Volkswagen Workshop Service and Repair Manuals

Notes:

• ◆ Parts marked with * can only be serviced by specially-equipped service workshops, since refrigerant circuit must be evacuated beforehand with extraction station V.A.G 1691.
• ◆ Before performing service requiring the opening of the refrigerant circuit, the system must be converted to refrigerant R134a:

=> Workshop Manual "Air conditioning - with refrigerant R12, 1974 ▸"

• Dust and pollen filter
• ◆ Removing , item -4 -
• Plenum chamber cover
• ◆ Removing and installing => Page 80-1 , item -3 -

• Water drain valve
• ◆ Behind bulkhead insulation
• ◆ Removing and installing => Fig.2
• Heat exchanger and vacuum hose guide
• Two-way valve for fresh/recirculating air flap -N63-
• ◆ Open when electrically connected
• ◆ Vacuum hose connection diagram => Page 87-31
• Radiator fan control unit -J293-
• Strip fuse -S88-, in radiator fan control unit -J293-
• ◆ Note Part No.

• Vacuum reservoir
• ◆ Insertion depth for vacuum hose: 30 mm
• ◆ Removing and installing => Fig.5
• Vacuum hose
• ◆ Vacuum hose connection diagram => Page 87-31
• 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 AAA => Fig.3
• ◆ Removing and installing on vehicles with engine code ABF => Fig. 4

• Condenser*
• Pressure relief valve*
• ◆ Checking => Fig. 5
• Magnetic coupling -N25-*
• Ambient temperature switch -F38-
• ◆ Switches off magnetic coupling -N25- at low ambient temperature (off at 2°C, on at 7°C).
• ◆ Removing andinstalling => Fig.7

• Air conditioner pressure switch -F129-
• ◆ Checking => Fig.8
• ◆ Removing and installing:
• ‒ Tightening torque 8 Nm
• ‒ Renew O ring seal (note Part No.).
• Fluid reservoir with drier*
• Sight glass*
• Evacuating and charging valve*
• Expansion valve*
• ◆ Checking of insulation piece for expansion valve => Fig.1

→ Fig.1     Checking expansion valve insulation piece

•      1 -     Insulator
•      2 -     Expansion valve

• ◆ The insulator prevents drop in air conditioner efficiency caused by increasing temperatures in the engine compartment.

→ Fig.2     Removing and installing water drain valve

•      1 -     Water drain valve
•      2 -     Bulkhead
•      3 -     Water drain pipe, on evaporator housing
•      4 -     Mounting plate

• ◆ Install water drain valve with opening of lip seal facing downward.
• ◆ Water drain valve must not be bonded with underbody protection.

→ Fig.3     Removing and installing thermo switch for air conditioner shut-off -F163- and thermo switch for coolant fan, 3rd speed -F165- on vehicles with engine code AAA

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 -     Thermostat housing
•      3 -     O ring
•      4 -     Thermo switch -F163-/-F165-, brown
•      5 -     Temperature sender switch -G2-/-F87-, yellow
•      6 -     Coolant temperature sender -G62-, blue

→ Fig.4     Removing and installing thermo switch for air conditioner shut-off -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 -     Air conditioner cut-off thermo switch -F163-
•      5 -     Connector

→ Fig.5     Checking pressure relief valve on compressor

• ◆ Task: protects refrigerant circuit against excessive pressures
• ◆ The pressure relief valve tell-tale indicates if valve has operated. An adhesive attached plate is pushed out.
  In this case, take vehicle to specialist workshop.

→ Fig.6     Removing and installing vacuum reservoir

•      1 -     Plastic pipe
• Installation depth: 30mm
•      2 -     Rubber seal
•      3 -     Vacuum reservoir
•      4 -     Nut
•      5 -     Wheel housing liner

• ◆ Removing and installing wheel housing liner

=> General body repairs; Repair Group 66; Removing and installing wheel housing liner

→ Fig.7     Removing and installing ambient temperature switch -F38-

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

→ Fig.8     Checking air conditioner pressure switch -F129-

• ◆ Visual check: Ensure that O-ring 10.8 mm x 1.8 mm is seated in groove

Switch part between contacts -T4a/1- and -T4a/2- of connector housing switches magnetic coupling -N25- off when refrigerant circuit insufficiently filled or pressure 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)

Checking switch part:

• ‒ Briefly bridge circuit between chambers 1 and 2 with engine running. If the magnetic coupling -N25- switches on, the refrigerant system is empty. Take vehicle to specialist service workshop.

Switch part between contacts -T4a/3- and -T4a/4- of connector housing switches coolant fan -V7- to 2nd speed when refrigerant pressure rises.

• ‒ Closes above 16 bar and opens again below 12.5 bar (switching threshold)