Service

Workshop Manual
T-Roc 2018 ➤
Heating, air conditioner
Edition 03.2021

Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
80 - Heating
87 - Air conditioning system

Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness
and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as
a matter of course, be observed.
 T-Roc 2018 ➤
Heating, air conditioner - Edition 03.2021

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on air conditioning systems . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 1
1.3 Safety precautions when using testers and measuring instruments during a road test . . . . 2
1.4 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Safety precautions when handling refrigerants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.6 Safety precautions for working on vehicles with auxiliary/supplementary heater . . . . . . . . 3
1.7 Safety precautions when working on the SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Identification of heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Type plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Notes concerning odours in air conditioned vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.4 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.5 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.6 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.7 Fitting radiators, coolers and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.8 Working on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.9 Refrigerant circuit seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.1 Refrigerant capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.2 Refrigerant oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.3 Oil distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

80 - Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1 Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

87 - Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1 Overview of fitting locations - air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.1 Overview of fitting locations - components not located in passenger compartment . . . . . . 20
1.2 Overview of fitting locations - components located in front section of passenger
compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2 Refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.1 System overview - refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2 Assembly overview – condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3 Removing and installing refrigerant circuit pressure sender G805 . . . . . . . . . . . . . . . . . . . . 31
2.4 Removing and installing refrigerant line with internal heat exchanger . . . . . . . . . . . . . . . . 32
2.5 Removing and installing expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.6 Removing and installing condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.7 Removing and installing desiccant bag or cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.8 Removing and installing evacuating and charging valves on low and high-pressure side . . 53
2.9 Commissioning air conditioning system after filling refrigerant circuit . . . . . . . . . . . . . . . . 55
2.10 Removing and installing refrigerant line from air conditioner compressor to condenser . . 55
2.11 Removing and installing refrigerant line from air conditioner compressor to evaporator . . 58
2.12 Removing and installing refrigerant line from evaporator to air conditioner compressor . . 62
2.13 Removing and installing damper weight for refrigerant line, low-pressure side . . . . . . . . . . 66
2.14 Commissioning air conditioning system after filling refrigerant circuit . . . . . . . . . . . . . . . . 66

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3 Air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

3.1 Assembly overview – drive unit of air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . 68
3.2 Assembly overview - pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.3 Removing air conditioning compressor from and installing on bracket . . . . . . . . . . . . . . . . 76
3.4 Removing and installing air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.5 Checking high-pressure safety valve on air conditioner compressor . . . . . . . . . . . . . . . . . . 83
3.6 Removing and installing pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4 Control motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.1 Overview of fitting locations – control motors at front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.2 Removing and installing temperature flap control motor V68 . . . . . . . . . . . . . . . . . . . . . . . . 94
4.3 Removing and installing defroster flap control motor V107 . . . . . . . . . . . . . . . . . . . . . . . . 96
4.4 Removing and installing air recirculation flap control motor V113 . . . . . . . . . . . . . . . . . . . . 98
4.5 Removing and installing left temperature flap control motor V158 . . . . . . . . . . . . . . . . . . . . 99
4.6 Removing and installing right temperature flap control motor V159 . . . . . . . . . . . . . . . . . . 101
4.7 Removing and installing fresh air/air recirculation, air flow flap control motor V425 . . . . . . 102
4.8 Removing and installing front air distribution flap control motor V426 . . . . . . . . . . . . . . . . 104
4.9 Removing and installing air distribution flap control motor V428 . . . . . . . . . . . . . . . . . . . . 105
4.10 Removing and installing air distribution flap actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5 Front heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
5.1 Assembly overview - flaps and partitions in air distribution housing . . . . . . . . . . . . . . . . . . 114
5.2 Assembly overview – heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.3 Assembly overview – evaporator housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.4 Removing and installing evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.5 Checking auxiliary air heater element Z35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
5.6 Removing and installing auxiliary air heater element Z35 . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5.7 Removing and installing heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . 123
5.8 Removing and installing holder for heater and air conditioning unit . . . . . . . . . . . . . . . . . . 129
5.9 Dismantling and assembling heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . 130
5.10 Removing and installing air distribution housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.11 Removing and installing dust and pollen filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
5.12 Removing and installing fresh air blower V2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.13 Removing and installing fresh air blower control unit J126 . . . . . . . . . . . . . . . . . . . . . . . . 139
5.14 Removing and installing heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
5.15 Removing and installing coolant pipes on heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . 164
5.16 Removing and installing evaporator temperature sensor G308 . . . . . . . . . . . . . . . . . . . . . . 167
5.17 Removing and installing condensation drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
5.18 Checking condensation drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
5.19 Removing and installing baffle plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
6 Air duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
6.1 Assembly overview – air duct and air distribution in passenger compartment . . . . . . . . . . 174
6.2 Removing and installing driver side footwell vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
6.3 Removing and installing front passenger side footwell vents . . . . . . . . . . . . . . . . . . . . . . . . 176
6.4 Removing and installing rear footwell vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
6.5 Removing and installing air ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
6.6 Removing and installing forced ventilation for passenger compartment . . . . . . . . . . . . . . 181
6.7 Checking forced ventilation for passenger compartment . . . . . . . . . . . . . . . . . . . . . . . . . . 182
6.8 Removing and installing fresh air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
6.9 Removing and installing cover for fresh air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
6.10 Removing and installing air intake duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
6.11 Removing and installing air duct for defroster vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
6.12 Removing and installing air duct for centre vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
7 Operating and display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
7.1 Overview of operating and display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
7.2 Removing and installing operating and display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
8 Other controlling and regulating components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

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8.1 Removing and installing sunlight penetration photosensor G107 . . . . . . . . . . . . . . . . . . . . 194

8.2 Working principles of air quality sensor G238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
8.3 Removing and installing air quality sensor G238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
8.4 Removing and installing ambient temperature sensor G17 . . . . . . . . . . . . . . . . . . . . . . . . 197
8.5 Removing and installing humidity sender for air conditioning system G260 . . . . . . . . . . . . 197
8.6 Removing and installing left vent temperature sender G150 . . . . . . . . . . . . . . . . . . . . . . . . 198
8.7 Removing and installing right vent temperature sender G151 . . . . . . . . . . . . . . . . . . . . . . 199
8.8 Removing and installing footwell vent temperature sender G192 . . . . . . . . . . . . . . . . . . . . 201

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iv Contents
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00 – Technical data
1 Safety information
(VRL015319; Edition 03.2021)
⇒ p1.1 recautions when working on air conditioning systems”,
page 1
⇒ m1.2 easures when working on vehicles with a start/stop
system”, page 1
⇒ p1.3 recautions when using testers and measuring instru‐
ments during a road test”, page 2
⇒ p1.4 recautions when working on the cooling system”, page
2
⇒ p1.5 recautions when handling refrigerants”, page 2
⇒ p1.6 recautions for working on vehicles with auxiliary/supple‐
mentary heater”, page 3
⇒ p1.7 recautions when working on the SCR system”, page 4

1.1 Safety precautions when working on air conditioning systems

Risk of fatal injury and explosion from sources of ignition
Risk of fatal injury and explosion from sources of ignition in
the vicinity of air conditioning systems and refrigerant tanks.
Escaping refrigerant could ignite and cause an explosion. Risk
of explosion leading to loss of life or serious injuries.
– Never bring sources of ignition close to air conditioning sys‐
tems and refrigerant tanks.
– Avoid electrostatic discharge, sparks from tools striking sur‐
faces and hot surfaces.

Risk of irreparable damage to refrigerant lines

There is a risk of irreparable damage to the refrigerant lines due
to rupture of the inner foil.
– Never bend refrigerant lines to a radius tighter than
r < 100 mm.

1.2 Safety measures when working on vehicles with a start/stop system

Risk of injury due to unexpected motor start
If the vehicle’s start/stop system is activated, the engine can
start unexpectedly. A message in the dash panel insert indi‐
cates whether the start/stop system is activated.
– Deactivate start/stop system by switching off the ignition.

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1.3 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury caused by unsecured testing and measuring in‐
struments
When the front passenger airbag is triggered in an accident, in‐
sufficiently secured testing and measuring instruments become
dangerous projectiles.
– Secure testing and measuring instruments on the rear seat.
or
– Have a second person operate the test and measuring
equipment on the rear seat.

1.4 Safety precautions when working on the cooling system

Danger of scalding by hot coolant
On a warm engine, the cooling system is under high pressure.
Danger of scalding by steam and hot coolant.
– Wear protective gloves.
– Wear protective goggles.
– Reduce excess pressure by covering cap of coolant expan‐
sion tank with cloths and opening it carefully.

1.5 Safety precautions when handling refrigerants

Risk of suffocation and poisoning from refrigerant
Coughing and nausea leading to suffocation and poisoning from
refrigerant vapours possible.
– Never inhale refrigerant vapours.
– Only work on the refrigerant circuit and refrigerant tanks in
well ventilated areas.
– Never work in or near cellars or other low lying areas.
– Switch on the extraction system.

Risk of freezing injury from refrigerant

When working on the air conditioning system, there is a risk of
highly pressurised refrigerant escaping from the system. There
is a risk of injury to the skin and parts of the body due to
freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have elapsed since evacuation and
the coolant circuit has not been opened, evacuate the refrig‐

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erant again. Pressure could build up in the refrigerant circuit

from continued evaporation.

Risk of irreparable damage to refrigerant lines

There is a risk of irreparable damage to the refrigerant lines due
to rupture of the inner foil.
– Never bend refrigerant lines to a radius tighter than
r < 100 mm.

1.6 Safety precautions for working on vehicles with auxiliary/supplementary

heater
Danger of fire and explosion from auxiliary/supplementary heat‐
er
In fire and explosion-endangered areas, a spark or the high
temperature of the auxiliary/supplementary heater can cause a
fire or an explosion. Risk of burns.
– Switch the auxiliary/supplementary heater off in fire and ex‐
plosion-endangered areas.

Danger of poisoning from exhaust fumes

Auxiliary/supplementary heaters produce poisonous exhaust
fumes. Risk of poisoning and injuries to respiratory system.
– In closed areas, switch on the auxiliary/supplementary heat‐
er only when it is connected to an exhaust extractor system.
– In closed areas without an exhaust extractor system, switch
the auxiliary/supplementary heater off.

Risk of damage when starting the engine

If components of the fuel system or coolant circuit of the aux‐
iliary/supplementary heater are removed or opened, there is
a possibility of causing damage to the auxiliary/supplementary
heater.
– Never attempt to start the engine when components are
removed or opened.

Malfunction caused by air in the fuel supply system

After work has been performed on the fuel tank or the fuel
delivery unit, the metering pump will draw air and supply it to
the auxiliary heater. The air in the fuel system may cause the
auxiliary heater to malfunction.
– Fill fuel take-off pipe with fuel.

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Risk of accidents and risk of injury due to activated timer of

auxiliary/supplementary heater
If the vehicle’s timer for the auxiliary/supplementary heater is
active, the heater may switch on unexpectedly. This poses a
risk of poisoning from exhaust gases, a risk of burns caused by
hot auxiliary/supplementary heater components as well as a risk
of fire and explosions caused by high temperatures.
– Deactivate timer for auxiliary/supplementary heater.

1.7 Safety precautions when working on the SCR system

Risk of injury due to reducing agent
The reducing agent may cause eye and skin irritations as well
as injuries to the respiratory system and poisoning.
– Wear protective goggles.
– Wear protective gloves.
– Always wear protective clothes.
– Make sure that a sufficient amount of fresh air is supplied. In
closed areas, switch on the exhaust gas extractor system.

Risk of damage caused by reducing agent

If reducing agent gets onto trim panels and body components,
the reducing agent may solidify after a while and thus damage
the surface.
– Make sure that no reducing agent gets onto the trim panels
or body components.
– If any reducing agent does get onto surfaces, remove it im‐
mediately using water and a cloth.

Risk of injury due to reducing agent

The reducing agent may cause eye and skin irritations as well
as injuries to the respiratory system and poisoning.
– Wear protective goggles.
– Wear protective gloves.
– Always wear protective clothes.
– Make sure that a sufficient amount of fresh air is supplied. In
closed areas, switch on the exhaust gas extractor system.

Risk of damage caused by reducing agent

If reducing agent gets onto trim panels and body components,
the reducing agent may solidify after a while and thus damage
the surface.

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– Make sure that no reducing agent gets onto the trim panels
or body components.
– If any reducing agent does get onto surfaces, remove it im‐
mediately using water and a cloth.

When removing and installing components of the SCR system,

note the following:
♦ The tank for reducing agent must be empty when working
on the SCR system. Information on when the reducing agent
tank has to be emptied can be obtained from the respective
description of work. Drain reducing agent tank ⇒ Rep. gr. 26;
SCR system (selective catalytic reduction); Draining reduc‐
ing agent tank.
Automatic return of reducing agent
• After the ignition has been switched off, the reducing agent
is returned from the metering line leading to the reducing
agent injector -N474- back to the reducing agent tank.
• Before any work is done in this area, it is necessary to wait
until all the reducing agent has been returned to the tank;
this can take up to 10 minutes after the ignition is switched
off.
• Similarly, it is not permissible to disconnect the battery until
all the reducing agent has been returned to the tank, i.e. 10
minutes after the ignition is switched off ⇒ Electrical system;
Rep. gr. 27; Battery; Disconnecting and connecting battery.

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2 Identification
⇒ o2.1 f heater and air conditioning unit”, page 6

2.1 Identification of heater and air condi‐

tioning unit
⇒ o2.1.1 f heater and air conditioning unit made by Valeo”, page
6
⇒ o2.1.2 f Denso heater and air conditioning unit”, page 6

2.1.1 Identification of heater and air condi‐

tioning unit made by Valeo
Determining manufacturer of heater and air conditioning unit
– Remove centre console ⇒ General body repairs, interior;
Rep. gr. 68; Centre console; Removing and installing centre
console.
A heater and air conditioning unit of the manufacturer Valeo is
installed when the coolant pipes are routed as in the figure.

Note

♦ The combined fitting of different makes of component is not

permissible.
♦ Allocate components correctly when installing ⇒ Electronic
parts catalogue (ETKA).

2.1.2 Identification of Denso heater and air

conditioning unit
Determining manufacturer of heater and air conditioning unit
– Remove centre console ⇒ General body repairs, interior;
Rep. gr. 68; Centre console; Removing and installing centre
console.
A heater and air conditioning unit of the manufacturer Denso is
installed when the coolant pipes are routed as in the figure.

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Note

♦ The combined fitting of different makes of component is not

permissible.
♦ Allocate components correctly when installing ⇒ Electronic
parts catalogue (ETKA).

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3 General information
⇒ p3.1 lates”, page 8
⇒ c3.2 oncerning odours in air conditioned vehicles”, page 10

3.1 Type plates

⇒ p3.1.1 lates, refrigerant R134a”, page 8
⇒ p3.1.2 lates, refrigerant R1234yf”, page 9

3.1.1 Type plates, refrigerant R134a

Type plate with capacities in kg for refrigerant R134a and refrig‐
erant oil

1- Designation of refrigerant oil

2- Name of refrigerant
3- Refrigerant capacity in kg

Note

♦ A tolerance of ±0.015 kg is permissible although not indica‐

ted on the type plate.
♦ Capacities for refrigerant R134a and refrigerant oil ⇒ page
17 .

Type plate with capacities in g for refrigerant R134a and refrig‐

erant oil

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1- Name of refrigerant
2- Refrigerant capacity in g
3- Designation of refrigerant oil

Note

♦ A tolerance of ±15 g is permissible although not indicated on

the type plate.
♦ Capacities for refrigerant R134a and refrigerant oil ⇒ page
17 .

3.1.2 Type plates, refrigerant R1234yf

Type plate with capacities in kg for refrigerant R1234yf and
refrigerant oil

1- Designation of refrigerant oil

2- Name of refrigerant

3. General information 9
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3- Refrigerant capacity in kg

Note

♦ A tolerance of ±0.015 kg is permissible although not indica‐

ted on the type plate.
♦ Capacities for refrigerant R1234yf and refrigerant oil ⇒ page
17 .

Type plate with capacities in g for refrigerant R1234yf and re‐

frigerant oil

1- Designation of refrigerant oil

2- Name of refrigerant
3- Refrigerant capacity in g

Note

♦ A tolerance of ±15 g is permissible although not indicated on

the type plate.
♦ Capacities for refrigerant R1234yf and refrigerant oil ⇒ page
17 .

3.2 Notes concerning odours in air condi‐

tioned vehicles
Special tools and workshop equipment required

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♦ Suction feed spray gun -V.A.G 1538- together with probe

for evaporator cleaning, straight -V.A.G 1538/5- or probe for
evaporator cleaning, curve -V.A.G 1538/6-

♦ Ultrasonic air conditioner cleaning unit -VAS 6189B-

♦ If the evaporator emits unpleasant odours, clean the evapo‐

rator.
♦ For cleaning the evaporator, Volkswagen has tested and
approved ultrasonic A/C cleaner -VAS 6189A- as well as
suction feed spray gun -V.A.G 1538- with probe for evapora‐
tor cleaning, straight -V.A.G 1538/5- or probe for evaporator
cleaning, curved -V.A.G 1538/6-.
♦ Instructions on cleaning the evaporator are supplied with the
equipment.
♦ As soon as Volkswagen releases new procedures, corre‐
sponding information is found in the workshop manual ⇒ Air
conditioning systems with refrigerant R1234yf - General
information; Rep. gr. 87; Refrigerant circuit; Possible com‐
plaints or ⇒ Air conditioning system with refrigerant R134a;
Rep. gr. 00; Complaints; Odours from heater and air condi‐
tioner unit

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4 Repair instructions
⇒ f4.1 or cleanliness”, page 12
⇒ i4.2 nformation”, page 12
⇒ r4.3 epair instructions”, page 12
⇒ c4.4 orrosion”, page 13
⇒ a4.5 nd bolts”, page 13
⇒ a4.6 nd attachment of lines”, page 13
⇒ r4.7 adiators, coolers and condensers”, page 14
⇒ o4.8 n refrigerant circuit”, page 14
⇒ c4.9 ircuit seals”, page 15

4.1 Rules for cleanliness

Even small amounts of contamination/soiling can lead to de‐
fects. Therefore, observe the following rules for cleanliness
when working on the air conditioning system:
♦ Seal open lines and connections immediately with clean
plugs for example from the engine bung set -VAS 6122-.
♦ Place removed parts on a clean surface and cover them
over. Use only lint-free cloths.
♦ If repair work cannot be performed immediately, carefully
cover or seal components.
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing. Do not use parts
that have been stored outside their packaging (e.g. in tool
boxes).
♦ If system is open, do not work with compressed air.
♦ Protect disconnected electrical connectors from dirt and wa‐
ter, and reconnect them only when dry.

4.2 General information

♦ The engine control unit has a self-diagnosis capability. Be‐
fore carrying out repairs and for fault finding, first read event
memory.
♦ For trouble-free operation of electrical components, a volt‐
age of at least 11.5 volts is necessary.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not be burnt in the engine and
damage the Lambda probe.
♦ Vehicles are fitted with a crash fuel shut-off circuit. It reduces
the danger of a fire in a crash as the fuel pump is switched
off via the fuel pump relay.
♦ The system also improves the starting characteristics of the
engine. When the driver door is opened, the fuel pump is ac‐
tivated for 2 seconds to develop pressure in the fuel system.

4.3 General repair instructions

Refer to the following sections for relevant procedures:
♦ Repairing wiring harnesses and connectors ⇒ Electrical sys‐
tem, General information; Rep. gr. 97; Wiring harness and
connector repair.

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♦ Releasing and dismantling connector housings ⇒ Electrical

system, General information; Rep. gr. 97; Wiring harness
and connector repair; Releasing and dismantling contact
housings.
♦ Cleaning contact surfaces ⇒ Electrical system, General in‐
formation; Rep. gr. 97; Repair case -VAS 6410-.
♦ Vehicle diagnostic, testing and information systems ⇒ Elec‐
trical system, General information; Rep. gr. 97; Vehicle diag‐
nostic, testing and information systems.

