Volkswagen Workshop Service and Repair Manuals

Note:

Parts marked with * can only be serviced in specially equipped Service workshops. The refrigerant must be evacuated with Service station V.A.G 1770 or V.A.G 1771.

• Sight glass*
• ◆ Will be discontinued
• Evacuating and charging valve*
• ◆ Low pressure side
• Evacuating and charging valve*
• ◆ High pressure side

• Air conditioner pressure switch -F129-
• ◆ Testing => Fig.2
• ◆ Removing and installing:
• ‒ Tightening torque 8 Nm
• ‒ Renew O ring seal (note Part No.).
• Ambient temperature switch -F38-
• ◆ Switches off magnetic coupling -N25- at low ambient temperature (off at -1°C, on at +7°C).
• ◆ Removing and installing => Fig.4
• Dust and pollen filter
• ◆ Removing , Fig.5
• Expansion valve*
• ◆ Opening must be sealed sufficiently to stop water ingress
• ◆ Checking insulation piece for expansion valve => Fig.6

• Plenum chamber cover
• Water drain valve
• ◆ Behind bulkhead insulation
• ◆ Removing and installing => Fig.3
• ◆ Valve lips must not be sealed with underseal
• Heat exchanger and vacuum hose guide
• Vacuum reservoir
• ◆ Insertion depth for vacuum hose: 30 mm
• ◆ Removing and installing => Fig.7
• Vacuum hose
• ◆ Vacuum hose connection diagram => Page 87-34
• Non-return valve
• Direction of suction indicated by arrow

• Two way valve for fresh and recirculating air flap -N63-
• ◆ Open when electrically connected
• ◆ Vacuum hose connection diagram => Page 87-34
• ◆ Installing => Fig.5
• Radiator fan control unit -J293-
• 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 or ABV
• ◆ 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.1

• Condenser*
• Pressure relief valve*
• ◆ Checking => Fig. 8
• Magnetic coupling -N25-*
• Fluid reservoir with drier*

→ Fig.1     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.2     Checking air conditioner pressure switch -F129-

• ◆ Visual check: Ensure that O-ring (colour: red) 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)
• ‒ 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 the coolant fan -V7- to second speed if the pressure in the refrigerant circuit increases.

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

→ Fig.3     Removing and installing water drain valve

•      1 -     Bulkhead
•      2 -     Evaporator housing
•      3 -     Valve flap, shown raised
•      4 -     Water drain valve
•      5 -     Hexagon key 14 mm

Removing:

• ‒ Turn valve 45° with hexagon key -5- and pull out.

Installing:

• ‒ When installing ensure lip lies downward.

→ Fig.4     Removing and installing ambient temperature switch -F38-

Installed in plenum chamber right

•      1 -     Connector
•      2 -     Ambient temperature switch
•      3 -     Retainer

→ Fig.5     Installing fresh air and recirculating air flap two-way valve -N63-

•      1 -     Cap
• Check air passage slot
•      2 -     Two-way valve (other designs possible)

→ Fig.6     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.7     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.8     Checking pressure relief valve on compressor

• ◆ Task: protects refrigerant circuit against over-pressure
• ◆ 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.