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Heating & Air Conditioning

87 AIR CONDITIONING

A/C REFRIGERANT SYSTEM, NOTES

Safety measures

The subassemblies and lines of the air conditioner are filled with Tetrafluoroethane also known as refrigerant R-134a.

A label on the lock carrier in the engine compartment indicates the refrigerant type and capacity.

WARNING: Always use an Underwriter's Laboratory (UL) approved refrigerant recovery/recycling/recharging unit such as Kent-Moore ACR4, or equivalent, whenever discharging an R-134a A/C system

As of January, 1992 any person who services a motor vehicle air conditioner MUST, by law, be properly trained and certified and use approved refrigerant recycling equipment. Technicians must complete an EPA approved recycling course to be certified

State and Provincial governments may have additional requirements regarding air conditioning servicing. Always comply with local laws

WARNING: A/C system is filled with refrigerant gas which is under pressure

Always be careful that refrigerant does not come in contact with your skin

If liquid refrigerant has come in contact with your skin or eyes:

Do not rub skin or eyes

Immediately flush with cool water for 15 minutes

Rush to a doctor or hospital

Do not attempt to treat yourself

Work in a well ventilated area because refrigerant gases are heavier than air, displace oxygen and may cause suffocation in areas of poor air circulation, like under the car

Avoid breathing refrigerant vapors. Exposure may irritate eyes, nose and throat

2006 Volkswagen Touareg

HVAC Heating & Air Conditioning



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Sunday, September 20, 2009 9:32:16 AM © 2005 Mitchell Repair Information Company, LLC.

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Sunday, September 20, 2009 9:32:22 AM Page 1 © 2005 Mitchell Repair Information Company, LLC.

Always wear hand and eye protection (gloves and goggles) when working around the A/C system

Keep refrigerant containers stored below 50°C (122°F) and never drop from high places. DO NOT warm refrigerant containers with an open flame. If refrigerant needs to be warmed, place bottom of tank in warm water.

WARNING: Keep refrigerant away from open flames because poisonous gas will be produced if it burns. Do not smoke when refrigerant gases are present for the same reason

Electric welding near refrigerant hoses causes R-134a to decompose from ultraviolet light. Discharge system before electric welding

Pressurized R-134a refrigerant in the presence of oxygen may form a combustible mixture. Never introduce compressed air into any R-134a container (full or empty), A/C component or piece of service equipment

Do not expose any component of the A/C system to high temperatures (for example, open flames). Excessive heat will cause a pressure increase which could burst the system

Do not steam clean condensers or evaporators. Use only cold water or compressed air

CAUTION: Before beginning repairs on the electrical system:

Switch off all electrical consumers.

Switch ignition off and remove ignition key.

CAUTION: R-12 and R-134a refrigerant are NOT compatible. Never add R-12 refrigerant to an R-134a system or R-134a refrigerant to an R-12 system. If the refrigerants are mixed, total system contamination will occur and compressor failure may result

Refrigerant oils used for the R-134a system and R-12 system are NOT compatible. Use only the specified synthetic oil (Polyalkylene Glycol/PAG) for the R-134a refrigerant system. DO NOT use R-12 system oil in an R-134a system or R-134a system oil in an R-12 system. If the refrigerant oils are mixed, system contamination will occur and compressor failure may result

R-134a refrigerant system oil (PAG oil) absorbs moisture very rapidly. Moisture combines with the refrigerant to form acids which will damage



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the system. Use only the specified oil from a sealed container and ALWAYS reseal oil container immediately after use. DO NOT use oil if it has become contaminated with moisture

CAUTION: R-134a and R-12 A/C components including compressor, hoses, O-rings, evaporator, condenser, receiver-drier, etc. are NOT interchangeable. Components of the R-134a system are identified by lettering (R-134a) or by a green label (or stripe). In addition a label on the upper radiator support identifies which type refrigerant is used. Use only the correct system component for each refrigerant type

Immediately plug open connections on A/C components to prevent dirt and moisture contamination. Likewise, DO NOT remove new components from packaging until ready to install. Immediately tighten component connections after installation

Always use separate refrigerant recovery/recycling/recharging servicing equipment for R-12 and R-134a systems. DO NOT use one piece of equipment for both R-12 and R-134a systems. The residual traces of refrigerant will contaminate and damage the equipment. Servicing equipment includes recovery/recycling/recharging unit, charging station, vacuum pump, manifold gauges, etc.

DO NOT use R-12 servicing equipment on R-134a systems or R-134a equipment on R-12 systems or damage to both the vehicle A/C system and servicing equipment may result. Use only equipment designed to meet Society of Automotive Engineers (SAE) standards

CAUTION: R-134a and R-12 systems use different size service fittings. NEVER use adaptors to convert an R-12 fitting to R-134a size or R-134a fitting to R-12 size

Always replace damaged and/or leaking A/C system components. Do not attempt repair by soldering or welding

Work area must be extremely clean when working on A/C system components

Discharge A/C system before removing any A/C system component

Always reinstall caps over A/C service valves

Always replace O-rings, DO NOT reuse. Use only the correct size and type of O-rings specified for use with R-134a refrigerant. Lubricate O-ring with refrigerant oil before installing



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A/C refrigerant R-134a, properties

Commercial designation

The following designations are used and appear on component labels and factor tags:

R-134a

Tetrafluoroethane

CH2F CF3

H-KW 134a

SUVA® 134a

ARCTON® 134a

Color

Refrigerant R-134a is colorless and is invisible as a gas. R-134a when viewed through the sight glass may appear milky due to the mixture of refrigerant and lubricating oil (PAG oil).

Temperature/pressure relationship

R-134a in an enclosed container will have a specific temperature/pressure relationship.

Refrigerant oil

A special Polyalkylene Glycol (PAG) synthetic oil is used in R-134a systems. This oil is NOT compatible with mineral based oils used in R-12 systems. See safety measures. Refer to Safety measures, for Warnings and Cautions regarding proper oil usage.

Airborne properties

Temperature in °C (°F) Pressure in bar (psi) -30 (-22) 0.0 (0.0)-20 (-4) 0.3 (4.4)-10 (14) 1.0 (14.5)0 (32) 1.9 (27.5)10 (50) 3.1 (45.0)20 (68) 4.7 (68.2)30 (86) 6.7 (97.2)40 (104) 9.1 (132.0)50 (122) 12.2 (177.0)60 (140) 15.8 (229.2)70 (158) 20.2 (293.0)



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Escaped refrigerant gases are heavier than air and will gather first in low places, like under the car. R-134a refrigerant gas displaces oxygen and may cause suffocation in low areas of poor air circulation.

Refrigerant R-134a is not poisonous in any state (liquid or gas) and is safe when used properly.

Affects on plastic

Refrigerant R-134a will deteriorate some plastics. Therefore, when making system repairs, use only genuine VW replacement parts which are specified for use with R-134a refrigerant.

Affects on metal

In its pure state, refrigerant R-134a is chemically stable and will not attack iron, copper, brass or aluminum. However, the mixture of R-134a and PAG oil may deteriorate certain metals (copper). Therefore, when making system repairs, use only genuine VW replacement parts which are specified for use with R-134a refrigerant.

Water solubility

Liquid R-134a refrigerant will absorb only very minute quantities of moisture. However, R-134a vapor can absorb large amounts of moisture.

Flammability

R-134a refrigerant is not flammable.

Refrigerant containers

DO NOT exceed maximum rated capacity of refrigerant container.

Leak detection

Use halogen leak detector Hitec HI400A-TEL or UL approved equivalent to check for R-134a system leaks.

R-134a refrigerant oil

A special Polyalkylene Glycol (PAG) synthetic oil is used in R-134a systems.

A/C refrigerant system, identification

A/C refrigerant system is charged with refrigerant R-134a.

A label specifying refrigerant type may be located on the compressor or radiator support.

NOTE: Before carrying out any work on the A/C refrigerant system, refer to all CAUTIONS and WARNINGS in A/C refrigerant system safety measures. Refer to Safety measures .



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Fig. 1: A/C Refrigerant System, Identification Courtesy of VOLKSWAGEN UNITED STATES, INC.

A/C refrigerant circuit with expansion valve and receiver drier

1 - Evaporator

2 - Expansion valve

3 - High pressure service valve

4 - Sight glass (if equipped)

5 - Receiver drier

6 - Condenser

7 - Compressor

A/C refrigerant system, component overview

NOTE: Arrows indicate direction of refrigerant flow.

NOTE: Components illustrated here are for reference only. Actual components installed on Touareg may appear differently.



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Fig. 2: View Of A/C Refrigerant System Compressor Courtesy of VOLKSWAGEN UNITED STATES, INC.

Compressor

A variable displacement, externally regulated compressor is used in the Touareg. The compressor is driven continuously (no A/C clutch). Compressor output is regulated by the Climatronic control module -J255- based on input signals from the high pressure sensor -G65- and evaporator vent temperature sensors. -J255- provides an output signal to A/C compressor regulator valve -N280- in accordance with the interior temperature setting and refrigerant system pressures/engine load.

The compressor on V6 and V8 models is driven by a ribbed belt on the engine. Compressor on V10 TDI models is driven by a Hardy-coupling attached to the power steering pump.

Low-pressure refrigerant gas from the evaporator is compressed by the compressor. After compression, the refrigerant gas (now high-pressure) flows to the condenser.

Fig. 3: View Of A/C Refrigerant Condenser

NOTE: The compressor contains refrigerant oil that is mixable under all temperatures with the refrigerant.

A label on the compressor may indicate that compressor is for R-134a systems only.



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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Condenser

The condenser transfers heat from the compressed refrigerant gas to the outside air which causes the refrigerant to change state from a gas to a liquid.

Fig. 4: View Of Reservoir With Receiver Drier Cartridge Courtesy of VOLKSWAGEN UNITED STATES, INC.

Reservoir with receiver drier cartridge

Reservoir with receiver drier cartridge is integrated into the condenser.

Any moisture in the system forms as droplets and is absorbed in the drier desiccant cartridge.

Fig. 5: View Of Reservoir With Receiver Drier Cartridge

NOTE: The condenser for the R-134a refrigerant system may be identified with a green label.

NOTE: To ensure optimum system operation, replace receiver drier cartridge every time refrigerant system is opened.



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A/C Compressor Regulator Valve -N280-

-N280- is integrated with the compressor.

-N280- is actuated by a signal from the Climatronic Control Module -J255- in accordance with the interior temperature setting and refrigerant system pressures/engine load.

Internal refrigerant pressure is regulated on the low pressure side.

Fig. 6: View Of Expansion Valve Courtesy of VOLKSWAGEN UNITED STATES, INC.

Expansion valve

The expansion valve restricts and controls refrigerant flow to the evaporator thus lowering refrigerant temperature and pressure.

Fig. 7: View Of Evaporator Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE: The R-134a expansion valve may be identified as such with a label.



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Evaporator

Liquid refrigerant entering the evaporator absorbs heat from air passing through the evaporator fins and cools the air. As the refrigerant absorbs heat it turns to vapor and then is suctioned by the compressor.

Fig. 8: View Of O-Ring Courtesy of VOLKSWAGEN UNITED STATES, INC.

O-rings

O-rings seal connections between A/C system components.

Fig. 9: Identifying Pressure Relief Valve Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE: Always use correct size O-rings (dimensions -a- and -b-).

Do not reuse O-rings, always replace. Use only new O-rings that are compatible with R-134a refrigerant and refrigerant (PAG) oil on R-134a systems.

O-rings for use only on R-134a systems may be red, green, violet or black.

Lubricate O-rings with the appropriate refrigerant oil before installing (only use PAG oil).



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Pressure relief valve

The pressure relief valve -1- is integrated with the compressor. At pressures above 40 bar (580 psi), the pressure relief valve opens to relieve excessive outlet pressure. When the system pressure is reduced, the valve closes to prevent total refrigerant loss.

Evidence of refrigerant oil in the area of the relief valve indicates valve has operated.

Fig. 10: Identifying High Pressure Sensor G65 Courtesy of VOLKSWAGEN UNITED STATES, INC.

High pressure sensor -G65-

The signal generated by -G65- is provided as an input to the Climatronic Control Module -J255- and Motronic Engine Control Module (ECM) -J220-. As the amount of torque needed to drive the A/C compressor varies according to the refrigerant system pressure, the ECM processes this signal in order to enhance engine performance.

High pressure sensor -G65- -B-, transmits a square wave signal to -J255- and -J220- at a rate which varies according to the refrigerant system pressure. -J255- reacts to the pulse rate of the signal from -G65 as follows:

If the refrigerant system pressure rises, -J255- provides an appropriate signal to the Engine Control Module (ECM) -J220- via the Powertrain CAN Bus for radiator fan(s) speed control (radiator fan speed increases).

Where excessive or insufficient refrigerant system pressure is present (E.g.: insufficient air flow over condenser or when overcharged), compressor output is regulated via -J255- control of A/C Compressor Regulator Valve -N280- (no or very little load is applied).

A/C system hoses and lines

The mixture of refrigerant oil (PAG oil) and refrigerant R-134a attacks some metals and alloys (for example, copper) and breaks down certain hose material. Use only factory specified replacement hoses and lines.

Hoses and lines are fastened together with threaded couplings/fittings and are retained (to bodywork or components) with specially isolated hose clamps.



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A/C refrigerant system, replacing components

Before carrying out any work on the A/C refrigerant system, refer to all CAUTIONS and WARNINGS in A/C refrigerant system safety measures. Refer to Safety measures .