4.4 Contact corrosion

Contact corrosion can occur if unsuitable fasteners (bolts, nuts,
washers, etc.) are used.
For this reason, only connecting elements with a special surface
coating have been fitted.
In addition, rubber, plastic and adhesives are made of non-con‐
ductive materials.
If there is any doubt about the suitability of parts, a general rule
is to use new parts ⇒ Electronic parts catalogue (ETKA).

4.5 Nuts and bolts

♦ Specified torques given are for unoiled nuts, bolts and

screws.
♦ Always renew self-locking nuts and bolts.
♦ Always renew nuts and bolts with turning further angle.

4.6 Routing and attachment of lines

Risk of damage to lines
Lines may become damaged by moving or hot components.
– Route lines in their original positions.
– Ensure there is sufficient clearance to moving or hot compo‐
nents.
– If necessary, renew cable ties, heat insulation sleeves, clips
and similar that had to be taken off for removal. Install in the
same position.

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4.7 Fitting radiators, coolers and condens‐

ers
Even if installed correctly, the radiator, the condenser and the
charge air cooler may have small dents in their fins. This does
not mean that these components have been damaged. It is not
permissible to renew radiators, charge air coolers or condens‐
ers only because of such minor dents.

4.8 Working on refrigerant circuit

Risk of freezing injury from refrigerant
When working on the air conditioning system, there is a risk of
highly pressurised refrigerant escaping from the system. There
is a risk of injury to the skin and parts of the body due to
freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have elapsed since evacuation and
the coolant circuit has not been opened, evacuate the refrig‐
erant again. Pressure could build up in the refrigerant circuit
from continued evaporation.

Note

♦ The refrigerant circuit must be purged with refrigerant

R134a / R1234yf under the following conditions:
♦ If dirt or other contamination is in the circuit.
♦ The search for faults in the electrical system, the vacuum
system and the air ducts did not turn up any fault.(Moisture
is in the refrigerant circuit and builds up pressure.)
♦ If the refrigerant circuit has been left open for longer than
normally required for repairs (e.g. following an accident).
♦ When pressure and temperature measurements in the refrig‐
erant circuit indicate that there is moisture in the refrigerant
circuit.
♦ There is doubt about the amount of refrigerant oil in the
refrigerant circuit.
♦ The air conditioner compressor has to be exchanged be‐
cause of internal damage (e.g. noisy or lack of power).

For details regarding the procedure of purging with refrigerant

R134a / R1234yf, refer to the following section of the ELSA:
Vehicles with R134a refrigerant
♦ ⇒ Air conditioning system with refrigerant R134a; Rep.
gr. 00; Cleaning refrigerant circuit of contaminants
Vehicles with R1234yf refrigerant
♦ ⇒ Air conditioning systems with refrigerant R1234yf - general
information; Rep. gr. 87; Refrigerant circuit; Cleaning the
refrigerant circuit

14 Rep. gr.00 - Technical data

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For notes on testers and tools for repair work on climate-con‐

trolled vehicles, refer to the following section of the ELSA:
Vehicles with R134a refrigerant
♦ ⇒ Air conditioning system with refrigerant R134a; Rep.
gr. 00; Testers and tools
Vehicles with R1234yf refrigerant
♦ ⇒ Air conditioning systems with refrigerant R1234yf - general
information; Rep. gr. 00; Testers and tools
For information on opening the refrigerant circuit, refer to the
following section of the ELSA:
Vehicles with R134a refrigerant
In some cases, it is no longer necessary on air conditioning sys‐
tems with R134a refrigerant to renew the desiccant bag each
time the refrigerant circuit is opened ⇒ Air conditioning system
with R134a refrigerant; Rep. gr. 00; Renewing components.
Vehicles with R1234yf refrigerant
In some cases, it is no longer necessary on air conditioning
systems with refrigerant R1234yf to renew the desiccant bag
each time the refrigerant circuit is opened ⇒ Air conditioning
system with refrigerant R1234yf; Rep. gr. 87; Refrigerant circuit;
Renewing components.

4.9 Refrigerant circuit seals

♦ Renew seals after removal.
♦ Moisten seals with refrigerant oil before installing.
♦ Ensure proper seating of seal -1- in groove -arrow- of re‐
spective refrigerant line.

♦ Make sure connections of refrigerant lines in question are

clean.
♦ Install only seals resistant to refrigerant R134a/R1234yf and
respective refrigerant oil ⇒ Electronic parts catalogue (ET‐
KA).
The dimensions -a- and -b- depend on the fitting location of the
seal ⇒ Electronic parts catalogue (ETKA).

4. Repair instructions 15
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5 Technical data
⇒ c5.1 apacity”, page 17
⇒ o5.2 il capacities”, page 17
⇒ d5.3 istribution”, page 18

5.1 Refrigerant capacity

⇒ f5.1.1 or refrigerant R134a”, page 17
⇒ f5.1.2 or refrigerant R1234yf”, page 17

5.1.1 Capacities for refrigerant R134a

Total capacity
0.500 kg ± 0.015 kg or 500 g ± 15 g
0.500 kg ± 0.015 kg or 500 g ± 15 g

Note

A tolerance of ± 15 g is permissible although not indicated on

the identification plate.

5.1.2 Capacities for refrigerant R1234yf

Total capacity
0.460 kg ± 0.015 kg or 460 g ± 15 g

Note

A tolerance of ± 15 g is permissible although not indicated on

the identification plate.

5.2 Refrigerant oil capacities

⇒ o5.2.1 il capacities, refrigerant R134a”, page 17
⇒ o5.2.2 il capacities, refrigerant R1234yf”, page 18

5.2.1 Refrigerant oil capacities, refrigerant

R134a
Depending on the manufacturer, different refrigerant oils are
used; part number ⇒ Electronic parts catalogue (ETKA).
Refrigerant oil is very hygroscopic. Therefore refrigerant oils
from containers which have been open for a longer period of
time are unusable.
– Reseal open containers immediately to protect against in‐
gress of moisture.
– Note the type plate on the air conditioner compressor.
Air conditioner compressor man‐ Period Total amount of oil in refrigerant cir‐
ufacturer cuit 1)
Denso Up to week 28/2019 110 ± 10 cm3

Volkswagen Technical Site: http://vwts.ru http://vwts.info 5. Technical data 17

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Air conditioner compressor man‐ Period Total amount of oil in refrigerant cir‐
ufacturer cuit 1)
Denso As of week 28/2019 80 ± 10 cm3
Sanden 75 ± 10 cm3
Mahle 110 ± 10 cm3
1) This quantity of refrigerant oil is contained in a replacement air conditioner compressor and corresponds to the total capacity.

5.2.2 Refrigerant oil capacities, refrigerant

R1234yf
Depending on the manufacturer, different refrigerant oils are
used; part number ⇒ Electronic parts catalogue (ETKA).
Refrigerant oil is very hygroscopic. Therefore refrigerant oils
from containers which have been open for a longer period of
time are unusable.
– Reseal open containers immediately to protect against in‐
gress of moisture.
– Note the type plate on the air conditioner compressor.
Air conditioner compressor man‐ Period Total amount of oil in refrigerant cir‐
ufacturer cuit 2)
Denso Up to week 28/2019 110 ± 10 cm3
Denso As of week 28/2019 80 ± 10 cm3
Sanden 75 ± 10 cm3
Mahle 110 ± 10 cm3
2) This quantity of refrigerant oil is contained in a replacement air conditioner compressor and corresponds to the total capacity.

5.3 Oil distribution

♦ During operation of the air conditioner, the refrigerant oil in
the air conditioner compressor prior to initial operation is
distributed throughout the refrigerant circuit.
♦ The distribution of the refrigerant oil depends on the operat‐
ing mode of the air conditioner when it was switched off, the
ambient temperatures etc. Consequently, it is not possible
to make a general statement about how the refrigerant oil
is distributed within the refrigerant circuit. Observe notes on
replacing refrigerant circuit components ⇒ Air conditioning
system with refrigerant R134a; Rep. gr. 00; Renewing com‐
ponents (Air conditioning system with refrigerant R134a, Re‐
newing refrigerant circuit components) or ⇒ Air conditioning
systems with refrigerant R1234yf - General information; Rep.
gr. 87; Refrigerant circuit; Renewing components.

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80 – Heating
1 Heating

Note

♦ Only heaters with air conditioning are currently offered for

this specific model.
♦ For information on repairs, refer to ⇒ g r.87“Air conditioning
system”, page 20 .

1. Heating 19
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87 – Air conditioning system

1 Overview of fitting locations - air
conditioning system
⇒ o1.1 f fitting locations - components not located in passenger
compartment”, page 20
⇒ o1.2 f fitting locations - components located in front section of
passenger compartment”, page 22

1.1 Overview of fitting locations - compo‐

nents not located in passenger com‐
partment

Note

The following information applies to left-hand drive vehicles.

Right-hand drive vehicles are similar.

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1 - Forced ventilation in pas‐

senger compartment
❑ Qty. 2
❑ Removing and instal‐
ling ⇒ page 181
❑ Checking ⇒ page 182
2 - Humidity sender for air
conditioning system -G260-
❑ Removing and instal‐
ling ⇒ page 197
3 - Expansion valve
❑ Removing and instal‐
ling ⇒ page 36
4 - Desiccant bag
❑ Removing and instal‐
ling ⇒ page 43
❑ Assembly overview ⇒
page 29
5 - Ambient temperature sen‐
sor -G17-
❑ Removing and instal‐
ling ⇒ page 197
6 - Condenser
❑ With integrated desic‐
cant bag
❑ Assembly overview ⇒
page 29
❑ Removing and instal‐
ling ⇒ page 40
7 - Air conditioner compressor
❑ Assembly overview ⇒
page 68
❑ Removing from and installing on bracket ⇒ page 76
❑ Removing and installing ⇒ page 78
8 - Service connection
❑ High-pressure side
❑ Removing and installing evacuating and charging valves ⇒ page 53
9 - Pressure sender for refrigerant circuit -G805-
❑ Removing and installing ⇒ page 31
10 - Service connection
❑ Low-pressure side
❑ Removing and installing evacuating and charging valves ⇒ page 53
11 - Refrigerant line
❑ With internal heat exchanger
❑ From condenser and air conditioner compressor
❑ Removing and installing ⇒ page 32
12 - Air quality sensor -G238-
❑ Only vehicles with Climatronic
❑ Principle of operation ⇒ page 195
❑ Removing and installing ⇒ page 196
13 - Fresh air intake

1. Overview of fitting locations - air conditioning system 21

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❑ Removing and installing ⇒ page 183
14 - Cover
❑ For fresh air intake duct
❑ Removing and installing ⇒ page 184

1.2 Overview of fitting locations - compo‐

nents located in front section of pas‐
senger compartment
⇒ o1.2.1 f fitting locations - components inside of front passen‐
ger compartment, left-hand drive vehicles”, page 22
⇒ o1.2.2 f fitting locations - components inside of front passen‐
ger compartment, right-hand drive vehicles”, page 24

1.2.1 Overview of fitting locations - components inside of front passenger com‐

partment, left-hand drive vehicles

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1 - Left vent temperature

sender -G150-
❑ Removing and instal‐
ling ⇒ page 198
2 - Footwell vent on driver
side
❑ Assembly overview ⇒
page 174
❑ Removing and instal‐
ling ⇒ page 175
3 - Footwell vent temperature
sender -G192-
❑ Removing and instal‐
ling ⇒ page 201
4 - Front air distribution flap
control motor -V426- with air
distribution flap control motor
-V428-
❑ Fitting location over‐
view ⇒ page 90
❑ Vehicles with air condi‐
tioning system, remov‐
ing and installing ⇒
page 105
❑ Vehicles with Clima‐
tronic, removing and in‐
stalling ⇒ page 104
5 - Temperature flap control
motor -V68- or left tempera‐
ture flap control motor -V158-
❑ Fitting location over‐
view ⇒ page 90
❑ Vehicles with air condi‐
tioning system, remov‐
ing and installing ⇒
page 94
❑ Vehicles with Climatronic, removing and installing ⇒ page 99
6 - Evaporator
❑ Removing and installing ⇒ page 118
7 - Sunlight penetration photosensor -G107-
❑ Removing and installing ⇒ page 194
8 - Evaporator temperature sensor -G308-
❑ Check with ⇒ Vehicle diagnostic tester
❑ Removing and installing ⇒ page 167
9 - Defroster flap control motor -V107-
❑ Fitting location overview ⇒ page 90
❑ Removing and installing ⇒ page 96
10 - Right temperature flap control motor -V159-
❑ Fitting location overview ⇒ page 90
❑ Removing and installing ⇒ page 101
11 - Dust and pollen filter
❑ Different versions ⇒ Electronic parts catalogue (ETKA)
❑ Change interval ⇒ Maintenance tables

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❑ Removing and installing ⇒ page 132
12 - Air recirculation flap control motor -V113- or fresh air/recirculated air, air flow flap control motor -V425-
❑ Fitting location overview ⇒ page 90
❑ Vehicles with air conditioning system, removing and installing ⇒ page 98
❑ Vehicles with Climatronic, removing and installing ⇒ page 102
13 - Right vent temperature sender -G151-
❑ Removing and installing ⇒ page 199
14 - Fresh air blower -V2-
❑ Removing and installing ⇒ page 136
15 - Footwell vent on front passenger side
❑ Assembly overview ⇒ page 174
❑ Removing and installing ⇒ page 176
16 - Condensation drain hose
❑ Removing and installing ⇒ page 169
❑ Checking ⇒ page 173
17 - Heat exchanger
❑ Removing and installing ⇒ page 141
18 - Auxiliary air heater element -Z35-
❑ With auxiliary air heater control unit -J604-.
❑ Checking ⇒ page 119
❑ Removing and installing ⇒ page 120
19 - Operating and display unit
❑ Overview of operating and display units ⇒ page 187
❑ Removing and installing ⇒ page 191

1.2.2 Overview of fitting locations - components inside of front passenger com‐

partment, right-hand drive vehicles

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1 - Air recirculation flap con‐

trol motor -V113- or fresh air/
recirculated air, air flow flap
control motor -V425-
❑ Fitting location over‐
view ⇒ page 90
❑ Vehicles with air condi‐
tioning system, remov‐
ing and installing ⇒
page 98
❑ Vehicles with Clima‐
tronic, removing and in‐
stalling ⇒ page 102
2 - Dust and pollen filter
❑ Removing and instal‐
ling ⇒ page 132
3 - Temperature flap control
motor -V68- or left tempera‐
ture flap control motor -V158-
❑ Fitting location over‐
view ⇒ page 90
❑ Vehicles with air condi‐
tioning system, remov‐
ing and installing ⇒
page 94
❑ Vehicles with Clima‐
tronic, removing and in‐
stalling ⇒ page 99
4 - Front air distribution flap
control motor -V426- with air
distribution flap control motor
-V428-
❑ Fitting location over‐
view ⇒ page 90
❑ Vehicles with air condi‐
tioning system, remov‐
ing and installing ⇒ page 105
❑ Vehicles with Climatronic, removing and installing ⇒ page 104
5 - Sunlight penetration photosensor -G107-
❑ Removing and installing ⇒ page 194
6 - Evaporator
❑ Removing and installing ⇒ page 118
7 - Evaporator temperature sensor -G308-
❑ Removing and installing ⇒ page 167
8 - Right temperature flap control motor -V159-
❑ Fitting location overview ⇒ page 90
❑ Removing and installing ⇒ page 101
9 - Defroster flap control motor -V107-
❑ Fitting location overview ⇒ page 90
❑ Removing and installing ⇒ page 96
10 - Footwell vent temperature sender -G192-
❑ Check with ⇒ Vehicle diagnostic tester
❑ Removing and installing ⇒ page 201
11 - Right vent temperature sender -G151-

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❑ Check with ⇒ Vehicle diagnostic tester
❑ Removing and installing ⇒ page 199
12 - Footwell vent on driver side
❑ Assembly overview ⇒ page 174
❑ Removing and installing ⇒ page 175
13 - Operating and display unit
❑ Removing and installing ⇒ page 191
14 - Condensation drain hose
❑ Checking ⇒ page 173
❑ Removing and installing ⇒ page 171
15 - Heat exchanger
❑ Removing and installing ⇒ page 141
16 - Auxiliary air heater element -Z35-
❑ With auxiliary air heater control unit -J604-.
❑ Checking ⇒ page 119
❑ Removing and installing ⇒ page 120
17 - Footwell vent on front passenger side
❑ Assembly overview ⇒ page 174
❑ Removing and installing ⇒ page 176
18 - Fresh air blower -V2-
❑ Removing and installing ⇒ page 136
19 - Left vent temperature sender -G150-
❑ Check with ⇒ Vehicle diagnostic tester
❑ Removing and installing ⇒ page 198

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2 Refrigerant circuit
⇒ o2.1 verview - refrigerant circuit”, page 27
⇒ o2.2 verview – condenser”, page 29
⇒ a2.3 nd installing refrigerant circuit pressure senderG805”,
page 31
⇒ a2.4 nd installing refrigerant line with internal heat exchang‐
er”, page 32
⇒ a2.5 nd installing expansion valve”, page 36
⇒ a2.6 nd installing condenser”, page 40
⇒ a2.7 nd installing desiccant bag or cartridge”, page 43
⇒ a2.8 nd installing evacuating and charging valves on low and
high-pressure side”, page 53
⇒ a2.9 ir conditioning system after filling refrigerant circuit”,
page 55
⇒ a2.10 nd installing refrigerant line from air conditioner com‐
pressor to condenser”, page 55
⇒ a2.11 nd installing refrigerant line from air conditioner com‐
pressor to evaporator”, page 58
⇒ a2.12 nd installing refrigerant line from evaporator to air con‐
ditioner compressor”, page 62
⇒ a2.13 nd installing damper weight for refrigerant line, low-
pressure side”, page 66
⇒ a2.14 ir conditioning system after filling refrigerant circuit”,
page 66

2.1 System overview - refrigerant circuit

2. Refrigerant circuit 27
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1 - Refrigerant line
❑ Low-pressure side
❑ Leads to refrigerant line
with internal heat ex‐
changer
❑ Depending on the vehi‐
cle model, type of re‐
frigerant lines and pro‐
duction period, an ad‐
ditional damper weight
may be installed on the
refrigerant line ⇒ Elec‐
tronic parts catalogue
(ETKA).
❑ Removing and instal‐
ling damper weight ⇒
page 66
2 - Refrigerant line
❑ High-pressure side
❑ Leads to refrigerant line
with internal heat ex‐
changer
3 - Refrigerant line
❑ With internal heat ex‐
changer
❑ From condenser and
air conditioner com‐
pressor
❑ Removing and instal‐
ling ⇒ page 32
4 - Expansion valve
❑ Removing and instal‐
ling ⇒ page 36
5 - Air conditioner compressor
❑ Assembly overview ⇒ page 68
❑ Removing from and installing on bracket ⇒ page 76
❑ Removing and installing ⇒ page 78
6 - Receiver with desiccant bag
❑ Denso condenser ⇒ page 43
❑ Modine condenser ⇒ page 45
7 - Condenser
❑ With integrated desiccant bag
❑ Assembly overview ⇒ page 29
❑ Removing and installing ⇒ page 40
8 - Refrigerant line
❑ To condenser
9 - Nuts
❑ Qty. 2
❑ 8 Nm
10 - Bolt
❑ 8 Nm
11 - Bolts

28 Rep. gr.87 - Air conditioning system

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❑ Qty. 2
❑ 4.5 Nm ± 0.5 Nm
12 - Bolts
❑ Qty. 2
❑ 22 Nm
13 - High-pressure safety valve on air conditioner compressor
❑ Checking ⇒ page 83
14 - Air conditioner compressor regulating valve -N280-
15 - Oil drain plug
❑ Different versions. Refer to ⇒ Electronic parts catalogue (ETKA)
❑ Specified torque:
♦ Denso air conditioner compressor - 30 Nm
♦ Sanden air conditioner compressor - 10 Nm
16 - Cap
❑ Different versions. Refer to ⇒ Electronic parts catalogue (ETKA)
❑ Modine: 5 Nm
17 - Bolts
❑ Qty. 2
❑ 8 Nm
18 - Service connection
❑ High-pressure side
❑ Removing and installing evacuating and charging valves ⇒ page 53
19 - Pressure sender for refrigerant circuit -G805-
❑ Removing and installing ⇒ page 31
20 - Service connection
❑ Low-pressure side
❑ Removing and installing evacuating and charging valves ⇒ page 53

2.2 Assembly overview – condenser

The illustration shows the Denso condenser.

