Volkswagen Workshop Service and Repair Manuals

Repairs to the combined air conditioner/heater system which require no special equipment -from model year 1980-

Due to the introduction of new controls for the air conditioner and a new switch for the fresh air blower, the additional current flow diagram and the vacuum hose connection layout have change. In conjunction with this, so have the fault finding instructions.

• Vacuum unit for air distribution housing
• ◆ connection layout
• ◆ checking => page 87-102

• Air conditioner controls complete
• ◆ removing and installing => Figs.1 , 4
• ◆ servicing => page 87-59
• ◆ checking => page 87-102
• ◆ connection layout => page 87-83
• Air conditioner trim
• Switch for fresh air blower, air conditioner
• Double vacuum unit
• ◆ connection layout => page 87-83
• ◆ checking => page 87-102
• Control valve cable
• ◆ adjusting =>Figs. 2 and 3
• Control valve
• Feeler pipe
• Flap box vacuum unit
• ◆ connection layout => page 87-83
• ◆ checking => page 87-102

→ Fig.1     Removing feeler pipe

• ‒ Pull the feeler pipe - 1 - out of the copper pipe - 2 - on the evaporator. Insertion depth marking - 3 -.

Note:

Do not kink the feeler pipe

→ Fig.2     Removing air conditioner controls

• ‒ Remove instrument panel insert.
• ‒ Pull off the multi-point connector, control valve cable and vacuum hoses.
• ‒ Take out controls complete with feeler pipe.

→ Fig.3     Adjusting control valve cable

• ‒ Press the control valve lever in the direction of the arrow as for as it will go.

→ Fig.4     Adjusting control valve cable

• ‒ Push the lower control lever as far as it will go in the direction of the arrow and attach cable.
• ‒ Connect vacuum hose as per connection layout => page 87-83 , and plug in multipoint plug.
• ‒ Push the feeler pipe 180 mm (up to the marking) into the evaporator copper pipe.

Note:

If the feeler pipe has become kinked, renew temperature switch.