Replacement A/C compressors, evaporators and condensers supplied by the Parts Department are filled with Nitrogen. If gas (Nitrogen) does not escape when the component is first opened, the component may be faulty (leaking) and must not be installed.

Replacement A/C compressors are filled with the total refrigerant oil quantity needed for the entire refrigerant system.

Always replace the drier cartridge whenever the refrigerant system has been left open. Install immediately after opening to prevent moisture contamination of drier desiccant. Moreover, keep refrigerant system and other replacement components sealed for as long as possible to minimize the chance of dirt and moisture contamination.

Always plug open refrigerant line connections to prevent dirt and moisture contamination.

If the system has been discharged because of a damaged or leaking component (refrigerant hose/line, compressor, evaporator, condenser, etc.), flush the refrigerant system first with compressed air, then with Nitrogen (available locally) and collect the oil that runs out. This will remove the refrigerant oil which may be saturated with moisture.

If the compressor is not replaced after flushing the system, fill compressor with the correct type and quantity of refrigerant oil specified under A/C system capacities. Refer to Refrigerant (PAG) oil R-134a, capacities. Fill compressor with the total system oil capacity.

Also take into account whether or not vehicle is equipped with the Four-zone Climatronic system. Extra refrigerant oil must be added accordingly.

If the compressor is replaced, do not add additional oil as the total amount of oil required is already in the compressor.

NOTE: During servicing, all couplings, fittings and related fasteners must be torqued to specifications given in the respective system overviews.

Ensure that only special tools (as specified) are used while servicing.

CAUTION: Do not kink or bend refrigerant lines excessively. The internal structure of the line will become damaged.

Refrigerant lines must not be bent in a radius smaller than 100 mm.

CAUTION: DO NOT flush R-134a refrigerant system with R-11. R-11 is not compatible with refrigerant R134a and PAG oil and will cause total system contamination.



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Dispose of contaminated refrigerant oil following laws governing hazardous waste disposal. Do not combine any refrigerant oil with any other old oils such as engine oil or transmission fluid.

CLIMATRONIC

General information

Depending on engine and equipment level, Touareg from m.y 2004 are equipped with either a Dual-zone (right/left - front) or Four-zone (right/left - front/rear) 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 on vehicles with Dual-zone Climatronic, and also the rear seat passengers on vehicles with Four-zone Climatronic. 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 system's functional status (mode selection, temperature and air distribution) is displayed in LCD readouts.

All automatic or manual function selections are input into the A/C control head via buttons located below the display.

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 setting, operation modes, approximate outside temperature and blower speed are indicated on the A/C control head display at all times. The defrost, vent and footwell air distribution symbols only appear in the display when air distribution is selected manually (AUTO function override). During manual air distribution, the "AUTO" display remains off until such time the "AUTO" button is pressed.

The system can be switched off completely by pressing the front passenger "decrease fan speed" button until "OFF" appears in the display.

Climate control options



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Automatic temperature and fan speed mode

Manual temperature and fan speed mode

Manual selection of air recirculation mode

Manual selection of air flow to instrument panel vents

Manual selection of air flow to footwell vents

Manual selection of air flow to windshield defroster

On Board Diagnostic (OBD)

The Climatronic control module -J255- is controlled by an internal microprocessor with On Board Diagnostic (OBD) capability. If malfunctions, short or open circuits occur on monitored components, Diagnostic Trouble Codes (DTC) are stored in memory.

Perform On Board Diagnostic programs using VAS 5051/5052 Vehicle Diagnostic Testing and Information System in operating mode "Guided Fault Finding". Refer to Components, checking and adjusting with VAS 5051/5052 Vehicle Diagnostic Testing and Information System.

Components, checking and adjusting with VAS 5051/5052 Vehicle Diagnostic Testing and Information System

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 ">" to confirm.

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)"

Select "Heating, ventilation, air conditioning (Repair Gr. 01, 80...87"

NOTE: Pressing the button "AUTO" overrides any manually input settings.

In ECON operation, only the compressor is switched off. Heating and A/C operation continues to be controlled electronically.

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.

Climatronic, manual operation. Refer to Owner's Manual.

A malfunction is present, check the Diagnostic Trouble Code (DTC) memory using the VAS 5051/5052 Vehicle Diagnostic Testing and Information System in operating mode "Guided Fault Finding". Refer to On Board Diagnostic (OBD).



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Select "Systems capable of self-diagnosis"

Select "Climatronic"

Review the following information on the program procedures displayed. Choose desired program procedure and press ">" to confirm.

Follow tester prompts to perform desired program.

"Basic setting"

Basic setting of A/C system must be performed after the climatronic control module was replaced, an adjustment motor was replaced or an existing climatronic control module was recorded.

Select "Functions"

Select "Basic settings of climate system"

"Basic setting in case of service"

This basic setting procedure must be performed before the removal/replacement of any adjustment motors. During the procedure, all motors are automatically moved to a pre-determined "service" position.

Select "Functions"

Select "Basic setting in case of service"

"Coding Control module for climatronic"

This program must be performed after the climatronic control module was replaced or an existing climatronic control module requires recoding.

Select "Functions"

Select "Coding Control module for climatronic".

Dual-zone Climatronic, A/C control head display & functions



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Fig. 11: Identifying Dual-Zone Climatronic, A/C Control Head Display & Functions Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Left temperature regulator

Rotate to increase or decrease left front passenger compartment temperature setting.

2 - Automatic operation button

In automatic mode the Climatronic maintains the selected interior temperature automatically. With this setting the vent air temperature, the blower speed and the air distribution are controlled automatically.

3 - Left selected temperature display

Units can be changed from degrees Celsius to degrees Fahrenheit and vice versa. Refer to Temperature display units, changing (Celsius - Fahrenheit).



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4 - Left blower speed display

In automatic operation, the actual blower speed is displayed.

5 - Left blower speed selection button

6 - Upper air distribution button

7 - Center air distribution button

8 - Footwell air distribution button

9 - Right blower speed selection button

10 - Right blower speed display

In automatic operation the actual blower speed is displayed.

11 - Right selected temperature display


12 - Windshield defrost button

13 - Air recirculation button

Press to recirculate interior air when outside air quality is poor.

14 - Automatic air recirculation button

Press to automatically recirculate interior air when outside air quality is poor.

15 - Residual heat function button

When residual heat function is switched on the residual heat of engine is pumped through the heater core.

NOTE: Recirculating air is switched on automatically under the following conditions:

When the windshield washer system is operated.

When Sensor for air quality -G238- is activated.

When reverse gear is selected (from 2 minutes after engine start).

Blower speed "O" selected (Climatronic off).

When A/C Control Head -E87- (Climatronic) is switched off.



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16 - Rear defroster button

17 - Right temperature regulator

Rotate to increase or decrease right front passenger compartment temperature setting.

18 - "ECON" button

Press button to switch air conditioning (cooling) on and off.

In ECON mode the compressor is regulated to minimum cooling output. Heating and A/C operation continues to be controlled automatically.

Four-zone Climatronic, A/C control head display & functions

Fig. 12: Identifying Four-Zone Climatronic, A/C Control Head Display & Functions Courtesy of VOLKSWAGEN UNITED STATES, INC.



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2 - Left automatic operation button










9 - Windshield defrost button

10 - Rear defroster button

Depending on outside temperature, rear defroster remains on between 4 and 20 minutes.

11 - Air recirculation button

Press to recirculate interior air when outside air quality is poor.









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18 - Right automatic operation button




20 - Residual heat function button

When residual heat function is switched on the residual heat of engine is pumped through the heater core.

21 - Synchronization button

Synchronizes all seating position settings with driver's setting.

22 - Automatic air recirculation button

Press to automatically recirculate interior air when outside air quality is poor.

23 - Rear zone button

Press button to control rear seating position settings from front A/C control head.

24 - "ECON" button

Press button to switch air conditioning (cooling) on and off.

In ECON mode the compressor is regulated to minimum cooling output. Heating and A/C operation continues to be controlled automatically.

Temperature display units, changing (Celsius - Fahrenheit)

NOTE: Recirculating air is switched on automatically under the following conditions:

When the windshield washer system is operated.

When Sensor for air quality -G238- is activated.

When reverse gear is selected (from 2 minutes after engine start).

Blower speed "O" selected (Climatronic off).

When A/C Control Head -E87- (Climatronic) is switched off.



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Vehicles with menu selection in wiper switch

Fig. 13: Identifying Menu Buttons & Call Up Menu Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press button -B- for longer than 2 seconds, until main menu "Comfort setup" appears in display.

Press button -B- up or down to select "Units" from menu.

Press -A- to call up menu.

Vehicles with menu selection in Multi-function steering wheel

Fig. 14: Identifying Main Menu Comfort Setup Display Buttons Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press button -A- or -B- until main menu "Comfort setup" appears in display.

Rotate thumbwheel -C- to select "Units" from menu.

Press -thumbwheel -C- to call up menu.

Climatronic Control Module -J255-, multi-pin connector assignments

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

VAG 1598/42- test box



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VAG 1598/41 -2- adapter cable

Template VAG 1598/41-2/4-

Multi-pin connector -A-, in wiring diagram T24ca

Fig. 15: Identifying Multi Pin Connector Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Center Vent Adjusting Motor -V102- (closed)

2 - Defroster Flap Motor Position Sensor -G135-

3 - Recirculation Flap Motor Position Sensor -G143-, signal

4 - Fresh Air Intake Duct Temperature Sensor -G89-

5 - Right Front Upper Body Outlet Temperature Sensor -G386-, signal

6 - Right Footwell Vent Temperature Sensor -G262-, signal

7 - Left Footwell Vent Temperature Sensor -G261-, signal

8 - Actuator for temperature flap left -V158- (open)

9 - Center Vent Adjusting Motor -V102- (open)

10 - Evaporator Temperature Sensor -G308-

11 - Footwell Flap Motor Position Sensor -G468-

12 - Potentiometer-actuator for temperature flap right -G221-, signal

13 - Potentiometer-actuator for temperature flap left -G220-, signal

14 - Center Vent Motor Position Sensor -G467-, signal



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15 - Left Front Upper Body Outlet Temperature Sensor -G385-, signal

16 - Actuator for temperature flap left -V158- (closed)

17 - Servo motor for fresh-/recirculating air door -V154- (open)

18 - Servo motor for fresh-/recirculating air door -V154- (closed)

19 - Actuator for temperature flap right -V159- (open)

20- Actuator for temperature flap right -V159- (closed)

21 - Footwell Flap Motor -V261- (open)

22 - Footwell Flap Motor -V261- (closed)

23 - Side Vent Motor -V262- (open) - Dual-zone Climatronic only

23 - Left Side Vent Motor -V299- (open) - Four-zone Climatronic only

24 - Side Vent Motor -V262- (closed) - Dual-zone Climatronic only

24 - Left Side Vent Motor -V299- (closed) - Four-zone Climatronic only

Multi-pin connector -B-, in wiring diagram T24cb


1 - Right Side Vent Motor -V300- - Four-zone Climatronic only

5 - Right Front Defrost/Upper Body Shut-off Flap Motor Position Sensor -G317- - Four-zone Climatronic only

9 - Right Side Vent Motor -V300- - Four-zone Climatronic only



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10 - Right Front Upper Body Outlet Position Sensor -G388- - Four-zone Climatronic only

11 - A/C Compressor Regulator Valve -N280-

14 - Right Footwell Flap Motor Position Sensor -G140- - Four-zone Climatronic only

17 - Right Center Vent Motor -V111- - Four-zone Climatronic only

18 - Right Center Vent Motor -V111- - Four-zone Climatronic only

19 - Actuator for temperature flap right -V159- - Four-zone Climatronic only

20 - Actuator for temperature flap right -V159- - Four-zone Climatronic only

Multi-pin connector -C-, in wiring diagram T24cc


5 - Side Vent Motor Position Sensor -G469- - Dual-zone Climatronic only

5 - Left Front Defrost/Upper Body Shut-off Flap Motor Position Sensor -G318- - Four-zone Climatronic only

6 - Defroster Flap Motor -V107- (open)

7 - Sunlight Photo Sensor -G107-

8 - Front Blower Regulation Sensor (Bitron) -G462- (voltage supply)

12 - Front Blower Regulation Sensor (Bitron) -G462- (feedback voltage)

14 - Residual Heat Relay -J708-




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17 - CAN Bus - High

18 - CAN Bus - Low

19 - Sensor for air quality -G238-, signal

21 - Refrigerant Temperature Sensor -G454-

23 - High Pressure Sensor -G65-

24 - Defroster Flap Motor -V107- (closed)

Multi-pin connector -D-, vacant


Multi-pin connector -E-, in wiring diagram T12cb


1 - + 5V for control motors and sunlight penetration sensor



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2 - Front Blower Regulation Sensor (Bitron) -G462- (activation)


8 - Control motor signal Ground (GND) and temperature sensor

9 - Terminal 31 - Ground (GND)



12 - Signal Ground (GND) for temperature sensor

Four-zone Climatronic, rear A/C control head display & functions



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Fig. 20: Identifying Four-Zone Climatronic, Rear A/C Control Head Display & FunctionsCourtesy of VOLKSWAGEN UNITED STATES, INC.



