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 , 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 87-70
• 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 87-70

• Thermo switch for air conditioner cut-off -F163- and thermo switch for coolant fan, 3rd speed -F165-
• ◆ Thermo switch for air conditioner shut-off -F163- only on vehicles with engine codes AAA, AAZ, ABF and ADZ
• ◆ 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 => Page 87-144 , Fig.3
• Magnetic coupling -N25-*
• Ambient temperature switch -F38-
• ◆ Switches off magnetic coupling -N25- at low ambient temperature (off at 2°C, on at 7°C).
• ◆ Vehicles up to 07.95:
  Removing and installing => Fig.6
• ◆ Vehicles from 08.95:
  Located in plenum chamber, right; Removing and installing => Fig. 7
• Air conditioner pressure switch -F129-
• ◆ Checking air conditioner pressure switch -F129- => Page 87-145
• ◆ 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 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 downwards.
• ◆ Water drain valve must not be clogged with underbody sealant.

→ 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     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.6     Removing and installing ambient temperature switch -F38-

(Vehicles up to 07.95)

•      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.7     Removing and installing ambient temperature switch -F38-

(Vehicles from 08.95)

Note:

Removing and installing right-hand plenum chamber cover => Page 80-1 , item -3 -.

•      1 -     Ambient temperature switch
•      2 -     Plastic clip