2. Refrigerant circuit 29
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1 - Condenser
❑ Different versions. Re‐
fer to ⇒ Electronic parts
catalogue (ETKA)
❑ Removing and instal‐
ling ⇒ page 40
2 - Plug
❑ With seals
❑ Different versions. Re‐
fer to ⇒ Electronic parts
catalogue (ETKA)
❑ Renew if damaged
❑ Denso condenser 5 Nm
3 - Seal
❑ Renew after removal
❑ Moisten with refrigerant
oil before fitting
4 - Seal
❑ Renew after removal
❑ Moisten with refrigerant
oil before fitting
5 - Desiccant bag/cartridge
❑ Different versions. Re‐
fer to ⇒ Electronic parts
catalogue (ETKA)
❑ Removing and instal‐
ling:
♦ Denso condenser ⇒ page
43

Note

♦ In some cases, it is no lon‐

ger necessary on air condition‐
ing systems with refrigerant
R1234yf to renew the desiccant
bag each time the refrigerant
circuit is opened ⇒ Air condi‐
tioning system with refrigerant
R1234yf; Rep. gr. 87; Refrig‐
erant circuit; Renewing compo‐
nents.
♦ In some cases, it is no lon‐
ger necessary on air condition‐
ing systems with R134a refrig‐
erant to renew the desiccant
bag each time the refrigerant
circuit is opened ⇒ Air condi‐
tioning system with R134a re‐
frigerant; Rep. gr. 00; Renewing
components.

6 - Filter
❑ Different versions. Refer to ⇒ Electronic parts catalogue (ETKA)
7 - Seal

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❑ Renew after removal
❑ Moisten with refrigerant oil before fitting
8 - Refrigerant line
❑ To expansion valve
9 - Bolt
❑ 8 Nm
10 - Refrigerant line
❑ From air conditioner compressor

2.3 Removing and installing refrigerant cir‐

cuit pressure sender -G805-
Special tools and workshop equipment required
♦ Socket 24 mm -T40284-

♦ Engine bung set -VAS 6122-

Removing

– Disconnect electrical connector -1-.

2. Refrigerant circuit 31
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CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant. If handled incorrectly, union could break off and refrig‐
erant could escape.
There is a risk of injury to the skin and parts of the body due
to freezing.
– Wear protective gloves.
– Wear protective goggles.
– Counterhold refrigerant lines using a suitable tool.

– Counterhold refrigerant lines using a suitable tool. While do‐

ing so, detach pressure sender for refrigerant circuit -G805-
-2- using socket 24 mm -T40284-.

CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due
to freezing.
– Wear protective gloves.
– Wear protective goggles.
– If, when detaching the pressure sender, refrigerant es‐
capes from the refrigerant line for longer than 1 second,
tighten the pressure sender and renew the non-return
valve that is defective.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have elapsed since evacuation
and the coolant circuit has not been opened, evacuate the
refrigerant again. Pressure could build up in the refrigerant
circuit from continued evaporation.

– For any further work, immediately seal open lines and con‐
nections with clean plugs from engine bung set -VAS 6122-.
– Unscrew pressure sender for refrigerant circuit -G805- -2-.
Installing
Install in reverse order of removal, observing the following:
– Renew seal for pressure sender for refrigerant circuit -G805-
-2-.
Specified torques
Component Specified torque
Pressure sender for refrigerant circuit -G805- -2-. 8 Nm

2.4 Removing and installing refrigerant line

with internal heat exchanger
Special tools and workshop equipment required

32 Rep. gr.87 - Air conditioning system

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♦ Engine bung set -VAS 6122-

Removing
Vehicles with TDI engine

– Press release tabs on crankcase breather hose -1- and dis‐

connect hose from cylinder head cover.
– Move clear vacuum hoses at air pipe -arrows-.
– Release hose clip -3-.
– Remove bolt -2-, swivel air pipe and connection to rear and
detach from turbocharger.
Vehicles with 1.5 l or 2.0 l engine
– Remove throttle valve module -GX3- ⇒ Rep. gr. 24; Intake
manifold; Removing and installing throttle valve module
GX3.
Continued for all vehicles

– To do this, unscrew nuts -1- and -3-.

– Fold heat shield -2- as far as possible in -direction of arrow-.

2. Refrigerant circuit 33
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Vehicles with R134a refrigerant

– Drain refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00; Working with air conditioner
service station.
Vehicles with R1234yf refrigerant
– Drain refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87; Working
with air conditioner service station; Draining refrigerant cir‐
cuit.
Continued for all vehicles

CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due
to freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have elapsed since evacuation
and the coolant circuit has not been opened, evacuate the
refrigerant again. Pressure could build up in the refrigerant
circuit from continued evaporation.

– For any further work, immediately seal open lines and con‐
nections with clean plugs from engine bung set -VAS 6122-.
– Unscrew bolt -7-.

– Pull off refrigerant line -6- with internal heat exchanger from
expansion valve.
– Unscrew nuts -1- and -3-.
– Pull off refrigerant lines -2- and -4-.
– Remove refrigerant line -5- with internal heat exchanger.

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Installing

Install in reverse order of removal, observing the following:

– Clean the connections on the expansion valve -2- and inter‐
nal heat exchanger -4-, and check for damage.
– Thoroughly clean connections of refrigerant lines and check
lines for damage.
– Moisten new seals -1- and -3- with refrigerant oil before
installing.
– Insert seals -1- and -3- into groove on connection of internal
heat exchanger.
– Insert internal heat exchanger on expansion valve.
– Tighten bolt -5-.

– Connect refrigerant lines -2- and -4- with internal heat ex‐
changer to connections.
– Screw on nuts -1- and -3- and tighten them.

2. Refrigerant circuit 35
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NOTICE
Risk of damage to air conditioner compressor if refrigerant
circuit is empty.
– Never start the engine if the refrigerant circuit is empty.

Vehicles with R134a refrigerant

– Charge refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00; Working with air conditioner
service station.
– Perform leakage test on re-established line connections of
refrigerant circuit ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00; Detecting leaks in refrigerant circuit.
Vehicles with R1234yf refrigerant
– Charge refrigerant circuit ⇒ Air conditioning systems with
refrigerant R1234yf - general information; Rep. gr. 87; Work‐
ing with air conditioner service station; Charging refrigerant
circuit.
– Perform leakage test on re-established line connections of
refrigerant circuit ⇒ Air conditioning systems with refrigerant
R1234yf - General information; Rep. gr. 87; Refrigerant cir‐
cuit; Detecting leaks.
Continued for all vehicles
– Commissioning air conditioning system after charging refrig‐
erant circuit ⇒ page 55 .
Specified torques
♦ ⇒ o2.1 verview - refrigerant circuit”, page 27

2.5 Removing and installing expansion

valve
Special tools and workshop equipment required
♦ Engine bung set -VAS 6122-

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Removing
Vehicles with TDI engine

– Press release tabs on crankcase breather hose -1- and dis‐

connect hose from cylinder head cover.
– Move clear vacuum hoses at air pipe -arrows-.
– Release hose clip -3-.
– Swing air pipe with connecting piece towards rear and pull it
off turbocharger.
Vehicles with 1.5 l or 2.0 l engine
– Remove throttle valve module -GX3- ⇒ Rep. gr. 24; Intake
manifold; Removing and installing throttle valve module
GX3.
Continued for all vehicles

– To do this, unscrew nuts -1- and -3-.

– Fold heat shield -2- as far forwards as possible in
-direction of arrow-.
Vehicles with R134a refrigerant
– Drain refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00; Working with air conditioner
service station.
Vehicles with R1234yf refrigerant
– Drain refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87; Working
with air conditioner service station; Draining refrigerant cir‐
cuit.

2. Refrigerant circuit 37
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Continued for all vehicles

CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due
to freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have elapsed since evacuation
and the coolant circuit has not been opened, evacuate the
refrigerant again. Pressure could build up in the refrigerant
circuit from continued evaporation.

– For any further work, immediately seal open lines and con‐
nections with clean plugs from engine bung set -VAS 6122-.
– Unscrew nuts -1- and -3-.

– Unscrew bolt -7-.

– Detach refrigerant line with internal heat exchanger -5- from
expansion valve and remove.
– Unscrew bolts -1- and -3-.

– Carefully pull expansion valve -4- out of heat insulation -2-.

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Installing

Install in reverse order of removal, observing the following:

– Moisten new seals -1- with refrigerant oil before installing.
– Press new seals -1- on connecting pipes -2-.
– Check refrigerant lines for contamination and damage; clean
or renew component if necessary ⇒ Electronic parts cata‐
logue (ETKA).
– Press refrigerant pipe -2- by hand into expansion valve.

– Screw bolt -1- in by hand.

– Tighten bolt -1-.

Note

Disregard items -1, 3- and -4-.

If heat insulation -2- is missing or improperly installed, it may

lead to reduced performance of the air conditioning system (due
to changes in the set mapped values through heat radiation).

2. Refrigerant circuit 39
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NOTICE
Risk of damage to air conditioner compressor if refrigerant
circuit is empty.
– Never start the engine if the refrigerant circuit is empty.

Vehicles with R134a refrigerant

– Charge refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00; Working with air conditioner
service station.
– Perform leakage test on re-established line connections of
refrigerant circuit ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00; Detecting leaks in refrigerant circuit.
Vehicles with R1234yf refrigerant
– Charge refrigerant circuit ⇒ Air conditioning systems with
refrigerant R1234yf - general information; Rep. gr. 87; Work‐
ing with air conditioner service station; Charging refrigerant
circuit.
– Perform leakage test on re-established line connections of
refrigerant circuit ⇒ Air conditioning systems with refrigerant
R1234yf - General information; Rep. gr. 87; Refrigerant cir‐
cuit; Detecting leaks.
Continued for all vehicles
– Commissioning air conditioning system after charging refrig‐
erant circuit ⇒ page 55 .
Specified torques
♦ ⇒ o2.1 verview - refrigerant circuit”, page 27

2.6 Removing and installing condenser

Special tools and workshop equipment required
♦ Engine bung set -VAS 6122-

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Removing

– Remove front bumper cover ⇒ General body repairs, exte‐

rior; Rep. gr. 63; Front bumper; Removing and installing
bumper cover.
– Release air ducts -2- from upper mountings -arrow-.
– Press down locking device -4- in -direction of arrow- and pull
air duct -2- towards front.
– Remove air duct downwards.
Vehicles with R134a refrigerant
– Drain refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00; Working with air conditioner
service station.
Vehicles with R1234yf refrigerant
– Drain refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87; Working
with air conditioner service station; Draining refrigerant cir‐
cuit.
Continued for all vehicles

CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due
to freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have elapsed since evacuation
and the coolant circuit has not been opened, evacuate the
refrigerant again. Pressure could build up in the refrigerant
circuit from continued evaporation.

– For any further work, immediately seal open lines and con‐
nections with clean plugs from engine bung set -VAS 6122-.
– Unscrew bolts -5-.

2. Refrigerant circuit 41
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– Remove refrigerant lines -3- from connection on condenser.

Note

Only the left side is described as follows. The description for the
right side is basically the same.

– Press locking lug -1- in -direction of arrow A-. While doing

this, remove condenser -2- from mountings in direction of
-arrow B-.

Installing
Install in reverse order of removal, observing the following:
– Moisten new seals with refrigerant oil before installing refrig‐
erant line.

NOTICE
Risk of damage to air conditioner compressor if refrigerant
circuit is empty.
– Never start the engine if the refrigerant circuit is empty.

– If the condenser has been renewed, 10% of the total quan‐

tity of refrigerant oil specified for the fitted air conditioning
compressor must be filled into the refrigerant circuit ⇒ o5.2 il
capacities”, page 17 .
Vehicles with R134a refrigerant
– Charge refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00; Working with air conditioner
service station.
– Perform leakage test on re-established line connections of
refrigerant circuit ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00; Detecting leaks in refrigerant circuit.
Vehicles with R1234yf refrigerant
– Charge refrigerant circuit ⇒ Air conditioning systems with
refrigerant R1234yf - general information; Rep. gr. 87; Work‐
ing with air conditioner service station; Charging refrigerant
circuit.
– Perform leakage test on re-established line connections of
refrigerant circuit ⇒ Air conditioning systems with refrigerant
R1234yf - General information; Rep. gr. 87; Refrigerant cir‐
cuit; Detecting leaks.
Continued for all vehicles
– Commissioning air conditioning system after charging refrig‐
erant circuit ⇒ page 55 .

42 Rep. gr.87 - Air conditioning system

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Specified torques
♦ ⇒ o2.2 verview – condenser”, page 29
♦ Front bumper; Assembly overview - front bumper cover
⇒ General body repairs, exterior; Rep. gr. 63; Front bumper;
Assembly overview - front bumper cover.

2.7 Removing and installing desiccant bag

or cartridge
⇒ a2.7.1 nd installing desiccant bag or cartridge, Denso con‐
denser”, page 43
⇒ a2.7.2 nd installing desiccant bag or cartridge, Modine con‐
denser”, page 45
⇒ a2.7.3 nd installing desiccant bag or cartridge, Showa/Keihin
condenser”, page 50

2.7.1 Removing and installing desiccant bag

or cartridge, Denso condenser
Special tools and workshop equipment required
♦ Engine bung set -VAS 6122-

♦ Commercially available claw grip

Removing
– Depending on engine fitted, remove parts of charge air sys‐
tem ⇒ Rep. gr. 21; Charge air system; Assembly overview -
charge air system.
– Drain refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87; Working
with air conditioner service station; Draining refrigerant cir‐
cuit.
– Remove condenser -1- ⇒ page 40 to gain access to desic‐
cant bag/desiccant cartridge -2-.

2. Refrigerant circuit 43
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CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due
to freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have elapsed since evacuation
and the coolant circuit has not been opened, evacuate the
refrigerant again. Pressure could build up in the refrigerant
circuit from continued evaporation.

– Unscrew plug -2-.

– Using a suitable tool, pull desiccant bag upwards out of re‐
ceiver.
– Insert service tool -A- in receiver and engage with filter -2- in
direction of -arrow-.

– Pull out filter -2- from condenser -1-.

– Immediately seal open receiver with clean plugs from engine
bung set -VAS 6122-.
Installing
Install in reverse order of removal, observing the following:

Note

The plug, seals and desiccant bag must always be renewed

after opening the receiver ⇒ Electronic parts catalogue (ETKA).

– Moisten new seals with refrigerant oil before installing refrig‐

erant line.
– Through the opening, check threads and sealing surfaces of
receiver on condenser for contamination or damage.
– Insert new filter -2- in condenser -1- in direction of -arrow-
with service tool -A-.

44 Rep. gr.87 - Air conditioning system

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– Filter must be placed on base of receiver.

NOTICE
If positioned incorrectly, condenser could fail.
– Place filter on base of receiver.

– Take desiccant bag out of transport bag and insert it into

receiver.
– Start plug and screw in.
– Continue installation in reverse order of removal.

NOTICE
Risk of damage to air conditioner compressor if refrigerant
circuit is empty.
– Never start the engine if the refrigerant circuit is empty.

– Charge refrigerant circuit ⇒ Air conditioning systems with

refrigerant R1234yf - general information; Rep. gr. 87; Work‐
ing with air conditioner service station; Charging refrigerant
circuit.
– Perform leakage test on re-established line connections of
refrigerant circuit ⇒ Air conditioning systems with refrigerant
R1234yf - General information; Rep. gr. 87; Refrigerant cir‐
cuit; Detecting leaks.
– Commissioning air conditioning system after charging refrig‐
erant circuit ⇒ page 66 .
Specified torques
♦ ⇒ o2.2 verview – condenser”, page 29
Component Specified torque
Plug 5 Nm

2.7.2 Removing and installing desiccant bag

or cartridge, Modine condenser
Special tools and workshop equipment required

2. Refrigerant circuit 45
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♦ Engine bung set -VAS 6122-

♦ Socket T50
Removing
– Depending on engine fitted, remove parts of charge air sys‐
tem ⇒ Rep. gr. 21; Charge air system; Assembly overview -
charge air system.
– Remove condenser ⇒ page 40 to gain access to desiccant
bag/desiccant cartridge.

CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due
to freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have elapsed since evacuation
and the coolant circuit has not been opened, evacuate the
refrigerant again. Pressure could build up in the refrigerant
circuit from continued evaporation.

– Unscrew protective cap -1- from receiver -2- using sock‐

et T50.

– Press sealing cap -2- in slightly.

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– Remove circlip -1-.

– Screw an M12 bolt into cap and pull it carefully out of receiv‐
er -4-.
– Pull desiccant bag -3- out of receiver using a commercially
available pick-up tool.
– To prevent damage to the receiver, it is essential to hook
e. g. a welding wire into the strainer as shown in the illustra‐
tion.
Version 1

– Carefully pull strainer -2- with welding wire -1- out of receiv‐
er.
Version 2

– Carefully pull strainer -1- out of receiver -2- with welding wire
-A-.
Continued for all vehicles
– If repair work is interrupted, seal open receiver with plug -2-
to prevent ingress of dirt and moisture.

2. Refrigerant circuit 47
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Installing
Install in reverse order of removal, observing the following:

NOTICE
Risk of damage to air conditioner compressor if refrigerant
circuit is empty.
– Never start the engine if the refrigerant circuit is empty.

Note

The protective cap, seals and desiccant bag must always be

renewed after opening the receiver ⇒ Electronic parts catalogue
(ETKA).

Version 1
– Through the opening, check threads and sealing surfaces of
receiver on condenser for contamination or damage.

– Insert filter element (with strainer) -2- in correct installation

position into receiver of condenser.
• The filter element must be inserted as far as stop.
Version 2
– Through the opening, check threads and sealing surfaces of
receiver -2- on condenser for contamination or damage.

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– Insert filter element (with strainer) -1- in correct installation

position into receiver -2- of condenser.
• The filter element must be inserted as far as stop.
Continued for all vehicles

Note

Keep the air-tight transport bag, in which the desiccant bag

is delivered, sealed as long as possible. Only open transport
bag immediately before inserting the desiccant bag into the
condenser. After the transport bag has been opened, the desic‐
cant bag will become saturated with moisture within a short time
and is then unusable.

– Take desiccant bag out of transport bag and insert it into

receiver of condenser.
– Insert sealing cap -2- and press it downwards until circlip -1-
can engage in groove.

– Moisten new seals with refrigerant oil before installing refrig‐

erant line.
– Screw in protective cap -1- using socket insert T50.

2. Refrigerant circuit 49
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Vehicles with R134a refrigerant

– Charge refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00; Working with air conditioner
service station.
– Perform leakage test on re-established line connections of
refrigerant circuit ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00; Detecting leaks in refrigerant circuit.
Vehicles with R1234yf refrigerant
– Charge refrigerant circuit ⇒ Air conditioning systems with
refrigerant R1234yf - general information; Rep. gr. 87; Work‐
ing with air conditioner service station; Charging refrigerant
circuit.
– Perform leakage test on re-established line connections of
refrigerant circuit ⇒ Air conditioning systems with refrigerant
R1234yf - General information; Rep. gr. 87; Refrigerant cir‐
cuit; Detecting leaks.
Continued for all vehicles
– Commissioning air conditioning system after charging refrig‐
erant circuit ⇒ page 55 .
Specified torques
♦ ⇒ o2.2 verview – condenser”, page 29
Component Specified torque
Plug 3 Nm

2.7.3 Removing and installing desiccant bag

or cartridge, Showa/Keihin condenser
Special tools and workshop equipment required
♦ Engine bung set -VAS 6122-

50 Rep. gr.87 - Air conditioning system

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♦ Socket T50
Removing
– Depending on engine fitted, remove parts of charge air sys‐
tem ⇒ Rep. gr. 21; Charge air system; Assembly overview -
charge air system.
– Remove condenser -1- ⇒ page 40 to gain access to desic‐
cant bag/desiccant cartridge -2-.

CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due
to freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have elapsed since evacuation
and the coolant circuit has not been opened, evacuate the
refrigerant again. Pressure could build up in the refrigerant
circuit from continued evaporation.

– Unscrew plug -A-.

– Pull desiccant cartridge -E- upwards out of receiver of con‐

denser.
– Seal open receiver immediately with plug -A- to prevent in‐
gress of dirt and moisture.
Installing
Install in reverse order of removal, observing the following:

Note

The protective cap, seals and desiccant bag must always be

renewed after opening the receiver ⇒ Electronic parts catalogue
(ETKA).

2. Refrigerant circuit 51
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– Moisten new seals with refrigerant oil before installing.

– Through the opening, check threads and sealing surfaces of
receiver on condenser for contamination or damage.
– Assemble plug -A- with seals -B- and -C-.

– Remove dryer cartridge -E- from transport bag and insert it

in receiver.
– Install plug -A-.

NOTICE
Risk of damage to air conditioner compressor if refrigerant
circuit is empty.
– Never start the engine if the refrigerant circuit is empty.

Vehicles with R134a refrigerant

– Charge refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00; Working with air conditioner
service station.
– Perform leakage test on re-established line connections of
refrigerant circuit ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00; Detecting leaks in refrigerant circuit.
Vehicles with R1234yf refrigerant
– Charge refrigerant circuit ⇒ Air conditioning systems with
refrigerant R1234yf - general information; Rep. gr. 87; Work‐
ing with air conditioner service station; Charging refrigerant
circuit.
– Perform leakage test on re-established line connections of
refrigerant circuit ⇒ Air conditioning systems with refrigerant
R1234yf - General information; Rep. gr. 87; Refrigerant cir‐
cuit; Detecting leaks.
Continued for all vehicles
– Commissioning air conditioning system after charging refrig‐
erant circuit ⇒ page 55 .
Specified torques
♦ ⇒ o2.2 verview – condenser”, page 29

52 Rep. gr.87 - Air conditioning system

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Component Specified torque

Plug 5 Nm

2.8 Removing and installing evacuating

and charging valves on low and high-
pressure side
Special tools and workshop equipment required
♦ Adapter set for service connections -T10364- or socket -
T10364/4A-

♦ Engine bung set -VAS 6122-

Removing
Vehicles with R134a refrigerant
– Drain refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00; Working with air conditioner
service station.
Vehicles with R1234yf refrigerant
– Drain refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87; Working
with air conditioner service station; Draining refrigerant cir‐
cuit.

2. Refrigerant circuit 53
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Continued for all vehicles

CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due
to freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have elapsed since evacuation
and the coolant circuit has not been opened, evacuate the
refrigerant again. Pressure could build up in the refrigerant
circuit from continued evaporation.

– Immediately seal open line with clean plugs from engine

bung set -VAS 6122-.
– Unscrew valve core -1- with adapter set for service connec‐
tions -T10364-.

Installing
Install in reverse order of removal, observing the following:

NOTICE
Risk of damage to air conditioner compressor if refrigerant
circuit is empty.
– Never start the engine if the refrigerant circuit is empty.

Vehicles with R134a refrigerant

– Charge refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00; Working with air conditioner
service station.
– Perform leakage test on re-established line connections of
refrigerant circuit ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00; Detecting leaks in refrigerant circuit.
Vehicles with R1234yf refrigerant
– Charge refrigerant circuit ⇒ Air conditioning systems with
refrigerant R1234yf - general information; Rep. gr. 87; Work‐
ing with air conditioner service station; Charging refrigerant
circuit.
– Perform leakage test on re-established line connections of
refrigerant circuit ⇒ Air conditioning systems with refrigerant

54 Rep. gr.87 - Air conditioning system

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R1234yf - General information; Rep. gr. 87; Refrigerant cir‐

cuit; Detecting leaks.
Continued for all vehicles
– Commissioning air conditioning system after charging refrig‐
erant circuit ⇒ page 55 .
Specified torques
Component Specified torque
Valve insert -1- 2 Nm

2.9 Commissioning air conditioning system

after filling refrigerant circuit
NOTICE
Risk of damage to air conditioner compressor. There may be
an accumulation of refrigerant oil in the compression chamber
of a removed air conditioner compressor.
– After installing a new air conditioner compressor or adding
new refrigerant oil, fully turn the air conditioner compressor
10 times by hand before the poly V-belt is fitted.

– Start engine with air conditioner compressor switched off

(version with magnetic clutch).
– Set air conditioner compressor to lowest possible setting; se‐
lect “ECON” mode or “A/C Off” (if version without magnetic
clutch but with regulating valve).
– Wait until idling speed has stabilised:
– Switch air conditioner compressor on and let system run for
at least 2 minutes with engine idling.

NOTICE
Risk of damage to the air conditioner compressor or air condi‐
tioner service station.
Opening the valves with the air conditioning system switched
on can cause a short circuit between the high pressure and
low pressure side.
– Never open valves on the high pressure or low pressure
side with the air conditioning system switched on.

– If necessary, check pressures in refrigerant circuit using air

conditioner service station.
– Switch off engine.
– Turn out handwheel on quick-release coupling adapter.
– Detach the charging hose from the refrigerant circuit.
– Screw protective caps back on.

2.10 Removing and installing refrigerant line

from air conditioner compressor to con‐
denser
Special tools and workshop equipment required

2. Refrigerant circuit 55
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♦ Engine bung set -VAS 6122-

Removing
– If necessary, remove parts of air filter ⇒ Rep. gr. 24; Air filter;
Assembly overview - air filter housing or ⇒ Rep. gr. 23; Air
filter; Assembly overview - air filter housing.
– If necessary, remove parts of the air ducting ⇒ Rep. gr. 24;
Intake manifold; Assembly overview - intake manifold or
⇒ Rep. gr. 23; Intake manifold; Assembly overview - intake
manifold.
– If necessary, remove parts of charge air system air ducting
⇒ Rep. gr. 21; Charging; charge air system.
– Remove front bumper cover ⇒ General body repairs, exte‐
rior; Rep. gr. 63; Front bumper; Removing and installing
bumper cover.
– If fitted, remove noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 66; Noise insulation; Removing and installing
noise insulation.
Vehicles with R134a refrigerant
– Drain refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00; Working with air conditioner
service station.
Vehicles with R1234yf refrigerant
– Drain refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87; Working
with air conditioner service station; Draining refrigerant cir‐
cuit.
Continued for all vehicles

CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due
to freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have elapsed since evacuation
and the coolant circuit has not been opened, evacuate the
refrigerant again. Pressure could build up in the refrigerant
circuit from continued evaporation.

– For any further work, immediately seal open lines and con‐
nections with clean plugs from engine bung set -VAS 6122-.

56 Rep. gr.87 - Air conditioning system

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Note

Only items -3- and -5- are relevant.

– Unscrew bolt -5- of upper refrigerant line -3-.

– Detach upper refrigerant line -3- from condenser -1-.
– Unscrew bolt -1-.

– Remove refrigerant line -2- from air conditioner compressor

-3-.

NOTICE
Risk of damage to refrigerant lines from rupture of inner foil.
– Never bend refrigerant lines to a radius tighter than
r < 100 mm.

– Remove refrigerant line -2- downwards.

Installing
Install in reverse order of removal, observing the following:

NOTICE
Risk of damage to air conditioner compressor if refrigerant
circuit is empty.
– Never start the engine if the refrigerant circuit is empty.

2. Refrigerant circuit 57
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Vehicles with R134a refrigerant

– Charge refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00; Working with air conditioner
service station.
– Perform leakage test on re-established line connections of
refrigerant circuit ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00; Detecting leaks in refrigerant circuit.
Vehicles with R1234yf refrigerant
– Charge refrigerant circuit ⇒ Air conditioning systems with
refrigerant R1234yf - general information; Rep. gr. 87; Work‐
ing with air conditioner service station; Charging refrigerant
circuit.
– Perform leakage test on re-established line connections of
refrigerant circuit ⇒ Air conditioning systems with refrigerant
R1234yf - General information; Rep. gr. 87; Refrigerant cir‐
cuit; Detecting leaks.
Continued for all vehicles
– Commissioning air conditioning system after charging refrig‐
erant circuit ⇒ page 55 .
Specified torques
♦ ⇒ o2.1 verview - refrigerant circuit”, page 27

2.11 Removing and installing refrigerant line

from air conditioner compressor to
evaporator
Special tools and workshop equipment required
♦ Engine bung set -VAS 6122-

Removing
– Remove front bumper cover ⇒ General body repairs, exte‐
rior; Rep. gr. 63; Front bumper; Removing and installing
bumper cover.
– Remove right engine mounting ⇒ Rep. gr. 10; Assembly
mountings; Removing and installing engine mounting.

58 Rep. gr.87 - Air conditioning system

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Vehicles with TDI engine

– Press release tabs on crankcase breather hose -1- and dis‐

connect hose from cylinder head cover.
– Move clear vacuum hoses at air pipe -arrows-.
– Release hose clip -3-.
– Swing air pipe with connecting piece towards rear and pull it
off turbocharger.
Vehicles with 1.5 l or 2.0 l engine
– Remove throttle valve module -GX3- ⇒ Rep. gr. 24; Intake
manifold; Removing and installing throttle valve module
GX3.
Continued for all vehicles

– To do this, unscrew nuts -1- and -3-.

– Fold heat shield -2- as far forwards as possible in
-direction of arrow-.

2. Refrigerant circuit 59
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Note

Disregard position -1-.

– Disconnect electrical connector -2-.

Vehicles with R134a refrigerant
– Drain refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00; Working with air conditioner
service station.
Vehicles with R1234yf refrigerant
– Drain refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87; Working
with air conditioner service station; Draining refrigerant cir‐
cuit.
Continued for all vehicles

CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due
to freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have elapsed since evacuation
and the coolant circuit has not been opened, evacuate the
refrigerant again. Pressure could build up in the refrigerant
circuit from continued evaporation.

– For any further work, immediately seal open lines and con‐
nections with clean plugs from engine bung set -VAS 6122-.

60 Rep. gr.87 - Air conditioning system

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Note

Disregard items -1-, -2- and -4-.

– Unscrew nut -3-.

– Separate refrigerant lines.

Note

Only items -3- and -5- are relevant.

– Unscrew bolt -5- of lower refrigerant line -3-.

– Detach lower refrigerant line -3- from condenser -1-.
– Remove refrigerant line -2- upwards.
Installing
Install in reverse order of removal, observing the following:
– Engage refrigerant line so that it is positioned between clip
mounting and support.

2. Refrigerant circuit 61
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NOTICE
Risk of damage to air conditioner compressor if refrigerant
circuit is empty.
– Never start the engine if the refrigerant circuit is empty.

Vehicles with R134a refrigerant

– Charge refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00; Working with air conditioner
service station.
– Perform leakage test on re-established line connections of
refrigerant circuit ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00; Detecting leaks in refrigerant circuit.
Vehicles with R1234yf refrigerant
– Charge refrigerant circuit ⇒ Air conditioning systems with
refrigerant R1234yf - general information; Rep. gr. 87; Work‐
ing with air conditioner service station; Charging refrigerant
circuit.
– Perform leakage test on re-established line connections of
refrigerant circuit ⇒ Air conditioning systems with refrigerant
R1234yf - General information; Rep. gr. 87; Refrigerant cir‐
cuit; Detecting leaks.
Continued for all vehicles
– Commissioning air conditioning system after charging refrig‐
erant circuit ⇒ page 55 .
Specified torques
♦ ⇒ o2.1 verview - refrigerant circuit”, page 27

2.12 Removing and installing refrigerant line

from evaporator to air conditioner com‐
pressor
Special tools and workshop equipment required
♦ Engine bung set -VAS 6122-

Removing
– Remove right engine mounting ⇒ Rep. gr. 10; Assembly
mountings; Removing and installing engine mounting.
– If necessary, remove parts of air filter ⇒ Rep. gr. 24; Air filter;
Assembly overview - air filter housing or ⇒ Rep. gr. 23; Air
filter; Assembly overview - air filter housing.
– If necessary, remove parts of the air ducting ⇒ Rep. gr. 24;
Intake manifold; Assembly overview - intake manifold or

62 Rep. gr.87 - Air conditioning system

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⇒ Rep. gr. 23; Intake manifold; Assembly overview - intake

manifold.
– If necessary, remove parts of charge air system air ducting
⇒ Rep. gr. 21; Charging; charge air system.
– If fitted, remove noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 66; Noise insulation; Removing and installing
noise insulation.
Vehicles with TDI engine

– Press release tabs on crankcase breather hose -1- and dis‐

connect hose from cylinder head cover.
– Move clear vacuum hoses at air pipe -arrows-.
– Release hose clip -3-.
– Swing air pipe with connecting piece towards rear and pull it
off turbocharger.
Vehicles with 1.5 l or 2.0 l engine
– Remove throttle valve module -GX3- ⇒ Rep. gr. 24; Intake
manifold; Removing and installing throttle valve module
GX3.
Continued for all vehicles

– To do this, unscrew nuts -1- and -3-.

– Fold heat shield -2- as far forwards as possible in
-direction of arrow-.
Vehicles with R134a refrigerant
– Drain refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00; Working with air conditioner
service station.

2. Refrigerant circuit 63
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Vehicles with R1234yf refrigerant

– Drain refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87; Working
with air conditioner service station; Draining refrigerant cir‐
cuit.
Continued for all vehicles

CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due
to freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have elapsed since evacuation
and the coolant circuit has not been opened, evacuate the
refrigerant again. Pressure could build up in the refrigerant
circuit from continued evaporation.

– For any further work, immediately seal open lines and con‐
nections with clean plugs from engine bung set -VAS 6122-.

Note

Disregard items -1-, -2- and -3-.

– Unscrew nut -4-.

– Separate refrigerant lines.
– Unscrew bolt -1-.

64 Rep. gr.87 - Air conditioning system

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– Remove refrigerant line -2- from air conditioner compressor

-3-.

NOTICE
Risk of damage to refrigerant lines from rupture of inner foil.
– Never bend refrigerant lines to a radius tighter than
r < 100 mm.

– Remove refrigerant line -2- upwards.

Installing
Install in reverse order of removal, observing the following:
– Engage refrigerant line so that positioning ring is located
before bracket as seen in direction of engine.

NOTICE
Risk of damage to air conditioner compressor if refrigerant
circuit is empty.
– Never start the engine if the refrigerant circuit is empty.

Vehicles with R134a refrigerant

– Charge refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00; Working with air conditioner
service station.
– Perform leakage test on re-established line connections of
refrigerant circuit ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00; Detecting leaks in refrigerant circuit.
Vehicles with R1234yf refrigerant
– Charge refrigerant circuit ⇒ Air conditioning systems with
refrigerant R1234yf - general information; Rep. gr. 87; Work‐
ing with air conditioner service station; Charging refrigerant
circuit.
– Perform leakage test on re-established line connections of
refrigerant circuit ⇒ Air conditioning systems with refrigerant
R1234yf - General information; Rep. gr. 87; Refrigerant cir‐
cuit; Detecting leaks.
Continued for all vehicles
– Commissioning air conditioning system after charging refrig‐
erant circuit ⇒ page 55 .
Specified torques
♦ ⇒ o2.1 verview - refrigerant circuit”, page 27

2. Refrigerant circuit 65
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2.13 Removing and installing damper

weight for refrigerant line, low-pressure
side
Removing

– Unscrew bolts -3-.

– Remove damper weight -2- from refrigerant line on low-pres‐
sure-side -1-.
Installing
Install in reverse order of removal, observing the following:
– Fit damper weight -2- on refrigerant line on low-pressure-
side -1-. Take specified dimension -a- = 30 ± 5 mm into
account while doing so.

Note

Ensure that the damper weight -2- is firmly seated on the refrig‐
erant line and that it won't make contact with any other compo‐
nents during any condition.

Specified torques
Component Specified torque
Bolts -3- 10 Nm

2.14 Commissioning air conditioning system

after filling refrigerant circuit
NOTICE
Risk of damage to air conditioner compressor. There may be
an accumulation of refrigerant oil in the compression chamber
of a removed air conditioner compressor.
– After installing a new air conditioner compressor or adding
new refrigerant oil, fully turn the air conditioner compressor
10 times by hand before the poly V-belt is fitted.

66 Rep. gr.87 - Air conditioning system

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– Start engine with air conditioner compressor switched off

(version with magnetic clutch).
– Set air conditioner compressor to lowest possible setting; se‐
lect “ECON” mode or “A/C Off” (if version without magnetic
clutch but with regulating valve).
– Wait until idling speed has stabilised:
– Switch air conditioner compressor on and let system run for
at least 2 minutes with engine idling.

NOTICE
Risk of damage to the air conditioner compressor or air condi‐
tioner service station.
Opening the valves with the air conditioning system switched
on can cause a short circuit between the high pressure and
low pressure side.
– Never open valves on the high pressure or low pressure
side with the air conditioning system switched on.

– If necessary, check pressures in refrigerant circuit using air

conditioner service station.
– Switch off engine.
– Turn out handwheel on quick-release coupling adapter.
– Detach the charging hose from the refrigerant circuit.
– Screw on caps again.

2. Refrigerant circuit 67
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3 Air conditioner compressor

⇒ o3.1 verview – drive unit of air conditioner compressor”, page
68
⇒ o3.2 verview - pulley”, page 72
⇒ a3.3 ir conditioning compressor from and installing on brack‐
et”, page 76
⇒ a3.4 nd installing air conditioner compressor”, page 78
⇒ h3.5 igh-pressure safety valve on air conditioner compres‐
sor”, page 83
⇒ a3.6 nd installing pulley”, page 84

3.1 Assembly overview – drive unit of air

conditioner compressor
⇒ o3.1.1 verview – drive unit of air conditioner compressor”,
page 68
⇒ o3.1.2 verview - drive unit of air conditioner compressor with
air conditioning system magnetic clutchN25”, page 70

3.1.1 Assembly overview – drive unit of air conditioner compressor

68 Rep. gr.87 - Air conditioning system

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1 - Air conditioner compressor

❑ Different versions. Re‐
fer to ⇒ Electronic parts
catalogue (ETKA)
❑ Removing from and in‐
stalling on bracket ⇒
page 76
❑ Removing and instal‐
ling ⇒ page 78
2 - Seal
❑ Renew after removal
❑ Moisten with refrigerant
oil before installation
3 - Refrigerant line
❑ High-pressure side
4 - Bolts
❑ Qty. 2
❑ 22 Nm
5 - Refrigerant line
❑ Low-pressure side
6 - Seal
❑ Renew after removal
❑ Moisten with refrigerant
oil before installation
7 - High-pressure safety valve
❑ Protects refrigerant cir‐
cuit from excessive
pressure
❑ Checking ⇒ page 83
8 - Air conditioner compressor
regulating valve -N280-
❑ Check with ⇒ Vehicle diagnostic tester
9 - Bolts
❑ Qty. 3
❑ 25 Nm
10 - Pulley
❑ With overload protection
❑ Different versions. Refer to ⇒ Electronic parts catalogue (ETKA)
❑ Assembly overview ⇒ page 72
11 - Dowel sleeves
❑ Qty. 2
12 - Oil drain plug
❑ If oil drain plug is not available as replacement part - do not unscrew oil drain plug.
❑ Do not remove unless refrigerant circuit is empty.
❑ Renew oil drain plug/seal after each removal
❑ Different versions ⇒ Electronic parts catalogue (ETKA)
❑ Denso air conditioner compressor - 30 Nm
❑ Mahle/Delphi air conditioner compressor - 20 ± 1 Nm
❑ Sanden air conditioner compressor: 15 ± 1 Nm

Volkswagen Technical Site: http://vwts.ru http://vwts.info 3. Air conditioner compressor 69

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3.1.2 Assembly overview - drive unit of air conditioner compressor with air
conditioning system magnetic clutch -N25-

70 Rep. gr.87 - Air conditioning system

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1 - Air conditioner compressor

❑ Different versions. Re‐
fer to ⇒ Electronic parts
catalogue (ETKA)
❑ Removing and instal‐
ling ⇒ page 78
❑ Removing from and in‐
stalling on bracket ⇒
page 76
2 - Seal
❑ Renew after removal
❑ Different versions. Re‐
fer to ⇒ Electronic parts
catalogue (ETKA)
❑ Moisten with refrigerant
oil before installation
3 - Refrigerant line, high-pres‐
sure side
4 - Bolt
❑ 22 Nm
5 - Refrigerant line, low-pres‐
sure side
6 - Seal
❑ Renew after removal
❑ Different versions. Re‐
fer to ⇒ Electronic parts
catalogue (ETKA)
❑ Moisten with refrigerant
oil before installation
7 - High-pressure safety valve
8 - Electrical connector for air
conditioning system magnetic
clutch -N25-
9 - Air conditioner compressor regulating valve -N280-
❑ Check with ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode and ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations
10 - Electrical connector for air conditioner compressor regulating valve -N280-
11 - Bolt
❑ 25 Nm
12 - Pulley with air conditioning system magnetic clutch -N25-
❑ Different versions. Refer to ⇒ Electronic parts catalogue (ETKA)
❑ Assembly overview ⇒ page 74
13 - Dowel sleeve
❑ Qty. 2
14 - Oil drain plug
❑ If oil drain plug is not available as replacement part - do not unscrew oil drain plug.
❑ Do not remove unless refrigerant circuit is empty.
❑ Renew oil drain plug/seal after each removal
❑ Different versions ⇒ Electronic parts catalogue (ETKA)
❑ Denso air conditioner compressor - 30 Nm
❑ Mahle/Delphi air conditioner compressor - 20 ± 1 Nm

3. Air conditioner compressor 71

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❑ Sanden air conditioner compressor: 15 ± 1 Nm

3.2 Assembly overview - pulley

⇒ o3.2.1 verview - pulley, Denso air conditioner compressor”,
page 72
⇒ o3.2.2 verview - belt pulley, Sanden air conditioner compres‐
sor”, page 72
⇒ o3.2.3 verview - belt pulley, air conditioner compressor with
air conditioning system magnetic clutchN25”, page 74

3.2.1 Assembly overview - pulley, Denso air conditioner compressor

1 - Bolts
❑ Qty. 3
❑ 4.5 Nm
2 - Cap
3 - Nut
❑ 25 Nm
❑ To loosen and tight‐
en the hexagon nut,
hold the pulley in po‐
sition with a commer‐
cially available oil filter
strap wrench.
4 - Drive plate
❑ With overload protec‐
tion. Deploys in the
event of excessive tor‐
que (e.g. if the air
conditioner compressor
cannot rotate freely).
The pulley then ro‐
tates without driving
the air conditioner com‐
pressor.
5 - Retaining ring
❑ Renew
❑ Do not reverse when
installing (flat side
faces air conditioner
compressor)
6 - Pulley
❑ Different versions. Re‐
fer to ⇒ Electronic parts
catalogue (ETKA)
❑ Sensitive to impact,
handle with care
❑ Removing and installing ⇒ page 84
7 - Air conditioner compressor
❑ Clean the drive shaft of air conditioner compressor before fitting the pulley.

3.2.2 Assembly overview - belt pulley, Sanden air conditioner compressor

72 Rep. gr.87 - Air conditioning system

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1 - Nut
❑ 25 Nm

Note

To protect the thread of the air con‐

ditioner compressor drive shaft, an
additional plastic cap is fitted (not
shown in illustration).

– To loosen and tighten the hexagon nut, hold the pulley in position with a commercially available oil
filter strap wrench.
– Clean thread of nut which was tightened with locking fluid (e.g. with a thread tap). If it is not cleaned,
the drive shaft may be torn off when it is removed the next time.

– Clean thread of air conditioner compressor drive shaft using a wire brush.

– Install nut with locking fluid. Locking fluid ⇒ Electronic parts catalogue (ETKA).

2 - Bolt
❑ 12 Nm
– To loosen and tighten bolts, hold pulley in position with a commercially available oil filter strap wrench.

– Threaded holes must be cleaned (e.g. with a thread tap) if self-locking bolts or bolts coated with
locking fluid are screwed into them. Otherwise there is a danger that the bolts will shear off when
refitted.

3. Air conditioner compressor 73

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– Clean threads of bolts which are to be installed with locking fluid using a wire brush. Then install bolts
with locking fluid. Locking fluid ⇒ Electronic parts catalogue (ETKA).

3 - Drive plate
❑ With overload protection (mountings of spring elements). Deploys in the event of excessive torque
(e.g. if the air conditioner compressor cannot rotate freely). The belt pulley then rotates without driving
the air conditioner compressor.
❑ The spring elements of the drive plate absorb vibrations and noise.
4 - Retaining ring
❑ Renew
❑ Do not reverse when installing; chamfer -A- faces away from air conditioner compressor (flat side
towards air conditioner compressor).
5 - Pulley
❑ With rubber elements -B- and threaded plates -C- for decoupling belt pulley from air conditioner drive
shaft (absorb vibrations and noise).

Note

Depending on design, the threaded

plates may also be connected by
means of a ring.

6 - Air conditioner compressor

❑ Clean the drive shaft of air conditioner compressor before fitting the pulley.

3.2.3 Assembly overview - belt pulley, air

conditioner compressor with air condi‐
tioning system magnetic clutch -N25-
If the belt pulley with air conditioning system magnetic clutch
-N25- is not available as an individual part, the entire air con‐
ditioner compressor must be renewed ⇒ Electronic parts cata‐
logue (ETKA).

Note

♦ If the pulley overload protection device has been triggered, make sure that the air conditioner compressor
is free to move before renewing the pulley. If the air conditioner compressor is not free to move, renew it
completely.
♦ The air conditioner compressor does not need to be detached from the engine to allow for removing the
belt pulley ⇒ page 76 .
♦ Various types of poly V-belt pulleys (with a different diameter) may be installed depending on the design
of the air conditioner compressor and the type of engine ⇒ Electronic parts catalogue (ETKA).
♦ The belt pulley and the magnetic clutch are available as a replacement part with one common part
number. The belt pulley and the drive plate may be attached to each other with a bolt (the bolt is not
required). This bolt is used during manufacturing to apply a specified amount of grease to the thread of
the drive plate. The amount of grease is sufficient for screwing the drive plate onto the compressor shaft
one time (therefore, never reuse a drive plate which has been unscrewed) ⇒ Electronic parts catalogue
(ETKA).

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1 - Sealing cap
❑ Not always fitted
2 - Clutch plate
❑ Renew
❑ Screwed onto drive
shaft of air conditioner
compressor.
– Clean contact surfaces
of clutch plate and belt
pulley before screwing
them on.

– Clean thread of com‐

pressor shaft before
screwing on clutch
plate.

– After tightening, check

clearance between belt
pulley and clutch plate,
and adjust it as neces‐
sary ⇒ page 87 .

Note

The thread of the new clutch plate

is greased with a specified amount
of a certain grease by the manu‐
facturer.
❑ Different versions ⇒ Electronic parts catalogue (ETKA)
If the clutch plate is not available as an individual part, the entire air conditioner compressor must be
renewed ⇒ Electronic parts catalogue (ETKA).
❑ With overload protection. Deploys in the event of excessive torque (e.g. if the air conditioner compres‐
sor cannot rotate freely). The belt pulley then rotates without driving the air conditioner compressor
with activated magnetic clutch -N25-.
Removing and installing

– To remove, counterhold compressor shaft -C-, and use a suitable tool to turn clutch plate anti-clock‐
wise, as described for the drive plate on an air conditioner compressor without magnetic clutch.
❑ Specified torque 30 Nm
3 - Washer
4 - Spacer
❑ For adjusting clearance between clutch plate and belt pulley
❑ Checking clearance ⇒ page 89 .

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5 - Locking ring
❑ Renew
❑ Install correctly (flat side faces air conditioner compressor)
❑ When installing retaining ring, make sure that it is not bent open more than required.
– Install retaining ring correctly; chamfer -A- faces away from air conditioner compressor (flat side
towards air conditioner compressor).

6 - Pulley
❑ The belt pulley is sensitive to impact and should therefore be treated with care.
❑ Clean the air conditioner compressor flange before pushing on the belt pulley.
❑ Different versions ⇒ Electronic parts catalogue (ETKA)
❑ If the belt pulley cannot be pulled off the air conditioner compressor flange by hand, refer to ⇒ page
88
If the belt pulley with air conditioning system magnetic clutch -N25- is not available as an individual part, the
entire air conditioner compressor must be renewed ⇒ Electronic parts catalogue (ETKA).

7 - Locking ring
❑ Renew
❑ Install correctly (flat side faces air conditioner compressor)
❑ When installing retaining ring, make sure that it is not bent open more than required.
– Install retaining ring correctly; chamfer -A- faces away from air conditioner compressor (flat side
towards air conditioner compressor).

8 - Solenoid
❑ When installing, make sure retainer for cable -B- is positioned correctly.
❑ Depending on version, connector -D- may be secured on air conditioner compressor with a retainer.
9 - Air conditioner compressor
❑ Depending on the version of the engine and the country-specific version of the vehicle, different
versions may be installed ⇒ Electronic parts catalogue (ETKA).
❑ Clean the air conditioner compressor flange before pushing on the belt pulley.
❑ Clean the compressor shaft, and apply a small amount of grease to the thread.

3.3 Removing air conditioning compressor

from and installing on bracket
Special tools and workshop equipment required
♦ Welding wire
Removing

Note

Instead of the poly V-belts being removed completely, they are

just removed from the air conditioner compressor pulley.

– Relieve tension from poly V-belt ⇒ Rep. gr. 13; Cylinder

block on pulley side; Removing and installing poly V-belt.
– Remove poly V-belt from air conditioner compressor pulley.
R model
– Remove air intake pipe for throttle valve module -GX3-/
charge air cooler ⇒ Rep. gr. 21; Charge air system; Remov‐
ing and installing air intake pipe.

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Continued for all vehicles

Vehicles with air conditioning system magnetic clutch -N25-
– Disconnect electrical connector -2- of air conditioner com‐
pressor -1-.

Continued for all vehicles

– Depending on engine, remove front right wheel housing liner
⇒ General body repairs, exterior; Rep. gr. 66; Wheel housing
liner; Removing and installing front wheel housing liner.
– Disconnect electrical connector -1-.

– Unscrew bolts -2-. While doing so, detach air conditioner

compressor -3- from bracket.

NOTICE
Risk of damage to refrigerant lines from rupture of inner foil.
– Never bend refrigerant lines to a radius tighter than
r < 100 mm.

– Secure air conditioner compressor -3- to body with suitable

material (e.g. welding wire -2-).

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Installing

Install in reverse order of removal, observing the following:

– Thoroughly clean contact surfaces on air conditioner com‐
pressor -2- and ancillary bracket.
– Insert dowel sleeves -1- into air conditioner compressor -2-.

NOTICE
Risk of damage to air conditioner compressor. There may be
an accumulation of refrigerant oil in the compression chamber
of a removed air conditioner compressor.
– After installing a new air conditioner compressor or adding
new refrigerant oil, fully turn the air conditioner compressor
10 times by hand before the poly V-belt is fitted.

Specified torques
♦ ⇒ o3.1 verview – drive unit of air conditioner compressor”,
page 68

3.4 Removing and installing air conditioner

compressor
Special tools and workshop equipment required

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♦ Engine bung set -VAS 6122-

♦ Vehicle diagnostic tester

Note

The refrigerant circuit must be purged with refrigerant R134a /

R1234yf under the following conditions:

♦ If dirt or other contamination is in the circuit.

♦ The search for faults in the electrical system, the vacuum
system and the air ducts did not turn up any fault.(Moisture
is in the refrigerant circuit and builds up pressure.)
♦ If the refrigerant circuit has been left open for longer than
normally required for repairs (e.g. following an accident).
♦ When pressure and temperature measurements in the refrig‐
erant circuit indicate that there is moisture in the refrigerant
circuit.
♦ There is doubt about the amount of refrigerant oil in the
refrigerant circuit.
♦ The air conditioner compressor has to be exchanged be‐
cause of internal damage (e.g. noisy or lack of power).
For details regarding the procedure of purging with refrigerant
R134a / R1234yf, refer to the following section of the ELSA:
Vehicles with R134a refrigerant
⇒ Air conditioning system with refrigerant R134a; Rep. gr. 00;
Cleaning refrigerant circuit of contaminants
Vehicles with R1234yf refrigerant
♦ ⇒ Air conditioning systems with refrigerant R1234yf - general
information; Rep. gr. 87; Refrigerant circuit; Cleaning the
refrigerant circuit
Removing

Note

♦ If only removal of the ancillary bracket is planned, the refrig‐

erant circuit remains unopened ⇒ page 76 .
♦ Instead of the poly V-belts being removed completely, they
are just removed from the air conditioner compressor pulley.

– Relieve tension from poly V-belt ⇒ Rep. gr. 13; Cylinder

block on pulley side; Removing and installing poly V-belt.
– Remove poly V-belt from air conditioner compressor pulley.

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– Depending on engine, remove front right wheel housing liner

⇒ General body repairs, exterior; Rep. gr. 66; Wheel housing
liner; Removing and installing front wheel housing liner.
– Remove poly V-belt ⇒ Rep. gr. 13; Cylinder block, pulley
end; Removing and installing poly V-belt.
Vehicles with R134a refrigerant
– Drain refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00; Working with air conditioner
service station.
Vehicles with R1234yf refrigerant
– Drain refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87; Working
with air conditioner service station; Draining refrigerant cir‐
cuit.
Continued for all vehicles

CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due
to freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have elapsed since evacuation
and the coolant circuit has not been opened, evacuate the
refrigerant again. Pressure could build up in the refrigerant
circuit from continued evaporation.

– For any further work, immediately seal open lines and con‐
nections with clean plugs from engine bung set -VAS 6122-.
R model
– Remove air intake pipe for throttle valve module -GX3-/
charge air cooler ⇒ Rep. gr. 21; Charge air system; Remov‐
ing and installing air intake pipe.
Continued for all vehicles
– Disconnect electrical connector -1-.

Vehicles with air conditioning system magnetic clutch -N25-

– Disconnect electrical connector -2- of air conditioner com‐
pressor -1-.

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Continued for all vehicles

– Unscrew bolts -2-.

NOTICE
Risk of damage to refrigerant lines from rupture of inner foil.
– Never bend refrigerant lines to a radius tighter than
r < 100 mm.

– Remove refrigerant lines -3-.

– Unscrew bolts -4-. While doing so, detach air conditioner
compressor -5- from bracket.
Installing
Install in reverse order of removal, observing the following:
Procedure for installing new air conditioner compressor
– Determine refrigerant oil volume in removed air conditioner
compressor by draining oil into measuring beaker.

Note

Collect refrigerant oil from the new air conditioner compressor in

a suitable container for reuse.

– Drain refrigerant oil from new air conditioner compressor.

– Fill exact same amount of refrigerant oil into the new, emp‐
tied air conditioner compressor as that determined in the
removed air conditioner compressor.
Vehicles with R134a refrigerant
♦ ⇒ Air conditioning system with refrigerant R134a; Rep.
gr. 00; Renewing components

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Vehicles with R1234yf refrigerant

♦ ⇒ Air conditioning systems with refrigerant R1234yf - general
information; Rep. gr. 87; Refrigerant circuit; Renewing com‐
ponents
Continued for all vehicles
– Thoroughly clean contact surfaces on air conditioner com‐
pressor -2- and ancillary bracket.

– Insert dowel sleeves -1- into air conditioner compressor -2-.

Note

Ensure proper seating of seal -1- in groove -arrow- of respective

refrigerant line.

– Moisten new seals with refrigerant oil before installing refrig‐

erant line.

NOTICE
Risk of damage to air conditioner compressor if refrigerant
circuit is empty.
– Never start the engine if the refrigerant circuit is empty.

Vehicles with R134a refrigerant

– Charge refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00; Working with air conditioner
service station.
– Perform leakage test on re-established line connections of
refrigerant circuit ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00; Detecting leaks in refrigerant circuit.

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Vehicles with R1234yf refrigerant

– Charge refrigerant circuit ⇒ Air conditioning systems with
refrigerant R1234yf - general information; Rep. gr. 87; Work‐
ing with air conditioner service station; Charging refrigerant
circuit.
– Perform leakage test on re-established line connections of
refrigerant circuit ⇒ Air conditioning systems with refrigerant
R1234yf - General information; Rep. gr. 87; Refrigerant cir‐
cuit; Detecting leaks.
Continued for all vehicles
– Commissioning air conditioning system after charging refrig‐
erant circuit ⇒ page 55 .
Procedure for installing new air conditioner compressor
– Use ⇒ Vehicle diagnostic tester to run-in air conditioner com‐
pressor.
Specified torques
♦ ⇒ o3.1 verview – drive unit of air conditioner compressor”,
page 68

3.5 Checking high-pressure safety valve

on air conditioner compressor
Sequence of operations

CAUTION
Risk of freezing injury caused by refrigerant. The high-pres‐
sure safety valve releases refrigerant when the engine is run‐
ning and the pressure in the refrigerant circuit is too high.
There is a risk of injury on hands and other parts of the body
due to freezing.
– Wear protective gloves.
– Wear protective goggles.
– Switch off engine.

Checking high-pressure safety valve on air conditioner com‐

pressor, Denso

The high-pressure safety valve -arrow- has been activated

when refrigerant oil is found in the immediate vicinity.

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Note

On air conditioner compressors from other manufacturers the

high-pressure safety valve is located in a similar position.

3.6 Removing and installing pulley

⇒ a3.6.1 nd installing Denso belt pulley”, page 84
⇒ a3.6.2 nd installing Sanden belt pulley”, page 86
⇒ a3.6.3 nd installing belt pulley, air conditioner compressor
with air conditioning system magnetic clutchN25”, page 86

3.6.1 Removing and installing Denso belt

pulley

Note

♦ The pulley is sensitive to impact and should therefore be

handled with extreme care.
♦ If the belt pulley overload protection has deployed, check
freedom of movement of air conditioner compressor before
renewing belt pulley. If air conditioner compressor does not
rotate freely, it must be renewed.
♦ If the drive plate overload protection device has been trig‐
gered, the pulley can rotate with the outer section of the
drive plate without the air conditioner compressor shaft and
the hexagon flats attached to the drive plate (inner section of
drive plate) also rotating.

Special tools and workshop equipment required

♦ Commercially available oil filter strap wrench
Removing

– Remove poly V-belt ⇒ Rep. gr. 13; Cylinder block, pulley

end; Removing and installing poly V-belt.
– Pull off sealing cap -1-.
– Counterhold pulley with oil filter strap wrench and remove
bolts -arrows-.
– Remove nut -2-, counter holding drive shaft -1- for air condi‐
tioner compressor to do so.

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– Detach drive plate -3- with nut.

Note

♦ The torque for driving the air conditioner compressor is ap‐

plied to the air conditioner compressor shaft via the threaded
connection of the drive plate.
♦ If the drive plate has become so firmly screwed onto the
air conditioner compressor shaft that it can no longer be
loosened (the 7 mm hexagon flats can no longer transmit the
necessary torque), the air conditioner compressor must be
renewed.

– Remove circlip -2-.

– Detach pulley -1-.

Installing
Install in reverse order of removal, observing the following:

Note

Renew retaining ring.

– Clean drive shaft of air conditioner compressor before fitting

the belt pulley
– Fit belt pulley onto drive shaft of air conditioner compressor.
• The belt pulley must be fitted without excessive force being
applied.
– Insert circlip in correct position.
• Flat side faces air conditioner compressor

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– Clean thread of air conditioner compressor drive shaft before

bolting on drive plate.

Note

The thread of the new drive plate is greased with a specified

amount of a certain grease by the manufacturer.

Specified torques
♦ ⇒ o3.2.1 verview - pulley, Denso air conditioner compres‐
sor”, page 72

3.6.2 Removing and installing Sanden belt

pulley

Note

♦ The pulley is sensitive to impact and should therefore be

treated with extreme care.
♦ If the belt pulley overload protection has deployed, check
freedom of movement of air conditioner compressor before
renewing belt pulley. If air conditioner compressor does not
rotate freely, it must be renewed.
♦ If the drive plate overload protection device has been trig‐
gered, the pulley can rotate with the outer section of the
drive plate without the air conditioner compressor shaft and
the hexagon flats attached to the drive plate (inner section of
drive plate) also rotating.

– Remove poly V-belt ⇒ Rep. gr. 13; Cylinder block, pulley

end; Removing and installing poly V-belt.
– Removing and installing belt pulley ⇒ page 72 .

3.6.3 Removing and installing belt pulley, air

conditioner compressor with air condi‐
tioning system magnetic clutch -N25-
Special tools and workshop equipment required
♦ Sleeve from magnetic clutch puller -V.A.G 1719-

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♦ Depth gauge -VAS 6082-

If the belt pulley with air conditioning system magnetic clutch

-N25- is not available as an individual part, the entire air con‐
ditioner compressor must be renewed ⇒ Electronic parts cata‐
logue (ETKA).
Removing and installing clutch plate ⇒ page 87
Pulling off belt pulley ⇒ page 88
Checking clearance between belt pulley and clutch plate ⇒
page 89
Removing and installing clutch plate
– Remove front noise insulation. ⇒ General body repairs, ex‐
terior; Rep. gr. 66; Noise insulation; Assembly overview -
noise insulation
– Relieve tension on poly V-belt, and remove it ⇒ Rep. gr. 13;
Cylinder block (pulley end); Removing and installing poly
V-belt.
– Remove sealing cap -A-.

– Use a commercially available hexagon socket wrench to

counterhold drive shaft of air conditioner compressor -B- and
turn clutch plate -C- in direction of -arrow-.

3. Air conditioner compressor 87

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Note

The torque for driving the air conditioner compressor is applied

to the compressor shaft via the threaded attachment of the
clutch plate -C-. If the clutch plate -C- was tightened to the
compressor shaft -B- during operation such that it can no longer
be loosened (the 7 mm hexagon flats can no longer transmit
the necessary torque), the air conditioner compressor must be
renewed.

Pulling off belt pulley

Note

If the circlip has been removed and the belt pulley -A- cannot
be pulled off the air conditioner compressor flange by hand (e.g.
due to dirt), carefully pull off belt pulley as described below.

If the belt pulley -A- is to be reused, fit the arms of the puller
in such a way that the outer side of the belt pulley will not be
damaged.

– Carefully pull off belt pulley -A- using a puller -B- (with
3 arms).

Note

♦ When pulling off belt pulley -A-, do not support the spindle of
the puller -B- on the shaft of the air conditioner compressor.
♦ Use a sleeve -C- (e.g. sleeve V.A.G 1719/1 from the mag‐
netic clutch puller -V.A.G 1719-) to support the spindle of the
puller -B- on the air conditioner compressor flange.
♦ After the belt pulley -A- has been pulled off, clean the air
conditioner compressor thoroughly. It must be possible to
push on the belt pulley -A- by hand.

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Checking clearance between belt pulley and clutch plate

Note

♦ The clearance must be within the permissible range over the

complete circumference.
♦ The clearance can also be measured when the air condition‐
er compressor is installed.
♦ If the clearance is outside the permissible range, remove the
clutch plate, and adjust the clearance to the specified value
by removing or adding spacers.

– Remove front noise insulation. ⇒ General body repairs, ex‐

terior; Rep. gr. 66; Noise insulation; Assembly overview -
noise insulation
– Relieve tension on poly V-belt, and remove it ⇒ Rep. gr. 13;
Cylinder block (pulley end); Removing and installing poly
V-belt.
• The clutch plate -C- is tightened to the specified torque of
30 Nm to the air conditioner compressor shaft -E-.

– Use a depth gauge -F- to measure dimension “1” between

belt pulley -B- and clutch plate -C- at 3 positions on the
circumference of clutch plate -C- (note measured values).
– Apply a voltage of 12 V to 1-pin connector -A-.
– Connect compressor housing -D- to earth.
– Use a depth gauge -F- to measure dimension “2” between
belt pulley -B- and clutch plate -C- at 3 positions on the
circumference of clutch plate -C- (note measured values).
– Calculate clearance from dimensions “1” and “2”.
Specification for gap: 0.4 to 0.6 mm (up to 0.8 mm on a used
magnetic clutch).

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4 Control motors
⇒ o4.1 f fitting locations – control motors at front”, page 90
⇒ a4.2 nd installing temperature flap control motorV68”, page
94
⇒ a4.3 nd installing defroster flap control motorV107”, page 96
⇒ a4.4 nd installing air recirculation flap control motorV113”,
page 98
⇒ a4.5 nd installing left temperature flap control motorV158”,
page 99
⇒ a4.6 nd installing right temperature flap control motorV159”,
page 101
⇒ a4.7 nd installing fresh air/air recirculation, air flow flap control
motorV425”, page 102
⇒ a4.8 nd installing front air distribution flap control motorV426”,
page 104
⇒ a4.9 nd installing air distribution flap control motorV428”,
page 105
⇒ a4.10 nd installing air distribution flap actuator”, page 107

4.1 Overview of fitting locations – control

motors at front
⇒ o4.1.1 f fitting locations - front control motors, air conditioning
system, left-hand drive vehicles”, page 90
⇒ o4.1.2 f fitting locations - front control motors, air conditioning
system, right-hand drive vehicles”, page 91
⇒ o4.1.3 f fitting locations - front Climatronic control motors,
left-hand drive vehicles”, page 92
⇒ o4.1.4 f fitting locations - front Climatronic control motors,
right-hand drive vehicles”, page 93

4.1.1 Overview of fitting locations - front control motors, air conditioning system,
left-hand drive vehicles

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1 - Temperature flap control

motor -V68-
❑ With potentiometer for
temperature flap control
motor -G92-.
❑ Check with ⇒ Vehicle
diagnostic tester
❑ Removing and instal‐
ling ⇒ page 94
2 - Air distribution flap control
motor -V428-
❑ With potentiometer for
air distribution flap con‐
trol motor -G645-
❑ Check with ⇒ Vehicle
diagnostic tester
❑ Removing and instal‐
ling ⇒ page 105
3 - Air recirculation flap con‐
trol motor -V113-
❑ Check with ⇒ Vehicle
diagnostic tester
❑ Removing and instal‐
ling ⇒ page 98

4.1.2 Overview of fitting locations - front control motors, air conditioning system,
right-hand drive vehicles

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1 - Temperature flap control

motor -V68-
❑ With potentiometer for
temperature flap control
motor -G92-.
❑ Check with ⇒ Vehicle
diagnostic tester
❑ Removing and instal‐
ling ⇒ page 94
2 - Air distribution flap control
motor -V428-
❑ With potentiometer for
air distribution flap con‐
trol motor -G645-
❑ Check with ⇒ Vehicle
diagnostic tester
❑ Removing and instal‐
ling ⇒ page 105
3 - Air recirculation flap con‐
trol motor -V113-
❑ Check with ⇒ Vehicle
diagnostic tester
❑ Removing and instal‐
ling ⇒ page 98

4.1.3 Overview of fitting locations - front Climatronic control motors, left-hand

drive vehicles

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1 - Left temperature flap con‐

trol motor -V158-
❑ With potentiometer for
left temperature flap
control motor -G220-.
❑ Check with ⇒ Vehicle
diagnostic tester
❑ Removing and instal‐
ling ⇒ page 99
2 - Front air distribution flap
control motor -V426-
❑ With potentiometer for
front air distribution flap
control motor -G642-
❑ Check with ⇒ Vehicle
diagnostic tester
❑ Removing and instal‐
ling ⇒ page 104
3 - Fresh air/air recirculation,
air flow flap control motor -
V425-
❑ With potentiometer for
fresh air/recirculated air
and air flow flap control
motor -G644-
❑ Check with ⇒ Vehicle
diagnostic tester
❑ Removing and instal‐
ling ⇒ page 102
4 - Right temperature flap
control motor -V159-
❑ With potentiometer for
right temperature flap
control motor -G221-
❑ Check with ⇒ Vehicle
diagnostic tester
❑ Removing and installing ⇒ page 101
5 - Defroster flap control motor -V107-
❑ With potentiometer for defroster flap control motor -G135-.
❑ Check with ⇒ Vehicle diagnostic tester
❑ Removing and installing ⇒ page 96

4.1.4 Overview of fitting locations - front Climatronic control motors, right-hand

drive vehicles

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1 - Fresh air/air recirculation,

air flow flap control motor -
V425-
❑ With potentiometer for
fresh air/recirculated air
and air flow flap control
motor -G644-
❑ Check with ⇒ Vehicle
diagnostic tester
❑ Removing and instal‐
ling ⇒ page 102
2 - Front air distribution flap
control motor -V426-
❑ With potentiometer for
front air distribution flap
control motor -G642-
❑ Check with ⇒ Vehicle
diagnostic tester
❑ Removing and instal‐
ling ⇒ page 104
3 - Left temperature flap con‐
trol motor -V158-
❑ With potentiometer for
left temperature flap
control motor -G220-.
❑ Check with ⇒ Vehicle
diagnostic tester
❑ Removing and instal‐
ling ⇒ page 99
4 - Defroster flap control mo‐
tor -V107-
❑ With potentiometer for
defroster flap control
motor -G135-.
❑ Check with ⇒ Vehicle
diagnostic tester
❑ Removing and installing ⇒ page 96
5 - Right temperature flap control motor -V159-
❑ With potentiometer for right temperature flap control motor -G221-
❑ Check with ⇒ Vehicle diagnostic tester
❑ Removing and installing ⇒ page 101

4.2 Removing and installing temperature

flap control motor -V68-
Special tools and workshop equipment required

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♦ Torque screwdriver -VAS 6494-

♦ Vehicle diagnostic tester

Removing
– Remove footwell vent on driver side ⇒ page 175 .
Right-hand drive vehicles
– Remove baffle plate ⇒ page 173 .
– Remove centre console ⇒ General body repairs, interior;
Rep. gr. 68; Centre console; Removing and installing centre
console.
Continued for all vehicles

– Pull off actuating lever -2- from air distribution housing.

– Unscrew bolts -arrows-.
– Remove temperature flap control motor -V68- -3- from air
distribution housing.
– Disconnect electrical connector -1-.
Installing

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Install in reverse order of removal, observing the following:

Note

♦ Check operation of flaps and hinge mechanism before fitting.

♦ Make sure levers and shafts are properly fitted in the
mounts.

– Mount temperature flap control motor -V68- -1- on air distri‐

bution housing.
– Insert actuating lever -3- into air distribution housing. Gear
wheel on actuating lever -3- must engage in gear wheel -2-
on temperature flap control motor -V68- -1-.
• Long tooth -4- must engage in recess -arrow- on actuating
lever -3-.

Note

If gear wheel -2- on temperature flap control motor -V68- -1- is

not aligned with gear wheel on actuating lever -3- for tempera‐
ture flap, turn mounting in temperature flap control motor -V68-.

– Initiate basic setting using ⇒ Vehicle diagnostic tester.

– Check operation of heater and air conditioning system.
Specified torques
Component Specified torque
Bolts for control motor 1.5 Nm

4.3 Removing and installing defroster flap

control motor -V107-
Special tools and workshop equipment required
♦ Torque wrench -VAS 6253A-

♦ Vehicle diagnostic tester

Removing
– Remove glove compartment ⇒ General body repairs, interi‐
or; Rep. gr. 68; Compartments/covers; Removing and instal‐
ling glove compartment.

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Right-hand drive vehicles

– Remove dash panel ⇒ General body repairs, interior; Rep.
gr. 70; Dash panel; Removing and installing dash panel.
Continued for all vehicles
– Disconnect electrical connector -1-.

– Unscrew bolts -arrows-.

– Remove defroster flap control motor -V107- -2- from heater
and air conditioning unit.
Installing

Install in reverse order of removal, observing the following:

Note

♦ Check operation of flaps and hinge mechanism before fitting.

♦ Make sure levers and shafts are properly fitted in the
mounts.
♦ Mounting -1- on defroster flap control motor -V107- can be
fitted on relay lever -2- in only one position.
♦ If mounting -1- on defroster flap control motor -V107- and
relay lever -2- are not aligned, turn mounting in defroster flap
control motor -V107-.

– Install defroster flap control motor -V107- on heater and air

conditioning unit.
– Initiate basic setting using ⇒ Vehicle diagnostic tester.
– Check operation of heater and air conditioning system.

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Specified torques
♦ ⇒ page 96

4.4 Removing and installing air recircula‐

tion flap control motor -V113-
Special tools and workshop equipment required
♦ Torque screwdriver -VAS 6494-

♦ Vehicle diagnostic tester

Removing
– Remove glove compartment ⇒ General body repairs, interi‐
or; Rep. gr. 68; Compartments/covers; Removing and instal‐
ling glove compartment.
Right-hand drive vehicles
– Remove central tube for dash panel ⇒ General body repairs,
interior; Rep. gr. 70; Central tube for dash panel; Removing
and installing central tube for dash panel.
Continued for all vehicles
– Disconnect electrical connector -1-.

– Unscrew bolts -2-.

– Remove air recirculation flap control motor -V113- -3- from
air intake duct.

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Installing

Install in reverse order of removal, observing the following:

Note

♦ Check operation of flaps and hinge mechanism before fitting.

♦ Make sure levers and shafts are properly fitted in the
mounts.
♦ Fresh air flap must be set to closed position to allow for
installation of air recirculation flap control motor -V113-.
♦ Actuating shaft -2- must be at stop -1- -arrow-.
♦ If actuating shaft -2- of air recirculation flap control motor
-V113- is not against fresh air mode stop -1-, turn mounting
in control motor.

– Initiate basic setting using ⇒ Vehicle diagnostic tester.

– Check operation of heater and air conditioning system.
Specified torques
♦ ⇒ page 96

4.5 Removing and installing left tempera‐

ture flap control motor -V158-
Special tools and workshop equipment required
♦ Torque screwdriver -VAS 6494-

♦ Vehicle diagnostic tester

Removing
– Remove footwell vent on driver side ⇒ page 175 .

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Right-hand drive vehicles

– Remove baffle plate ⇒ page 173 .
– Remove centre console ⇒ General body repairs, interior;
Rep. gr. 68; Centre console; Removing and installing centre
console.
Continued for all vehicles
– Pull off actuating lever -2- from air distribution housing.

– Unscrew bolts -arrows-.

– Remove left temperature flap control motor -V158- -3- from
air distribution housing.
– Disconnect electrical connector -1-.
Installing

Install in reverse order of removal, observing the following:

Note

♦ Check operation of flaps and hinge mechanism before fitting.

♦ Make sure levers and shafts are properly fitted in the
mounts.

– Fit left temperature flap control motor -V158- -1- on air distri‐
bution housing. While doing this, make sure that gear wheel
-2- of control motor engages in gear wheel on actuating
lever -3-.
• Long tooth -4- must engage in recess -arrow- on actuating
lever -3-.

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Note

If gear wheel -2- on left temperature flap control motor -V158-

-1- is not aligned with gear wheel on actuating lever -3- for
temperature flap, turn mounting in left temperature flap control
motor - V158-.

– Initiate basic setting using ⇒ Vehicle diagnostic tester.

– Check operation of heater and air conditioning system.
Specified torques
♦ ⇒ page 96

4.6 Removing and installing right tempera‐

ture flap control motor -V159-
Special tools and workshop equipment required
♦ Torque screwdriver -VAS 6494-

♦ Vehicle diagnostic tester

Removing
– Remove footwell vent on front passenger side ⇒ page 176 .
– Disconnect electrical connector -1-.

– Pull off actuating lever -2- from air distribution housing.

– Unscrew bolts -arrows-.
– Remove right temperature flap control motor -V159- -3- from
air distribution housing.

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Installing

Install in reverse order of removal, observing the following:

Note

♦ Check operation of flaps and hinge mechanism before fitting.

♦ Make sure levers and shafts are properly fitted in the
mounts.

– Mount right temperature flap control motor -V159- -1- on air

distribution housing.
– Insert actuating lever -3- into air distribution housing. Make
sure that gear wheel -4- on actuating lever -3- engages
in gear wheel -2- on right temperature flap control motor
-V159- -1-.
• Long tooth -4- must engage in recess -arrow- on actuating
lever -3-.

Note

If gear wheel -2- on right temperature flap control motor -V159-

-1- is not aligned with gear wheel on actuating lever -3- for
temperature flap, turn mounting in right temperature flap control
motor -V159-.

– Initiate basic setting using ⇒ Vehicle diagnostic tester.

– Check operation of heater and air conditioning system.
Specified torques
♦ ⇒ page 96

4.7 Removing and installing fresh air/air re‐

circulation, air flow flap control motor
-V425-
Special tools and workshop equipment required

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♦ Torque screwdriver -VAS 6494-

♦ Vehicle diagnostic tester

Removing
– Remove glove compartment ⇒ General body repairs, interi‐
or; Rep. gr. 68; Compartments/covers; Removing and instal‐
ling glove compartment.
Right-hand drive vehicles
– Remove central tube for dash panel ⇒ General body repairs,
interior; Rep. gr. 70; Central tube for dash panel; Removing
and installing central tube for dash panel.
Continued for all vehicles
– Disconnect electrical connector -1-.

– Unscrew bolts -2-.

– Remove air recirculation flap control motor -V113- -3- from
air intake duct.
Installing

Install in reverse order of removal, observing the following:

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Note

♦ Check operation of flaps and hinge mechanism before fitting.

♦ Make sure levers and shafts are properly fitted in the
mounts.
♦ Fresh air flap must be set to closed position to allow for
installation of air recirculation flap control motor -V113-.
♦ Actuating shaft -2- must be at stop -1- -arrow-.
♦ If actuating shaft -2- of air recirculation flap control motor
-V113- is not against fresh air mode stop -1-, turn mounting
in control motor.

– Initiate basic setting using ⇒ Vehicle diagnostic tester.

– Check operation of heater and air conditioning system.
Specified torques
♦ ⇒ page 96

4.8 Removing and installing front air distri‐

bution flap control motor -V426-
Special tools and workshop equipment required
♦ Torque screwdriver -VAS 6494-

♦ Vehicle diagnostic tester

Removing
– Remove dash panel ⇒ General body repairs, interior; Rep.
gr. 70; Dash panel; Removing and installing dash panel.
– Unscrew bolts -arrows-.

– Remove front air distribution flap control motor -V426- -1-

from air distribution housing.

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– Disconnect electrical connector -2-.

Installing

Install in reverse order of removal, observing the following:

Note

♦ Check operation of flaps and hinge mechanism before fitting.

♦ Make sure levers and shafts are properly fitted in the
mounts.
♦ Mounting -1- on front air distribution flap control motor -
V426- can be fitted on relay lever -2- in only one position.
♦ If mounting -1- on front air distribution flap control motor
-V426- and relay lever -2- are not aligned, turn mounting in
front air distribution flap control motor -V426-.

– Mount front air distribution flap control motor -V426- on air

distribution housing.
– Initiate basic setting using ⇒ Vehicle diagnostic tester.
– Check operation of heater and air conditioning system.
Specified torques
♦ ⇒ page 96

4.9 Removing and installing air distribution

flap control motor -V428-
Special tools and workshop equipment required
♦ Torque screwdriver -VAS 6494-

♦ Vehicle diagnostic tester

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Removing
– Remove dash panel ⇒ General body repairs, interior; Rep.
gr. 70; Dash panel; Removing and installing dash panel.
– Unscrew bolts -arrows-.

– Remove front air distribution flap control motor -V428- -1-

from air distribution housing.
– Disconnect electrical connector -2-.
Installing
Install in reverse order of removal, observing the following:

Note

♦ Check operation of flaps and hinge mechanism before fitting.

♦ Make sure levers and shafts are properly fitted in the
mounts.
♦ Mounting -1- on front air distribution flap control motor -
V428- can be fitted on relay lever -2- in only one position.

If mounting -1- on front air distribution flap control motor -V428-

and relay lever -2- are not aligned, turn mounting in front air
distribution flap control motor -V428-.

– Mount front air distribution flap control motor -V428- on air

distribution housing.
– Initiate basic setting using ⇒ Vehicle diagnostic tester.
– Check operation of heater and air conditioning system.
Specified torques
♦ ⇒ page 96

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4.10 Removing and installing air distribution

flap actuator
⇒ a4.10.1 nd installing front air distribution flap actuator, air
conditioning system, left-hand drive vehicles”, page 107
⇒ a4.10.2 nd installing front air distribution flap actuator, air
conditioning system, right-hand drive vehicles”, page 109
⇒ a4.10.3 nd installing front air distribution flap actuator, Clima‐
tronic, right-hand drive vehicles”, page 110
⇒ a4.10.4 nd installing front air distribution flap actuator, Clima‐
tronic, right-hand drive vehicles”, page 112

4.10.1 Removing and installing front air dis‐

tribution flap actuator, air conditioning
system, left-hand drive vehicles
Removing
– Remove central tube for dash panel ⇒ General body repairs,
interior; Rep. gr. 70; Central tube for dash panel; Removing
and installing central tube for dash panel.
– Remove air duct for defroster vent ⇒ page 185 .
– Unbolt air distribution flap control motor ⇒ page 105 .
– Carefully press off actuating lever -7- -arrow-.

– Carefully press off actuating lever -3- from defroster flap

lever -2-.
– Unscrew bolts -1-, -4- and -8-.
– Remove actuation unit -9- upwards.
Installing
Install in reverse order of removal, observing the following:

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Note

♦ Check operation of flaps and hinge mechanism before fitting.

♦ Make sure levers and shafts are properly fitted in the
mounts.

– Check that the two gear wheels are correctly aligned.

• The rectangular tooth -2- must engage in the gap -3- of the
gear wheel -1-.
– When fitting actuation unit, actuating lever -5- must engage
in lever -6- of centre vent flap.

Specified torques
♦ ⇒ o5.2 verview – heater and air conditioning unit”, page 116
♦ Dash panel; Assembly overview - dash panel ⇒ General
body repairs, interior; Rep. gr. 70; Dash panel; Assembly
overview - dash panel.

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4.10.2 Removing and installing front air dis‐

tribution flap actuator, air conditioning
system, right-hand drive vehicles
Removing
– Remove central tube for dash panel ⇒ General body repairs,
interior; Rep. gr. 70; Central tube for dash panel; Removing
and installing central tube for dash panel.
– Remove air duct for defroster vent ⇒ page 185 .
– Unbolt air distribution flap control motor ⇒ page 105 .
– Carefully press off actuating lever -7- -arrow-.

– Carefully press off actuating lever -3- from defroster flap

lever -2-.
– Unscrew bolts -1-, -4- and -8-.
– Remove actuation unit -9- upwards.
Installing
Install in reverse order of removal, observing the following:

Note

♦ Check operation of flaps and hinge mechanism before fitting.

♦ Make sure levers and shafts are properly fitted in the
mounts.

– Check that the two gear wheels are correctly aligned.

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• The rectangular tooth -2- must engage in the gap -3- of the
gear wheel -1-.
– When fitting actuation unit, actuating lever -5- must engage
in lever -6- of centre vent flap.

Specified torques
♦ ⇒ o5.2 verview – heater and air conditioning unit”, page 116
♦ Assembly overview - central tube for dash panel ⇒ General
body repairs, interior; Rep. gr. 70; Central tube for dash
panel; Assembly overview - dash panel central tube

4.10.3 Removing and installing front air distri‐

bution flap actuator, Climatronic, right-
hand drive vehicles
Removing
– Remove central tube for dash panel ⇒ General body repairs,
interior; Rep. gr. 70; Central tube for dash panel; Removing
and installing central tube for dash panel.
– Remove air duct for defroster vent ⇒ page 185 .
– Unbolt air distribution flap control motor ⇒ page 104 .
– Carefully press off actuating lever -5- -arrow-.

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– Unscrew bolts -1-, -2- and -6-.

– Remove actuation unit -7- upwards.
Installing
Install in reverse order of removal, observing the following:

Note

♦ Check operation of flaps and hinge mechanism before fitting.

♦ Make sure levers and shafts are properly fitted in the
mounts.

– Check that the two gear wheels are correctly aligned.

• The rectangular tooth -2- must engage in the gap -3- of the
gear wheel -1-.
– When fitting actuation unit, actuating lever -3- must engage
in lever -4- of centre vent flap.

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Specified torques
♦ ⇒ o5.2 verview – heater and air conditioning unit”, page 116
♦ Dash panel; Assembly overview - dash panel ⇒ General
body repairs, interior; Rep. gr. 70; Dash panel; Assembly
overview - dash panel.

4.10.4 Removing and installing front air distri‐

bution flap actuator, Climatronic, right-
hand drive vehicles
Removing
– Remove central tube for dash panel ⇒ General body repairs,
interior; Rep. gr. 70; Central tube for dash panel; Removing
and installing central tube for dash panel.
– Remove air duct for defroster vent ⇒ page 185 .
– Unbolt air distribution flap control motor ⇒ page 104 .
– Carefully press off actuating lever -5- -arrow-.

– Unscrew bolts -1-, -2- and -6-.

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– Remove actuation unit -7- upwards.

Installing
Install in reverse order of removal, observing the following:

Note

♦ Check operation of flaps and hinge mechanism before fitting.

♦ Make sure levers and shafts are properly fitted in the
mounts.

– Check that the two gear wheels are correctly aligned.

• The rectangular tooth -2- must engage in the gap -3- of the
gear wheel -1-.
– When fitting actuation unit, actuating lever -3- must engage
in lever -4- of centre vent flap.

Specified torques
♦ ⇒ o5.2 verview – heater and air conditioning unit”, page 116
♦ Assembly overview - central tube for dash panel ⇒ General
body repairs, interior; Rep. gr. 70; Central tube for dash
panel; Assembly overview - dash panel central tube

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5 Front heater and air conditioning

unit
⇒ o5.1 verview - flaps and partitions in air distribution housing”,
page 114
⇒ o5.2 verview – heater and air conditioning unit”, page 116
⇒ o5.3 verview – evaporator housing”, page 118
⇒ a5.4 nd installing evaporator”, page 118
⇒ a5.5 uxiliary air heater elementZ35”, page 119
⇒ a5.6 nd installing auxiliary air heater elementZ35”, page 120
⇒ a5.7 nd installing heater and air conditioning unit”, page 123
⇒ a5.8 nd installing holder for heater and air conditioning unit”,
page 129
⇒ a5.9 nd assembling heater and air conditioning unit”, page
130
⇒ a5.10 nd installing air distribution housing”, page 130
⇒ a5.11 nd installing dust and pollen filter”, page 132
⇒ a5.12 nd installing fresh air blowerV2”, page 136
⇒ a5.13 nd installing fresh air blower control unitJ126”, page
139
⇒ a5.14 nd installing heat exchanger”, page 141
⇒ a5.15 nd installing coolant pipes on heat exchanger”, page
164
⇒ a5.16 nd installing evaporator temperature sensorG308”,
page 167
⇒ a5.17 nd installing condensation drain”, page 169
⇒ c5.18 ondensation drain”, page 173
⇒ a5.19 nd installing baffle plate”, page 173

5.1 Assembly overview - flaps and partitions in air distribution housing

View from front

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1 - Right heated air flap

❑ From heat exchanger
❑ Actuated via right cold
air flap
2 - Operating lever
❑ For flap control
3 - Right cold air flap
❑ From evaporator
4 - Actuating lever on right of
temperature control flap
❑ Depending on equip‐
ment
❑ Only with Climatronic
❑ Actuated by tempera‐
ture flap control motor
-V159-
5 - Actuating lever of flap for
defrost function
❑ Depending on equip‐
ment
❑ Only with Climatronic
❑ Actuated by defroster
flap control motor -
V107-
6 - Actuating lever of flap for
defrost function
❑ Depending on equip‐
ment
❑ Only with air condition‐
ing system
❑ Actuated by air distribu‐
tion flap control motor -
V428- via defroster and
air distribution actuation unit
7 - Air distribution flap actuating lever
8 - Left actuating lever
9 - Left cold air flap
❑ From evaporator
10 - Operating lever
❑ For flap control
11 - Left heated air flap
❑ From heat exchanger
❑ Actuated via left cold air flap

View from rear

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1 - Flap for rear air duct

❑ Depending on equip‐
ment
❑ For air conditioning
system, air duct sealed
with sealing plugs
❑ For Climatronic, for rear
vent in centre console
2 - Operating lever
❑ Depending on equip‐
ment
❑ For flap control
3 - Left flap for left dash panel
vent
4 - Operating lever
❑ For actuation of vent
flaps
5 - Left flap for centre vent
6 - Right flap for right dash
panel vent
7 - Right flap for centre vent

5.2 Assembly overview – heater and air conditioning unit

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1 - Evaporator housing
❑ Upper part
❑ Dismantling and as‐
sembling ⇒ page 130
2 - Seal
❑ For sealing and insula‐
tion
3 - Bracket
❑ Qty. 2
4 - Air intake duct
❑ Removing and instal‐
ling ⇒ page 185
5 - Dust and pollen filter
❑ Different versions
⇒ Electronic parts cata‐
logue (ETKA)
❑ Change interval
⇒ Maintenance tables
❑ Removing and instal‐
ling ⇒ page 132
6 - Dust and pollen filter cover
7 - Fresh air blower -V2-
❑ Removing and instal‐
ling ⇒ page 136
8 - Fresh air blower control
unit -J126-
❑ Removing and instal‐
ling ⇒ page 139
9 - Bolts
❑ Qty. 5
❑ 1.5 Nm
10 - Air distribution housing
Volkswagen Technical Site: http://vwts.ru http://vwts.info
❑ Removing and installing ⇒ page 130
11 - Heat exchanger
❑ Removing and installing ⇒ page 141
12 - Heat exchanger bracket
13 - Auxiliary air heater element -Z35-
❑ Checking ⇒ page 119
❑ Removing and installing ⇒ page 120
14 - Evaporator housing
❑ Lower part
❑ Dismantling and assembling ⇒ page 130
15 - Evaporator
❑ Check foam seals for damage and proper attachment
❑ Removing and installing ⇒ page 118
16 - Clamps
❑ Qty. 2
❑ 2 Nm

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17 - Coolant pipes on heat exchanger

❑ Removing and installing ⇒ page 164

5.3 Assembly overview – evaporator housing

1 - Evaporator housing
❑ Upper part
❑ Dismantling and as‐
sembling ⇒ page 130
2 - Evaporator housing
❑ Lower part
❑ Dismantling and as‐
sembling ⇒ page 130
3 - Bolts
❑ Qty. 8
❑ 1.5 Nm
4 - Evaporator
❑ Removing and instal‐
ling ⇒ page 118
5 - Sealing and insulation
❑ Heat insulation for ex‐
pansion valve
6 - Retaining clip
7 - Oil seals
❑ Qty. 2
❑ Renew after removal
8 - Expansion valve
❑ Removing and instal‐
ling ⇒ page 36
9 - Bolts
❑ Qty. 2
❑ 10 Nm
10 - Sealing and insulation
❑ Heat insulation for ex‐
pansion valve
11 - Bolts
❑ Qty. 3
❑ 1 Nm

5.4 Removing and installing evaporator

Removing
– Dismantling heater and air conditioning unit ⇒ page 130 .
– Pull out evaporator -1- from bottom part of air conditioner
and heater -2-.

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Installing
Install in reverse order of removal, observing the following:
– Inspect seals -3- for damage. Renew if necessary ⇒ Elec‐
tronic parts catalogue (ETKA).
– Clean evaporator housing.
– Check the condensation drain ⇒ page 173 .

5.5 Checking auxiliary air heater element

-Z35-
Special tools and workshop equipment required
♦ Vehicle diagnostic tester
♦ 100A pick-up clamp -VAS 6356/4A-

Sequence of operations
Conditions for testing:
• Intake air temperature less than 19°C
• Coolant temperature less than 80°C
• Passenger compartment temperature approx. 20°C
• Battery voltage higher than 11 V
• Alternator load no greater than 50%
• Engine speed greater than 450 rpm
• Turn rotary knob for interior temperature to maximum heat
output (on vehicles with Climatronic select highest level).
– Remove centre console ⇒ General body repairs, interior;
Rep. gr. 68; Centre console; Removing and installing centre
console.

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CAUTION
Risk of burns on metal surfaces of auxiliary air heater ele‐
ment. The heater elements may become very hot.
Risk of burns to the skin.
– Wear protective gloves.
– Never touch the metal surfaces of the heater element.

Note

Disregard items -2- and -arrow-.

– Measure current draw with ⇒ Vehicle diagnostic tester and

current clamp 100A -VAS 6356/4A- at earth wire -1-.
Heating output Current draw
Low heating output 30 A
Medium heating output 60 A
High heating output 80 A

5.6 Removing and installing auxiliary air

heater element -Z35-
⇒ a5.6.1 nd installing auxiliary air heater elementZ35 (LHD)”,
page 120
⇒ a5.6.2 nd installing auxiliary air heater elementZ35 (RHD)”,
page 122

5.6.1 Removing and installing auxiliary air

heater element -Z35- (LHD)
Special tools and workshop equipment required

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♦ Torque screwdriver -VAS 6494-

Removing
– Remove centre console ⇒ General body repairs, interior;
Rep. gr. 68; Centre console; Removing and installing centre
console.

CAUTION
Risk of burns on metal surfaces of auxiliary air heater ele‐
ment. The heater elements may become very hot.
Risk of burns to the skin.
– Wear protective gloves.
– Never touch the metal surfaces of the heater element.

– Unscrew nut -1-.

– Detach earth cable -2-.

– Disconnect electrical connector -3-. To do this, slide catch
-4- upwards, and push release inwards.
– Unscrew bolts -arrows-.
– Pull out auxiliary air heater element -Z35- -5- from heater
and air conditioning unit.
Installing
Install in reverse order of removal, observing the following:

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Specified torques
♦ ⇒ o5.2 verview – heater and air conditioning unit”, page 116
Component Specified torque
Unscrew nut -1- for earth cable -2-. 9 Nm

5.6.2 Removing and installing auxiliary air

heater element -Z35- (RHD)
Special tools and workshop equipment required
♦ Torque screwdriver -VAS 6494-

Removing
– Disconnect battery ⇒ Electrical system; Rep. gr. 27; Battery;
Disconnecting and reconnecting battery.
– Remove centre console ⇒ General body repairs, interior;
Rep. gr. 68; Centre console; Removing and installing centre
console.
– Remove glove compartment ⇒ General body repairs, interi‐
or; Rep. gr. 68; Compartments/covers; Removing and instal‐
ling glove compartment.

CAUTION
Risk of burns on metal surfaces of auxiliary air heater ele‐
ment. The heater elements may become very hot.
Risk of burns to the skin.
– Wear protective gloves.
– Never touch the metal surfaces of the heater element.

– Unscrew nut -1-.

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– Detach earth cable -2-.

– Disconnect electrical connector -3-. To do this, slide catch
-4- upwards, and push release inwards.
– Unscrew bolts -arrows-.
– Pull out auxiliary air heater element -Z35- -5- from heater
and air conditioning unit.
Installing
Install in reverse order of removal, observing the following:
Specified torques
♦ ⇒ o5.2 verview – heater and air conditioning unit”, page 116
♦ Compartments/covers; Assembly overview - glove compart‐
ment ⇒ General body repairs, interior; Rep. gr. 68; Compart‐
ments/covers; Assembly overview - glove compartment.
♦ Centre console; Assembly overview – centre console ⇒ Gen‐
eral body repairs, interior; Rep. gr. 68; Centre console; As‐
sembly overview – centre console
Component Specified torque
Unscrew nut -1- for earth cable -2-. ⇒ page 122

5.7 Removing and installing heater and air

conditioning unit
Special tools and workshop equipment required

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♦ Hose clamps to 25 mm -3094-

♦ Engine bung set -VAS 6122-

♦ Drip tray for workshop hoist -VAS 6208-

♦ Compressed air gun

Removing
– Disconnect the refrigerant line with internal heat exchanger
at the expansion valve ⇒ page 32 .
– For any further work, immediately seal open lines and con‐
nections with clean plugs from engine bung set -VAS 6122-.
– Place drip tray for workshop hoist -VAS 6208- beneath en‐
gine.

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– Mark coolant hoses -1- and -4-.

Note

The heat exchanger is designed for a certain direction of cool‐

ant flow. Therefore, the coolant hoses must be connected to the
correct sides.

– Clamp off coolant hoses -1- and -4- using hose clamps for
hoses up to 25 mm -3094-.

CAUTION
The cooling system could be under pressure. Danger of
scalding by steam and hot coolant.
Skin and other parts of the body may be scalded.
– Wear protective gloves.
– Wear protective goggles.
– Reduce excess pressure by covering cap of coolant ex‐
pansion tank with suitable cloth and opening it carefully.

– Lift retaining clips -2- and -3-.

– Push a suitable hose -A- onto upper connection of heat ex‐
changer.

– Hold suitable container -B- under lower connection leading

to heat exchanger -C-.
– Carefully blow out the remaining coolant into the container
-B- through the hose from the heat exchanger using a pneu‐
matic gun -A-.
– Remove central tube for dash panel ⇒ General body repairs,
interior; Rep. gr. 70; Central tube for dash panel; Removing
and installing central tube for dash panel.

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– Remove air guide leading to air duct for rear vent in centre
console ⇒ page 180 .
– Lift rear footwell vents under front seats and pull them to‐
wards rear to ease removal of footwell vents from heater and
air conditioning unit.
– Remove rear footwell vents from heater and air conditioning
unit.

Note

Disregard positions -1- and -2-.

– Disconnect electrical connector -3-.

Note

Disregard items -1, 2, 3- and -4-.

– Disconnect electrical connector -5-.

– Detach condensation hose -2- from heater and air condition‐
ing unit -1-.

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– Pull heater and air conditioning unit -1- off retainers on ple‐
num chamber bulkhead.
– Detach wiring harness -1- in area indicated by -arrows-.

– Remove wiring duct -2- from mountings -arrows-.

– Disconnect connectors on heater and air conditioner unit.

Note

The following work steps must be performed by a second me‐

chanic.

– Remove heater and air conditioning unit to the side.

Installing
Install in reverse order of removal, observing the following:
– Ensure that the condensation drain hose -3- is properly seat‐
ed.

