Volkswagen Workshop Service and Repair Manuals

Notes:

• ◆ Parts marked * can only be serviced in specially equipped Service workshops, as the refrigerant must be evacuated with Service station V.A.G 1885.
• ◆ Removing and installing components without item numbers

• Central vent positioning motor -V102-
• ◆ Checking: self diagnosis using V.A.G 1551
• ◆ Removing and installing: remove central vent -4-

• Adjuster for central vent positioning motor -E160-
• ◆ Checking: self diagnosis using V.A.G 1551
• ◆ Removing and installing: remove central vent -4-
• Dash panel temperature sensor -G56- with temperature sensor fan -V42-
• ◆ Task: Temperature sensor controls temperature flap and fresh air blower in dependence on temperature
• ◆ In event of -G56- failure: continued operation assuming value of +24°C
• ◆ Checking: self diagnosis using V.A.G 1551
• ◆ Removing and installing: remove central vent -4-

• Central vent
• ◆ Central vent, central vent positioning motor -1 -, adjuster for positioning motor -2 -, dash panel temperature sensor -3 - and temperature sensor fan -3 - are a single replacement part
• ◆ Removing => Fig. 1
• Climatronic control unit -J255-
• ◆ Checking: self diagnosis using V.A.G 1551
• ◆ Removing => Fig.3
• Control and display unit -E87-
• ◆ Operation and function
• ◆ Checking: self diagnosis using V.A.G 1551
• ◆ Removing => Fig.3

• Blower control unit -J126-
• ◆ Task: precisely controls fresh air blower speed depending on voltage
• ◆ Checking: self diagnosis using V.A.G 1551
• ◆ Removing => Fig.2
• Air flow flap positioning motor -V71-*
• ◆ Checking: Self diagnosis using V.A.G 1551
• ◆ Removing: first remove dash panel and complete air conditioner
• Guide flap*

• Vacuum unit for fresh/recirculating air flap*
• ◆ Removing: first remove dash panel and complete air conditioner
• ◆ Vacuum hose connection diagram => Page 87-128
• Vacuum pipe
• ◆ Vacuum hose connection diagram => Page 87-128
• Connector retainer
• ◆ For connector -T5a-, to intake air control flap positioning motor -V71- and on vehicles up to 07.95 additionally retainer for connector -T2h- to fresh air intake duct temperature sensor -G89-
• ◆ Removing and installing => Fig.4

• Fresh air intake duct temperature sender -G89-*
• ◆ Task: temperature sensor controls temperature flap and fresh air blower depending on temperature
• ◆ In event of failure: ambient temperature sensor -G17- takes over task. If both sensors are defective, operation continues assuming value of +10°C. Air recirculation is not possible. Control and display unit -E87- reads: "--"
• ◆ Checking: self diagnosis using V.A.G 1551
• ◆ Removing: first remove air flow flap positioning motor -8 -.

• Fresh air blower -V2-
• ◆ Checking: self diagnosis using V.A.G 1551
• ◆ Removing=> Fig.6
• Evaporator temperature switch -E33-
• ◆ Only installed in vehicles up to 07.93
• ◆ Behind cover
• ◆ Insertion depth of sensor tube: 330 mm
• ◆ Task: prevents icing up
• ◆ Switching temperatures: opens at or below -20 C
• ◆ Checking: self diagnosis V.A.G 1551
• ◆ Renewing => Fig.3

• Valve strip -N53-
• ◆ If no current is flowing in the valve strip, no vacuum is created
• ◆ Removing and installing=> Fig.7
• ◆ Vacuum hose connection diagram => Page 87-128
• Central flap positioning motor -V70-
• ◆ Checking: self diagnosis using V.A.G 1551
• ◆ Removing and installing => Fig.8
• Temperature flap positioning motor -V68-
• ◆ Checking: self diagnosis using V.A.G 1551
• ◆ Checking and adjusting end position of installed positioning motor
• ◆ Removing: first remove central console

• Front vent temperature sender -G152-
• ◆ Only installed in vehicles from 08.95
• ◆ Function: Controls the air distribution defrost/footwell and the fresh air blower speed dependent upon the vent temperature.
• ◆ Emergency running in event of front vent temperature sender-G152- failure: Continued operation assuming value of +80°C
• ◆ Checking: self diagnosis using V.A.G 1551
• ◆ Removing and installing=> Fig.10
• Distributor and evaporator housing*
• ◆ With heat exchanger
• ◆ with evaporator

