Volkswagen > Golf, Jetta, GTI, Cabrio > Heating Air Conditioning 87 - A/C controls and mechanical components, servicing

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1 x-ebahn:///c:/program%20files/ebahn/data/vw-a-a3-h28ebn/vw/a/a3/repair%20ma Page 1 of 13 Volkswagen > Golf, Jetta, GTI, Cabrio > Heating Air Conditioning 87 - A/C controls and mechanical components, servicing A/C and heating system components, engine compartment CAUTION! Parts marked with an asterisk (*) can be serviced only after the A/C refrigerant system has been discharged by a certified technician using EPA-approved refrigerant recovery and recycling equipment safety measures, A/C refrigerant system (R-134a), safety measures

2 x-ebahn:///c:/program%20files/ebahn/data/vw-a-a3-h28ebn/vw/a/a3/repair%20ma Page 2 of Dust and pollen filter Where applicable 2 - Plenum cover Removing/installing - -"> 3 -

3 x-ebahn:///c:/program%20files/ebahn/data/vw-a-a3-h28ebn/vw/a/a3/repair%20ma Page 3 of 13 Evaporator water drain valve Located behind bulkhead insulation Removing/installing Fig 2 Removing and installing evaporator water drain valve 4 - Heater core connections and vacuum hose guide 5 - Fresh Air/Recirculating Flap Two-Way Valve N63 Valve open when voltage applied Vacuum hose layout Vacuum hose layout 6 - Coolant Fan Control (FC) Control Module J293 With fuse Fuse Strip S88 (1993 my) With fuses Coolant Fan Second and Third Speed Fuse S107 and Coolant Fan First Speed and A/C Clutch Fuse S108 (1994 my micro ) Connector terminal identification: micro 0993 Fig 5 Connector terminal identification of Coolant Fan Control (FC) Control Module J293 ( 0993) 1093 micro Fig 6 Connector terminal identification of Coolant Fan Control (FC) Control Module J293 (1093 ) 7 - Vacuum reservoir Insert vacuum hose 30 mm (12 in) into reservoir Removing/installing Fig 7 Removing and installing vacuum reservoir

4 x-ebahn:///c:/program%20files/ebahn/data/vw-a-a3-h28ebn/vw/a/a3/repair%20ma Page 4 of Vacuum hose Vacuum hose layout Vacuum hose layout 9 - A/C Cut-Out Thermal Switch F163 and Third Speed Coolant Fan Control (FC) Thermal Switch F165 A/C Cut-Out Thermal Switch F163 only on vehicles with engine codes AAA, AAZ, ABA, ACC A/C Cut-Out Thermal Switch F163 switches A/C Clutch N25 off at high engine coolant temperature; OFF (switch open) above 119 degree C (246 degree F); ON (switch closed) below 112 degree C (234 degree F) Third Speed Coolant Fan Control (FC) Thermal Switch F165 only on vehicles with 3- speed coolant fan motor Third Speed Coolant Fan Control (FC) Thermal Switch F165 switches radiator coolant fan to 3rd speed as engine coolant temperature increases; 3rd speed ON (switch closed) above 112 degree C (234 degree F); OFF (switch open) below 108 degree C (226 degree F) Removing and installing (engine code AAA) Fig 3 Removing and installing A/C Cut- Out Thermal Switch F163 and Third Speed Coolant Fan Control (FC) Thermal Switch F165 (28 liter VR6 engine code AAA) Removing and installing (engine code ABA) Fig 4 Removing and installing A/C Cut- Out Thermal Switch F163 (20 liter engine code ABA) 10 - Condenser* 11 - Pressure relief valve* Checking Fig 11 Checking pressure relief valve on compressor

5 x-ebahn:///c:/program%20files/ebahn/data/vw-a-a3-h28ebn/vw/a/a3/repair%20ma Page 5 of A/C Clutch N25 * 13 - Ambient Temperature Switch F38 Switches A/C Clutch N25 OFF when outside temperature is too low Switch opens (compressor OFF): below 2 degree C (36 degree F) Switch closes (compressor ON): above 7 degree C (45 degree F) Installation location ( micro 0795) Switch F38 ( 0795) Installation location (0895 micro ) Switch F38 (0895 ) Fig 8 Installation location of Ambient Temperature Fig 9 Installation location of Ambient Temperature 14 - A/C Pressure Switch F129 Checking Fig 10 Checking A/C Pressure Switch F129 8 Nm (71 in lb) Always replace O-ring seal (note Part No) 15 - Receiver dryer* 16 - Sight glass* Not applicable to all vehicles 17 -

6 x-ebahn:///c:/program%20files/ebahn/data/vw-a-a3-h28ebn/vw/a/a3/repair%20ma Page 6 of 13 High and low-pressure service valves* 18 - Expansion valve* Insulator, installing and checking insulator Fig 1 Installing and checking expansion valve Fig 1 Installing and checking expansion valve insulator 1 Insulator 2 Expansion valve Insulation is used around expansion valve to prevent moisture (condensation) build-up and to protect expansion valve from high engine compartment temperatures and the resulting decrease in A/C system cooling performance Install insulator over expansion valve (arrow) Check insulator for damage and proper fit, and replace if necessary

