Volkswagen Golf 5 2004-> VW Rabbit GTI 2006-> (A5) A/C Refrigerant System General information Note: General A/C refrigerant system servicing procedures (e.g., component/system descriptions, extracting refrigerant, recharging, leak detection, troubleshooting etc.), repair and special tool information Repair Manual, Refrigerant R134a - Servicing, Repair Group 00, Specific A/C refrigerant system servicing procedures (e.g., component removal, installation and capacities) 87-5, A/C Refrigerant System, servicing. Additional information: Electrical Wiring Diagrams, Troubleshooting and Component Locations binder
Semi-automatic A/C System - Climatic Page 1 / 28 87-2 Semi-automatic A/C System - Climatic General information Before troubleshooting or servicing, technicians must be familiar with the functions and operation specifics of the standard or optional A/C system. Always read the owners manual and review applicable system functions. Note: Additional information: Owners Manual Self Study Program - Course Number 892503 "VW 2006 GTI Introduction" Wiring Diagrams and Component Locations On Board Diagnostic (OBD), functions Climatic system functions are controlled by the A/C Control Module J301 which has On Board Diagnostic (OBD) capability. If malfunctions occur in monitored components, Diagnostic Trouble Codes (DTC) will be stored in memory. Troubleshoot Climatic system malfunctions by performing OBD program using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding". Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052 - Connect VAS 5051/5052 to vehicle Data Link Connector (DLC) - Select operating mode "Guided Fault Finding" - Enter appropriate model, equipment and model year information and press ">" After all control modules have been registered and DTC memories checked, - Press "Go to" - Select "Function/Component Selection"
Semi-automatic A/C System - Climatic Page 2 / 28 - Select "Body, (Repair Gr. 01, 27, 50 to 97)" - Select "Heating, ventilation, air conditioning system (RG 01; 80-87" - Select "Self-diagnosis" - Select "08-Climatic" - Select "Functions" - Select "On Board Diagnostic (OBD) Functions" Review listed selections and choose as specified or desired. - Follow testers prompts. Heating and A/C system components in passenger compartment, servicing Note: Disconnect battery before removing components marked with ** Repair Manual, Electrical Equipment, Repair Group 27, A data plate indicates the refrigerant used and capacity.
Semi-automatic A/C System - Climatic Page 3 / 28 Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi Instrument panel ** Center air vents 80-1, Center air vents, removing and installing Right side window defroster air duct In right A-pillar Right air vent 80-1, Right / left air vent, removing and installing Heating and A/C controls -
Semi-automatic A/C System - Climatic Page 4 / 28 Climatic With Fresh Air/Recirculating Flap Switch E159 With Rear Window Defogger Switch E230 with Fresh Air Blower Switch E9 With A/C Control Module J301 With Immediate Heating Button E537 where applicable 87-2, Heating and A/C controls, removing and installing Recirculation Flap Motor V113 Checking: Use Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-2, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052 87-2, Recirculation Flap Motor V113, removing and installing Replacing: Initiate Basic Setting using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-2, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052. Right footwell air vent
Semi-automatic A/C System - Climatic Page 5 / 28 80-1, Right footwell air vent, removing and installing Fresh Air Blower V2 Depending on unit configuration, blower on vehicle may not be exactly as shown here 80-1, Fresh Air Blower V2, removing and installing Fresh Air Blower Series Resistor With Fuse N24 Depending on unit configuration, resistor with fuse may not be exactly as shown here 80-1, Fresh Air Blower Series Resistor With Fuse N24, removing and installing Heating and ventilation unit partition Removing 80-1, Heating and ventilation unit partition, removing Evaporator Vent Temperature Sensor G263 87-3, Evaporator Temperature Sensor G308, removing and installing Sealing caps Only in vehicles without air guide to vent installed in center console at rear
Semi-automatic A/C System - Climatic Page 6 / 28 Dust and pollen filter With activated charcoal filter 80-1, Dust and pollen filter, removing and installing Center console air duct Connection to center console air guide To remove, center console must be removed Repair Manual, Body Interior, Repair Group 68, Right rear footwell air duct 80-1, Rear footwell air ducts, removing and installing Left rear footwell air duct 80-1, Rear footwell air ducts, removing and installing Screws Qty. 8 Observe varying lengths Heating and A/C control adapter Auxiliary Heater Heating Element Z35 Only on models with Diesel engine 80-1, Auxiliary Heater Heating Element Z35,
Semi-automatic A/C System - Climatic Page 7 / 28 removing and installing Heater core 80-1, Heater core, removing and installing Left footwell air vent 80-1, Left footwell air vent, removing and installing Temperature Regulator Flap Motor V68 Checking: Use Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-2, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052 87-2, Temperature Regulator Flap Motor V68, removing and installing Replacing: Initiate Basic Setting using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-2, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052. Air distribution control - flexible cable 87-2, Air distribution control - flexible cable, removing and installing
Semi-automatic A/C System - Climatic Page 8 / 28 Footwell Outlet Temperature Sensor G192 87-2, Footwell Outlet Temperature Sensor G192, removing and installing Heating and A/C unit 87-2, Heating and A/C unit, removing and installing Disassembling and assembling 87-2, Heating and A/C unit, disassembly and assembly Left side window defroster air duct In left A-pillar Center Outlet Temperature Sensor G191 87-2, Center Outlet Temperature Sensor G191, removing and installing Heating and A/C unit, removing and installing Preparation: Special tools, testers and auxiliary items required
Semi-automatic A/C System - Climatic Page 9 / 28 Drip tray for VAS6100 VAS 6208 Hose clamps, up to 40 mm. 3093 Compressed air gun, commercially available Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. Note: To improve accessibility, additional components e.g., engine cover must be removed (depending on engine version). - Evacuate refrigerant circuit using refrigerant recycling/recovery unit Kent-Moore ACR4 (or UL approved equivalent)
Semi-automatic A/C System - Climatic Page 10 / 28 Repair Manual, Refrigerant R134a - Servicing, Repair Group 00,. Observe notes 87-5, General information. - Remove instrument panel Repair Manual, Body Interior, Repair Group 70, - Remove facing wall in plenum chamber. Repair Manual, Body Exterior, Repair Group 50, - Remove rear footwell air ducts 80-1, Rear footwell air ducts, removing and installing - Place Drip tray for VAS6100 VAS 6208 under engine. - Mark coolant hoses - 1 - Warning! Scalding danger! The cooling system is pressurized when the engine is warm. Wear gloves and other protection and carefully release system pressure if necessary before performing repairs. - Clamp off coolant hoses - 1 - using Hose clamps, up to 40 mm. 3093 and disconnect coolant hoses to heater core.
Semi-automatic A/C System - Climatic Page 11 / 28 - Connect a section of hose - A - onto upper connection. - Hold suitable container - B - under lower connection - C -. - Using a compressed air gun, carefully blow residual coolant from heater core at heater core connection. Warning! Frostbite danger! High pressure refrigerant may leak out if refrigerant circuit is not discharged. Always evacuate refrigerant prior to opening refrigerant circuit. - From engine compartment, remove bolts (12 Nm) - 1 - for refrigerant lines - 2 -. - Disconnect refrigerant lines from expansion valve - 3-. Caution! Always plug open refrigerant line connections to prevent dirt and moisture contamination.
