the air conditioner's charge level; the air conditioner is
switched off if the pressure is too low (for example, loss of
refrigerant).
– Check blower switch-on; radiator fan - V7- is switched to the
next higher speed when the pressure in the refrigerant circuit
rises (excessive pressure).
– Check air conditioner switch-off; the air conditioner is switched
off when pressure is excessive (for example when engine
cooling is insufficient).
8.4 Removing evacuating and charging

valve, low-pressure side
► 05.00 111
Sharan 1996 ➤

model)
♦ "Ratchet insert 1/4" - VAS 6234-

Sharan 1996 ➤
WARNING

circuit.
– Evacuate refrigerant circuit, e.g. with air conditioner service

station - VAS 6007A- (or later model) before renewing valve
-3-.
Note

fence.
♦ All components of the refrigerant circuit which have been
opened must be sealed with suitable plugs to prevent moisture
intrusion.
1- Connection with external thread and groove for O-ring

2- O-ring; 7.6 mm; 1.8 mm
3- Evacuating and charging valve (7 ± 7 Nm) with groove and
internal thread for cap
4- O-ring
5- Cap
8.5 Removing evacuation and charging

valve, high-pressure side
model)
► 05.00 113
Sharan 1996 ➤
♦ "Ratchet insert 1/4" - VAS 6234-
WARNING

circuit.

Sharan 1996 ➤
– Evacuate refrigerant circuit, e.g. with air conditioner service

station - VAS 6007A- (or later model) before renewing valve
-3-.
Note

fence.
intrusion.
1- Connection with internal thread

2- O-ring; 7.6 mm; 1.8 mm
3- Evacuating and charging valve (7 ± 7 Nm) with groove and
internal thread for cap
4- O-ring
5- Cap
8.6 Checking excess pressure relief valve

on air conditioner compressor
WARNING

too high.
Switch off engine.
♦ Function: protects refrigerant circuit against excessive pres‐

sure.
♦ The excess pressure relief valve indicates if the valve has op‐
erated. A small plate attached by adhesive will be pushed out.
8.7 Repairing refrigerant circuit for rear

seats
► 05.00 115
Sharan 1996 ➤
WARNING

circuit.
1 - Expansion valve for front

evaporator
❑ Aperture must be
sealed against splashed
water.
❑ The same component
as for the rear evapora‐
tor
2 - 5/8" pipe
❑ Release connection us‐
ing release tool
⇒ page 110
3 - 3/8" pipe
❑ Release connection us‐
ing release tool
⇒ page 110
4 - O-rings
❑ 13 mm; 1.9 mm
❑ Qty. 2.
5 - O-rings
❑ 8.1 mm; 1.8 mm
❑ Qty. 2.
6 - High-pressure hose
7 - Low-pressure hose
8 - O-ring
❑ 17.2 mm; 1.8 mm
9 - O-ring
❑ 11.1 mm; 1.8 mm
evaporator
sealed against splashed water.
❑ The same component as for the front evaporator
11 - O-ring
❑ 10.8 mm; 1.8 mm
12 - O-ring
❑ 14 mm; 1.8 mm

Sharan 1996 ➤
13 - 2nd evaporator
❑ Torque setting: 4.7 Nm
8.8 Removing expansion valve
WARNING

circuit.
– Extract refrigerant, e.g. with air conditioning service station -

Note
♦ Only the components marked with an * can be renewed with‐

out evacuating and opening the refrigerant circuit.
intrusion.
► 05.00 117
Sharan 1996 ➤
ment
and rear seats.
2 - Seal
❑ Watertight
3 - Threaded plate
4 - O-ring
❑ 10.8 mm; 1.8 mm
5 - Expansion valve
water.
Removing:
– Remove bolt -8-.
– Pull out refrigerant

pipes.
– Remove expansion
valve.
❑ Renew O-rings -4-, -7-,
-9- and -11-.
6 - Bolt
❑ 7 Nm
7 - O-ring
❑ 11.1 mm; 1.8 mm Volkswagen Technical Site: http://vwts.ru http://vwts.info
8 - Bolt
❑ 7 Nm ±1.1 Nm
9 - O-ring
❑ 17.2 mm; 1.8 mm
10 - Insulator*
11 - O-ring
❑ 14.0 mm; 1.8 mm

Sharan 1996 ➤
8.9 Removing and installing condenser
WARNING

circuit.