• Double vacuum unit - foot well/defrost flap
• ◆ Vacuum hose connection diagram => Page 87-128
• ◆ Removing and installing => Fig.9
• Relay
• ◆ Vehicles up to 07.95:
  Air conditioner system relay -J32- (control number 13 ) or Climatronic relay -J254- (control number 105)
• ◆ Vehicles from 08.95:
  Air conditioner system shut-off relay -J365- (control number 147)
• ◆ Vehicles from 08.95:
  Engine code 1Z; air conditioner magnetic clutch shut-off relay -J246- (control number 38)
• Heating and air conditioning fuse -S23-

• Climatronic control unit fuse -S101-
• Air conditioner system shut-off relay -J365-
• ◆ Only vehicles up to 07.95 and engine code ADY
• ◆ Above relay plate
• ◆ Control number 147
• Sunlight penetration photo sensor -G107-
• ◆ Tasks: controls temperature flap and fresh air blower depending on light intensity
• ◆ In event of failure: control unit -J255- assumes fixed value
• ◆ Checking: self diagnosis using V.A.G 1551
• ◆ Removing and installing: unclip from dash panel using screwdriver

→ Fig.1     Removing central vent

• ‒ Carefully lever out adjustable grilles -3- with tapered pliers
• ‒ Remove radio
• ‒ Lever out trim/seat heater switch -1- and trim -2-
  
• ‒ Remove 4 screws (arrows)
• ‒ Vento only: remove trim -4-
• ‒ Remove central vent

→ Fig.2     Renewing blower control unit -J126-

• ‒ Remove glove compartment.
• ‒ Pull off connector -2- and remove screw -3-.
• ‒ Seal area between series resistor -1- and air duct with AMV 176 000 05 before fitting.

→ Fig.3     Removing Climatronic control unit -J255- and control and display unit -E87-

• ‒ Lever out control and display unit from below with screwdriver (arrows)

Note:

Control and display unit cannot be levered out from above as this could damage the display.

• ‒ Remove ashtray
• ‒ Remove 6 screws and console with switches
• ‒ Remove control unit

→ Fig.4     Removing and installing connector retainer

•      1 -     Screw
•      2 -     Retainer
•      3 -     Connector for air flow flap -V71-
•      4 -     Connector for fresh air intake duct temperature sensor -G89- (only vehicles up to 07.95)

→ Fig.5     Replacing evaporator temperature switch -E33-

•      1 -     Temperature switch with housing
•      2 -     Rubber bush
•      3 -     Sensor pipe with insertion depth marking
•      4 -     Pan-headed capping screw
•      5 -     Connector

Note:

In cases of repair the temperature switch need not be replaced, instead bridge contacts -5-.

→ Fig.6     Removing and installing fresh air blower -V2-

• ‒ Remove passenger side shelf.
• ‒ Pull off connector -1-.
• ‒ Unscrew Qty. 5 screws -arrows- and remove fresh air blower -2- downwards.

→ Fig.7     Removing and installing valve strip -N53-

•      1 -     Valve strip
•      2 -     Connector
•      3 -     Vacuum hose, red
•      4 -     Vacuum hose, green
•      5 -     Vacuum hose, black
•      6 -     Vacuum hose, yellow

• ‒ Removing:
• ‒ Remove glove compartment
• ‒ Pull off vacuum hoses and connector
• ‒ Unscrew valve strip -arrow-
• ‒ Installing:
• ‒ Use valve strip 357 907 533 as replacement part
• ‒ Connect up vacuum hose according to colour coding on connection pipes (white connection on replacement part must be sealed with a cap).

→ Fig.8     Removing and installing central flap positioning motor -V70-

•      1 -     Central flap positioning motor
•      2 -     Intermediate gear
•      3 -     Central flap bearing

• ‒ Removing:
• ‒ First remove central console
• ‒ Installing:
• ‒ For correct setting of central flap, markings -arrows- must be aligned

→ Fig.9     Removing and installing double vacuum unit

•      1 -     Vacuum hose, green
•      2 -     Vacuum hose, yellow
•      3 -     Double vacuum unit
•      4 -     Retainer
•      5 -     Lever for footwell/defrost flap

• ‒ Removing:
• ‒ First remove central console

→ Fig.10     Removing and installing front vent temperature sender -G152-

• ‒ Remove front left footwell trim
• ‒ Pull connector -1- off front vent temperature sender -G152- -2-
• ‒ Turn front vent temperature sender -G152- -2- by 90° and remove