2 - Left automatic operation button






5 - Left side window air distribution button

6 - Left side window - center air distribution button

7 - Right side window air distribution button

8 - Right side window - center air distribution button





11 - Right automatic operation button






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14 - Right footwell air distribution button

15 - Left footwell air distribution button


Rear A/C Control Head (Climatronic) -E265-, multi-pin connector assignments

Multi-pin connector -A-, vacant

Multi-pin connector -B-, in wiring diagram T20ca

Fig. 21: Identifying Multi Pin Connector B, C, & D Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Rear Blower Regulation Sensor -G463- (voltage supply)

2 - Left Rear Air Flap Motor -V239-

3 - Right Rear Air Flap Motor -V240-



7 - Left B-Pillar/Footwell Shut-off Flap Motor -V212-

8 - Right B-Pillar/Footwell Shut-off Flap Motor -V211-

9 - Left Rear Upper Body Vent Motor -V315-




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12 - Right Rear Temperature Flap Motor -V314-


14 - Left Rear Temperature Flap Motor -V313-


16 - Right Rear Upper Body Vent Motor -V316-

17 - Right Rear Upper Body Vent Motor -V316-

Multi-pin connector -C-, in wiring diagram T16ca




4 - Left Rear Air Flap Position Sensor -G389-

5 - Left B-Pillar/Footwell Shut-off Flap Motor Position Sensor -G329-

6 - Right B-Pillar/Footwell Shut-off Flap Motor Position Sensor -G328-

7 - Right Rear Air Flap Position Sensor -G390-

12 - Rear Blower Regulation Sensor -G463- (pulse-width modulation activation)

13 - Right Rear Upper Body Vent Position Sensor -G472-

14 - Left Rear Temperature Flap Position Sensor -G391-



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15 - Right Rear Temperature Flap Position Sensor -G392-

16 - Left Rear Upper Body Vent Position Sensor -G471-

Multi-pin connector -D-, in wiring diagram T16cb


1 - Terminal 30 (B+)

3 - 5 volt reference voltage supply for rear position sensors -G328-, -G329-, -G389-, -G390-, -G391-, -G392-, -G471- and -G472-

6 - Ground (GND) signal for -G405 and -G406-

7 - Ground (GND) signal for rear position sensors -G328-, -G329-, -G389-, -G390-, -G391-, -G392-, -G471- and -G472-

8 - CAN Bus - High

10 - Right Rear Vent Temperature Sensor -G406-

11 - Left Rear Vent Temperature Sensor -G405-

12 - Rear Evaporator temperature Sensor -G464-

13 - Rear Blower Regulation Sensor -G463- (feedback voltage)

14 - CAN Bus shielding


16 - CAN Bus - Low



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Climatronic components, overview

Fig. 24: Climatronic Components, Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.

Climatronic components in passenger compartment, servicing. Refer to Climatronic components in passenger compartment, servicing


Removing and installing. Refer to High Pressure Sensor -G65-, removing and installing


Removing and installing. Refer to Fresh Air Intake Duct Temperature Sensor -G89-, removing and installing



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3 - Front Blower Regulation Sensor (Bitron) -G462-

Removing and installing. Refer to Front Blower Regulation Sensor (Bitron) -G462-, removing and installing

4 - Front Blower Regulation Motor (Bitron) -V305-

Removing and installing. Refer to Front Blower Regulation Motor (Bitron) -V305-, removing and installing


Removing and installing. Refer to Sunlight Photo Sensor -G107-, removing and installing

6 - Right Footwell Vent Temperature Sensor -G262-

Removing and installing. Refer to Right Footwell Vent Temperature Sensor -G262-, removing and installing


Removing and installing. Refer to Evaporator Temperature Sensor -G308-, removing and installing

8 - Right Front Upper Body Outlet Temperature Sensor -G386-

Removing and installing. Refer to Right Front Upper Body Outlet Temperature Sensor -G386-, removing and installing

9 - Left Front Upper Body Outlet Temperature Sensor -G385-

Removing and installing. Refer to Left Front Upper Body Outlet Temperature Sensor -G385-, removing and installing

10 - Climatronic Control Module -J255-

Climatronic Control Module -J255-, A/C Control Head -E87- and Instrument Panel Interior Temperature Sensor -G56- with Interior Temperature Sensor Fan -V42- are integrated and cannot be serviced separately

Removing and installing. Refer to Climatronic Control Module -J255-, removing and installing

11 - Coolant Pump -V36-

Gasoline engines only

12 - Sensor for air quality -G238-



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Removing and installing. Refer to Sensor for air quality -G238-, removing and installing

13 - Left Footwell Vent Temperature Sensor -G261-

Removing and installing. Refer to Left Footwell Vent Temperature Sensor -G261-, removing and installing


-N280- integrated with compressor and cannot be serviced separately.

Removing and installing compressor. Refer to A/C compressor and bracket - 6-cylinder engine, assembly


Removing and installing. Refer to Refrigerant Temperature Sensor -G454-, removing and installing

16 - Outside Air Temperature Sensor -G17-

Removing and installing. Refer to Outside Air Temperature Sensor -G17-, removing and installing

MANUAL A/C SYSTEM, DUAL-ZONE AND FOUR-ZONE CLIMATRONIC CONTROL AND REGULATION COMPONENTS, FRONT

General information

Climatronic Control Module -J255-, removing and installing

Removing

Remove radio/navigation unit

Refer to 91 RADIO, TELEPHON E, NAVIGATION, TRIP COMPUTER

NOTE: Servicing refrigerant circuit. Refer to General information.

Following repairs and/or replacement of components, initiate basic setting. Refer to Components, checking and adjusting with VAS 5051/5052 Vehicle Diagnostic Testing and Information System.


Determine system or component fuse/fuses using applicable wiring diagram or owner's manual.

Remove system or component fuse/fuses.



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Remove outer switches or switch blanks from switch panel.

Fig. 25: Pressing Lock With Screwdriver Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press lock in direction of -arrow- and slide control module out from instrument panel.

Disconnect electrical connection.

Installing

Install in reverse order of removal, noting the following:

If climatronic control module was replaced, initiate basic setting and code control module. Refer to Components, checking and adjusting with VAS 5051/5052 Vehicle Diagnostic Testing and Information System.

Sunlight Photo Sensor -G107-, removing and installing

Removing

NOTE: Illustration shows switch panel removed.

CAUTION: In the event of a collision where occupants may make contact with interior trim, some interior knobs and buttons are designed to break away in a controlled manner in order to protect the occupant. When installing the A/C control head, do not press on control buttons or display in order to engage locking tabs. Damage will result.



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Fig. 26: Unclipping Photosensor Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unclip photosensor -1- up and out from instrument panel in direction of -arrows-.


Installing

Install in reverse order of removal.

Dust and pollen filter with activated charcoal filter element, function

A dust and pollen filter with additional activated charcoal filter element is installed together with the Sensor for air quality -G238- (Refer to Sensor for air quality -G238-, function).

While he activated charcoal filter element filters out dust and pollen from the air drawn into the heating and A/C system, it also filters out ozone, benzol, nitrogen dioxide etc. gasses.

The role of the activated charcoal filter is to store the impurities in the air drawn into the heating and A/C system until the fresh air flap is closed and the air conditioning system is operating in air recirculation mode. The Climatronic Control Module -J255- switches from fresh air to air recirculation mode as soon as the air quality sensor detects gas-type impurities in the surrounding air (the "Automatic air recirculation" function must be selected).

The activated charcoal layer in the dust and pollen filter reacts in different ways to undesirable substances in the air:

- Certain undesirable substances are stored permanently in the activated charcoal layer.

- Others are converted into substances similar to the way a catalytic converter functions.

- For other substances, the activated charcoal functions like a condenser. With an increase in undesirable substances, these are stored continually until a predetermined level of saturation is achieved. With a decrease in undesirable substances, the activated charcoal layer gradually releases the particles.

Because the activated charcoal layer permanently stores a percentage of particles, replacing the dust and pollen filter before the prescribed replacement period would be advantageous, if:



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- the vehicle is driven in areas with heavy air pollution.

- the vehicle is driven mainly with the "Automatic air recirculation" function switched off.

- the vehicle is not fitted with an air quality sensor (does not feature "Automatic air recirculation" function).

On vehicles with air quality sensor, the air conditioning system should generally be operated with the "Automatic air recirculation" function activated. If it is necessary or desired to switch the function off, the following should be observed:

-The activated charcoal layer in the dust and pollen filter will become saturated after a certain period of time.

-A saturated filter is not capable of storing any more undesirable substances and these will flow unrestricted into the vehicle.

The main function of the dust and pollen filter and the air quality sensor is to prevent high and sustained levels of pollution from entering the passenger compartment of the vehicle. To allow this to be effective, the following should be observed:

-If the vehicle is being driven in an area with relatively clean air (air has low content of undesirable substances), switching over from fresh air to air recirculation mode is actuated at a later stage than in an area with a high level of pollution (e.g. industrial area).

-Changing over from fresh air to air recirculation mode is dependent on the level of pollution only if the level of undesirable substances increases (e.g. when driving through cloud of carbon rich exhaust fumes from diesel powered HGV).

The filter with activated charcoal can be installed in all vehicle types (also vehicles without air quality sensor). These vehicles, however, have the same limitations for operation of an air conditioning system with deactivated "Automatic air recirculation".

Dust and pollen filter with activated charcoal filter element, removing and installing

The dust and pollen filter element (with activated charcoal filter) is located in front passenger footwell.

Removing

Remove footwell trim on front passenger side.

Refer to 68 - INTERIOR EQUIPMENT



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Fig. 27: Identifying Screws & Filter Element Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove screws -1-.

Filter element can be removed after removing cover -2-.

Installing


Fig. 28: Identifying Installed Position Of Filter Courtesy of VOLKSWAGEN UNITED STATES, INC.

Note installed position of filter -arrows-.

Sensor for air quality -G238-, function

The air quality sensor detects the quality of the outside air and the presence of gasoline and/or diesel fumes.

The Climatronic Control Module -J255- analyses the signal from the Sensor for air quality -G238-. The

NOTE: Replacement interval for dust and pollen filter with activated charcoal filter. Refer to 01 - MAINTENANCE



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air conditioning system is actuated depending on the degree and type of gas/fume detected in the outside air.

-At an ambient temperature higher than approx. + 2°C, recirculated air is actuated when there is a nominal increase in hazardous substances in the outside air.

-At an ambient temperature between approx. + 2°C and approx. - 5°C, switching over to recirculated air is not actuated until there is a strong increase in hazardous substances in the outside air. The compressor is also actuated at the same time.

-At an ambient temperature less than approx. - 5°C, again, switching over to recirculated air is not actuated until there is a strong increase in hazardous substances in the outside air, and then only for approx. 15 sec (the compressor is not actuated). If the level decreases, the air conditioning system is switched back to fresh air mode.

The "Automatic air recirculation" function can be switched off at any time. If the function is active, the compressor is actuated when "Automatic air recirculation" is required, even at ambient temperatures less than + 2°C. At temperatures less than approx. - 5°C, operation of the compressor is not possible.

On vehicles with "Automatic air recirculation", the compressor can also be actuated, even if the recirculated air function has been activated manually (via Recirculation button), up to a temperature from approx. - 5°C.

In order that the air conditioning system does not operate continually in recirculated air mode in areas with consistently high levels of gas/fumes in the outside air, the sensor features an intelligent function (it adapts its sensitivity to the current environmental conditions).

If the level of gas/fumes in the outside air remains relatively high over a long period of time, the intelligent sensor starts to adapt itself to the change in environmental conditions so that, generally, the demand for recirculated air is less than 12 minutes in areas where the outside air quality is poor. If a succession of peaks in poor air quality is detected, the air conditioning system can operate over a longer period of time in recirculated air mode.

A certain amount of time is required for repositioning of the air conditioning system flaps. In order that undesirable gas/fumes enter the passenger compartment (e.g. when driving through a cloud of diesel smoke) in the time it takes for the flaps to close, a dust and pollen filter with an activated charcoal layer is installed. A saturated filter is not capable of performing this function and should be replaced. Refer to Dust and pollen filter with activated charcoal filter element, removing and installing.

To prevent frequent operation of the recirculation/fresh air flap, the flap is not actuated immediately if there is a nominal increase in undesirable gas/fumes in the outside air (the sensor does not send a message to the Climatronic Control Module -J255-). For this the activated charcoal filter insert in the dust and pollen filter is adequate. Refer to Dust and pollen filter with activated charcoal filter element, function.

To prevent frequent operation of the recirculation/fresh air flap, the message for "Automatic air recirculation" from the sensor continues for at least 25 sec (minimum waiting period), even if the hazardous content in the outside air reduces to such a degree that recirculated air would no longer be necessary.

If the compressor is switched off (e.g. in ECON mode), the maximum period of "Automatic air recirculation" is restricted to approx. 15 sec by the Climatronic Control Module -J255-, so that



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condensation does not build up on the windows.

To ensure windows are cleared of condensation as quickly as possible, the Climatronic Control Module -J255- blocks the recirculation of air in the "Defrost" mode.

The Sensor for air quality -G238- requires approx. 30 sec to become operational once the ignition has been switched on (warm-up time). In this time, the sensor does not request "Automatic air recirculation" from the Climatronic Control Module -J255-.

The Sensor for air quality -G238- is a highly sensitive electronic component which, upon direct contact with solvents, fuels and certain chemical compositions, could be damaged beyond repair. For this reason, do not install sensors that may have come into contact with these substances.

Sensor for air quality -G238-, removing and installing

Removing

Remove left plenum chamber cover.

Fig. 29: Identifying Air Quality Sensor Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unclip air quality sensor -1- from plenum chamber cover.


Installing

NOTE: The Sensor for air quality -G238- is installed in the left front plenum chamber.

The Sensor for air quality -G238- is a highly sensitive electronic component that could be damaged beyond repair by direct contact with solvents, fuels and certain chemical compositions.

Do not install a sensor that has been kept, for example, in a tool box.

Do not store removed sensors in areas where they can come into contact with solvents, fuels and certain chemical compositions (fluids or vapors).



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Fresh Air Intake Duct Temperature Sensor -G89-, removing and installing

Removing

Remove front passenger footwell trim


Fig. 30: Exploded View Of Temperature Sensor Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove temperature sensor -1- in direction of -arrow-.


Installing


Outside Air Temperature Sensor -G17-, removing and installing

Removing

Remove radiator grille.

Refer to 66 - EXTERIOR EQUIPMENT



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Fig. 31: Unclipping Temperature Sensor From Lock Support Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unclip temperature sensor -1- from lock support.


Installing


Climatronic components in passenger compartment, servicing



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Fig. 32: Identifying Climatronic Components Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - A/C Control Head -E87- and Climatronic Control Module -J255-

A/C Control Head -E87-, Climatronic Control Module -J255- and Instrument Panel Interior Temperature Sensor -G56- with Interior Temperature Sensor Fan -V42- are integrated and cannot be serviced separately

Removing and installing. Refer to Climatronic Control Module -J255-, removing and installing

2 - Retaining plate with Defroster Flap Motor -V107-, Side Vent Motor -V262- and Center Vent Adjusting Motor -V102-

Removing and installing. Refer to Upper retaining plate for Defroster Flap Motor -V107-, Side Vent Motor -V262- and Center Vent Adjusting Motor -V102-, removing



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3 - Air distribution housing, upper part

4 - Left Front Upper Body Outlet Temperature Sensor -G385-

Removing and installing. Refer to Left Front Upper Body Outlet Temperature Sensor -G385-, removing and installing

5 - Right Front Upper Body Outlet Temperature Sensor -G386-

Removing and installing. Refer to Right Front Upper Body Outlet Temperature Sensor -G386-, removing and installing

6 - Actuator for temperature flap right -V159-

Removing and installing. Refer to Actuator for temperature flap right -V159-, removing and installing

7 - Glovebox cooling vent


Removing and installing. Refer to Evaporator Temperature Sensor -G308-, removing and installing


Removing and installing. Refer to Fresh Air Intake Duct Temperature Sensor -G89-, removing and installing

10 - Front Blower Regulation Sensor (Bitron) -G462-

Removing and installing. Refer to Front Blower Regulation Sensor (Bitron) -G462-, removing and installing

11 - Front Blower Regulation Motor (Bitron) -V305-

Removing and installing. Refer to Front Blower Regulation Motor (Bitron) -V305-, removing and installing

12 - Servo motor for fresh-/recirculating air door -V154-

Removing and installing. Refer to Servo motor for fresh-/recirculating air door -V154-, removing and installing

13 - Dust and pollen filter with activated charcoal filter element

Removing and installing. Refer to Dust and pollen filter with activated charcoal filter element, removing and installing



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14 - Right Footwell Vent Temperature Sensor -G262-

Removing and installing. Refer to Right Footwell Vent Temperature Sensor -G262-, removing and installing

15 - Left Footwell Vent Temperature Sensor -G261-

Removing and installing. Refer to Left Footwell Vent Temperature Sensor -G261-, removing and installing

Front Blower Regulation Motor (Bitron) -V305-, removing and installing

Removing



Fig. 33: Exploded View Of Electrical Connector & Screws Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove screws -1-.

Disconnect electrical connection -A-.

Installing


Front Blower Regulation Sensor (Bitron) -G462-, removing and installing






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Removing

Open glove compartment.

Fig. 34: Identifying Scribed Area Courtesy of VOLKSWAGEN UNITED STATES, INC.

Cut out scribed area -arrows-.


Fig. 35: Identifying Connector Screws Courtesy of VOLKSWAGEN UNITED STATES, INC.




CAUTION: Electrical cables are located directly behind cutting area. Blade on cutting appliance must not exceed 15mm.



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Remove screws -1-.

Remove control module.

Installing


Obtain and install cover for opening

Right Footwell Vent Temperature Sensor -G262-, removing and installing

Removing

Remove lower instrument panel trim:

Refer to 70 - INTERIOR TRIM

Fig. 36: Turning Temperature Sensor Courtesy of VOLKSWAGEN UNITED STATES, INC.

Turn temperature sensor -1- in direction of -arrow- approx. 90°.


Remove sensor.

WARNING: Heat sink may be hot. If blower was used recently, let heat sink cool before removal.






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Installing


Left Footwell Vent Temperature Sensor -G261-, removing and installing

Removing



Fig. 37: Turning Temperature Sensor Courtesy of VOLKSWAGEN UNITED STATES, INC.



Remove sensor.

Installing


Right Front Upper Body Outlet Temperature Sensor -G386-, removing and installing









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Removing



Fig. 38: Turning Temperature Sensor Connector A Courtesy of VOLKSWAGEN UNITED STATES, INC.



Remove sensor.

Installing


Left Front Upper Body Outlet Temperature Sensor -G385-, removing and installing

Removing



Remove retaining plate from upper control motors. Refer to Upper retaining plate for Defroster Flap Motor -V107-, Side Vent Motor -V262- and Center Vent Adjusting Motor -V102-, removing






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Fig. 39: Turning Temperature Sensor Connector Courtesy of VOLKSWAGEN UNITED STATES, INC.



Remove sensor.

Installing


Evaporator Temperature Sensor -G308-, removing and installing

Removing








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Fig. 40: Turning Temperature Sensor Connector Courtesy of VOLKSWAGEN UNITED STATES, INC.


Disconnect electrical connection.-A-.

Remove sensor.

Installing


Front evaporator water drain hose and valve, checking



Fig. 41: Identifying Front Evaporator Water Drain Hose And Valve Courtesy of VOLKSWAGEN UNITED STATES, INC.

It should be possible to fit hose -A- to the heating and A/C unit connection without force.

Drain hose should not be kinked by the insulation mat.



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Correct insulation mat as necessary.

Drain hose must be fitted securely to the heating and A/C unit connection.

Evaporator water drain valve is located in lower right of engine compartment below bulkhead.

Check valve -1- from below when vehicle is raised.

A/C flap motors, general information

NOTE:

Fig. 42: Identifying Drive Assembly Valve Courtesy of VOLKSWAGEN UNITED STATES, INC.

Valve -1- is shown with drive assembly removed.

The condensation drainage valve must not be bonded by wax or underbody protection, it must close correctly.


Determine system or component fuse/fuses using applicable wiring diagram or owner's manual.

Remove system or component fuse/fuses.

NOTE: Prior to motor removal, initiate "Basic setting in case of service". Refer to Components, checking and adjusting with VAS 5051/5052 Vehicle Diagnostic Testing and Information System.

Following repairs and/or replacement of motors, initiate basic setting. Refer to Components, checking and adjusting with VAS 5051/5052 Vehicle Diagnostic Testing and Information System.

If malfunction message "Adaptation limit exceeded" is present, check motor/flap connecting piece. There should be no play between motor shaft and connecting piece.



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Dual-zone Climatronic - A/C flap motors in heating and A/C unit, overview

Fig. 43: Identifying Dual-Zone Climatronic - A/C Flap Motors In Heating And A/C Unit Courtesy of VOLKSWAGEN UNITED STATES, INC.

Refer to VAS 5051/5052 Vehicle Diagnostic Testing and Information System. Use in operating mode "Guided Fault Finding"

1 - Defroster Flap Motor -V107-

With Defroster Flap Motor Position Sensor -G135-

Removing and installing. Refer to Defroster Flap Motor -V107-, removing and installing

2 - Side Vent Motor -V262-

NOTE: Checking flap motors:



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With Side Vent Motor Position Sensor -G469-

Removing and installing. Refer to Side Vent Motor -V262-, removing and installing

3 - Center Vent Adjusting Motor -V102-

With Center Vent Motor Position Sensor -G467-

Removing and installing. Refer to Center Vent Adjusting Motor -V102-, removing and installing

4 - Retaining plate with Defroster Flap Motor -V107-, Side Vent Motor -V262- and Center Vent Adjusting Motor -V102-

Removing and installing. Refer to Upper retaining plate for Defroster Flap Motor -V107-, Side Vent Motor -V262- and Center Vent Adjusting Motor -V102-, removing

5 - Retaining plate with Actuator for temperature flap right -V159-

On air distribution housing on right side

6 - Actuator for temperature flap right -V159-

On air distribution housing on right side

With Potentiometer-actuator for temperature flap right -G221-

Removing and installing. Refer to Actuator for temperature flap right -V159-, removing and installing

7 - Footwell Flap Motor -V261-

With Footwell Flap Motor Position Sensor -G468-

Removing and installing. Refer to Footwell Flap Motor -V261-, removing and installing

8 - Retaining plate with Footwell Flap Motor -V261- and Actuator for temperature flap left -V158-

Removing and installing. Refer to Lower retaining plate for Footwell Flap Motor -V261- and Actuator for temperature flap left -V158-

9 - Actuator for temperature flap left -V158-

With Potentiometer-actuator for temperature flap left -G220-

Removing and installing. Refer to Actuator for temperature flap left -V158-, removing and installing

Servo motor for fresh-/recirculating air door -V154-, removing and installing

Removing




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Fig. 44: Identifying Servo Motor Components Courtesy of VOLKSWAGEN UNITED STATES, INC.


Remove screws -1-.

Unclip control -B-.

Remove motor.

Installing


Initiate basic setting. Refer to Components, checking and adjusting with VAS 5051/5052 Vehicle Diagnostic Testing and Information System.

Upper retaining plate for Defroster Flap Motor -V107-, Side Vent Motor -V262- and Center Vent Adjusting Motor -V102-, removing

Removing

Initiate VAS 5051/5052 function "Basic setting in case of service". Refer to Components, checking and adjusting with VAS 5051/5052 Vehicle Diagnostic Testing and Information System.

When ""SF"" appears on left of Climatronic display, switch ignition off.

Remove lower retaining plate for Footwell Flap Motor -V261- and Actuator for temperature flap left -V158-. Refer to Lower retaining plate for Footwell Flap Motor -V261- and Actuator for temperature flap left -V158-

NOTE: Motors can only be reinstalled when both the system and motors themselves are set in the service position.



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Fig. 45: Identifying Defroster Flap Motor, Side Vent Motor, & Center Vend Adjusting Motor Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove screws -3-.


Pull retaining plate and control motors out downward.

Installing


Fig. 46: Identifying Guide & Control Motor Mounting Courtesy of VOLKSWAGEN UNITED STATES, INC.

Ensure guide -A- of control motors fit into mounting -B-.


Defroster Flap Motor -V107-, removing and installing

NOTE: Screws -1- should not be loosened or removed in order to remove retaining plate. They are used for guiding the retaining plate only.



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Removing

Remove upper retaining plate -2- for Defroster Flap Motor -V107-, Side Vent Motor -V262- and Center Vent Adjusting Motor -V102-. Refer to Upper retaining plate for Defroster Flap Motor -V107-, Side Vent Motor -V262- and Center Vent Adjusting Motor -V102-, removing


Remove screws -4- (qty: 3) from defroster flap control motor -A-.

Remove control motor from retaining plate -2-.

Installing



Side Vent Motor -V262-, removing and installing

Removing




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Remove screws -4- (qty: 3) from side vent control motor -B-.


Installing



Center Vent Adjusting Motor -V102-, removing and installing

Removing





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Remove screws -4- (qty: 3) from center vent control motor -C-.


Installing



Lower retaining plate for Footwell Flap Motor -V261- and Actuator for temperature flap left -V158-


When "SF" appears on the left Climatronic display, switch ignition off.



Removing and installing entry and start authorization control module:

Refer to 94 - LIGHTS, SWITCHES - EXTERIOR

Removing relay carrier in left front footwell:

Refer to 97 - WIRING

Remove onboard supply control module:





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Fig. 50: Identifying Servo Motors, Screws & Bracket Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove screws -B-.


Pull retaining plate and control motors out downward.

Installing





Actuator for temperature flap left -V158-, removing and installing




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Removing


Remove lower retaining plate -2- for Footwell Flap Motor -V261- and Actuator for temperature flap left -V158-. Refer to Lower retaining plate for Footwell Flap Motor -V261- and Actuator for temperature flap left -V158-

Remove screws -4- (qty: 3) from left temperature flap control motor -A-.


Installing



Footwell Flap Motor -V261-, removing and installing

Removing

Remove lower retaining plate -2- for Footwell Flap Motor -V261- and Actuator for temperature flap left -V158-. Refer to Lower retaining plate for Footwell Flap Motor -V261- and Actuator for temperature flap left -V158-



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Remove screws -4- (qty: 3) from footwell flap control motor -B-.


Installing



Actuator for temperature flap right -V159-, removing and installing

Removing


When "SF" appears on the left of the Climatronic operating display, switch ignition off.






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Fig. 54: Identifying Retaining Plate, Screws & Servo Motor Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove screws -5-.


Pull retaining plate with control motors out downward.

Remove screws -3- (qty: 3) from temperature flap control motor -4-.