– Disconnect and seal refrigerant pipes at condenser.
– Remove front bumper. ⇒ Rep. gr. 63
1 - Lock carrier
2 - Bolts with captive washers
❑ 4.5 ± 0.7 Nm
❑ Qty. 2.
3 - Bracket for radiator cowl
4 - Self-tapping screws
❑ 10 Nm
❑ Qty. 6.
5 - Bolts
❑ 10 Nm
❑ Qty. 2.
6 - Clips
7 - Condenser
8 - Hexagon bolt
❑ 10 Nm
► 05.00 119
Sharan 1996 ➤
8.10 Removing and installing receiver with

dryer
Note
Under certain conditions, it is not necessary to renew the receiver

with dryer every time that the refrigerant circuit is opened. Refer
to ELSA under Heating, ventilation, air conditioning system; Air
conditioning system with refrigerant R134a ⇒ Air conditioning
system with refrigerant R134a; Rep. gr. 00 ; Renewing compo‐
nents .

♦ Air conditioning service station - VAS 6007A- (or later model).
8.10.1 Removing
Note
♦ Observe notes ⇒ page 104 .

♦ The previously used air conditioner service stations can still
be used ⇒ Volkswagen Workshop Equipment catalogue.
♦ All of the refrigerant circuit's components that have been
opened must be sealed with suitable plugs to prevent the in‐
gress of moisture.

Sharan 1996 ➤
WARNING

circuit.

VAS 6007A- (or later model) before opening refrigerant circuit.
– Remove air conditioning system pressure switch - F129- or
high-pressure sender - G65- -3-.
– Remove securing bolt for refrigerant pipes -5-.
– Remove securing bolts -2- and remove receiver with dryer
cartridge -1-.
8.10.2 Installing
Installation is carried out in the reverse order. When installing,
note the following:
Note
♦ Tighten bolts -2- to 20 ± 3 Nm.

♦ Install high-pressure switch -3-, 8 ± 1 Nm
♦ Renew 8.13 mm and 1.78 mm O-rings -4-.
♦ Tighten bolt -5- to 7 + 1 Nm.
8.11 Removing and installing air conditioner

compressor
♦ Torque wrench - V.A.G 1331/-
♦ Air conditioner service station

► 05.00 121
Sharan 1996 ➤
Removing
Note
♦ If a new air conditioner compressor is installed, the function

“Compressor first run” must be performed in the Guided Fault
Finding.
♦ The refrigerant circuit must be purged with refrigerant R134a
under the following circumstances:
♦ When pressure and temperature measurements in the refrig‐
erant circuit indicate that there is moisture in the refrigerant
circuit.
erant circuit.
R134a .
♦ If only the ancillary bracket is to be removed, the refrigerant
lines on the air conditioner compressor need not be loosened.
It is sufficient to secure the air conditioner compressor to the
body with suitable material, e.g. welding wire.
ment and tools .
station .
– Extract refrigerant using air conditioner service station before

opening refrigerant circuit. Comply with notes ⇒ page 104 .
– Remove noise insulation under engine ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Noise insulation; Assembly over‐
view - noise insulation .

Sharan 1996 ➤
– Remove poly V-belt ⇒ Rep. gr. 13 ; Cylinder block (pulley

end); Removing and installing poly V-belt .
WARNING

circuit.
– Remove bolts (22 Nm ± 1 Nm) -2- from air conditioner com‐

pressor and separate refrigerant pipes -3- from air conditioner
compressor.
– Remove hexagon bolts (45 Nm) -5- and remove air conditioner
compressor from bracket -1-.
Installing
Installation is carried out in reverse order of removal. Note the
following:
– Observe running-in procedures ⇒ page 100 .
– Renew seals -4-.
8.12 Removing and installing heater and air

conditioning unit
♦ E.g. air conditioning service station - VAS 6007A- (or later

model)
► 05.00 123
Sharan 1996 ➤
Removing
WARNING

circuit.

– Remove dash panel ⇒ Rep. gr. 70. .
WARNING
Risk of scalding.

– Remove dust and pollen filter with filter housing ⇒ page 20 .