Semi-automatic A/C System - Climatic Page 12 / 28 Where applicable, use sealing caps from replacement expansion valve. - Cover floor carpet in vehicle interior with leak-proof foil and absorbent paper. Note : Observe screw position, length and orientation during removal. Screw 4 Nm Screw
Semi-automatic A/C System - Climatic Page 13 / 28 Qty. 2 4 Nm Cable bracket Heating and A/C unit Removing: - Disconnect condensation water drain hose from heating and A/C unit 87-3, Heating and A/C unit condensation water drain hose, checking. - Disconnect electrical connections from heating and A/C unit. Note : All cable ties opened or cut during air conditioner removal must be reinstalled at the same locations during installation. The wiring harness air conditioner" is removed together with the air conditioner unit. - Remove screws Item - 6 - from bracket Item - 5 -. - Remove supports Item - 8 - and Item - 9 -. - Remove screws Item - 10 - and Item - 12 - and remove bracket Item - 11 -. - Remove screws Item - 2 - and Item - 1 - from cable bracket Item - 3 -. Note : To be able to reach bolt Item - 1 -, heating and A/C unit on driver side must be pulled out slightly from facing wall.
Semi-automatic A/C System - Climatic Page 14 / 28 When removing heat unit, ensure the two coolant pipes of the heater core do not get caught and bent or damaged on plenum chamber or sound insulation pan. Also pay attention to wiring harness, individual wiring connections may get damaged when pulling too forcefully on wiring harness. - Remove heating and A/C unit. Installing: Install in reverse order of removal, noting the following: Note : The assistance of a second mechanic is necessary to install the heating and ventilation unit. - When inserting heating and ventilation unit, have the second mechanic guide both coolant pipes to heater core through the seal (from engine compartment) 87-2, Heating and A/C unit seal at bulkhead, installation position. - When installing, ensure condensation water drain hose is seated correctly 87-3, Heating and A/C unit condensation water drain hose, checking - After installing heater core, replace engine coolant completely (refer to applicable Engine repair manual, Rep. Gr. 19.
Semi-automatic A/C System - Climatic Page 15 / 28 Bracket Screws 8 Nm Assembly carrier Right support Left support Screws Qty. 2 8 Nm Bracket Screws Qty. 2 8 Nm Heating and A/C unit seal at bulkhead, installation position Note: Note installation position of seal - A - during assembly. Heating and A/C unit, disassembly and assembly
Semi-automatic A/C System - Climatic Page 16 / 28 Temperature Regulator Flap Motor V68 Checking: Use Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-2, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052 87-2, Temperature Regulator Flap Motor V68, removing and installing Replacing: Initiate Basic Setting using Vehicle Diagnostic, Testing and
Semi-automatic A/C System - Climatic Page 17 / 28 Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-2, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052. Bracket Screws screws must be removed to separate air distribution and evaporator housings. Cover Recirculation Flap Motor V113 Checking: Use Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-2, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052 87-2, Recirculation Flap Motor V113, removing and installing Replacing: Initiate Basic Setting using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-2, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052. Air intake housing With recirculating air flap
Semi-automatic A/C System - Climatic Page 18 / 28 Evaporator housing - upper part Disassembly and assembly 87-3, Evaporator housing, disassembly and assembly Evaporator housing - lower part Disassembly and assembly 87-3, Evaporator housing, disassembly and assembly Evaporator 87-5, Evaporator, removing and installing Evaporator Vent Temperature Sensor G263 87-3, Evaporator Temperature Sensor G308, removing and installing Glove compartment cooling vent Glove compartment cooling hose Fresh Air Blower Series Resistor With Fuse N24 80-1, Fresh Air Blower Series Resistor With Fuse N24, removing and installing Fresh Air Blower V2 80-1, Fresh Air Blower V2, removing and installing Dust and pollen filter
Semi-automatic A/C System - Climatic Page 19 / 28 With activated charcoal filter 80-1, Dust and pollen filter, removing and installing Cover For dust and pollen filter Heater core 80-1, Heater core, removing and installing Heater core trim Auxiliary Heater Heating Element Z35 Only models with Diesel engine 80-1, Auxiliary Heater Heating Element Z35, removing and installing Air distribution housing Heating and A/C controls, removing and installing Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. Note: Heating and A/C controls consist of two separable housings. Before removing controls, set rotary control knobs to the following positions: Heater control to "cold"
Semi-automatic A/C System - Climatic Page 20 / 28 Blower control to "0" Air flow control to "footwell" - Remove radio. Repair Manual, Communication, Repair Group 91, - Remove long screws - 2 - and short screws - 3 - and remove controls - 1 - from center console. - Disengage electrical connection retainer - A - by pulling in direction of - arrow 1 -. - Disengage electrical connection retainer - B - to connector - arrow 2 - and disconnect electrical connection - C -. - Disengage electrical connection retainer - D - and disconnect electrical connection - D -.
Semi-automatic A/C System - Climatic Page 21 / 28 Installing: Install in reverse order of removal, ensuring rotary control knobs have not been moved from the positions as specified for removal. Heating and A/C controls, multi-pin connector assignments Special tools, testers and auxiliary items required adapter cable VAG 1598/47 20-pin electrical connection, T20c 3 - Center Outlet Temperature Sensor G191 5 - High Pressure Sensor G65 7 - CAN Bus - Low 8 - CAN Bus - High 12 - Right seat heater (optional - where applicable) 13 - Left seat heater (optional - where applicable) 15 - Terminal 75 seat heater (optional) 16 - A/C Compressor Regulator Valve N280 19 - Positive - B+ (Terminal 30A) 20 - Ground (GND) - Terminal 31
Semi-automatic A/C System - Climatic Page 22 / 28 Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi 16-pin electrical connection, in wiring diagram T16e 1 - Temperature Regulator Flap Motor V68, warm 2 - Evaporator Vent Temperature Sensor G263 4 - Footwell Outlet Temperature Sensor G192 5 - Temperature Regulator Flap Motor Position Sensor G92 7 - + 5 V for Temperature Regulator Flap Motor Position Sensor G92 8 - Ground (GND) for Temperature Regulator Flap Motor Position Sensor G92, Center Outlet Temperature Sensor G191, Footwell Outlet Temperature Sensor G192 and Evaporator Vent Temperature Sensor G263 9 - Recirculation Flap Motor V113, open 10 - Recirculation Flap Motor V113, close 11 - Temperature Regulator Flap Motor V68, cold 5-pin electrical connection, T5 1-3rd blower speed 2-2nd blower speed 3-1st blower speed
Semi-automatic A/C System - Climatic Page 23 / 28 4-4th blower speed 5 - Terminal X Air distribution control - flexible cable, removing and installing Removing Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove heating and A/C controls 87-2, Heating and A/C controls, removing and installing - Carefully pull out adapter. - Press in retaining tab - arrow - and remove flexible cable. Installing: Install in reverse order of removal, ensuring air distribution rotary control knob has not been moved from the positions as specified for removal. Note: When installing flexible cable, adapter and rotary switches on heating and ventilation controls must be oriented in a specific manner. Checking 87-2, Air distribution control - flexible cable operation, checking Air distribution control - flexible cable operation, checking
Semi-automatic A/C System - Climatic Page 24 / 28 Check function of air distribution control flexible cable as follows: - Set fresh air blower to maximum speed. If air flow flows from defroster air vents in the "Defrost" position and no air flows from footwell air vents, installation of flexible cable is correct. If this is not the case, remove flexible cable from adapter. Place Heating and ventilation controls onto adapter and rotate rotary knob for air distribution 1 2 rotation (180 ). Then reconnect flexible cable. Repeat test. Heating and A/C unit condensation water drain hose, checking - Remove front passengers side footwell cover. Note: The condensation water drain hose - 1 - must be able to be connected to connection of heating and A/C unit without pre-tension. Condensation water drain hose must sit securely on heating and A/C unit. Recirculation Flap Motor V113, removing and installing Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove glove compartment
Semi-automatic A/C System - Climatic Page 25 / 28 Repair Manual, Body Interior, Repair Group 68, - Remove cover for flap motors. - Disconnect electrical connection from motor -1-. - Remove motor - 1 - Installing: Install in reverse order of removal, noting the following: Note: After installing, check recirculation flap function. Initiate "Basic Setting" function using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding". Temperature Regulator Flap Motor V68, removing and installing Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove left footwell air vent 80-1, Left footwell air vent, removing and installing - Unclip Data Bus On Board Diagnostic Interface J533 from bracket.