Remove control motor from retaining plate -1-

Installing




Initiate basic setting. Refer to Components, checking and adjusting with VAS 5051/5052 Vehicle




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Diagnostic Testing and Information System.

Ventilation system, checking

Checking

Remove rear bumper cover

Refer to 63 - BUMPERS

Fig. 56: Identifying Vent Frame Courtesy of VOLKSWAGEN UNITED STATES, INC.

Sealing lips in vent frame -1- must move and close freely.

FOUR-ZONE CLIMATRONIC CONTROL AND REGULATION COMPONENTS, REAR

Rear A/C Control Head (Climatronic) -E265-, removing and installing

Special tools, workshop equipment and auxiliary items required

NOTE: Passenger compartment air is vented to the outside trough openings in the luggage compartment trim.

In order for the ventilation system to work properly, these openings must not be blocked.

Vent frames are located in both rear quarter panels, behind the bumper cover.



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Fig. 57: Releasing Lever T10039 Courtesy of VOLKSWAGEN UNITED STATES, INC.

T10039/1 release lever



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Fig. 58: Exploded View Of Rear A/C Control Head (Climatronic)Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Trim

Removing

Carefully pry up from bottom using T10039/1

2 - Screws

Qty: 4

5 Nm

3 - Mounting frame

Removing

Remove screws -2-.

Pull mounting frame with vent and control head out from console.

Disconnect electrical connections.

Rear heating and A/C unit, component overview



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Fig. 59: Identifying Rear Heating And A/C Unit Components Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Left lower B-pillar air channel

Removing:

Remove driver's seat

Refer to 72 - SEAT - FRAMES

NOTE: Servicing refrigerant circuit. Refer to General information.

Following repairs and/or replacement of components, initiate basic setting. Refer to Components, checking and adjusting with VAS 5051/5052 Vehicle Diagnostic Testing and Information System.



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Remove left B-pillar trim


Lift carpet and remove two screws (2 Nm)

2 - Left footwell air channel

Removing:





Removing:

Remove center console


Remove screws at motor.


Removing:





Remove screws at motor


Removing:




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Remove screws at motor.


Removing:

Remove passenger's seat




Remove screws at motor

7 - Right B-pillar & footwell air channel with shut-off flap

Removing




8 - Right footwell air channel

Removing:




9 - Right lower B-pillar air channel

Removing:





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Remove right B-pillar trim



10 - Right air channel

Removing

Remove rear seat cushion and backrest


Lift carpet and remove screw at air channel (1.4 Nm)

11 - Right upper B-pillar air channel

Removing:





12 - Right B-pillar air outlet

Removing:





13 - Right air channel

Removing




Microsoft



Lift carpet and remove screw at air channel (1.4 Nm)


Removing. Refer to Right Rear Vent Temperature Sensor -G406-, removing and installing.

15 - Right rear air channel

Removing

Remove left rear side trim


16 - Rear heating and A/C unit

Removing and installing. Refer to Rear heating and A/C unit, removing and installing.

Rear heating and A/C unit, service position. Refer to Rear heating and A/C unit, service position

17 - Left rear air channel

Removing




Removing. Refer to Left Rear Vent Temperature Sensor -G405-, removing and installing.

19 - Left air channel

Removing



Lift carpet and remove two screws (1.4 Nm) and nut (2 Nm) at air channel

20 - Left air channel

Removing



Microsoft




Lift carpet and remove screw (1.4 Nm) at air channel

21 - Left B-pillar & footwell air channel with shut-off flap

Removing




22 - Left B-pillar air outlet

Removing:





23 - Left upper B-pillar air channel

Removing:





Rear heating and A/C unit, service position



Microsoft


Fig. 60: Identifying Screws & Rear Heating & A/C Unit Courtesy of VOLKSWAGEN UNITED STATES, INC.



NOTE: Service position allows access to unit components (motors, etc.) for servicing.

Servicing refrigerant circuit. Refer to General information.


Refrigerant hoses remain connected when rear heating and A/C unit is in service position.



Microsoft


Remove screws -A- (8 Nm)

Tilt complete unit to right.

Left Rear Air Flap Motor -V239-, removing and installing

Removing

Bring rear heating and A/C unit into service position. Refer to Rear heating and A/C unit, service position.

Fig. 61: Removing/Installing Servo Motor Screws Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove screws -1-


Remove motor from housing

Installing



Right Rear Air Flap Motor -V240-, removing and installing

NOTE: After returning rear heating and A/C unit from service position (and/or removing and reinstalling) always ensure proper installation of rear evaporator water drain hose/valve. Refer to Rear evaporator water drain valve/hose, checking.

NOTE: After returning rear heating and A/C unit from service position, always ensure proper installation of rear evaporator water drain hose/valve. Refer to Rear evaporator water drain valve/hose, checking.



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Removing



Fig. 62: Identifying Electrical Connector Screws Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove screws -1-.


Remove motor from housing.

Installing



Left Rear Temperature Flap Motor -V313-, removing and installing

Removing




Microsoft


Fig. 63: Identifying Temperature Flap Motor & Screws Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove screws -2-


Remove motor from housing

Installing



Right Rear Temperature Flap Motor -V314-, removing and installing

Removing






Microsoft


Fig. 64: Identifying Right Rear Temperature Flap Motor, Lever & Screws Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unhook lever from motor -2-.

Remove screws -1-.



Installing



Left Rear Vent Temperature Sensor -G405-, removing and installing

Removing

Remove left rear seat backrest


Carefully pry up floor mats in area of sensor.



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Fig. 65: Twisting To Loosen Sensor Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosen sensor by twisting in direction of -arrow-.

Remove sensor from air channel.

Installing

Install in reverse order of removal

Right Rear Vent Temperature Sensor -G406-, removing and installing

Removing

Remove luggage compartment loading floor trim


Fig. 66: Twisting Sensor To Loosen It Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosen sensor by twisting in direction of -arrow-.

Remove sensor from air channel.



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Installing

Install in reverse order of removal

Rear Blower Regulation Motor (Bitron) -V306-, removing and installing

Removing


Fig. 67: Lifting Latch to Rotate Motor Assembly & Disconnect Electrical Connector Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical connection -1- at motor.

Lift latch slightly -2- and rotate motor assembly in direction of -arrow-.


Installing


Rear Blower Regulation Sensor-G463-, removing and installing

Removing






Microsoft


Disconnect electrical connections at sensor.

Fig. 68: Identifying Sensor Housing Screws Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove screws -1-

Remove sensor from housing.

Installing


Rear evaporator water drain valve/hose, checking

Check valve as follows to ensure proper function:

Fig. 69: Fitting Drain Hose Securely To Housing Courtesy of VOLKSWAGEN UNITED STATES, INC.

Drain hose must fit securely on housing -arrow- and must not be kinked or twisted.

Valve must not be blocked by debris or wax.

Valve must open and close freely.



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Lift vehicle and check valve from underneath.

A/C COMPRESSOR AND BRACKET

A/C compressor and bracket - 6-cylinder engine, assembly


Fig. 70: Torque Wrench V.A.G 1331 Courtesy of VOLKSWAGEN UNITED STATES, INC.

VAG 1331 Torque wrench (or 5-50 Nm equivalent)

Fig. 71: A/C Service Station - VAS 6007A Courtesy of VOLKSWAGEN UNITED STATES, INC.

If it is necessary to open the refrigerant circuit, for example when replacing compressor, use refrigerant recycling/recovery unit Kent-Moore ACR4 (or UL approved equivalent - VAS 6007A illustrated for reference only).

NOTE:



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1 - Compressor

Removing without opening refrigerant circuit:

Removing ribbed belt

Fig. 72: Exploded View Of A/C Compressor Components Courtesy of VOLKSWAGEN UNITED STATES, INC.

The compressor bracket and related components can be removed and installed without having to open the refrigerant circuit.


Observe length of removed bolts and reinstall accordingly.



Microsoft


Refer to 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK

Ribbed belt routing. Refer to 6-cylinder Engine, ribbed belt routing

Remove bolts - A/C compressor and bracket - 6-cylinder engine, assembly.

Remove compressor from bracket and secure to body using appropriate material (e.g. welding wire)

2 - Bracket

For Generator (GEN), compressor and power steering pump

Removing:

First remove Generator (GEN), compressor - A/C compressor and bracket - 6-cylinder engine, assembly and power steering pump

Removing and installing Generator (GEN)

Refer to 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL ; Removing and installing Generator (GEN); 6-cylinder gasoline engine

Removing and installing power steering pump

Refer to 48 - STEERING : Removing and installing vane pump on vehicles with 6-cylinder engine

Installing:

First install bolts - A/C compressor and bracket - 6-cylinder engine, assembly.

3 - Hex socket bolt M8x38

23 Nm


23 Nm

Qty: 2

5 - Spacer

Qty: 2

Ensure correct seating in bracket

6 - Bolt M10x100

45 Nm



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23 Nm

Qty: 2

6-cylinder Engine, ribbed belt routing

Fig. 73: Identifying Ribbed Belt Routing Courtesy of VOLKSWAGEN UNITED STATES, INC.

A/C compressor and bracket - 8-cylinder engine, assembly


Fig. 74: Torque Wrench V.A.G 1331

NOTE: When installing the belt ensure it is correctly seated in the ribbed belt pulley.



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Refrigerant recycling/recovery unit Kent-Moore ACR4 (or UL approved equivalent - VAS 6007A illustrated for reference only).

NOTE:



Microsoft



43 Nm

Qty: 2

Fig. 76: Exploded View Of A/C Refrigerant System Courtesy of VOLKSWAGEN UNITED STATES, INC.


Observe length of removed bolts and reinstall accordingly..

WARNING: Compressor must only be removed after refrigerant circuit has been discharged.



Microsoft


2 - Compressor

Removing

Discharge refrigerant circuit. Refer to A/C refrigerant system, discharging .

Remove ribbed belt


Ribbed belt routing. Refer to 8-cylinder Engine, ribbed belt routing

Remove bolts for oil dipstick bracket

Remove bolts for power steering line bracket.

Unclip retainers for trim cover. Refer to Engine compartment trim cover retainers, removing

Remove left air filter housing


Disconnect electrical connection at Refrigerant Temperature Sensor -G454-

Remove refrigerant lines from compressor.

Remove bolts - A/C compressor and bracket - 8-cylinder engine, assembly


25 Nm

Qty: 3


43 Nm

Qty: 2

5 - Bracket

For A/C compressor and power steering pump

Removing

Remove compressor.

Remove power steering pump

CAUTION: Immediately plug open connections on A/C components and lines to prevent dirt and moisture contamination.



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Refer to 48 - STEERING

Remove bolts - A/C compressor and bracket - 8-cylinder engine, assembly.

Installing

Install in reverse order of removal, noting the following: Loosely install bolts first - A/C compressor and bracket - 8-cylinder engine, assembly. Then install bolts.

Note torque specifications

6 - Spacer

Qty: 4

Ensure correct seating in bracket

Engine compartment trim cover retainers, removing

Fig. 77: Identifying Retainers & Trim cover Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unclip retainers for trim cover -arrows-.

8-cylinder Engine, ribbed belt routing



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Fig. 78: 8-Cylinder Engine, Ribbed Belt Routing Courtesy of VOLKSWAGEN UNITED STATES, INC.

A/C compressor and bracket - 10-cylinder TDI engine




NOTE: When installing the belt ensure it is correctly seated in the ribbed belt pulley.



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NOTE:



Microsoft


Refer to

10 - ENGINE - ASSEMBLY for 3.2L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BAA, BMX

10 - ENGINE - ASSEMBLY for 3.6L V6 4V ENGINE MECHANICAL, FUEL INJECTION

Fig. 81: Identifying A/C Refrigerant System Courtesy of VOLKSWAGEN UNITED STATES, INC.


Observe length of removed bolts and reinstall accordingly..

For removing and installing the compressor the engine must be removed first.



Microsoft


IGNITION, ENGINE CODES: BHL, BHK

10 - ENGINE - ASSEMBLY for 4.2 LITER V8 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): BAR

10 - ENGINE - ASSEMBLY for 4.2 LITER V8 5V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AXQ, BHX

10 - ENGINE - ASSEMBLY for 5.0 LITER V10 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BKW, BWF

; Removing and installing engine

1 - Compressor

Removing:


Remove engine

Refer to


10 - ENGINE - ASSEMBLY for 3.6L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BHL, BHK




Remove engine mount - A/C compressor and bracket - 10-cylinder TDI engine

Remove bolts - A/C compressor and bracket - 10-cylinder TDI engine from compressor.

2 - Bolts M8x90

20 Nm

Qty: 3

3 - Bolt M10x84




Microsoft


60 Nm

Qty: 4

4 - Engine mount

Removing

Refer to


10 - ENGINE - ASSEMBLY for 3.6L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BHL, BHK




5 - Overload protection

HEATING AND A/C UNIT, SERVICING

Air intake duct, removing and installing

Removing

Remove wiper arms

Refer to 92 - WINDSHIELD WIPER AND WASHER SYSTEM

Remove plenum chamber cover

Refer to 64 - GLASS, WINDOWS



Microsoft


Fig. 82: Identifying Air Intake Duct & Screws Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove screws -1- and unclip grille -A- from air intake duct.

Fig. 83: Identifying Retaining Clamps Courtesy of VOLKSWAGEN UNITED STATES, INC.

Reach into air intake duct from above and loosen retaining clamps -1-.

Remove air intake duct from plenum chamber.

Installing




Microsoft


Fig. 84: Identifying Water Drain Valve Courtesy of VOLKSWAGEN UNITED STATES, INC.

Before installing, ensure water drain valve -arrow- is not soiled, clean if necessary.

Heater core, removing and installing

Removing


Refer to 70 - INTERIOR TRIM .

Remove entry and start authorization control module

Refer to 94 - LIGHTS, SWITCHES - EXTERIOR

Removing relay carrier in left front footwell


Remove onboard power supply control module


Position drip tray VAS 6208 (or equivalent) under engine.

Drain cooling system

NOTE: Always refill and bleed engine cooling system after opening and performing related repairs

WARNING: 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.



Microsoft


Refer to 19 - ENGINE - COOLING SYSTEM for 3.2L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BAA, BMX

Refer to 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AXQ, BHX

Refer to 10 - ENGINE - ASSEMBLY for 5.0 LITER V10 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BKW, BWF

Remove right heater core cover.

Fig. 85: Identifying Left Heater Core Cover Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosen bolt -1- and remove bolt -2-.

Unclip cover from mounting -3-.

Pull carpet off center tunnel (in work area).

Remove left heater core cover.

Fig. 86: Identifying Heater Cover & Screws Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove screws -1- and -2- and unclip cover.



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Remove footwell vent.

Cover carpet in area under heater core using waterproof foil and water absorbing paper.

Fig. 87: Identifying Coolant Hoses Retaining Clips Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull retaining clips -1- from coolant hoses.

Slowly pull coolant lines off of heater core and collect coolant that leaks out in a container.

Fig. 88: Lifting Retaining Pin Out From Locking Device & Pull Retaining Pin Out In Direction Of Arrow B Courtesy of VOLKSWAGEN UNITED STATES, INC.

Lift retaining pin -1- out from locking device -arrow A- and pull retaining pin out in direction of -arrow- B.

Fold cover downward and take heater core out to left.

NOTE: Bolt -2- is hidden by the heater core cover.

NOTE: A retaining pin is located under the heater core on the left-hand side, this connects the lower heater core cover to the heating and A/C unit.



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Installing


Secure connections using clamps of standard used in series production.

Fig. 89: Securing Clips On Heater Core Courtesy of VOLKSWAGEN UNITED STATES, INC.

When installing retaining clips ensure they are seated -arrow- securely on the heater core.

Refill and bleed cooling system




A/C REFRIGERANT SYSTEM, SERVICING

General information


CAUTION: Use care not to allow coolant to leak onto carpet.

NOTE: Always replace O-rings.



Microsoft




Fig. 91: Drip Tray For VAS 6100, VAS 6208 Courtesy of VOLKSWAGEN UNITED STATES, INC.

VAS 6208 Drip tray for shop crane VAS 6100 (or equivalent)



Microsoft


Fig. 92: Hose Clamps 3093 Courtesy of VOLKSWAGEN UNITED STATES, INC.

3093 Hose clamps (> 40mm)



NOTE:



Microsoft


Pressures and temperatures, checking. Refer to A/C refrigerant system pressures and temperatures, checking

Fig. 94: Exploded View Of A/C Refrigerant System Courtesy of VOLKSWAGEN UNITED STATES, INC.


Evacuate refrigerant circuit using refrigerant recycling/recovery unit Kent-Moore ACR4 (or UL approved equivalent).

O-rings used on R-134a systems may be red, green, violet or black.




Microsoft


Testing with pressure gauges. Refer to A/C refrigerant system, testing with pressure gauges

Discharging. Refer to A/C refrigerant system, discharging

Evacuating and recharging. Refer to A/C refrigerant system, evacuating and recharging

Troubleshooting. Refer to A/C refrigerant system, troubleshooting

1 - Expansion valve

Engine compartment right

Removing. Refer to Expansion valve, removing and installing


Removing and installing. Refer to High Pressure Sensor -G65-, removing and installing


Removing and installing. See High pressure service valve, removing

4 - Low pressure service valve

Removing and installing. See Low pressure service valve, removing


Removing and installing. Refer to Refrigerant Temperature Sensor -G454-, removing and installing

6 - Compressor

Manufacturer: Denso

Designation 7SEU16C

Note installation/running in procedures. Refer to Compressor, procedure after installation

Without A/C Clutch -N25-

Compressor applications overview: Refer to Compressor applications, overview

7 - Condenser

Removing and installing. Refer to Condenser, removing

8 - Reservoir with drier cartridge

Integrated with condenser



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Replace every time refrigerant circuit has been opened.

Drier cartridge, replacing. Refer to Drier cartridge, replacing

Low pressure service valve, removing

Fig. 95: Identifying Low Pressure Service Valve Courtesy of VOLKSWAGEN UNITED STATES, INC.

Observe notes. Refer to General information.

Discharge refrigerant circuit. Refer to A/C refrigerant system, discharging

1 - Connection with external thread and groove for O-ring

2 - O-ring

7.6 mm; 1.8 mm

3 - Service valve

4 - O-ring

7.6 mm; 1.8 mm

5 - Cap

High pressure service valve, removing

WARNING: Low pressure service valve must only be removed after refrigerant circuit has been discharged.



Microsoft


Fig. 96: Identifying High Pressure Service Valve Courtesy of VOLKSWAGEN UNITED STATES, INC.



1 - Connection with internal thread

2 - O-ring

10.8 mm; 1.8 mm

3 - Service valve with groove and internal thread for cap.

4 - O-ring

10.8 mm; 1.8 mm

5 - Cap

Drier cartridge, replacing

Removing



Remove front bumper.

WARNING: High pressure service valve must only be removed after refrigerant circuit has been discharged.

WARNING: Drier cartridge must only be removed after refrigerant circuit has been discharged.



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Refer to 63 - BUMPERS

Pull cover cap off upward.

Fig. 97: Exploded View Of Sealing Cap Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press sealing cap in direction of -arrow-.

Remove circlip -1-.

Screw socket head bolt into threaded hole in sealing cap.

Fig. 98: Pulling Dryer Cartridge Out Using Long Nose Pliers Courtesy of VOLKSWAGEN UNITED STATES, INC.

Using long nose pliers, pull dryer cartridge out in direction of -arrow-.

Installing


Pressure relief valve on compressor, checking

WARNING: Frostbite danger!



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Evidence of refrigerant oil in the area of the relief valve indicates valve has operated.

Fig. 99: Identifying Pressure Relief Valve Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pressure relief valve -1- on vehicles with Denso compressor and 6/10-cylinder engine.

Compressor, procedure after installation

Excessive refrigerant outlet pressures are vented by the pressure relief valve with considerable force.

Should relief valve operate, stay clear of venting refrigerant and switch off engine.

NOTE: The compressor is continuously driven by the ribbed belt pulley/Hardy coupling (no A/C clutch).

Should a compressor malfunction (lock-up) the overload protection for the compressor shaft is triggered. An indication the compressor has locked-up is deformations/bumps on the ribbed belt pulley, but these are not always easy to detect. Another indicator is abraded rubber material in the area of the ribbed belt pulley/overload protection.

The compressor has an internal oil circuit to ensure the compressor is not damaged should the refrigerant circuit be empty. Prerequisite for the internal lubrication is residual refrigerant oil in compressor.

As there is no refrigerant in the circuit the oil required to lubricate is not fed to the compressor.

A/C Compressor Regulator Valve -N280- is not activated when the refrigerant circuit is empty and the compressor idles with the engine.

CAUTION: Do not start engine with open refrigerant system (E.g.: refrigerant lines not connected to compressor or other refrigerant system components). Compressor will overheat and will be damaged.



Microsoft


If possible, start engine only with a completely filled refrigerant circuit.

In order to prevent damage after installing new compressor or recharging refrigerant, perform the following before starting engine:

V6 & V8

Turn compressor 10 revolutions by hand.

V10 TDI

Turn compressor 10 revolutions on Hardy coupling by hand and then install compressor.

then....

Switch on ignition (do not start engine!)

Select "Econ" mode on Climatronic control head

Start engine and wait until idle speed stabilizes.

Open all instrument panel vents.

Select "Low" temperature setting on Climatronic control head.

Select "Auto" mode on Climatronic control head (compressor regulation activated) and allow engine to run for 5 minutes at idle.

If it is necessary to start engine with empty refrigerant circuit, proceed as follows:

Refrigerant circuit must be fully assembled/closed.

At least 1/4 of the prescribed refrigerant oil must be in the compressor.

Engine speed must not exceed 2500 RPM.

Run engine only as long as absolutely necessary.

Compressor applications, overview

High Pressure Sensor -G65-, removing and installing

Removing

Remove air intake duct. Refer to Air intake duct, removing and installing.

Engine

Manufacturer

Engine Codes

3.2L Motronic 162 kW

Denso 7SEU16C

AZZ/BAA

4.9 ltr. TDI 230 kW

Denso 7SEU16C

BKW



Microsoft


Fig. 100: Identifying Refrigerant Sensor Courtesy of VOLKSWAGEN UNITED STATES, INC.


Unscrew sensor -1- from refrigerant line fitting in plenum chamber.

Installing


Replace O-ring.

Refrigerant Temperature Sensor -G454-, removing and installing

Removing



WARNING: Refrigerant Temperature Sensor -G454- must only be removed after refrigerant circuit has been discharged.



Microsoft


Fig. 101: Identifying Connector And A/C Pressure/Temperature Sensor G395 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical connection -1-.

Unscrew sensor -2- from compressor refrigerant line fitting.

Installing


Fig. 102: Identifying O-Ring Courtesy of VOLKSWAGEN UNITED STATES, INC.

Replace O-ring -1-.

When installing, ensure O-ring is seated correctly.

Expansion valve, removing and installing

Removing




WARNING: Expansion valve must only be removed after refrigerant circuit has been discharged.



Microsoft


Fig. 103: Identifying Socket Head Screws Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove socket head screws -1- (10 Nm) and pull refrigerant lines out of expansion valve.

Fig. 104: Removing/Installing Expansion Valve Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove screws -1- from expansion valve -2-.

1 - Bolts

2 - Expansion valve

3 - Retaining plate

4 - O-ring

5 - O-ring




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Installing


Replace O-rings -4- and -5-.

Condenser, removing








Microsoft


Fig. 107: Exploded View Of Refrigerant Recycling/Recovery Unit Courtesy of VOLKSWAGEN UNITED STATES, INC.


1 - Clip

2 - O-ring

23.8 mm; 2.4 mm

Always replace

WARNING: Condenser must only be removed after refrigerant circuit has been discharged.



Microsoft


3 - O-ring

9.5 mm; 2.5 mm

Always replace

4 - Socket head bolts

15 Nm

Refrigerant line

5 - Condenser

Removing


Remove front bumper.

Refer to 63 - BUMPERS .

Remove front bumper carrier

Refer to 50 - BODY - FRONT

Remove bolts - Condenser, removing

Pull refrigerant lines out from condensor.

Release retainer clips - Condenser, removing from radiator mounting.

Tilt condenser upward out of lock carrier.

Heating and A/C unit, removing and installing





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Microsoft




Removing



Remove instrument panel



Remove all air ducts to heating and A/C unit.





WARNING: Heating and A/C unit must only be removed after refrigerant circuit has been discharged.




Microsoft



Fig. 111: Identifying Socket Head Screws Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove socket head screws -1- (10 Nm) and pull refrigerant lines out of expansion valve.

Remove coolant hoses from heater core. Refer to Heater core, removing and installing.

Remove evaporator water drain hose from heating and A/C unit.

Disconnect electrical connections to heating and A/C unit.

Remove mounting plate


Remove heating and A/C unit.

Installing


Heating and A/C unit, assembly




Microsoft


Fig. 112: Heating And A/C Unit, Assembly Courtesy of VOLKSWAGEN UNITED STATES, INC.

Heating and A/C unit, removing and installing. Refer to Heating and A/C unit, removing and installing.

1 - Air distribution housing, upper part

Upper part of housing secured to lower housing with clips -2- and screws -3-

2 - Clips

Qty: 3

3 - Screws

4 - Blower housing

5 - Evaporator

Evaporator seal, installing. See Evaporator seal, installing.

6 - Air distribution housing, lower part

Evaporator seal, installing



Microsoft


Fig. 113: Identifying Foam Seal Must Be Glued Around Circumference Of Evaporator Courtesy of VOLKSWAGEN UNITED STATES, INC.

Foam seal -arrows- must be glued around circumference of evaporator -A-.

Rear heating and A/C unit A/C refrigerant system components, servicing






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NOTE:



Microsoft


Pressures and temperatures, checking. Refer to A/C refrigerant system pressures and temperatures, checking

Fig. 116: Identifying Refrigerant Recycling/Recovery Unit Kent-Moore ACR4 Components Courtesy of VOLKSWAGEN UNITED STATES, INC.


Evacuate refrigerant circuit using refrigerant recycling/recovery unit Kent-Moore ACR4 (or UL approved equivalent).

O-rings used on R-134a systems may be red, green, violet or black.




Microsoft


Testing with pressure gauges. Refer to A/C refrigerant system, testing with pressure gauges

Discharging. Refer to A/C refrigerant system, discharging

Evacuating and recharging. Refer to A/C refrigerant system, evacuating and recharging

1 - Refrigerant line

High pressure side

Behind left rear wheel housing cover

2 - O-ring

Always replace

9.5 mm; 2.5 mm

3 - O-ring

Always replace

13.7 mm; 2.5 mm

4 - Socket head bolt M10x84

12 Nm ± 1

Qty: 2


Low pressure side



3.5 Nm ± 0.5


3.5 Nm ± 0.5


3.5 Nm ± 0.5




Microsoft


3.5 Nm ± 0.5

10 - O-ring

Always replace

13.7 mm; 2.5 mm

11 - O-ring

Always replace

9.5 mm; 2.5 mm


Low pressure side

Under vehicle


High pressure side

Under vehicle

14 - Bolt M6x16

8 Nm ± 1.2

15 - Bracket

16 - Bolt M6x16

8 Nm ± 1.2

17 - Spacer bracket


3.5 Nm ± 0.5


3.5 Nm ± 0.5

20 - Damper

21 - O-ring



Microsoft


Always replace

13.7 mm; 2.5 mm


12 Nm ± 1


High pressure side

Behind left front wheel housing cover

24 - O-ring

Always replace

13.7 mm; 2.5 mm


12 Nm ± 1


Low pressure side


27 - Coolant pipe

To rear heater core


28 - Coolant pipe

To rear heater core


29 - Coolant hose

To rear heater core


30 - Coolant hose

To rear heater core



Microsoft



Rear heating and A/C unit, removing and installing








Microsoft






Removing

WARNING: Rear heating and A/C unit must only be removed after refrigerant circuit has been discharged.

CAUTION: Switch off all electrical consumers.



Microsoft





Refer to 19 - ENGINE - COOLING SYSTEM for 5.0 LITER V10 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BKW, BWF



Remove left rear wheel housing cover

Refer to 66 - EXTERIOR EQUIPMENT

Remove left rear wheel housing cover.

Clamp off both coolant hoses to rear heater core using hose clamps 3093

Separate both coolant hose/pipe connections.

Remove bolts for refrigerant lines (12 Nm) and remove from mounting plate.

Fig. 121: Identifying Coolant Hose/Pipe Connections & Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.

Switch off ignition and remove ignition key.

NOTE: Always refill and bleed engine cooling system after opening and performing related repairs




Microsoft


Remove screws from mounting plate (10 Nm).



Fig. 122: Identifying Screws & Rear Heating & A/C Unit Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical connections at rear heating and A/C unit

Remove screws -A- (8 Nm)

Cover carpet in area under heating and A/C unit using waterproof foil and water absorbing paper.




Microsoft


Tilt rear heating and A/C unit into rear compartment and remove through rear hatch opening.

Installing


Secure connections using clamps of standard used in series production.

Refill and bleed cooling system


Refer to 19 - ENGINE - COOLING SYSTEM for 5.0 LITER V10 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BKW, BWF

Rear heating and A/C unit, assembly

CAUTION: Use care not to allow coolant to leak onto rear carpet.

NOTE: Always replace O-rings.

Fig. 123: Identifying Coolant Hose/Pipe Connections & Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.

Ensure evaporator water drain hose is not kinked -arrow-



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Fig. 124: Rear Heating And A/C Unit, Assembly Courtesy of VOLKSWAGEN UNITED STATES, INC.

Rear heating and A/C unit, removing and installing. Refer to Rear heating and A/C unit, removing and installing.

1 - Rear heater core

2 - Foam gasket

3 - Right air volume flap

4 - Coolant hose

Supply to rear heater core.

5 - Coolant hose

Return from rear heater core.


Removing and installing. Refer to Right Rear Temperature Flap Motor -V314-, removing and installing.

7 - Rear Blower Regulation Sensor -G463-

Removing and installing. Refer to Rear Blower Regulation Sensor-G463-, removing and installing.

8 - O-ring

Always replace

14.3 mm; 2.4 mm

9 - O-ring



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Always replace

10.8 mm; 1.8 mm

10 - O-ring

Always replace

14.3 mm; 2.4 mm

11 - O-ring

Always replace

10.8 mm; 1.8 mm

12 - Evaporator water drain valve/hose

Upon installation, ensure hose is not kinked.

13 - Bolt

14 - Expansion valve

15 - O-ring

Always replace

10.8 mm; 1.8 mm

16 - O-ring

Always replace

14.3 mm; 2.4 mm

17 - Rear evaporator

18 - Cover

Where applicable


Removing and installing. Refer to Left Rear Temperature Flap Motor -V313-, removing and installing.

20 - Rear Blower Regulation Motor (Bitron) -V306-

Removing and installing. Refer to Rear Blower Regulation Motor (Bitron) -V306-, removing and



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installing.

21 - Left air volume flap


Removing and installing. Refer to Left Rear Air Flap Motor -V239-, removing and installing.


Removing and installing. Refer to Right Rear Air Flap Motor -V240-, removing and installing.


Removing. Refer to Left Rear Vent Temperature Sensor -G405-, removing and installing.


Removing. Refer to Right Rear Vent Temperature Sensor -G406-, removing and installing.

26 - Foam gasket

A/C refrigerant system pressures and temperatures, checking



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Fig. 125: Checking A/C Refrigerant System Pressures & Temperatures Courtesy of VOLKSWAGEN UNITED STATES, INC.

The pressures and temperatures in the A/C system will vary depending on engine speed (RPM), coolant fan speed, engine coolant temperature, compressor regulation, outside temperature, humidity, etc.

Pressure and temperature specifications are based on the following:

Engine speed (RPM) at 1500

Fresh air blower on high speed

A/C adjusted to Max. cooling

Pressure and temperature specifications for listed components. Refer to A/C refrigerant system pressures and temperatures, checking .

1 - Evaporator



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2 - Low pressure service valve

3 - Compressor, low pressure side

4 - Compressor, high pressure side

5 - Condenser

6 - Receiver drier

7 - Sight glass

If equipped


9 - Expansion valve

Pressure and temperature specifications

Component Refrigerant state Approximate pressure (bar/psi)

Approximate temperature

1 - Evaporator, inlet to outlet Vapor to Gas -7°C (19°F)**2 - Low pressure service valve

Gas 1.2 bar (17.4 psi)* 1.8 bar (26 psi)***

-1°C (30°F) +1°C (33°F)***

3 - Compressor, low pressure side

Gas

4 - Compressor, high pressure side

Gas 65°C (149°F)

5 - Condenser Gas to Vapor 55°C (131°F) at outlet to Liquid 14 bar (203 psi) 6 - Receiver drier Liquid 7 - Sight glass (if equipped) Liquid 55°C (131°F)8 - High pressure service valve

Liquid

9 - Expansion valve Liquid to Vapor Inlet: 14 bar (203 psi) Outlet: 1.2 bar (17.4 psi)

Inlet: 55°C (131°F) Outlet: -7°C (19°F)

* Pressure maintained in refrigerant system by externally regulated compressor despite variables in temperature, load and engine speeds (RPM). Regulation actuated by -N280- Compressor Regulation Valve. ** Temperature maintained in the refrigerant system by the variable displacement compressor despite variables in temperature, load and engine speeds (RPM). *** Specification for system with two evaporators.



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A/C refrigerant system, testing with pressure gauges

Due to the constant temperature/pressure relationship of refrigerant R-134a, approximate high-side system temperature can be determined based on system pressure.

Pressure gauges may have one or more temperature scales in addition to the pressure scale. Since various refrigerants have different temperature/pressure relationships, each gauge is specific for a particular refrigerant.

Measuring pressure and temperature in a "switched-on" refrigerant system

Use the A/C refrigerant high-pressure gauge to measure high pressure between the compressor and restrictor (including condenser) with the A/C switched on.

Use the A/C refrigerant low-pressure gauge to measure low pressure between the restrictor and the compressor inlet (including evaporator) with the A/C switched on.

The temperature displays of the low- and high-pressure gauges apply only to a portion of the low- and high-pressure sides. The low-pressure gauge displays approximate temperature between the restrictor and evaporator outlet. The high-pressure gauge displays approximate temperature between the compressor outlet and restrictor.

Measuring pressure and temperature in a closed container or "switched-off" refrigerant system

Due to the constant temperature/pressure relationship of R-134a, approximate temperature in a closed container or in a switched-off A/C system can be determined based on its pressure.

If the temperature displayed on a gauge is lower than the actual temperature of the refrigerant, the refrigerant container or system is empty (discharged).

A/C refrigerant system, discharging

NOTE: The temperature/pressure relationship only holds true when the refrigerant system contains liquid and vapor, but not when it contains only gas. In the gaseous state, the temperature is approx. 10-30°C (18-54°F) higher than indicated on the pressure gauge.

NOTE: The temperature/pressure relationship only holds true when the refrigerant system contains liquid and vapor, but not when it contains only gas. In the gaseous state, the temperature is approx. 10-30°C (18-54°F) higher than indicated on the pressure gauge.

WARNING: Always use an Underwriter's Laboratory (UL) approved refrigerant recovery/recycling/recharging unit such as Kent-Moore ACR4, or UL approved equivalent, whenever discharging an R-134a A/C system.

Any person who services a motor vehicle air conditioner MUST, by law, be properly trained and certified and use approved refrigerant recycling equipment. Technicians must complete an EPA approved



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recycling course to be certified.

State and local governments may have additional requirements regarding air conditioning servicing. Always comply with state and local laws.

Always wear safety goggles when charging or discharging system.

CAUTION: Always use separate refrigerant recovery/recycling/recharging servicing equipment for R-12 and R-134a systems. DO NOT use one piece of equipment for both R-12 and R-134a systems. The residual traces of refrigerant inside the equipment will contaminate and damage the equipment. Servicing equipment includes recovery/recycling/recharging unit, charging station, vacuum pump, manifold gauges, etc.

DO NOT use R-12 servicing equipment on R-134a systems or R-134a equipment on R-12 systems or damage to both the vehicle A/C system and servicing equipment may result. Use only equipment designed to meet Society of Automotive Engineers (SAE) standards.

R-134a and R-12 systems use different size service fittings. NEVER use adaptors to convert an R-12 fitting to R-134a size or R-134a fitting to R-12 size.

NOTE: Refer to Safety measures prior to discharging or charging A/C refrigerant system.

NOTE: Make sure that initial set-up of the refrigerant recovery/recycling/recharging unit has been completed before discharging the A/C system.



Always follow manufacturer's instructions when using a refrigerant recovery/recycling/recharging unit.



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Fig. 126: Connecting Red High Pressure Hose Of Refrigerant Recovery/Recycling/Recharging Unit To High Pressure Service Valve (Fitting) On Vehicle And Open Coupler Valve Courtesy of VOLKSWAGEN UNITED STATES, INC.

Connect red high-pressure hose -A- of refrigerant recovery/recycling/recharging unit to high side fitting on vehicle and open coupler valve.

Connect blue low-pressure hose -B- of refrigerant recovery/recycling/recharging unit to low side fitting on vehicle and open coupler valve.

Following refrigerant recovery/recycling/recharging unit manufacturer's instructions, discharge A/C system into refrigerant recovery/recycling/recharging unit.

A/C refrigerant system, flushing with compressed air and nitrogen

Flush refrigerant system with compressed air and nitrogen if:

Refrigerant oil is dark and viscous (thick)

Too much refrigerant oil is in the system following compressor replacement

Unclear or do not know how much refrigerant oil is in the system

Moisture, dirt or other impurities have entered the refrigerant system (i.e. following an accident)

CAUTION: When using compressed nitrogen always use a pressure regulator and the proper adaptor hoses and fittings (available locally). During flushing, use existing exhaust/ventilation systems to draw off the gas mixture escaping from the A/C system.

DO NOT flush R-134a refrigerant system with R-11. R-11 is not compatible with R-134a refrigerant and PAG oil and will cause total system contamination.



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Unable to pull a constant vacuum during evacuation of a leak-free system due to excessive moisture in the system

Refrigerant system has been open longer than the time required for normal repairs (i.e. following an accident)

Based on temperature and pressure measurements, system is diagnosed with moisture contamination

Compressor is replaced due to noises or internal damage

Flushing is required after replacing certain components in certain situations. Refer to A/C refrigerant system, replacing components.

Flushing

Use compressed air and nitrogen (available locally) to remove moisture, impurities and old refrigerant oil from A/C refrigerant system.

First blow out old refrigerant oil and dirt with compressed air, then dry components with nitrogen.

DO NOT blow compressed air and nitrogen through the compressor or expansion valve. Only blow compressed air and nitrogen through disconnected, free flowing components (i.e. disconnected hose, condenser, evaporator, etc.)

DO NOT blow compressed air and nitrogen into a capped off A/C component. Pressurized R-134a refrigerant in the presence of oxygen may form a combustible mixture.

Always flush components in opposite direction of refrigerant flow.

Flush evaporator through the low-pressure line with the high-pressure line removed.

If any component has dark thick deposits that cannot be removed with compressed air, replace component.

Thin light gray deposits in refrigerant lines and hoses are normal and do not impair the function of the system.

Always replace receiver drier after flushing.

Dispose of contaminated refrigerant (PAG) oil following laws governing hazardous waste disposal. Do not combine PAG oil with any other old oils such as engine oil or transmission fluid.

A/C refrigerant system, evacuating and recharging

WARNING: Always use an Underwriter's Laboratory (UL) approved refrigerant recovery/recycling/recharging unit such as Kent-Moore ACR4, or UL approved equivalent, when evacuating and recharging an R-134a A/C system.

Any person who services a motor vehicle air conditioner MUST, by law, be properly trained and certified and use approved refrigerant recycling equipment. Technicians must complete an EPA approved recycling course to be certified.

State and local governments may have additional requirements



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A/C REFRIGERANT SYSTEM, TROUBLESHOOTING

A/C refrigerant system, troubleshooting

With Climatronic control set on "LO", the refrigerant system is functioning properly when the instrument panel vent air temperature is measured to be below 10°C (50°C)

Requirements

Electrical systems OK

Air flow distribution systems (controls, flap motors) OK

No Diagnostic Trouble Codes (DTCs) and no A/C compressor shut-off conditions stored/visible in the Climatronic On Board Diagnostic system. Check with VAS 5051/5052 tester in operating mode "Guided Fault Finding". Refer to Components, checking and adjusting with VAS 5051/5052 Vehicle Diagnostic Testing and Information System.

Correct and repair as necessary before proceeding.

If any one of the following system conditions exists, check A/C refrigerant system pressures. Refer to A/C refrigerant system pressures, checking.

regarding air conditioning servicing. Always comply with state and local laws.

Always wear safety goggles when discharging, evacuating and recharging an A/C system.



Always follow manufacturer's instructions when using a refrigerant recovery/recycling/recharging unit.

NOTE: Refer to R-134a safety measures prior to discharging or charging A/C refrigerant system. Refer to Safety measures .

Follow refrigerant recovery/recycling/recharging unit manufacturer's instructions for evacuating and recharging A/C system.

Evacuate refrigerant system for a minimum of 30 minutes.

When recharging A/C system, add correct amount of refrigerant and PAG oil to system. Refer to Refrigerant R134a, capacities.

After system recharge, manually rotate A/C compressor approx. 10 turns before starting engine. Start engine with A/C OFF. After idle speed has stabilized, switch A/C ON and let engine idle (compressor running) for a minimum of two minutes before raising engine speed.



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A/C does not cool (cooling has stopped completely)

Insufficient cooling during all driving speeds or engine speeds (RPM)

No cooling or insufficient cooling after a period of driving

Compressor noisy

Tighten compressor and compressor bracket mounting bolts using torque wrench.

Check routing of A/C refrigerant hoses and lines; hoses and lines must not contact other components and must be installed without tension or kinks, reposition or realign as necessary.

A/C compressor noisy immediately after switching A/C ON and/or when driving around corners or braking (refrigerant shock)-system overcharged

Discharge A/C refrigerant system. Refer to A/C refrigerant system, discharging , then evacuate and recharge. Refer to A/C refrigerant system, evacuating and recharging.

With an otherwise properly operating A/C system, water sprays out of instrument panel vents

Check evaporator drain pipe for proper routing (should not be kinked or pinched).

Check evaporator water drain valve.

Must not be plugged with wax, dirt or undercoating (clean if necessary)

Valve flap must open/close properly

Check plenum tray.

Must be properly installed and not damaged

A/C refrigerant system pressures, checking

Check A/C refrigerant system pressures using these tests:

1 - A/C system cooling performance

2 - Refrigerant system high side pressure test

3 - Refrigerant system low side pressure test

The combined results of these tests determines which part of the A/C system requires further troubleshooting and/or repairs.

Test conditions

A/C refrigerant system fully charged; discharge, evacuate and recharge system if necessary

Condenser and radiator clean and free of obstructions (spray clean if necessary)



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Air distribution can be adjusted correctly using control knobs (all air distribution flaps reach end positions)

Wiring OK per wiring diagram

No Diagnostic Trouble Codes (DTCs) and no A/C compressor shut-off conditions stored/visible in the Climatronic On Board Diagnostic system. Check with VAS 5051/5052 tester in operating mode "Guided Fault Finding". Refer to Components, checking and adjusting with VAS 5051/5052 Vehicle Diagnostic Testing and Information System.

Outside (ambient) air temperature between 20-30°C (68-86°F)

Vehicle is not parked in direct sunlight

Engine at operating temperature.

Drive belts for A/C compressor and Generator in good condition and properly tensioned

Test 1: A/C system cooling performance

Start engine.

Set temperature control to maximum cooling ("LO").

Adjust air distribution to instrument panel outlets.

Insert thermometer into center instrument panel outlet

Raise engine speed to approximately 2000 RPM.

Specified result

With humidity normal and outside (ambient) temperature between 20-25°C (68-77°F), system is cooling satisfactorily if air temperature from center instrument panel vent drops below 10°C (50°F) within 1 minute.

For higher ambient temperatures and/or higher humidity, specified air temperature from center instrument panel vent can be slightly higher.

If specified reading is not obtained, perform tests 2 and 3, then compare results of all three tests. Refer to Observed refrigerant pressures/cooling performance results.

Test 2: A/C system high pressure, checking

Connect high- and low-pressure hoses of refrigerant recovery/recycling/recharging unit Kent-Moore ACR4 (or UL approved equivalent), to high- and low-pressure service valves.

Start engine.






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Specified result

System high pressure rises from starting pressure to 20 bar (290 psi).

For higher ambient temperatures and/or higher humidity, specified pressure can rise to a maximum of 29 bar (420 psi).

If specified reading is not obtained, also perform test 3 and compare results of all three tests. Refer to Observed refrigerant pressures/cooling performance results.

Test 3: A/C system low pressure, checking

Connect high- and low-pressure hoses of refrigerant recovery/recycling/recharging unit Kent-Moore ACR4, (or UL approved equivalent), to high- and low-pressure service valves.

Start engine.




Specified result

Fig. 127: Permissible Tolerance Range Graph Courtesy of VOLKSWAGEN UNITED STATES, INC.

System low pressure falls from starting pressure to pressure indicated

A - Low pressure in bar

B - Actuating voltage for compressor regulating valve -N280-

C - Permissible tolerance

NOTE: Actuating voltage for -N280- is visible from Read Measuring Value Block.



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If specified reading is not obtained, compare results of all three tests. Refer to Observed refrigerant pressures/cooling performance results.

Observed refrigerant pressures/cooling performance results

Refer to VAS 5051/5052 in operating mode "Guided Fault Finding".

The low pressure adjusts automatically within the tolerance range within the output of the compressor depending on the actuating voltage for -N280-.

For higher ambient temperatures and/or higher humidity, the output may not always be sufficient to attain the specified value.

The specified working voltage for the regulating valve must be greater than 0.3 A in order to ensure that the regulating valve will be actuated.

At setting "maximum cooling performance", the actuating voltage is regulated to about 0.8 A (displayed in Read measuring Value Block).

In terms of absolute pressure, 0 bar corresponds to absolute vacuum. The normal ambient pressure (positive pressure) corresponds to 1 bar absolute pressure. On the scales of most pressure gauges, 0 bar corresponds to an absolute pressure of 1 bar (identifiable through the valve -1 below 0).

Observed Pressures/Temperature

Possible causes Corrective actions

High pressure remains constant or rises only slightly (overpressure when engine is stopped).

Low-pressure falls quickly to diagram value or lower.

Outlet temperature too high.

Actuation of -N280- faulty.

Insufficient refrigerant in circuit.

Check actuation of -N280-. Refer to Guided Fault Finding using VAS

5051/5052

Leak test and repair refrigerant system leak.

Refer to A/C refrigerant system, checking for leaks

Evacuate and recharge refrigerant circuit. Refer to A/C refrigerant system,

evacuating and recharging

High pressure normal.

Low pressure corresponds to diagram value.





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Low pressure too low (see diagram).





Temperature flap position incorrect.

Temperature flap motor malfunction.

Check Climatronic system Diagnostic Trouble Code (DTC) memory. Refer to Guided Fault Finding using VAS 5051/5052.

Check wiring and connections to temperature flap motor using wiring diagram.

Check for mechanical malfunction of temperature flap.

Observed Pressures/Temperature Possible causes Corrective actions

High pressure rises only slightly

Low pressure falls only slightly.



Compressor malfunctioning.

Check actuation of -N280-. Refer to Guided Fault Finding using VAS 5051/5052.

Flush refrigerant circuit with compressed air and nitrogen. Refer to A/C refrigerant system, flushing with compressed air and nitrogen.

Replace compressor. Refer to A/C compressor and bracket -6-cylinder engine, assembly.

High pressure rises above specification.

Low pressure falls quickly to diagram value or below.


Obstruction in refrigerant circuit.

Expansion valve malfunctioning.

Check for large temperature differences on refrigerant system components (lines, hoses etc.) using infra-red thermometer or feel temperature difference by hand.

Replace all kinked, pinched or damaged lines and hoses.

Replace expansion valve. Refer to Expansion valve, removing and installing.

Flush refrigerant circuit with



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compressed air and nitrogen. Refer to A/C refrigerant system, flushing with compressed air and nitrogen.

High and low pressures initially normal, then high pressure gradually rises above specification and low pressure falls to or below diagram value.

Outlet temperature initially at or below specification, then rises (too high).

Moisture in refrigerant circuit


Evacuate and recharge refrigerant circuit. Refer to A/C refrigerant system, evacuating and recharging




Low pressure too low (see diagram).

Outlet temperature at or below specification.


Evaporator icing (refrigerant

quantity ok).

Expansion valve malfunctioning.

Compressor malfunctioning.

Check actuation of -N280-. Refer to Guided Fault Finding using VAS 5051/5052.

Check evaporator temperature sensors. Refer to Guided Fault Finding using VAS 5051/5052.


Replace expansion valve. Refer to Expansion valve, removing and installing.

Replace compressor. Refer to A/C compressor and bracket - 6-cylinder engine, assembly.

High pressure normal or too high.

Low pressure too high (see diagram).

Compressor noisy (especially immediately after being switched on).


Excessive refrigerant in

circuit.

Completely extract and recover refrigerant from refrigerant circuit, noting quantity.

If amount of refrigerant extracted is equal to the system capacity, replace compressor. Refer to A/C compressor and bracket - 6-cylinder engine, assembly.

If the amount of extracted refrigerant



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1) Overfilling with refrigerant oil can occur when compressor is replaced and the total system refrigerant oil quantity is not adjusted. Refrigerant oil distribution. Refer to Refrigerant oil distribution.

A/C refrigerant system cooling performance, checking

Cooling performance can be checked using Climatronic On Board Diagnostic (OBD) program.

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 ">" to confirm.

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)"

Select "Heating, ventilation, air conditioning (Repair Gr. 01, 80...87"

Select "Systems capable of self-diagnosis"

significantly exceeds the system capacity, evacuate and recharge refrigerant circuit. Refer to A/C refrigerant system, evacuating and recharging .






Excessive refrigerant oil in

refrigerant circuit1).

Flush refrigerant circuit with compressed air and nitrogen. Refer to

A/C refrigerant system, flushing with compressed air and nitrogen.

Evacuate and recharge refrigerant circuit. Refer to A/C refrigerant

system, evacuating and recharging



Compressor noisy (especially immediately after being switched on).




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Select "Climatronic"

Select "Functions"

Select "Check cooling performance"

Follow tester prompts.

A/C refrigerant system, checking for leaks

Fig. 128: Checking For Refrigerant Leaks By Passing Detector Probe Under Suspected Leaking Components Courtesy of VOLKSWAGEN UNITED STATES, INC.

Use halogen leak detector, Hitec HI400A-TEL or equivalent, to check for refrigerant leaks

If the refrigerant system is discharged (empty), re-charge the system with approx. 100 g (3.5 oz.) of refrigerant in order to check for leaks.

Follow leak detector manufacturer's instructions.

A/C REFRIGERANT SYSTEM, CAPACITIES

Refrigerant R134a, capacities

NOTE: Refrigerant gas dissipates very quickly. Avoid drafty or windy areas when checking for leaks.

Always hold probe tip underneath area of suspected leak.

Compressor Manufacturer Capacities 7SEU16C

Vehicles with Dual-zone ClimatronicDenso 700 + 50g

7SEU16C Vehicles with Four-zone Climatronic

Denso 1050 + 50g



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Refrigerant (PAG) oil R-134a, identification

Do not obtain special refrigerant oil for use with refrigerant R134a from the general refrigerant/machine oil market.

Refrigerant (PAG) oil R-134a, capacities

1) This is the total A/C system refrigerant oil capacity. Replacement A/C compressors supplied by the Parts Department are filled with 200 cm3 of refrigerant oil.

2) Additional refrigerant oil necessary due to refrigerant hoses and rear evaporator as part of rear heating and A/C unit. Take additional capacity into account when replacing components and add oil as necessary.

Additional information

Refrigerant oil is very hygroscopic, therefore opened containers must be closed immediately after use to stop moisture contamination.

Dispose of contaminated refrigerant oil following laws governing hazardous waste disposal. Do not combine any refrigerant oil with any other old oils such as engine oil or transmission fluid.

Refrigerant oil distribution

Refrigerant oil is distributed through the refrigerant circuit, which is located in the sump of the compressor before initially switching the air conditioner system as follows:

Obtain using following Part No.: 7SEU16C- Denso compressor G 052 300 A2

CAUTION: Part numbers are for reference only. Always contact the parts department for the latest part number information.

Type Production period Capacity Vehicles with Dual-zone

Climatronic11.02 > 200 ± 10 cm3 1)

Vehicles with Four-zone Climatronic

03.03 > 200 ± 10 cm3 1) + 100 ± 10 cm3 2)

= 300 cm3

Compressor approx. 50%

Condenser approx. 10%

Suction hose approx. 10%

Evaporator approx. 20%



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Fluid reservoir approx. 10%



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