Sharan 1996 ➤
1 - Hexagon nut
❑ Qty. 6.
❑ 4 Nm
3 - Heater and air conditioning
unit
bling the heater and air
conditioning unit for
front and rear seats
⇒ page 152
Installing:
– Guide heater and air
conditioning unit to ple‐
num chamber bulkhead
and push studs through
intended holes.
– Screw hexagon nuts -1-

onto plenum chamber
bulkhead in engine
compartment and tight‐
en them.
– Check coolant level and

top up. ⇒ Rep. gr. 19
8.13 Dismantling and assembling heater and

air conditioning unit for front and rear
seats
– Drain coolant. ⇒ Rep. gr. 19
– Remove dash panel. ⇒ Rep. gr. 70
– Remove heating and air conditioning unit ⇒ page 123 .
► 05.00 125
Sharan 1996 ➤
8.13.1 Heater and air conditioning unit for front seats
1 - Heat exchanger
❑ Seals must be bonded
free of gaps all around
❑ After removal, com‐
pletely renew coolant.
2 - Evaporator
⇒ page 125 , Disman‐
tling and assembling
heater and air condition‐
ing unit for front and rear
seats.
3 - Evaporator housing
❑ With air recirculation
flap.
6 - Clip
7 - Air distribution housing

Sharan 1996 ➤
8.13.2 2nd heater and air conditioning unit for rear seats

take side
2 - 2nd evaporator
3 - O-ring
❑ 10.8 mm; 1.8 mm
4 - O-ring
❑ 14 mm; 1.8 mm
evaporator
water.
as for the front evapora‐
tor
6 - Bolt
❑ 7 Nm
7 - O-ring
❑ 11.1 mm; 1.8 mm
8 - O-ring
❑ 17.2 mm; 1.8 mm
unit - J391-
10 - Rear fresh air blower -
V80-
11 - Coolant hose
12 - Housing for heating and ventilation for passenger compartment, vent side
15 - Air distribution flap
16 - Heat exchanger for rear seats
17 - Temperature flap for passenger compartment
► 05.00 127
Sharan 1996 ➤
8.13.3 Removing and installing rear fresh air

blower control unit - J391-
Removing
– Separate connector -1- and remove bolt -2-.
Installing
– Install in reverse order.

Sharan 1996 ➤

which may be carried out only in suit‐
mechanics, vehicles 06.00 ►
WARNING

circuit.
Note
♦ The refrigerant circuit must be purged with refrigerant R134a:

♦ Pressure and temperature measurements in the refrigerant
circuit indicate that there is moisture in the refrigerant circuit.
erant circuit.
R134a .
ment and tools .
station .
06.00 ► 129
Sharan 1996 ➤

model)
♦ Release tools case - VAS 6127- with release tool - VAS

6127/1- , release tool - VAS 6127/2- and release tool - VAS
6127/3-
♦ Torque wrench - V.A.G 1783- adapter set for service connec‐

tions - T10364-

Sharan 1996 ➤
♦ Ratchet insert tool 1/4" - VAS 6234- for adapter set for service
connections - T10364-
9.1 Repairing components in refrigerant cir‐

cuit
Note

♦ If refrigerant lines have been renewed, spray them with cavity
sealant after installing and checking connections for leaks. Al‐
so spray between the retaining clips and the refrigerant lines.
fence.
♦ Observe the safety measures when working on an evacuated
refrigerant circuit ⇒ page 29 .
♦ Only the components marked with an * can be renewed with‐
out evacuating and opening the refrigerant circuit.
♦ To prevent the intrusion of moisture, all components of the re‐
frigerant circuit which have been opened must be sealed with
suitable plugs.
♦ The colour coding of O-rings for R134a refrigerant circuits has
been discontinued. Coloured and black O-rings are used.
♦ Under certain conditions, it is not necessary to renew the dryer
cartridge every time that the refrigerant circuit is opened. Refer
to ELSA under Heating, ventilation, air conditioning system;
Air conditioning system with refrigerant R134a ⇒ Air condi‐
tioning system with refrigerant R134a; Rep. gr. 00 ; Renewing
components .
ment and tools .
station .
9.2 Overview - components in the refrigerant circuits for front and rear seats
06.00 ► 131
Sharan 1996 ➤

ant circuit for rear seats
circuit for rear seats
⇒ page 139
ant circuit for front seats
circuit for front seats
⇒ page 132

seats

Sharan 1996 ➤
and rear seats.
2 - Seal
❑ Watertight
3 - Threaded plate
4 - O-ring
❑ 14.0 mm; 1.82 mm
5 - O-ring
❑ 11.1 mm; 1.82 mm
6 - Expansion valve
water.
❑ Task: the expansion
valve atomises the influ‐
ent refrigerant and reg‐
ulates the flow so that
the vapour, depending
on heat transport, be‐
comes a gas only upon
reaching the outlet of
the evaporator.
❑ Identification: the ex‐
pansion valves for
R134a refrigerant cir‐
cuits are marked with a
green sticker.
7 - Bolt
❑ 7 ± 1.1 Nm
8 - O-ring
❑ 17.2 mm; 1.82 mm
9 - O-ring
❑ 8.13 mm; 1.82 mm
10 - Bolt
❑ 7 ± 1.1 Nm
11 - Refrigerant line
13 - Bolt
❑ 6 ± 0.75 Nm
❑ With air conditioning system magnetic clutch - N25- .
06.00 ► 133
Sharan 1996 ➤

❑ Manufacturer: Sanden
Repairs to the magnetic clutch with the air conditioner compressor installed should only be performed only as
an exception.
❑ Repairing air conditioning system magnetic clutch - N25- with the air conditioner compressor removed
⇒ page 95
Note

components .

18 - O-ring
❑ 10.8 mm; 1.82 mm
19 - O-rings
❑ 10.8 mm; 1.82 mm
20 - Socket head screw
❑ 22 ± 1 Nm
21 - O-ring
❑ 10.8 mm; 1.82 mm
22 - Socket head screw
❑ 12 ± 1 Nm
23 - Condenser
24 - O-ring
❑ 14.3 mm; 2.40 mm

Sharan 1996 ➤
25 - Excess pressure relief valve
WARNING
ries.
valve.

26 - Nut
❑ 6 ± 1 Nm
28 - 3/4" pipe
Note
Depending on vehicle type, different

bolts are installed for the refrigerant
line on low-pressure side at air con‐
ditioner compressor inlet. M10x20
to 43 ± 6.5 Nm and M6x16 to
7 ± 1.1 Nm.
29 - O-ring
❑ 10.8 mm; 1.82 mm
30 - 3/8" pipe
31 - O-ring
❑ 10.8 mm; 1.82 mm
32 - Air conditioning system pressure switch - F129- * or high-pressure sender - G65- *
– Removing: remove bolt from lower part of right front wheel housing and push aside front wheel housing.
❑ 8 Nm
❑ Air conditioning system pressure switch - F129- and high-pressure sender - G65- can be removed without
having to evacuate refrigerant from refrigerant circuit.
Function:
❑ Checking high-pressure sender - G65- : ⇒ Vehicle diagnostic tester
06.00 ► 135
Sharan 1996 ➤
33 - O-rings
❑ 17.2 mm; 1.82 mm
❑ Qty. 3.
34 - O-rings
❑ 8.13 mm; 1.78 mm
❑ Qty. 3.
35 - Bolts
❑ 3 ± 0.45 Nm
9.2.2 Checking air conditioning system pres‐

sure switch - F129-
♦ The pressure switch can be removed without extracting the
refrigerant from the refrigerant circuit.
♦ Visual check: ensure that O-ring 10.8 mm x 1.8 mm is seated
in groove.
The switch part between chamber 1 and chamber 2 of connector
housing switches air conditioning system magnetic clutch - N25-
off when refrigerant circuit is insufficiently filled or pressure is too
high:
Opens below 1.2 bar and closes again above 2.4 bar (switching
threshold).
Opens above 32 bar and closes again below 24 bar (switching
threshold).
9.2.3 Checking switch unit

– Briefly bridge circuit between chambers 1 and 2 with engine
running. The refrigerant circuit is empty if the air conditioner
magnetic clutch - N25- switches on.
The switch unit between chamber -3- and chamber -4- of the con‐
nector housing switches the radiator fan - V7- to the second speed
via the radiator fan control unit - J293- when the pressure in the
refrigerant circuit rises.
Closes above 16 bar and opens below 12.5 bar (switching thresh‐
old).
9.2.4 Evaluating tests of air conditioning sys‐

tem pressure switch - F129-
♦ The following tests are performed with component installed.

Sharan 1996 ➤
To assess the air conditioner's performance, perform and evalu‐

ate the following tests:
– Check the air conditioner's charge level; the air conditioner is
switched off if the pressure is too low (for example, loss of
refrigerant).
– Check blower switch-on; radiator fan - V7- is switched to the
next higher speed when the pressure in the refrigerant circuit
rises (excessive pressure).
– Check air conditioner switch-off; the air conditioner is switched
off when pressure is excessive (for example when engine
cooling is insufficient).