Semi-automatic A/C System - Climatic Page 26 / 28 - Remove screws Item - 10 -, Item - 12 - and remove bracket Item - 11 -. - Remove cover for heater core. - Unhook brace from actuator lever - 1-. - Remove screws - 2 - and remove motor - 3-. Installing: Install in reverse order of removal, noting the following. Note: After installing Temperature Regulator Flap Motor V68, check temperature flap function. - Checking: Use Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding". - Replacing: Initiate Basic Setting using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding". Footwell Outlet Temperature Sensor G192, removing and installing Removing: - Remove instrument panel Repair Manual, Body Interior, Repair Group 70, - Remove screws Item - 12 - from bracket Item - 11 -.
Semi-automatic A/C System - Climatic Page 27 / 28 - Disconnect electrical connection at sensor - 1-. - Press bracket Item - 11 - lightly toward left, rotate sensor - 1-90 and remove from housing. Installing: Install in reverse order of removal. Center Outlet Temperature Sensor G191, removing and installing Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove left instrument panel cover. Repair Manual, Body Interior, Repair Group 70,
Semi-automatic A/C System - Climatic Page 28 / 28 - Disconnect electrical connection at sensor - 1-. - Rotate sensor - 2 -, rotate 90 in direction of - arrow - and remove from instrument panel. Installing: Install in reverse order of removal. Outside Air Temperature Sensor G17, removing and installing Removing: - Remove center air vent from front bumper cover catches. Repair Manual, Body Exterior, Repair Group 63, - Unclip Outside Air Temperature Sensor G17-1 - from bracket and disconnect electrical connection. Installing: Install in reverse order of removal, noting the following: Note: Ensure electrical connector is seated correctly to prevent water entry.
Automatic A/C system - Climatronic Page 1 / 46 87-3 Automatic A/C system - Climatronic General information GTI from model year 2006 may be equipped with a dualzone (right / left - front) Climatronic system. Climatronic is a fully automatic, digital-electronic climate control system. The temperature of the interior air supply, fresh air blower speeds and passenger compartment air distribution are regulated automatically. The system features fully digital electronic circuitry and On Board Diagnostic (OBD) capability. In addition to fully automatic function, air distribution settings and fresh air blower speeds can be selected manually to suit individual needs. The Climatronic Control Module J255 is the heart of the system. It receives input information from the integrated A/C control head and various electronic components (sensors and switches). This information is processed by the control module in accordance with specified values and provides corresponding output signals that control electrical components (actuators). The system controls interior air temperature and distribution for the driver and front passenger. The system continually samples and compares the selected interior air temperature with the actual air temperature measured by the system. Blower speeds, air temperature and distribution are then adjusted and regulated accordingly. The A/C control head integrated with -J255- contains all controls and relevant displays needed to operate the Climatronic system. The systems input temperatures are displayed in LCD displays. All automatic or manual function selections are input into the A/C control head via buttons located between and below the LCD displays. When "AUTO" mode is selected, fresh air blower speed and air distribution signals are automatically monitored and adjusted. The fresh air blower speed is high when there is a large difference between the selected temperature and the actual interior temperature, and low when the difference is small or the same. The interior temperature settings speed are indicated on the A/C control head display at all times. The system can be switched on and off by pressing the "OFF" button.
Automatic A/C system - Climatronic Page 2 / 46 Manually selected settings remain stored in memory after switching the ignition off and will be recalled on subsequent re-start. Only the function "Air recirculation" is erased after 20 minutes. Note: Pressing AUTO button overrides all manual settings. Climatronic, manual operation Owners Manual In "ECON" operation, A/C compressor output is regulated to almost zero delivery. Heating and A/C operation continues to be controlled electronically. Before troubleshooting or servicing, technicians must be familiar with the functions and operation specifics of the standard or optional A/C system. Always read the owners manual and review applicable system functions. Note: Additional information: Owners Manual Self Study Program - Course Number 892503 "VW 2006 GTI Introduction" Wiring Diagrams and Component Locations Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052 - Connect VAS 5051/5052 to vehicle Data Link Connector (DLC) - Select operating mode "Guided Fault Finding" - Enter appropriate model, equipment and model year information and press ">" After all control modules have been registered and DTC memories checked, - Press "Go to" - Select "Function/Component Selection" - Select "Body, (Repair Gr. 01, 27, 50 to 97)"
Automatic A/C system - Climatronic Page 3 / 46 - Select "Heating, ventilation, air conditioning system (RG 01; 80-87" - Select "Self-diagnosis" - Select "08-Climatronic" - Select "Functions" - Select "On Board Diagnostic (OBD) Functions" Review listed selections and choose as specified or desired. - Follow testers prompts. A/C Control Head E87, display and functions Left selected temperature display Displays selected temperature.
Automatic A/C system - Climatronic Page 4 / 46 Changing display value: With Climatronic on, simultaneously press and hold AUTO and ECON buttons to toggle between Fahrenheit to Celsius. Air recirculation button Press to recirculate interior air when outside air quality is poor. Central air distribution button Footwell air distribution button Upper air distribution button Right selected temperature display Displays selected temperature. Changing display value: With Climatronic on, simultaneously press and hold AUTO and ECON buttons to toggle between Fahrenheit to Celsius. Windshield defrost button Rear window defroster button Left temperature regulator Rotate to increase or decrease left front passenger compartment temperature setting. Blower speed regulator Interior temperature sensor Push button OFF Pressing OFF button to switch Climatronic system on or off.
