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 1770 or V.A.G 1771.
• ◆ Removing and installing components without item numbers

• Climatronic relay -J254-
• Heating and air conditioning fuse -S23-
• ◆ Only installed in vehicles up to 07.95

• 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
• Double vacuum unit - foot well/defrost flap
• ◆ Vacuum hose connection diagram
• ◆ Removing and installing => Fig.6
• Air intake*
• ◆ With fresh air and recirculating air flap and air flow flap

• 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 -7 -.

• Air flow flap positioning motor -V71-*
• ◆ Checking: Self diagnosis using V.A.G 1551
• ◆ Removing: first remove dash panel and complete air conditioner
• Valve block bracket
• Valve strip -N53-
• ◆ If no current is flowing in the valve strip, no vacuum is created
• ◆ Removing and installing=> Fig.5
• ◆ Vacuum hose connection diagram => Page 87-71
• 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

• Vacuum unit for fresh and recirculating air flap*
• ◆ Removing: first remove dash panel and complete air conditioner
• ◆ Vacuum hose connection diagram => Page 87-71
• Fresh air blower -V2-
• ◆ Checking: self diagnosis using V.A.G 1551
• ◆ Removing=> Page 87-19 , Fig. 3
• Central vent
• ◆ Removing => Page 80-10 , Fig.7
• Climatronic control unit -J255-
• ◆ Checking: self diagnosis using V.A.G 1551
• ◆ Removing => Fig.1

• Control and display unit -E87-
• ◆ Operation and function => Page 87-47
• ◆ Checking: self diagnosis using V.A.G 1551
• ◆ Removing => Fig.1
• Dash panel temperature sensor trim
• 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 => Fig. 3

• Air distributor
• ◆ Removing => Fig.87-13 , item 15
• Air conditioner switch-off relay -J365-
• ◆ Only on vehicles with ADY and AEK engines up to 07.95
• ◆ Behind the central console
• ◆ Control number 147
• Central vent vacuum unit
• ◆ Removing: Remove dash panel insert, rotate, pull out
• ◆ Vacuum hose connection diagram => Page 87-71

• Central flap positioning motor -V70-
• ◆ Checking: self diagnosis using V.A.G 1551
• ◆ Removing and installing => Fig.4
• 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 and footwell vent (removing footwell vent) , item 32 )

• 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.7
• Distributor and evaporator housing*
• ◆ With heat exchanger
• ◆ with evaporator
• Vacuum pipe
• ◆ Vacuum hose connection diagram => Page 87-71

→ Fig.1     Removing Climatronic control unit -J255- and control and display unit -E87-

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

Note:

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

• ‒ Release connectors and pull off.
• ‒ Press control unit clips (arrows -B-) together.
• ‒ Remove control unit.

→ Fig.2     Renewing blower control unit -J126-

• ‒ Remove shelf on passenger side
• ‒ 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 dash panel temperature sensor -G56- and temperature sensor blower -V42-

Remove through the radio aperture in the Climatronic instrument panel

• ‒ Remove radio.
• ‒ Remove temperature sender trim.
• ‒ Release temperature sensor -G56- and blower -V42- with a screwdriver (arrows) and take out through radio aperture.

→ Fig.4     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 and footwell vent.

Installing:

For correct setting of central flap markings (arrows) must be aligned.

→ Fig.5     Removing and installing valve strip -N53-

•      1 -     Valve strip
•      2 -     Vacuum hose, white
•      3 -     Vacuum hose, red
•      4 -     Vacuum hose, green
•      5 -     Vacuum hose, black
•      6 -     Vacuum hose, yellow
•      7 -     Valve block bracket
•      8 -     Connector

Removing:

• ‒ Remove shelf on passenger side
• ‒ Remove glove compartment.
• ‒ Pull off vacuum hoses and connections.
• ‒ Unscrew valve block -arrow-.

Installing:

• ‒ Use valve block 357 907 533 as replacement part.
• ‒ Connect up vacuum hose according to colour coding on connection pipes.

→ Fig.6     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 dash panel and heating and air conditioning unit

→ Fig.7     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