seats with 2nd evaporator
and rear seats
2 - Seal
❑ Watertight
3 - Threaded plate
4 - O-ring
❑ 14.0 mm; 1.82 mm
5 - O-ring
❑ 11.1 mm; 1.82 mm
6 - Expansion valve
water.
❑ Tasks: the expansion
valve atomises the influ‐
ent refrigerant and reg‐
ulates the flow so that
the vapour, depending
on heat transport, be‐
comes a gas only upon
reaching the outlet of
the evaporator
❑ Identification: the ex‐
pansion valves for
R134a refrigerant cir‐
cuits are marked with a
green sticker.
7 - Bolt
❑ 7 ± 1.1 Nm
8 - O-ring
❑ 17.2 mm; 1.82 mm
9 - O-ring
❑ 8.13 mm; 1.82 mm
06.00 ► 137
Sharan 1996 ➤
10 - Bolt
❑ 7 ± 1.1 Nm
❑ For vehicles with 2nd evaporator
❑ High-pressure side with union nut (9 + 1.3 Nm)
❑ For vehicles with 2nd evaporator
❑ Low-pressure side with union nut (13 + 2 Nm)
13 - O-rings
❑ 14.0 mm; 1.82 mm
❑ Qty. 3.
14 - O-rings
❑ 8.13 mm; 1.82 mm
❑ Qty. 3.
15 - O-ring
❑ 8.13 mm; 1.82 mm
Note
After installation work, spray cavity

sealant on the refrigerant lines and
their fasteners.
Note
After installation work, spray cavity

sealant on the refrigerant lines and
their fasteners.
18 - O-rings
❑ 14.0 mm; 1.82 mm

Sharan 1996 ➤
9.2.6 Repairing refrigerant circuit for rear seats

1 - O-ring
❑ 17.2 mm; 1.82 mm
2 - Expansion valve for front
evaporator
water.
3 - O-ring
❑ 8.13 mm; 1.82 mm
4 - Threaded plate
5 - Bolt
❑ 7 ± 1.1 Nm
6 - O-ring
❑ 8.13 mm; 1.82 mm
7 - 3/8" pipe
❑ With union nut 13 +
2 Nm for high-pressure
line to 2nd evaporator.
8 - O-ring
❑ 14.0 mm; 1.82 mm
❑ Qty. 1.
9 - 5/8" pipe
❑ With union nut 9 +
1.3 Nm for low-pressure
line to 2nd evaporator.
10 - Bolt
❑ 7 ± 1.1 Nm
11 - O-ring
❑ 8.13 mm; 1.78 mm
12 - O-ring
❑ 17.2 mm; 1.78 mm
13 - Expansion valve for 2nd evaporator for rear seats
❑ Aperture must be sealed against splashed water.
14 - O-ring
❑ 11.1 mm; 1.82 mm
15 - O-ring
❑ 14.0 mm; 1.82 mm
❑ Qty. 1.
16 - 5/8" pipe
17 - 3/8" pipe
18 - O-rings
❑ 8.13 mm; 1.78 mm
06.00 ► 139
Sharan 1996 ➤
❑ Qty. 3.
19 - O-rings
❑ 14.0 mm; 1.78 mm
❑ Qty. 3.
20 - O-ring
❑ 14.0 mm; 1.82 mm
❑ Qty. 3.
21 - O-rings
❑ 8.13 mm; 1.82 mm
❑ Qty. 3.
22 - Bolt
❑ 7 ± 1 Nm
23 - Nut
❑ 6 ± 0.9 Nm
24 - Nut
❑ 2 ± 0.3 Nm
27 - Bolt
❑ 4 ± 0.5 Nm
28 - 2nd evaporator
❑ Torque setting: 4.7 Nm
9.3 Removing expansion valve
WARNING

circuit.

Note
Only the components marked with an * can be renewed without

evacuating and opening the refrigerant circuit.

Sharan 1996 ➤
❑ For front seats
and rear seats.
2 - Seal
❑ Watertight
3 - Threaded plate
4 - O-ring
❑ 11.1 mm; 1.8 mm
5 - Expansion valve
water.
Removing:
– Remove windscreen
wiper system ⇒ Rep.
gr. 92 .
– Pull out refrigerant

pipes.
– Remove expansion
valve.
❑ Renew O-rings -4-, -7-,
-9- and -11-.
6 - Bolt
❑ 7 Nm
7 - O-ring
❑ 8.13 mm; 1.82 mm
8 - Bolt
❑ 7 Nm
9 - O-ring
❑ 17.2 mm; 1.8 mm
10 - Insulator*
11 - O-ring
❑ 14.0 mm; 1.8 mm
❑ From expansion valve to air conditioner compressor.
❑ With damper
06.00 ► 141
Sharan 1996 ➤
9.4 Removing and installing condenser
WARNING

circuit.

– Disconnect and seal refrigerant pipes at condenser.
It is not possible to access the 4 retaining bolts of the condenser
in some vehicles.
– In these vehicles, drill a 15 mm ∅ hole for each bolt.
Dimension “a” 15 mm and dimension “b” 17 mm
– Remove radiator ⇒ Rep. gr. 19 .
– To prevent intrusion of moisture, seal all components of re‐
frigerant circuit which have been opened with suitable plugs.

Sharan 1996 ➤
1 - Lock carrier
❑ Self-tapping screw 6.3 x
22 mm
❑ 6 ± 0.75 Nm
3 - Bolts
❑ Qty. 3.
❑ 12 ± 1 Nm
❑ Bolts with captive wash‐
ers M8×24 mm
❑ 5 ± 0.75 Nm
❑ Qty. 4.
❑ Self-tapping screws 6.5
x 16 mm
5 - Hole
❑ For self-tapping screws
-4-
❑ 12. 00 ►
6 - Condenser
7 - Receiver with dryer car‐
tridge
Note

components .
06.00 ► 143
Sharan 1996 ➤
9.5 2nd evaporator housing for rear seats

take side
2 - 2nd evaporator
❑ Installing seal on evap‐
orator ⇒ page 145
3 - Bolt
❑ 7 Nm
4 - O-ring
❑ 11.1 mm; 1.82 mm
5 - O-ring
❑ 14.0 mm; 1.82 mm
evaporator
water.
as for the front evapora‐
tor
7 - O-ring
❑ 8.13 mm; 1.78 mm
8 - O-ring
❑ 17.2 mm; 1.78 mm
9 - Seal
10 - O-rings
❑ 14 mm; 1.78 mm
11 - O-rings
❑ 8.13 mm; 1.78 mm
12 - Rear fresh air blower control unit - J391-
14 - Coolant hose
15 - Lip valve
16 - Housing for heating and ventilation for passenger compartment, vent side
19 - Air distribution flap
20 - Heat exchanger for rear seats
❑ Installing seal on heat exchanger ⇒ page 145
21 - Temperature flap for passenger compartment

Sharan 1996 ➤
Installing seal on evaporator

The evaporator must be sealed along the top and side against the
housing using seal -1-.
Installing seal on heat exchanger

The heat exchanger must be sealed along the sides against the
housing using seal -1-.
9.6 Remove dryer cartridge in receiver
Note
Under certain conditions, it is not necessary to renew the dryer

cartridge every time that the refrigerant circuit is opened. Refer to
ELSA under Heating, ventilation, air conditioning system; Air con‐
ditioning system with refrigerant R134a ⇒ Air conditioning system
with refrigerant R134a; Rep. gr. 00 ; Renewing components .
9.6.1 Removing
Note
♦ Observe notes ⇒ page 104 .

♦ The previously used air conditioner service stations can still
be used ⇒ Volkswagen Workshop Equipment catalogue.
♦ All of the refrigerant circuit's components that have been
opened must be sealed with suitable plugs to prevent the in‐
gress of moisture.
06.00 ► 145
Sharan 1996 ➤
WARNING

circuit.

VAS 6007A- (or later model) before opening refrigerant circuit.
It is not possible to access the 4 retaining bolts of the condenser
in some vehicles.
– In these vehicles, drill a 15 mm ∅ hole for each bolt.
Dimension “a” 15 mm and dimension “b” 17 mm
– Pull off cap -1- upwards.
– Before opening dryer, remove grease (optional) or corrosion

from its inner surface.
WARNING
Danger of freezing injuries or of sealing cover flying off.

If the refrigerant circuit has not been evacuated, it is pressur‐
ised. Refrigerant and refrigerant oil will escape while opening.
Extract refrigerant before opening refrigerant circuit. If the re‐
frigerant circuit is not opened within 10 minutes after it has
been evacuated, pressure may develop in coolant circuit due
to re-evaporation. Extract refrigerant again.
– Remove retaining ring -3-.

– Screw a socket head bolt (M5) -2- into thread of sealing cover.

Sharan 1996 ➤
– Unscrew bolt -2- from condenser and use a screwdriver to

push guide pin -1- of the condenser in the direction of the ar‐
row.
– Using a pair of pliers on socket head screw -2-, pull out sealing
cover -1- straight in the direction of the arrow.
– Using long nose pliers, pull out dryer cartridge -1- in direction
of arrow.
Installation is carried out in the reverse order. When installing,
note the following:
Caution
There is a risk the dryer may be leaking.

The o-rings can be damaged when the sealing cover is inser‐
ted.
Carefully insert the sealing cap into the dryer.
Note
To prevent corrosion, it is necessary to coat the area -2- with

grease - G 052 150 A2- before installing the cap -1-.
06.00 ► 147
Sharan 1996 ➤
Tasks of reservoir with dryer cartridge

The receiver collects the liquid droplets and directs them in a
continuous stream to the expansion valve. Moisture which has
entered the refrigerant circuit during assembly is collected by the
dryer cartridge in the receiver.
9.7 Removing and installing air conditioner

compressor
♦ Torque wrench - V.A.G 1331/-
♦ Air conditioner service station

Sharan 1996 ➤
Removing
Note
♦ If a new air conditioner compressor is installed, the function

“Compressor first run” must be performed in the Guided Fault
Finding.
♦ The refrigerant circuit must be purged with refrigerant R134a
under the following circumstances:
♦ When pressure and temperature measurements in the refrig‐
erant circuit indicate that there is moisture in the refrigerant
circuit.
erant circuit.
R134a .
♦ If only the ancillary bracket is to be removed, the refrigerant
lines on the air conditioner compressor need not be loosened.
It is sufficient to secure the air conditioner compressor to the
body with suitable material, e.g. welding wire.
ment and tools .
station .
– Extract refrigerant using air conditioner service station before

opening refrigerant circuit. Comply with notes ⇒ page 104 .
– Remove noise insulation under engine ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Noise insulation; Assembly over‐
view - noise insulation .
06.00 ► 149
Sharan 1996 ➤
– Remove poly V-belt ⇒ Rep. gr. 13 ; Cylinder block (pulley

end); Removing and installing poly V-belt .
WARNING

circuit.
– Remove bolts (22 Nm ± 1 Nm) -2- from air conditioner com‐

pressor and separate refrigerant pipes -3- from air conditioner
compressor.
– Remove hexagon bolts (45 Nm) -5- and remove air conditioner
compressor from bracket -1-.
Installing
Installation is carried out in reverse order of removal. Note the
following:
– Observe running-in procedures ⇒ page 100 .
– Renew seals -4-.
9.8 Removing and installing heater and air

conditioning unit
♦ E.g. air conditioning service station - VAS 6007A- (or later

model)

Sharan 1996 ➤
Removing
– Remove dash panel ⇒ Rep. gr. 70. .
WARNING
Risk of scalding.

06.00 ► 151
Sharan 1996 ➤
1 - Hexagon nut
❑ Qty. 6.
❑ 4 Nm
3 - Heater and air conditioning
unit
bling the heater and air
conditioning unit for
front and rear seats
⇒ page 152
Installing:
– Guide heater and air
conditioning unit to ple‐
num chamber bulkhead
and push studs through
intended holes.
– Screw hexagon nuts -1-

onto plenum chamber
bulkhead in engine
compartment and tight‐
en them.
– Check coolant level and

top up ⇒ Rep. gr. 19 .
9.9 Dismantling and assembling heater and

air conditioning unit for front and rear
seats
– Remove heater and air conditioning unit ⇒ page 150 .

Sharan 1996 ➤
1 - Heat exchanger
❑ Seals must be bonded
free of gaps all around
❑ After removal, com‐
pletely renew coolant.
2 - Evaporator
3 - Evaporator housing
❑ With air recirculation
flap.
6 - Clip
7 - Air distribution housing
06.00 ► 153
Sharan 1996 ➤
10 Capacities
⇒ “10.1 Refrigerant R134a”, page 154
⇒ “10.2 Refrigerant oil”, page 154
⇒ “10.3 Oil distribution”, page 155
10.1 Refrigerant R134a

Air conditioner com‐ Manufacturer Capacity
pressor
SD7–V16 Sanden, to 05.00 950+50 g
Vehicles with one
evaporator
SD7–V16 Sanden, from 06.00 700 + 50 g
Vehicles with one
evaporator
SD7–V16 Sanden, to 05.00 1350+50 g
Vehicles with sec‐
ond evaporator
SD7–V16 Sanden, from 06.00 950 ± 25 grammes
Vehicles with sec‐ 18)
ond evaporator
18) For this vehicles the capacity has changed. If the information tag on the lock
carrier is still stating a capacity of 1,050 g, attach information tag - 7M3 010 639
L- over it.
10.2 Refrigerant oil