7 x-ebahn:///c:/program%20files/ebahn/data/vw-a-a3-h28ebn/vw/a/a3/repair%20ma Page 7 of 13 Fig 2 Removing and installing evaporator water drain valve 1 Water drain valve 2 Bulkhead 3 Water drain tube (on evaporator housing) 4 Mounting recess To remove, carefully pull water drain valve from drain tube Install water drain valve so that valve flap opens from bottom Make sure valve flap is free of dirt, wax or undercoating; clean if necessary Fig 3 Removing and installing A/C Cut-Out Thermal Switch F163 and Third Speed Coolant Fan Control (FC) Thermal Switch F165 (28 liter VR6 engine code AAA) CAUTION! Cooling system may be under pressure Relieve system pressure before removing any engine coolant temperature sensors or

8 x-ebahn:///c:/program%20files/ebahn/data/vw-a-a3-h28ebn/vw/a/a3/repair%20ma Page 8 of 13 switches 1 Clip 2 Engine coolant thermostat housing 3 O-ring 4 A/C Cut-Out Thermal Switch F163 and Third Speed Coolant Fan Control (FC) Thermal Switch F165, brown 5 Engine Coolant Temperature (ECT) Gauge Sensor G2 and After-Run Coolant Fan Control (FC) Thermal Switch F87, yellow 6 Engine Coolant Temperature (ECT) Sensor G62, blue Carefully relieve cooling system pressure Disconnect harness connector from thermal switch Remove clip and pull thermal switch from housing Install in reverse order of removal Note: Refill coolant to proper level after removing and installing A/C switches or sensors Fig 4 Removing and installing A/C Cut-Out Thermal Switch F163 (20 liter engine code ABA)

9 x-ebahn:///c:/program%20files/ebahn/data/vw-a-a3-h28ebn/vw/a/a3/repair%20ma Page 9 of 13 CAUTION! Cooling system may be under pressure Relieve system pressure before removing any engine coolant temperature sensors or switches 1 Clip 2 Connection 3 O-ring 4 A/C Cut-Out Thermal Switch F163 5 Harness connector Note: Refill coolant to proper level after removing and installing A/C switches or sensors Fig 5 Connector terminal identification of Coolant Fan Control (FC) Control Module J293 ( micro 0993)

10 x-ebahn:///c:/program%20files/ebahn/data/vw-a-a3-h28ebn/vw/a/a3/repair%20ma Page 10 of 13 Fig 6 Connector terminal identification of Coolant Fan Control (FC) Control Module J293 (1093 micro ) Fig 7 Removing and installing vacuum reservoir 1 Vacuum hose Insert into reservoir 30 mm (12 in) 2 - Rubber grommet 3 - Vacuum reservoir 4 - Nut 5 - Wheel housing liner Remove wheel housing liner 66 Body Exterior, Interior Golf, GTI, Jetta - Repair Group Remove vacuum hose and nut from reservoir Remove reservoir

11 x-ebahn:///c:/program%20files/ebahn/data/vw-a-a3-h28ebn/vw/a/a3/repair%20ma Page 11 of 13 Install in reverse order of removal Fig 8 Installation location of Ambient Temperature Switch F38 ( micro 0795) 1 Bolt, M8 Tightening torque: 15Nm (11 ft lb) 2 - Mounting bracket 3 - Horn bracket 4 - Plastic clip 5 - Ambient Temperature Switch F Horn Fig 9 Installation location of Ambient Temperature Switch F38 (0895 micro ) 1 Ambient temperature switch 2 Plastic clip

12 x-ebahn:///c:/program%20files/ebahn/data/vw-a-a3-h28ebn/vw/a/a3/repair%20ma Page 12 of 13 Note: Removing and installing right-hand plenum cover Right plenum cover Fig 10 Checking A/C Pressure Switch F129 Red O-ring (108 mm x 18 mm) must fit properly in groove Functions Switches A/C Clutch N25 OFF if system pressure is too low (low refrigerant charge) Switching occurs between terminals 1 (T4a/1) and 2 (T4a/2) Switch opens (compressor OFF): below 12 bar (174 psi) Switch closes (compressor ON): above 24 bar (348 psi) Switches A/C Clutch N25 OFF if system pressure is too high Switching occurs between terminals 1 (T4a/1) and 2 (T4a/2) Switch opens (compressor OFF): above 320 bar (464 psi) Switch closes (compressor ON): below 240 bar (348 psi) Switches Coolant Fan V7 to second speed when A/C system pressure increases Switching occurs between terminals 3 (T4a/3) and 4 (T4a/4) Switch closes (2nd speed ON): above 160 bar (232 psi) Switch opens (2nd speed OFF): below 125 bar (1813 psi) Switch identified with a green label or marked "R-134a"

13 x-ebahn:///c:/program%20files/ebahn/data/vw-a-a3-h28ebn/vw/a/a3/repair%20ma Page 13 of 13 To remove, unscrew switch from Schrader valve Tightening torque: 8 Nm (71 in lb) Checking: If A/C Clutch N25 does not engage with A/C ON: Start engine Using a jumper wire, briefly bridge terminal 1 (T4a/1) and terminal 2 (T4a/2) of A/C pressure switch connector If A/C Clutch N25 now engages, refrigerant system is discharged (empty) Check A/C system for leaks, repair as necessary Note: With A/C Pressure Switch F129 removed and connector attached, A/C Clutch N25 should not engage and A/C should not cool Fig 11 Checking pressure relief valve on compressor Protects refrigerant circuit from excessive pressure Pressure relief valve tell-tale indicates when valve has been actuated by excessive pressure (adhesive-attached plate (arrow) is pushed out) If so, repairs must be carried out by an A/C specialist Copyright 2008 Volkswagen of America, Inc and Bentley Publishers All rights reserved Last processed: