Volkswagen Workshop Service and Repair Manuals

Note:

Parts marked with an * can only be serviced by specially equipped service workshops, as refrigerant must be evacuated with Service station V.A.G 1885.

• Dust and pollen filter
• ◆ Removing => Page 80-1, item-4-
• Plenum chamber cover
• ◆ Removing and installing => Page 80-1, item-3-
• Water drain valve
• ◆ Behind bulkhead insulation
• ◆ Removing and installing ; Fig. 2

• Coolant temperature sender -G62-
• ◆ Only vehicles up to 07.95
• ◆ Checking: self diagnosis using V.A.G 1551
• ◆ Task: coolant temperature sender controls air distribution defrost/footwell and fresh air blower speed depending on temperature
• ◆ In event of -G62- failure : operation continues assuming a value of +125°C
• ◆ Removing and installing on vehicles with engine code ABF => Fig. 1

• Heat exchanger and vacuum hose guide
• Radiator fan control unit -J293-
• ◆ Note Part No.
• Vacuum reservoir
• ◆ Insertion depth for vacuum hose: 30 mm
• ◆ Removing and installing => Page 87-56 ; Fig.5

• Thermo switch for air conditioner cut-off -F163- and thermo switch for coolant fan, 3rd speed -F165-
• ◆ Thermo switch for air conditioner cut-off -F163- only on vehicles with engine codes AAA or ABF
• ◆ Thermo switch for coolant fan, 3rd speed -F165- only on vehicles with 3-speed fan motor
• ◆ -F165- switch coolant fan: into 3rd speed as temperature increases (on at 112°C, off at 108°C).
• ◆ -F163- switches off magnetic coupling -N25- at excessively high coolant temperature (off at 119°C, on at 112°C).
• ◆ Removing and installing on vehicles with engine code ABF => Fig. 1
• ◆ Removing and installing on vehicles with engine code AAA => Page 87-56 ; Fig.3

• Vacuum hose
• ◆ Vacuum hose connection diagram => Page 87-128
• Condenser*
• Pressure relief valve*
• ◆ Checking => Page 87-144 , Fig.3
• Magnetic coupling -N25-*
• ◆ Checking: self diagnosis using V.A.G 1551 (current path to magnetic coupling checked)
• Air conditioner pressure switch -F129-
• ◆ Checking: self diagnosis using V.A.G 1551
• ◆ Removing and installing:
• ‒ Tightening torque 8 Nm
• ‒ Renew O ring seal (note Part No.).

• Ambient temperature sensor -G17-
• ◆ Function: temperature sensor controls temperature flap and fresh air blower, depending on temperature
• ◆ In event of failure: fresh air intake duct temperature sensor -G89- takes over task. If both sensors are defective, operation continues assuming a value of +10°C. Air recirculation not possible. Control and display unit -E87- indicates: "--"
• ◆ Vehicles up to 07.95:
  Removing and installing => Fig. 2
• ◆ Vehicles from 08.95:
  Removing and installing => Fig. 3
• ◆ Checking: self diagnosis using V.A.G 1551

• Fluid reservoir with drier*
• Sight glass*
• Evacuating and charging valve*
• Expansion valve*
• ◆ Checking insulation piece for expansion valve => Page 87-56 ; Fig.1

→ Fig.1     Removing and installing coolant temperature sender -G62- and air conditioner cut-off thermo switch -F163- on vehicles with engine code ABF

Notes:

• ◆ Cooling system is pressurized when engine is warm. If necessary, release pressure before carrying out repairs.
• ◆ Refill with coolant after installing thermo-switch.

•      1 -     Clip
•      2 -     Connection
•      3 -     O ring
•      4 -     Coolant temperature sender -G62-/air conditioner cut-off thermo switch -F163-

→ Fig.2     Removing and installing ambient temperature switch -G17-

(Vehicles up to 07.95)

•      1 -     Hexagon bolt, M8
• Torque setting 15 Nm
•      2 -     Temperature sensor retainer
•      3 -     Horn bracket
•      4 -     Plastic clip
•      5 -     Ambient temperature sensor
•      6 -     Horn

→ Fig.3     Removing and installing ambient temperature switch -G17-

(Vehicles from 08.95)

•      1 -     Horn
•      2 -     Ambient temperature sensor
•      3 -     Cover