Depending on the manufacturer, different refrigerant oils are
used; part number ⇒ Electronic Parts Catalogue (ETKA) .
Refrigerant oil is very hygroscopic. Therefore refrigerant oils from
containers which have been open for a longer period of time are
unusable.
– Reseal open containers immediately to protect against ingress
of moisture.
Type Production pe‐ Capacity
riod
Sharan from 06.95 19)
135 cm3 ± 15 cm3
with one
evapora‐
tor
Sharan from 01.96 19)
135 cm3 + 20)105 cm3
with sec‐
ond
evapora‐
tor
19) This quantity of refrigerant oil is contained in a replacement compressor and
is equivalent to the capacity.
20) This quantity of refrigerant oil must be added to the refrigerant circuit if the
vehicle is equipped with two evaporator systems.
Important information:
Because refrigerant oil is very hygroscopic, opened containers
must be closed immediately after use to prevent moisture from
entering.
Because of its chemical properties, refrigerant oil must not be
disposed of together with engine or gear oil.

Sharan 1996 ➤
10.3 Oil distribution

The oil, which is located in the sump of the air conditioner com‐
pressor before the air conditioner system is switched on for the
first time, distributes itself through the refrigerant circuit as follows:
♦ Air conditioner compressor approx. 50 %
♦ Condenser approx. 10 %
♦ Suction hose approx. 10 %
♦ Evaporator approx. 20 %
♦ Receiver approx. 10 %
10. Capacities 155

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Service

Service Department. Technical Information

87 - Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5.3 Repairing Climatronic - dash panel area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

♦ Guided fault finding for vehicles 06.00 ► ⇒ Vehicle diagnostic

1.1 Connecting vehicle diagnosis, testing

1.1.1 Test prerequisites:

1. Self-diagnosis of Climatronic, vehicles: ► 05.00 1

– Open ash tray -3-.

1.1.3 Selecting operating mode

1.1.4 Selecting vehicle system

1.1.5 Selecting diagnosis function

The display fields of the functions 04 Basic setting and 08 Read

1.3 Overview - available functions

2 Rep. gr.01 - Self-diagnosis

07 - Code control unit ⇒ page 12

1.4 Read control unit version

1.5 Reading and clearing fault memory

If no faults are detected although there is a complaint about the

1. Self-diagnosis of Climatronic, vehicles: ► 05.00 3

1.6 Fault table

Display on -VAS 5051- Possible cause of fault Rectifying fault

– Check alternator ⇒ Current flow dia‐

1) One of these texts will be displayed in addition to relevant component.

Display on -VAS 5051- Possible cause of fault Rectifying fault

2) One of these texts will be displayed in addition to relevant component.

Display on -VAS 5051- Possible cause of fault Rectifying fault

4 Rep. gr.01 - Self-diagnosis

Display on -VAS 5051- Possible cause of fault Rectifying fault

3) Fault is recognized after 30 seconds at earliest.

Display on -VAS 5051- Possible cause of fault Rectifying fault

– If faults are detected in ambient temper‐

4) One of these texts will be displayed in addition to relevant component.

Display on -VAS 5051- Possible cause of fault Rectifying fault

– If faults are also detected in sunlight pen‐

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

1. Self-diagnosis of Climatronic, vehicles: ► 05.00 5

Display on -VAS 5051- Possible cause of fault Rectifying fault

5) One of these texts will be displayed in addition to relevant component.

Display on -VAS 5051- Possible cause of fault Rectifying fault

6) This fault cannot be detected if ambient temperature is below 12° C or ambient

Display on -VAS 5051- Possible cause of fault Rectifying fault

– If faults are detected in ambient temper‐

Display on -VAS 5051- Possible cause of fault Rectifying fault

6 Rep. gr.01 - Self-diagnosis

Display on -VAS 5051- Possible cause of fault Rectifying fault

7) One of these texts will be displayed in addition to relevant component.

Display on -VAS 5051- Possible cause of fault Rectifying fault

Display on -VAS 5051- Possible cause of fault Rectifying fault

9) One of these texts will be displayed in addition to relevant component.

Display on -VAS 5051- Possible cause of fault Rectifying fault

1. Self-diagnosis of Climatronic, vehicles: ► 05.00 7

Display on -VAS 5051- Possible cause of fault Rectifying fault

Display on -VAS 5051- Possible cause of fault Rectifying fault

10) Only on vehicles with 2nd evaporator

Display on -VAS 5051- Possible cause of fault Rectifying fault

Display on -VAS 5051- Possible cause of fault Rectifying fault

8 Rep. gr.01 - Self-diagnosis

Display on -VAS 5051- Possible cause of fault Rectifying fault