Automatic A/C system - Climatronic Page 5 / 46 Push button AUTO Press AUTO button to automatically maintain the selected vehicle interior temperature. The blower speed and the air distribution are controlled automatically. Push button ECON Press ECON button to cause almost zero A/C compressor output. Heating and A/C operation continues to be controlled electronically. Right temperature regulator Rotate to increase or decrease right front passenger compartment temperature setting. Climatronic Control Module J255 with A/C Control Head E87, removing and installing Note: The Climatronic Control Module J255 and A/C Control Head E87 are integrated and cannot be serviced or repaired separately. Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove center instrument panel trim. Repair Manual, Body Interior, Repair Group 68,
Automatic A/C system - Climatronic Page 6 / 46 - Remove screws - 2 - and remove A/C Control Head E87-1 - from instrument panel. - Disconnect electrical connections from A/C Control Head E87. Installing: Install in reverse order of removal. Climatronic Control Module J255, multi-pin connector assignments Special tools, testers and auxiliary items required Test Box 105 Pin VAG1598/42 adapter cable VAG 1598/47
Automatic A/C system - Climatronic Page 7 / 46 20-pin electrical connection, T20c - A - 1 - Sunlight Photo Sensor 2 G134 or Sunlight Photo Sensor G107, signal 2 - High Pressure Sensor G65 3 - Sunlight Photo Sensor 2 G134 or Sunlight Photo Sensor G107, signal 5 - CAN Bus - High 6 - CAN Bus - Low 9 - + 5V for Sunlight Photo Sensor 2 G134 or Sunlight Photo Sensor G107 16 - Plus connection (15a) in vehicles with auxiliary heater 17 - Signal Ground (GND) for sensors 18 - A/C Compressor Regulator Valve N280 20 - Plus connection (15a); in vehicles with auxiliary heater plus connection (30a) 16-pin electrical connection, T16g -B- 1 - + 5V for control motors 2 - Left Temperature Flap Potentiometer/Actuator G220 3 - Right Temperature Flap Potentiometer/Actuator G221
Automatic A/C system - Climatronic Page 8 / 46 4 - Defroster Flap Motor Position Sensor G135 5 - Central Flap Motor Position Sensor G112 6 - Recirculation Flap Motor Position Sensor G143 7 - Back Pressure Flap Motor Position Sensor G113 8 - Left Footwell Vent Temperature Sensor G261 9 - Right Footwell Vent Temperature Sensor G262 10 - Fresh Air Intake Duct Temperature Sensor G89 11 - Evaporator Temperature Sensor G308 14 - Signal Ground (GND) potentiometer 15 - Left Vent Temperature Sensor G150 16 - Right Vent Temperature Sensor G151 16-pin electrical connection, T16f - C - 1 - Left Temperature Flap Motor V158, cold 2 - Left Temperature Flap Motor V158, warm 3 - Defroster Flap Motor V107, closed 4 - Defroster Flap Motor V107, open 5 - Central Air Flap Motor V70, upper body outlet 6 - Central Air Flap Motor V70, footwell 7 - Fresh/Recirculating Air Door Motor V154, recirculated air activation 8 - Fresh/Recirculating Air Door Motor V154, fresh air activation 9 - Air Flow Flap Motor V71, open 10 - Air Flow Flap Motor V71, close 11 - Right Temperature Flap Motor V159, cold 12 - Right Temperature Flap Motor V159, warm 15 - Fresh Air Blower V2 (PWM activation)
Automatic A/C system - Climatronic Page 9 / 46 16 - Fresh Air Blower V2, return message signal Heating and A/C components in passenger compartment, servicing Note: Disconnect battery before removing components marked with ** Repair Manual, Electrical Equipment, Repair Group 27, A data plate indicates the refrigerant used and capacity. Instrument panel **
Automatic A/C system - Climatronic Page 10 / 46 Repair Manual, Body Interior, Repair Group 70, Sunlight Photo Sensor G107 and Sunlight Photo Sensor 2 G134 Checking: Use Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052 Function: controls temperature flap and fresh air blow depending on light intensity Emergency running during failure: Climatronic Control Module J255 utilizes a fixed value 87-3, Sunlight Photo Sensor G107 / Sunlight Photo Sensor 2 G134, removing and installing Center air vents 80-1, Center air vents, removing and installing Right side window defroster air duct In right A-pillar Right air vent 80-1, Right / left air vent, removing and installing
Automatic A/C system - Climatronic Page 11 / 46 Right Vent Temperature Sensor G151 Checking: Use Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052 87-3, Left Vent Temperature Sensor G150 / Right Vent Temperature Sensor G151, removing and installing Climatronic Control Module J255 The Climatronic Control Module J255 and A/C Control Head E87 are integrated and cannot be serviced or repaired separately. Checking: Use Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052 87-3, Climatronic Control Module J255 with A/C Control Head E87, removing and installing Replacing: Initiate Basic Setting using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components,
Automatic A/C system - Climatronic Page 12 / 46 checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052. Air Flow Flap Motor V71 Checking: Use Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052 87-3, Air Flow Flap Motor V71, removing and installing Replacing: Initiate Basic Setting using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052. Fresh/Recirculating Air Door Motor V154 Checking: Use Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052 87-3, Fresh/Recirculating Air Door Motor V154, removing and installing
Automatic A/C system - Climatronic Page 13 / 46 Replacing: Initiate Basic Setting using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052. Fresh Air Intake Duct Temperature Sensor G89 Checking: Use Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052 Checking: Vehicle Diagnostic, testing info. system VAS 5051/5052 Function: Temperature sensor controls temperature flap and fresh air blower depending on temperature Repair Manual, Body Interior, Repair Group 70, Right footwell air vent 80-1, Right footwell air vent, removing and installing Fresh Air Blower V2 with Fresh Air Blower Control Module J126 Depending on configuration,
Automatic A/C system - Climatronic Page 14 / 46 the blower, blower electrical connection and control module on vehicle may not be exactly as shown here Checking: Use Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052 80-1, Fresh Air Blower V2, removing and installing Not applicable Heating and ventilation unit partition Removing 80-1, Heating and ventilation unit partition, removing Sealing caps Only in vehicles without air guide to air vent installed in center console at rear Dust and pollen filter With activated charcoal filter 80-1, Dust and pollen filter, removing and installing Center console air duct Connection to center console air guide To remove, center console must be removed
Automatic A/C system - Climatronic Page 15 / 46 Repair Manual, Body Interior, Repair Group 68, Right rear footwell air duct 80-1, Rear footwell air ducts, removing and installing Left rear footwell air duct 80-1, Rear footwell air ducts, removing and installing Evaporator Temperature Sensor G308 Checking: Use Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052 87-3, Evaporator Temperature Sensor G308, removing and installing Right Temperature Flap Motor V159 Checking: Use Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052 87-3, Right Temperature Flap Motor V159, removing
Automatic A/C system - Climatronic Page 16 / 46 and installing Replacing: Initiate Basic Setting using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052. Auxiliary Heater Heating Element Z35 Only on models with Diesel engine 80-1, Auxiliary Heater Heating Element Z35, removing and installing Heater core 80-1, Heater core, removing and installing Central Air Flap Motor V70 Checking: Use Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052 87-3, Central Air Flap Motor V70, removing and installing Replacing: Initiate Basic Setting using Vehicle Diagnostic, Testing and Information System VAS
Automatic A/C system - Climatronic Page 17 / 46 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052. Left footwell air vent 80-1, Left footwell air vent, removing and installing Left Temperature Flap Motor V158 Checking: Use Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052 87-3, Left Temperature Flap Motor V158, removing and installing Replacing: Initiate Basic Setting using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052. Left Footwell Vent Temperature Sensor G261 Checking: Use Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating
Automatic A/C system - Climatronic Page 18 / 46 mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052 87-3, Left Footwell Vent Temperature Sensor G261, removing and installing Defroster Flap Motor V107 Checking: Use Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052 87-3, Defroster Flap Motor V107, removing and installing Replacing: Initiate Basic Setting using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052. Heating and A/C unit 87-3, Heating and A/C unit, removing and installing Disassembly and assembly 87-3, Heating and A/C unit, disassembly and assembly
Automatic A/C system - Climatronic Page 19 / 46 Right Footwell Vent Temperature Sensor G262 Checking: Use Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052 87-3, Right Footwell Vent Temperature Sensor G262, removing and installing Left side window defroster air duct In left A-pillar Left Vent Temperature Sensor G150 Checking: Use Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052 87-3, Left Vent Temperature Sensor G150 / Right Vent Temperature Sensor G151, removing and installing Heating and A/C unit, removing and installing Preparation: Special tools, testers and auxiliary items required
Automatic A/C system - Climatronic Page 20 / 46 Drip tray for VAS6100 VAS 6208 Hose clamps, up to 40 mm. 3093 Compressed air gun, commercially available Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. Note: To improve accessibility, additional components e.g. engine cover must be removed (depending on engine version). - Evacuate refrigerant circuit using refrigerant recycling/recovery unit Kent-Moore ACR4 (or UL approved equivalent)
Automatic A/C system - Climatronic Page 21 / 46 Repair Manual, Refrigerant R134a - Servicing, Repair Group 00,. Observe notes 87-5, General information - Remove instrument panel Repair Manual, Body Interior, Repair Group 70, - Remove facing wall in plenum chamber. Repair Manual, Body Exterior, Repair Group 50, - Remove both rear footwell air ducts 80-1, Rear footwell air ducts, removing and installing - Place Drip tray for VAS6100 VAS 6208 under the engine. - Mark coolant hoses - 1 - Warning! Scalding danger! The cooling system is pressurized when the engine is warm. Wear gloves and other protection and carefully release system pressure if necessary before performing repairs. - Clamp off coolant hoses - 1 - using Hose clamps, up to 40 mm. 3093 and disconnect coolant hoses to heater core.
Automatic A/C system - Climatronic Page 22 / 46 - Connect a section of hose - A - onto upper connection. - Hold suitable container - B - under lower connection - C -. - Using a compressed air gun, carefully blow residual coolant from heater core at heater core connection. Warning! Frostbite danger! High pressure refrigerant may leak out if refrigerant circuit is not discharged. Always evacuate refrigerant prior to opening refrigerant circuit. - From the engine compartment, remove bolts - 1 - (12 Nm) for refrigerant lines - 2 -. - Disconnect refrigerant lines from expansion valve - 3-. Caution! Always plug open refrigerant line connections to prevent dirt and moisture contamination.
Automatic A/C system - Climatronic Page 23 / 46 Where applicable, use sealing caps from replacement expansion valve. - Cover floor carpet in vehicle interior with leak-proof foil and absorbent paper. Note : Observe screw position, length and orientation during removal. Screw 4 Nm Screws
Automatic A/C system - Climatronic Page 24 / 46 Qty. 2 4 Nm Cable bracket Heating and A/C unit Removing: - Disconnect condensation water drain hose from heating and A/C unit 87-3, Heating and A/C unit condensation water drain hose, checking. - Disconnect electrical connections from heating and A/C unit. Note : All cable ties opened or cut during air conditioner removal must be reinstalled at the same locations during installation. The wiring harness air conditioner" is removed together with the air conditioner unit. - Remove screws Item - 6 - from bracket Item - 5 -. - Remove support Item - 8 -. - Remove screws Item - 10 - and Item - 12 - and remove bracket Item - 11 -. - Remove screws Item - 2 - and Item - 1 - from cable bracket Item - 3 -. Note : To be able to reach the bolt Item - 1 -, heating and A/C unit on driver side must be pulled out slightly from facing wall.
Automatic A/C system - Climatronic Page 25 / 46 When removing heat unit, ensure the two coolant pipes of the heater core do not get caught and bent or damaged on plenum chamber or sound insulation pan. Also pay attention to wiring harness, individual wiring connections may get damaged when pulling too forcefully on wiring harness. - Remove heating and A/C unit. Installing: Install in reverse order of removal, noting the following: - When installing, note installation position of seal for heating and A/C unit to engine compartment 87-3, Heating and A/C unit seal at bulkhead, installation position - When installing, ensure condensation water drain hose is seated correctly 87-3, Heating and A/C unit condensation water drain hose, checking. - Fill with coolant (refer to applicable engine repair manual, Rep. Gr. 19). Bracket Screws 8 Nm Assembly carrier Right support Left support
Automatic A/C system - Climatronic Page 26 / 46 Screws Qty. 2 8 Nm Bracket Screws Qty. 2 8 Nm Heating and A/C unit seal at bulkhead, installation position Note: Note installation position of seal - A - during assembly. Heating and A/C unit, disassembly and assembly
Automatic A/C system - Climatronic Page 27 / 46 Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi Central Air Flap Motor V70 Checking: Use Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052 87-3, Central Air Flap Motor V70, removing and installing Replacing: Initiate Basic Setting using Vehicle Diagnostic, testing info. system VAS 5051/5052
Automatic A/C system - Climatronic Page 28 / 46 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052. Left Temperature Flap Motor V158 Checking: Use Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052 87-3, Left Temperature Flap Motor V158, removing and installing Replacing: Initiate Basic Setting using Vehicle Diagnostic, testing info. system VAS 5051/5052 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052. Defroster Flap Motor V107 Checking: Use Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052 87-3, Defroster Flap Motor V107, removing and installing
Automatic A/C system - Climatronic Page 29 / 46 Replacing: Initiate Basic Setting using Vehicle Diagnostic, testing info. system VAS 5051/5052 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052. Bracket Screws Remove screws to separate air distribution and evaporator housings. Cover Fresh/Recirculating Air Door Motor V154 Checking: Use Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052 87-3, Fresh/Recirculating Air Door Motor V154, removing and installing Replacing: Initiate Basic Setting using Vehicle Diagnostic, testing info. system VAS 5051/5052 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052. Air Flow Flap Motor V71 Checking: Use Vehicle
Automatic A/C system - Climatronic Page 30 / 46 Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052 87-3, Air Flow Flap Motor V71, removing and installing Replacing: Initiate Basic Setting using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052. Air intake housing With recirculating air flap (Climatic) With air flow flap (Climatronic) Evaporator housing - upper part Disassembling and assembling evaporator housing 87-3, Evaporator housing, disassembly and assembly Evaporator housing - lower part Disassembling and assembling evaporator housing 87-3, Evaporator housing, disassembly and assembly Evaporator
Automatic A/C system - Climatronic Page 31 / 46 87-5, Evaporator, removing and installing Evaporator Temperature Sensor G308 Checking: Use Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052 87-3, Evaporator Temperature Sensor G308, removing and installing Glove compartment cooling vent Glove compartment cooling hose Fresh Air Blower V2 with Fresh Air Blower Series Resistor With Fuse N24 Checking: Use Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052 80-1, Fresh Air Blower V2, removing and installing Dust and pollen filter With activated charcoal filter
Automatic A/C system - Climatronic Page 32 / 46 80-1, Dust and pollen filter, removing and installing Cover For dust and pollen filter Heater core 80-1, Heater core, removing and installing Heater core trim Auxiliary Heater Heating Element Z35 Only installed on vehicles with Diesel engine. 80-1, Auxiliary Heater Heating Element Z35, removing and installing Right Temperature Flap Motor V159 Checking: Use Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052 87-3, Right Temperature Flap Motor V159, removing and installing Replacing: Initiate Basic Setting using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating
Automatic A/C system - Climatronic Page 33 / 46 mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052. Air distribution housing Evaporator housing, disassembly and assembly - Separate evaporator housing from heating and A/C unit 87-3, Heating and A/C unit, disassembly and assembly. - Disconnect electrical connections from heating and A/C unit. Evaporator housing - lower section Evaporator
Automatic A/C system - Climatronic Page 34 / 46 Ensure insulation foam is not damaged 87-5, Evaporator, removing and installing Clip Evaporator housing - lower section Screw Expansion valve / bulkhead seal 87-5, Evaporator, removing and installing Bracket 87-5, Evaporator, removing and installing Left Footwell Vent Temperature Sensor G261, removing and installing Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove instrument panel Repair Manual, Body Interior, Repair Group 70, - Remove screws Item - 10 - from bracket Item - 11 -.
Automatic A/C system - Climatronic Page 35 / 46 - Disconnect electrical connection at sensor - 1-. - Press bracket Item - 11 - slightly toward left, rotate sensor - 1-90 and remove from housing. Installing: Install in reverse order of removal. Right Footwell Vent Temperature Sensor G262, removing and installing Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. Note: Right Footwell Vent Temperature Sensor G262 is depicted with instrument panel removed. It is not necessary to remove instrument panel. - Remove glove compartment Repair Manual, Body Interior, Repair Group 68,
Automatic A/C system - Climatronic Page 36 / 46 - Disconnect electrical connection at sensor -1-. - Rotate sensor - 1-90 and remove from housing. Installing: Install in reverse order of removal. Evaporator Temperature Sensor G308, removing and installing Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove front passengers footwell cover - 1-.
Automatic A/C system - Climatronic Page 37 / 46 - Disconnect electrical connection at sensor - 1-. - Rotate sensor in direction of - arrow - and remove. Outside Air Temperature Sensor G17, removing and installing Removing: - Remove center air vent from front bumper cover catches. Repair Manual, Body Exterior, Repair Group 63, - Unclip Outside Air Temperature Sensor G17-1 - from bracket and disconnect electrical connection. Installing: Install in reverse order of removal, noting the following: Note: Ensure electrical connector is seated correctly to prevent water entry.
Automatic A/C system - Climatronic Page 38 / 46 Left Vent Temperature Sensor G150 / Right Vent Temperature Sensor G151, removing and installing Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. Note: Removal of sensors on both sides is identical, only the sides are reversed. - Remove cover at left or right on instrument panel. Repair Manual, Body Interior, Repair Group 70, - Disconnect electrical connection - 1 - from sensor - 2 -. - Rotate sensor - 2-90 in direction of - arrow - and remove from instrument panel. Installing: Install in reverse order of removal. Sunlight Photo Sensor G107 / Sunlight Photo Sensor 2 G134, removing and installing Removing:
Automatic A/C system - Climatronic Page 39 / 46 - Unclip photo sensor - 1 - from instrument panel using appropriate tool. - Disconnect electrical connection from sunlight photo sensor. Installing: Install in reverse order of removal. Heating and A/C unit condensation water drain hose, checking - Remove front passengers side footwell cover. Note: Condensation water drain hose - 1 - must be able to be connected to connection of heating and A/C unit without pre-tension. Condensation water drain hose must sit securely on heating and A/C unit. Fresh/Recirculating Air Door Motor V154, removing and installing
Automatic A/C system - Climatronic Page 40 / 46 Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove glove compartment Repair Manual, Body Interior, Repair Group 68, - Remove motor cover. - Disconnect electrical connection from motor -1-. - Remove motor - 1 -. Installing: Install in reverse order of removal, noting the following. Note: After installing, check motor/flap function. Initiate "Basic Setting" function using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052. Air Flow Flap Motor V71, removing and installing Removing:
Automatic A/C system - Climatronic Page 41 / 46 Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove glove compartment Repair Manual, Body Interior, Repair Group 68, Note: Position of air flow flap must not be changed. - Remove cover - 1 -. - Remove Fresh/Recirculating Air Door Motor V154 87-3, Fresh/Recirculating Air Door Motor V154, removing and installing. - Disconnect electrical connection from motor - 2-. - Remove motor - 2 -. Installing: Install in reverse order of removal, noting the following. Note: After installing, check motor/flap function. Initiate "Basic Setting" function using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and
Automatic A/C system - Climatronic Page 42 / 46 Information System VAS 5051/5052. Defroster Flap Motor V107, removing and installing Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove drivers storage compartment. Repair Manual, Body Interior, Repair Group 68, - Remove left footwell air vent 80-1, Left footwell air vent, removing and installing. - Remove bracket Item - 11 -. - Disconnect electrical connection from motor - 2-. - Remove screws - 1 -, remove motor - 2 - and unhook brace. Installing: Install in reverse order of removal, noting the following. Note: After installing, check motor/flap function. Initiate "Basic Setting" function using Vehicle
Automatic A/C system - Climatronic Page 43 / 46 Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052. Left Temperature Flap Motor V158, removing and installing Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove left footwell air vent 80-1, Left footwell air vent, removing and installing. - Remove bracket Item - 11 -. - Remove heater core cover. - Disconnect electrical connection from motor -3-. - Unhook brace from actuator lever -1-. - Remove screws - 2 - and remove motor -3-. Installing: Install in reverse order of removal, noting the following. Note: After installing, check motor/flap function. Initiate "Basic Setting" function using Vehicle
Automatic A/C system - Climatronic Page 44 / 46 Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052. Right Temperature Flap Motor V159, removing and installing Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove glove compartment Repair Manual, Body Interior, Repair Group 68, - Remove right footwell air vent 80-1, Right footwell air vent, removing and installing. - Disconnect electrical connection from Right Temperature Flap Motor V159. - Remove screws - 1 - and remove motor. - Unhook brace - 2 - from motor. Installing: Install in reverse order of removal, noting the following. Note:
Automatic A/C system - Climatronic Page 45 / 46 After installing, check motor/flap function. Initiate "Basic Setting" function using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052. Central Air Flap Motor V70, removing and installing Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove instrument panel. Repair Manual, Body Interior, Repair Group 70, - Disconnect electrical connection from Central Air Flap Motor V70. - Remove screws - 1 - and remove motor. Installing: Install in reverse order of removal, noting the following. Note: After installing, check motor/flap function.
Automatic A/C system - Climatronic Page 46 / 46 Initiate "Basic Setting" function using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" 87-3, Components, checking and adjusting with Vehicle Diagnostic, Testing and Information System VAS 5051/5052.
A/C Compressor and Bracket Page 1 / 10 87-4 A/C Compressor and Bracket A/C compressor and bracket - 2.5L 5-cylinder gasoline engine, assembly Special tools, testers and auxiliary items required Torque wrench 550Nm VAG 1331 (or 5-50 Nm equivalent) Note: The compressor bracket and related components can be removed and installed without having to open the refrigerant circuit. If it is necessary to open the refrigerant circuit, for example when replacing compressor, first extract A/C refrigerant using recycling/recovery unit Kent- Moore ACR4 Repair Manual, Refrigerant R134a - Servicing, Repair Group 00,. Before carrying out any work on the A/C refrigerant system, refer to all CAUTIONS and WARNINGS in A/C refrigerant system safety measures Repair Manual, Refrigerant R134a - Servicing, Repair Group 00,
A/C Compressor and Bracket Page 2 / 10 Ribbed belt, removing Repair Manual, 2.5 Liter 5-Cyl. 4V Engine Mechanical, Fuel Injection Ignition, Engine Code(s): BGP, BGQ, Repair Group 13, Observe length of removed bolts and reinstall accordingly. Bracket For Generator (GEN) and A/C compressor Removing without opening refrigerant circuit:
A/C Compressor and Bracket Page 3 / 10 - Remove bolts - 6 -. - Remove A/C compressor from bracket and secure to body with appropriate material (e.g. welding wire) 87-4, A/C compressor, securing to body - Remove bolts - 2 - through - 4 - and remove bracket - 1 - from engine. Installing: - Install in reverse order of removal, noting the following: - Loosely install and then and torque bolts to specified value. - Route ribbed belt according to diagram 87-4, Ribbed belt, routing Socket head bolt M8x60 25 Nm Socket head bolt M8x110 25 Nm Hex socket bolt M8x30 25 Nm 4x A/C compressor 87-5, A/C compressor, removing and installing Hex bolts M8x85 25 Nm
A/C Compressor and Bracket Page 4 / 10 Qty. 3 Dowel sleeves Qty. 2 Ensure proper seating between bracket and A/C compressor A/C compressor, securing to body Ribbed belt, routing
A/C Compressor and Bracket Page 5 / 10 Upper idler pulley Ribbed belt pulley - generator Lower idler pulley Ribbed belt for generator and coolant pump Ribbed belt pulley - A/C compressor Ribbed belt for A/C compressor Ribbed belt pulley - crankshaft Tensioning roller for ribbed belt for A/C compressor Tensioning roller for ribbed belt for generator and coolant pump Ribbed belt pulley - coolant pump A/C compressor and bracket - 2.0L 4-cylinder TFSI engine, removing and installing Special tools, testers and auxiliary items required Torque Wrench 5-50Nm VAG1331 (or 5-50 Nm equivalent) Note : The compressor bracket and related components can be removed and installed without having to open the refrigerant circuit. If it is necessary to open the refrigerant circuit, for example when replacing compressor, first extract A/C refrigerant using recycling/recovery unit Kent- Moore ACR4 Repair Manual, Refrigerant R134a - Servicing, Repair Group 00,.
A/C Compressor and Bracket Page 6 / 10 Before carrying out any work on the A/C refrigerant system, refer to all CAUTIONS and WARNINGS in A/C refrigerant system safety measures Repair Manual, Refrigerant R134a - Servicing, Repair Group 00, Ribbed belt, removing Repair Manual, 2.0 Liter 4-Cyl. 4V Turbo Engine Mechanical, Fuel Injection Ignition, Engine Code(s): BPY, Repair Group 13, Observe length of removed bolts and reinstall accordingly.
A/C Compressor and Bracket Page 7 / 10 Hex socket bolt M10 45 Alignment bore 40 Nm Hex socket bolt M10 45 40 Nm Hex socket bolt M10 45 40 Nm Hex socket bolt M10 45 40 Nm A/C compressor
A/C Compressor and Bracket Page 8 / 10 87-5, A/C compressor, removing and installing Hex bolts M8 100 3x 25 Nm Hex socket bolt M10 45 Alignment bore 40 Nm Hex socket bolt M10 45 40 Nm Dowel sleeves 2x Ensure proper seating between auxiliary component bracket and A/C compressor Bracket For Generator (GEN) and A/C compressor Removing without opening refrigerant circuit: - Remove generator Repair Manual, Electrical Equipment, Repair Group 27, - Remove bolts - 6 -. Remove A/C compressor from bracket and secure to body with appropriate material (e.g. welding wire) 87-4, A/C compressor,
A/C Compressor and Bracket Page 9 / 10 securing to body - Remove bolts - 1 - to - 4 - and - 7 - and - 8 - and remove bracket - 10 - from engine. Installing - Install in reverse order of removal, noting the following: - Loosely install all bolts and then tighten in the following sequence: - 1 -, - 7 -, - 4 -, - 8 -, - 3 - and - 2 -. Torque bolts to specified value. - Route ribbed belt according to diagram 87-4, Ribbed belt, routing A/C compressor, securing to body
A/C Compressor and Bracket Page 10 / 10 Ribbed belt, routing Tensioner roller Ribbed belt pulley - generator Ribbed belt pulley - A/C compressor Ribbed belt Ribbed belt pulley - crankshaft
A/C Refrigerant System, servicing Page 1 / 20 87-5 A/C Refrigerant System, servicing General information Note: General A/C refrigerant system servicing procedures (e.g., component/system descriptions, extracting refrigerant, recharging, leak detection, troubleshooting etc.), repair and special tool information Repair Manual, Refrigerant R134a - Servicing, Repair Group 00, Before carrying out any work on the A/C refrigerant system, refer to all CAUTIONS and WARNINGS in A/C refrigerant system safety measures Repair Manual, Refrigerant R134a - Servicing, Repair Group 00, Evacuate refrigerant circuit using refrigerant recycling/recovery unit Kent-Moore ACR4 (or UL approved equivalent) Repair Manual, Refrigerant R134a - Servicing, Repair Group 00, Always plug open refrigerant line connections to prevent dirt and moisture contamination. Color coding of O-rings for the R134a refrigerant circuits has been discontinued. Both colored and black O-rings are used. Threaded connections of refrigerant circuit must be coated with polyethylene glycol (PEG) VW material
A/C Refrigerant System, servicing Page 2 / 20 no. 294440 before installing. Under certain conditions, fluid reservoir with dryer cartridge does not require replacement after the refrigerant circuit is opened. To confirm Repair Manual, Refrigerant R134a - Servicing, Repair Group 00, Additional information: Electrical Wiring Diagrams, Troubleshooting and Component Locations binder A/C refrigerant system components, servicing Warning! Frostbite danger! High pressure refrigerant may leak out if refrigerant circuit is not discharged. Always evacuate refrigerant prior to opening refrigerant circuit.
A/C Refrigerant System, servicing Page 3 / 20 Fluid reservoir with dryer cartridge 87-5, Fluid reservoir with dryer cartridge, removing and installing A/C compressor 87-5, A/C compressor, removing and installing Observe notes for installing A/C compressor 87-5, A/C compressor, procedure after installation Condenser
A/C Refrigerant System, servicing Page 4 / 20 87-5, Condenser, removing and installing High Pressure Sensor G65 Removing and installing 87-5,, removing and installing Bracket High pressure service valve Capacities 87-6, A/C Refrigerant System, capacities Bracket Low pressure service valve Capacities 87-6, A/C Refrigerant System, capacities Expansion valve Servicing function 87-5, Expansion valve, servicing function Hex nut 20 Nm Bracket
A/C Refrigerant System, servicing Page 5 / 20 High Pressure Sensor G65, removing and installing - Remove lower noise insulation (under engine). Repair Manual, Body Exterior, Repair Group 50, - Disconnect electrical connection from high pressure sensor - 1 -. - Remove sensor - 1 - from connection of refrigerant line. Note: Replace O-ring - 2 - Depending on engine version, sensor - 1 - may be installed on a different side in the vicinity of the condenser. Fluid reservoir with dryer cartridge, removing and installing Note: Observe notes 87-5, General information Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Evacuate refrigerant circuit using refrigerant recycling/recovery unit Kent-Moore ACR4 (or UL approved equivalent) Repair Manual, Refrigerant R134a - Servicing, Repair Group 00,.
A/C Refrigerant System, servicing Page 6 / 20 - Bring lock carrier into service position Repair Manual, Body Exterior, Repair Group 50, - Remove screws - arrows -. - Hang radiator assembly on Shop crane - load cap = 700-1200kg VAS 6100 and engine sling 2024A using workshop equipment (cable ties or welding wire) and unhook cooler from lock carrier, coolant hoses and refrigerant lines remain connected. - Remove bolt - 2 - and remove retaining clip. Warning! Frostbite danger! High pressure refrigerant may leak out if refrigerant circuit is not discharged. Always evacuate refrigerant prior to opening refrigerant circuit.
A/C Refrigerant System, servicing Page 7 / 20 - Remove screws - 1 - and pull fluid reservoir with dryer cartridge upward and out. Note: Depending on radiator assembly, there may be only one screw - 1 - present. Installing: Install in reverse order of removal, noting the following: Note: First tighten screw(s) - 1 - to 4.2 Nm 0.7 Nm and then bolt - 2 - When installing radiator assembly, ensure that sealing strips are seated correctly on radiator etc.. A/C compressor, removing and installing Note: Observe notes 87-5, General information Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Evacuate refrigerant circuit using refrigerant recycling/recovery unit Kent-Moore ACR4 (or UL approved equivalent) Repair Manual, Refrigerant R134a - Servicing, Repair Group 00,. - Remove ribbed belt as applicable: Remove ribbed belt on 2.0L TFSI engine
A/C Refrigerant System, servicing Page 8 / 20 Repair Manual, 2.0 Liter 4-Cyl. 4V Turbo Engine Mechanical, Fuel Injection Ignition, Engine Code(s): BPY, Repair Group 13, Remove ribbed belt on 2.5L gasoline engine Repair Manual, 2.5 Liter 5-Cyl. 4V Engine Mechanical, Fuel Injection Ignition, Engine Code(s): BGP, BGQ, Repair Group 13, - Remove noise insulation beneath engine
A/C Refrigerant System, servicing Page 9 / 20 Repair Manual, Body Exterior, Repair Group 50,. Warning! Frostbite danger! High pressure refrigerant may leak out if refrigerant circuit is not discharged. Always evacuate refrigerant prior to opening refrigerant circuit. - Remove bolts (22 Nm 1 Nm) - 1 - from A/C compressor and disconnect refrigerant lines from A/C compressor. - Remove hex screws (25 Nm) - 2 - and remove A/C compressor. Installing: - Install in reverse order of removal, noting the following: Note: Ensure alignment bushings - 3 - are seated correctly. Prior to operating compressor after installation, observe notes 87-5, A/C compressor, procedure after installation A/C compressor - pressure relief valve, checking Function: protects refrigerant circuit against excessive pressures Warning! Frostbite danger! Excessive refrigerant outlet pressures are
A/C Refrigerant System, servicing Page 10 / 20 vented by the pressure relief valve with considerable force. Should relief valve operate, stay clear of venting refrigerant and switch off engine. A/C compressor pressure relief valve - Sanden, checking Evidence of refrigerant oil in the area of the relief valve - arrow - indicates valve has operated. Replace valve and determine cause of excessive refrigerant system pressure. A/C compressor pressure relief valve - Denso, checking Evidence of refrigerant oil in the area of the relief valve - arrow - indicates valve has operated.
A/C Refrigerant System, servicing Page 11 / 20 Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi Replace valve and determine cause of excessive refrigerant system pressure. Expansion valve, servicing function Expansion valve, servicing Note: Observe notes 87-5, General information Bolts 12 Nm Qty. 2 Refrigerant lines on expansion valve
A/C Refrigerant System, servicing Page 12 / 20 O-ring 13.7 mm; 2.5 mm Expansion valve Removing: - Evacuate refrigerant circuit using refrigerant recycling/recovery unit Kent-Moore ACR4 (or UL approved equivalent) Repair Manual, Refrigerant R134a - Servicing, Repair Group 00,. Warning! Frostbite danger! High pressure refrigerant may leak out if refrigerant circuit is not discharged. Always evacuate refrigerant prior to opening refrigerant circuit. - Remove bolts Item - 1 - and disconnect refrigerant lines Item - 2 - from expansion valve. - Remove bolts Item - 8 - and remove expansion valve. Installing: - Install in reverse order of removal, noting the following: - Charge refrigerant circuit using refrigerant recycling/recovery unit Kent-Moore ACR4 (or UL
A/C Refrigerant System, servicing Page 13 / 20 approved equivalent) Repair Manual, Refrigerant R134a - Servicing, Repair Group 00,. Capacities 87-6, A/C Refrigerant System, capacities O-ring 14 mm; 1.82 mm Coat with refrigerant oil when installing O-ring 10.8 mm; 1.82 mm Coat with refrigerant oil when installing O-ring 9.5 mm; 2.5 mm Combination bolt 5 Nm Expansion valve, function The expansion valve restricts and controls refrigerant flow to the evaporator thus lowering refrigerant temperature and pressure. Evaporator, removing and installing Removing: - Remove heating and A/C unit: Climatic system 87-2, Heating and A/C unit,
A/C Refrigerant System, servicing Page 14 / 20 removing and installing Climatronic system 87-3, Heating and A/C unit, removing and installing - Disassemble heating and A/C unit: Climatic system 87-2, Heating and A/C unit, disassembly and assembly Climatronic system 87-3, Heating and A/C unit, disassembly and assembly - Disassemble evaporator housing 87-3, Evaporator housing, disassembly and assembly - Remove evaporator - A - from lower section of evaporator housing. Installing: - Install in reverse order of removal, noting the following: Note: Before inserting evaporator, check condensation water drain hose and clean drain if necessary. Before inserting evaporator, clean evaporator housing and evaporator if necessary.
A/C Refrigerant System, servicing Page 15 / 20 - When inserting evaporator - A - into lower section of evaporator housing and when assembling both housing halves, ensure foam seal - F - is not damaged. - Check seal - F - (it must be glued all around) before inserting evaporator. - Place bracket - C - and seal / insulation - B - onto connecting pipes of evaporator - D - and - E-. - Insert evaporator - A - into lower section of evaporator housing as shown in the illustration. Note: After assembling both housing halves, check seal / insulation - B - for correct seating at pass-through for both refrigerant lines - D - and - E -. Check seating of bracket - C - on both refrigerant lines - D - and - E - for correct seating. If heat protection insulation - B - is missing or not installed correctly, it can cause reduced performance of the A/C system (change of adjusted control characteristics of expansion valve due to radiant heat). Condenser, removing and installing Note: Observe notes 87-5, General information Removing: Caution!