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– Coding -2- and -arrow- must match heater and air condition‐
ing unit -1-.
– If a commercially available cable tie was installed to retain
the condensation drain -3-, renew it.
– The condensation drain hose must be routed below the wir‐
ing harness of the airbag control unit -J234- -4- in the figure.
– Moisten new seals with refrigerant oil before installing refrig‐
erant line.

NOTICE
Risk of damage to air conditioner compressor if refrigerant
circuit is empty.
– Never start the engine if the refrigerant circuit is empty.

Vehicles with R134a refrigerant

– Charge refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00; Working with air conditioner
service station.
– Perform leakage test on re-established line connections of
refrigerant circuit ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00; Detecting leaks in refrigerant circuit.
Vehicles with R1234yf refrigerant
– Charge refrigerant circuit ⇒ Air conditioning systems with
refrigerant R1234yf - general information; Rep. gr. 87; Work‐
ing with air conditioner service station; Charging refrigerant
circuit.
– Perform leakage test on re-established line connections of
refrigerant circuit ⇒ Air conditioning systems with refrigerant
R1234yf - General information; Rep. gr. 87; Refrigerant cir‐
cuit; Detecting leaks.
Continued for all vehicles
– Fill up with coolant ⇒ Rep. gr. 19; Cooling system/coolant;
Draining and filling coolant.
– Check operation of heater and air conditioning system.
Specified torques
♦ ⇒ o2.1 verview - refrigerant circuit”, page 27

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♦ ⇒ o5.2 verview – heater and air conditioning unit”, page 116

♦ Air filter; Assembly overview - air filter housing ⇒ Rep.
gr. 23; Air filter;Assembly overview - air filter housing
♦ Central tube for dash panel; Assembly overview - dash pan‐
el central tube ⇒ General body repairs, interior; Rep. gr. 70;
Central tube for dash panel; Assembly overview - central
tube for dash panel.

5.8 Removing and installing holder for

heater and air conditioning unit
Removing

– Remove heater and air conditioning unit ⇒ page 123 .

– Disconnect electrical connector -1-.
– Fold heat shield -2- to one side.
– To do this, unscrew nuts -3- and -5-.
– Detach holder -4- in interior.
Installing

Install in reverse order of removal, observing the following:

– Insert holders -1- and -3- into mounting on heater and air
conditioning unit -2- and place heater and air conditioning
unit in installation position.

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Specified torques
Component Specified torque
Nuts -3- and -5- 4.5 Nm

5.9 Dismantling and assembling heater

and air conditioning unit
Dismantling

– Remove air distribution housing ⇒ page 130 .

– Remove air intake ⇒ page 185 .
– Unscrew bolts -1-.
– Release clips -2-.
– Unscrew bolt -1-.

– Remove upper part of heater and air conditioning unit -2-

from lower part -3-.
Assembly
Assemble in the reverse order, observing the following:
Specified torques
♦ ⇒ o5.2 verview – heater and air conditioning unit”, page 116

5.10 Removing and installing air distribution

housing
Special tools and workshop equipment required

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♦ Torque screwdriver -V.A.G 1624-

Removing

– Remove coolant pipes on heat exchanger ⇒ page 164 .

– Separate electrical connector on fresh air and air recircula‐
tion flap control motor and lay wiring harness aside.
– Unscrew bolts -2-.
– Release retaining tabs -1- and -3-.
– Remove air distribution housing -4- from evaporator housing
in direction of -arrow-.
Installing
Install in reverse order of removal, observing the following:
Specified torques
♦ ⇒ o5.3 verview – evaporator housing”, page 118

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5.11 Removing and installing dust and pol‐

len filter
⇒ a5.11.1 nd installing dust and pollen filter, left-hand drive
vehicles”, page 132
⇒ a5.11.2 nd installing dust and pollen filter, right-hand drive
vehicles”, page 134

5.11.1 Removing and installing dust and pol‐

len filter, left-hand drive vehicles
Special tools and workshop equipment required
♦ Cover plate -T10532-

Removing
– Move glove compartment lid to service position ⇒ General
body repairs, interior; Rep. gr. 68; Compartments and cov‐
ers; Glove compartment lid, service position.
– Remove insulation.
– Release cover -1- -arrows-.

– Detach cover -1-.

– Push cover plate -T10532- -2- under pollen filter -1-.

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– Use cover -1- as a tool and hook the hooks on the side of
the cover -arrow- into the dust and pollen filter -2-.

NOTICE
Risk of damage to fresh air blower caused by dirt dropping out
of the dust and pollen filter when the cover plate is not seated
properly.
– Carefully pull out dust and pollen filter.
– Keep dust and pollen filter covered by cover plate.

– Pull out dust and pollen filter -2- with cover -1-. Do not pull
out cover plate -T10532- -3-.
– Remove dirt and foliage from cover plate -T10532- with a
commercially available vacuum cleaner.
– Remove cover plate -T10532- -2-.
Installing
Install in reverse order of removal, observing the following:

– Insert dust and pollen filter noting installation position.

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– Attach and engage cover -1- -arrows-.

– Insert insulation.
– Move glove compartment lid back from service position
⇒ General body repairs, interior; Rep. gr. 68; Compartments
and covers; Glove compartment lid, service position.

5.11.2 Removing and installing dust and pol‐

len filter, right-hand drive vehicles
Special tools and workshop equipment required
♦ Cover plate -T10609-

Removing
– Move glove compartment lid to service position ⇒ General
body repairs, interior; Rep. gr. 68; Compartments and cov‐
ers; Glove compartment lid, service position.
– Remove insulation.
– Release cover -1- -arrows-.

– Detach cover -1-.

– Push cover plate -T10609- -2- in -direction of arrow A- under
pollen filter -1-.

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– Push cover plate -T10609- -2- to stop in

-direction of arrow B-.
– Push cover plate -T10609- -3- in -direction of arrow C- under
cover plate -T10609- -2- and pollen filter -1-.
– Push cover plate -T10609- -3- to stop in
-direction of arrow D-.
– Hook bracket -4- into cover plate -T10609- -2- and cover
plate -T10609- -3-.
– Use cover -1- as a tool and hook the hooks on the side of
the cover -arrow- into the dust and pollen filter -2-.

NOTICE
Risk of damage to fresh air blower caused by dirt dropping out
of the dust and pollen filter when the cover plate is not seated
properly.
– Carefully pull out dust and pollen filter.
– Keep dust and pollen filter covered by cover plate.

– Pull out dust and pollen filter -2- with cover -1-.
– Counterhold cover plate -T10609- -3-, but do not pull it out.
– Remove dirt and foliage from cover plate -T10609-.
– Remove cover plate -T10609- -3-.
Installing
Install in reverse order of removal, observing the following:

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– Insert dust and pollen filter noting installation position.

– Attach and engage cover -1- -arrows-.
– Insert insulation.
– Move glove compartment lid back from service position
⇒ General body repairs, interior; Rep. gr. 68; Compartments
and covers; Glove compartment lid, service position.

5.12 Removing and installing fresh air blow‐

er -V2-
⇒ a5.12.1 nd installing fresh air blowerV2, LHD vehicles”, page
136
⇒ a5.12.2 nd installing fresh air blowerV2 (RHD)”, page 137

5.12.1 Removing and installing fresh air blow‐

er -V2-, LHD vehicles
Removing

CAUTION
Risk of burns when touching hot cooling surface of control
unit.
Risk of burns to the hands.
– Wear protective gloves.

– Remove baffle plate ⇒ General body repairs, interior; Rep.

gr. 68; Compartments/covers; Removing and installing foot‐
well cover on front passenger side.

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– Disconnect electrical connector -3-.

– If fitted, unscrew bolt -2-.
– Remove fresh air blower -V2- -1- from evaporator housing
lower part by lifting securing tab -4- and turning in direction
of -arrow- at the same time.
Installing
Install in reverse order of removal, observing the following:

NOTICE
Improper handling may damage the fresh air blower.
Imbalance leading to customer complaints may occur during
operation.
– Avoid applying excessive pressure to the fan wheel.
– Never change position of the balancing weights on fan
wheel.

– Ensure that arrow on locking tab -4- and arrow on bottom

part of evaporator housing align.

5.12.2 Removing and installing fresh air blow‐

er -V2- (RHD)
Removing
– Remove baffle plate ⇒ General body repairs, interior; Rep.
gr. 68; Compartments/covers; Removing and installing foot‐
well cover on front passenger side.
– Remove glove compartment ⇒ General body repairs, interi‐
or; Rep. gr. 68; Compartments/covers; Removing and instal‐
ling glove compartment.
– Remove footwell vent on front passenger side ⇒ page 177 .
– Disconnect electrical connectors.

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– Unscrew bolts -2-.

– Unclip retaining tabs -arrows-.
– Remove fresh air blower -V2- -1-downwards
-in direction of arrow-.

CAUTION
Risk of burns when touching hot cooling surface of control
unit.
Risk of burns to the hands.
– Wear protective gloves.

Installing
Install in the reverse order of removal. When doing this, note
the following:

NOTICE
Improper handling may damage the fresh air blower.
Imbalance leading to customer complaints may occur during
operation.
– Avoid applying excessive pressure to the fan wheel.
– Never change position of the balancing weights on fan
wheel.

Specified torques
Component Specified torque
Bolts -2- 1.5 Nm

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5.13 Removing and installing fresh air blow‐

er control unit -J126-
⇒ a5.13.1 nd installing fresh air blower control unitJ126, LHD
vehicles”, page 139
⇒ a5.13.2 nd installing fresh air blower control unitJ126, RHD
vehicles”, page 140

5.13.1 Removing and installing fresh air blow‐

er control unit -J126-, LHD vehicles
Special tools and workshop equipment required
♦ Torque screwdriver -VAS 6494-

Removing

– Remove baffle plate ⇒ General body repairs, interior; Rep.

gr. 68; Compartments/covers; Removing and installing foot‐
well cover on front passenger side.
– Separate connectors -2- and -3-.
– Unscrew bolts -1-.

CAUTION
Risk of burns when touching hot cooling surface of control
unit.
Risk of burns to the hands.
– Wear protective gloves.

– Remove fresh air blower control unit -J126- -4- from fresh air
blower -V2-.
Installing
Install in reverse order of removal, observing the following:

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Specified torques
♦ ⇒ o5.2 verview – heater and air conditioning unit”, page 116

5.13.2 Removing and installing fresh air blow‐

er control unit -J126-, RHD vehicles
Special tools and workshop equipment required
♦ Torque screwdriver -VAS 6494-

Removing
– Remove baffle plate ⇒ General body repairs, interior; Rep.
gr. 68; Compartments/covers; Removing and installing foot‐
well cover on front passenger side.
– Separate connectors -1- and -4-.

– Unscrew bolts -2-.

CAUTION
Risk of burns when touching hot cooling surface of control
unit.
Risk of burns to the hands.
– Wear protective gloves.

– Remove control unit -3- from fresh air blower -V2-.

Installing
Install in reverse order of removal, observing the following:
Specified torques
♦ ⇒ o5.2 verview – heater and air conditioning unit”, page 116

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5.14 Removing and installing heat exchang‐

er
⇒ a5.14.1 nd installing Valeo heat exchanger, left-hand drive
vehicles”, page 141
⇒ a5.14.2 nd installing Valeo heat exchanger, right-hand drive
vehicles”, page 147
⇒ a5.14.3 nd installing Denso heat exchanger, left-hand drive
vehicles”, page 153
⇒ a5.14.4 nd installing Denso heat exchanger, right-hand drive
vehicles”, page 158

5.14.1 Removing and installing Valeo heat ex‐

changer, left-hand drive vehicles
Special tools and workshop equipment required
♦ Hose clamps to 25 mm -3094-

♦ Engine bung set -VAS 6122-

♦ Drip tray for workshop hoist -VAS 6208-

♦ Compressed air gun

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Removing
Vehicles with TDI engine

– Press release tabs on crankcase breather hose -1- and dis‐

connect hose from cylinder head cover.
– Move clear vacuum hoses at air pipe -arrows-.
– Release hose clip -3-.
– Remove bolt -2-, swivel air pipe and connection to rear and
detach from turbocharger.
Vehicles with 1.5 l or 2.0 l engine
– Remove throttle valve module -GX3- ⇒ Rep. gr. 24; Intake
manifold; Removing and installing throttle valve module
GX3.
Continued for all vehicles
– Mark installation position of coolant hoses -1- and -4-.

Note

The heat exchanger is designed for a certain direction of cool‐

ant flow. Therefore, the coolant hoses must be connected to the
correct sides.

– Clamp off coolant hoses -1- and -4- using hose clamps for
hoses up to 25 mm -3094-.

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CAUTION
The cooling system could be under pressure. Danger of
scalding by steam and hot coolant.
Skin and other parts of the body may be scalded.
– Wear protective gloves.
– Wear protective goggles.
– Reduce excess pressure by covering cap of coolant ex‐
pansion tank with suitable cloth and opening it carefully.

– Lift retaining clips -2- and -3-.

– Disconnect coolant hoses -1- and -4- from heat exchanger
for heater.
– Push a suitable hose -A- onto upper connection of heat ex‐
changer.

– Hold suitable container -B- under lower connection leading

to heat exchanger -C-.
– Carefully blow out the remaining coolant into the container
-B- through the hose from the heat exchanger using a pneu‐
matic gun -A-.
– Seal off open lines and connections with clean plugs from
engine bung set -VAS 6122-.
– Remove centre console ⇒ General body repairs, interior;
Rep. gr. 68; Centre console; Removing and installing centre
console.
Vehicles with auxiliary air heater element -Z35-
– Remove auxiliary air heater element -Z35- ⇒ page 120 .
Continued for all vehicles
– Cover the area beneath the connections for the coolant ho‐
ses in the plenum chamber e.g. using impermeable sheeting
and absorbent paper.
– Lift locking element -6-, remove clip -5- and pull coolant line
-4- off heat exchanger.

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– Unscrew bolt -3-.

– Remove screw-type clip -2- and pull coolant line -1- off heat
exchanger.
– Seal off open lines and connections with clean plugs from
engine bung set -VAS 6122-.
– Remove bolts -1-, -3- and -5-.

– Release retainer tabs -4- -arrows- and detach cover -2-.

– If noise insulation cannot be pulled out, cut open tabs on
cover -arrows-.

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– Remove heat exchanger to left.

Installing
Install in reverse order of removal, observing the following:

Note

Renew oil seas.

– Check heater slot for dirt with heat exchanger removed.

– If necessary, remove any dirt and coolant residue.
– Vehicles with TDI engine: With auxiliary air heater element
removed, check heating element slot for dirt and clean if
necessary.
– Check connection -3- of heat exchanger and connection -2-
of coolant pipes for damage or contamination.

– Clean and smooth sealing surface for seals.

– Moisten new seals -4- with coolant (or lubricate lightly with
silicone grease) and fit them to coolant pipe -1-.
– Carefully slide heat exchanger into heater and air condition‐
ing unit as far as stop.

Note

When sliding in the heat exchanger, make sure not to damage

the connections and coolant pipes.

– Push coolant pipes into heat exchanger as far as stop.

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NOTICE
Risk of heat exchanger malfunction due to defective seals and
leaks.
– Never pinch seals.
– Never tilt coolant pipes.
– Slide on coolant pipes completely.

– Fit new clip -5- or screw-type clip -2- onto joint of coolant
pipe and heat exchanger.

– Tighten bolt -3- ⇒ o5.2 verview – heater and air conditioning

unit”, page 116 .
– Check clip and screw-type clip for proper seating on connec‐
tions of heat exchanger and coolant pipes. They should not
be in contact with air distribution housing or any other com‐
ponents.
Vehicles with petrol engine (1.8 and 2.0 l, 4 V, EA 888 gen 3,
turbocharger, chain drive)
– Check cooling system for irregularities listed in section
“Flushing cooling system”, flush cooling system if necessary
⇒ Rep. gr. 19; Cooling system/coolant; Flushing cooling sys‐
tem.
Vehicles with diesel engine (1.6 and 2.0 l, 4 V, turbocharger, EA
288)
Procedure for installing new heat exchanger:
– Flush cooling system ⇒ Rep. gr. 19; Cooling system, cool‐
ant; Flushing cooling system.
Procedure if old heat exchanger is to remain installed:
– Check cooling system for irregularities listed in section
“Flushing cooling system”, flush cooling system if necessary
⇒ Rep. gr. 19; Cooling system/coolant; Flushing cooling sys‐
tem.
Continued for all vehicles
– Fill up with coolant ⇒ Rep. gr. 19; Cooling system/coolant;
Draining and filling coolant.
– As a final step, check operation of heater and air conditioner.

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Specified torques
♦ ⇒ o5.2 verview – heater and air conditioning unit”, page 116
♦ Turbocharger; Assembly overview - turbocharger ⇒ Rep.
gr. 21; Turbocharger; Assembly overview - turbocharger.
♦ Centre console; Assembly overview – centre console ⇒ Gen‐
eral body repairs, interior; Rep. gr. 68; Centre console; As‐
sembly overview – centre console

5.14.2 Removing and installing Valeo heat ex‐

changer, right-hand drive vehicles
Special tools and workshop equipment required
♦ Hose clamps to 25 mm -3094-

♦ Engine bung set -VAS 6122-

♦ Drip tray for workshop hoist -VAS 6208-

♦ Compressed air gun

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Removing
Vehicles with TDI engine

– Press release tabs on crankcase breather hose -1- and dis‐

connect hose from cylinder head cover.
– Move clear vacuum hoses at air pipe -arrows-.
– Release hose clip -3-.
– Remove bolt -2-, swivel air pipe and connection to rear and
detach from turbocharger.
Vehicles with 1.5 l or 2.0 l engine
– Remove throttle valve module -GX3- ⇒ Rep. gr. 24; Intake
manifold; Removing and installing throttle valve module
GX3.
Continued for all vehicles
– Mark installation position of coolant hoses -1- and -4-.

Note

The heat exchanger is designed for a certain direction of cool‐

ant flow. Therefore, the coolant hoses must be connected to the
correct sides.

– Clamp off coolant hoses -1- and -4- using hose clamps for
hoses up to 25 mm -3094-.
– Lift retaining clips -2- and -3-.
– Disconnect coolant hoses -1- and -4- from heat exchanger
for heater.
– Push a suitable hose -A- onto upper connection of heat ex‐
changer.

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– Hold suitable container -B- under lower connection leading

to heat exchanger -C-.
– Carefully blow out the remaining coolant into the container
-B- through the hose from the heat exchanger using a pneu‐
matic gun -A-.
– Seal off open lines and connections with clean plugs from
engine bung set -VAS 6122-.
– Remove baffle plate ⇒ page 173 .
– Remove glove compartment ⇒ General body repairs, interi‐
or; Rep. gr. 68; Compartments/covers; Removing and instal‐
ling glove compartment.
– Remove footwell vent on front passenger side ⇒ page 176 .
– Remove centre console ⇒ General body repairs, interior;
Rep. gr. 68; Centre console; Removing and installing centre
console.
Vehicles with auxiliary air heater element -Z35-
– Remove auxiliary air heater element -Z35- ⇒ page 120 .
Continued for all vehicles
– Cover the area beneath the connections for the coolant ho‐
ses in the plenum chamber e.g. using impermeable sheeting
and absorbent paper.
– Lift locking element -6-, remove clip -5- and pull coolant line
-4- off heat exchanger.

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Note

The illustration shows a left-hand drive vehicle.

– Unscrew bolt -3-.

– Remove screw-type clip -2- and pull coolant line -1- off heat
exchanger.
– Seal off open lines and connections with clean plugs from
engine bung set -VAS 6122-.
– Remove bolts -1-, -3- and -5-.

Note

The illustration shows a left-hand drive vehicle.

– Release retainer tabs -4- -arrows- and detach cover -2-.

– If noise insulation cannot be pulled out, cut open tabs on
cover -arrows-.

– Remove heat exchanger to left.

Installing
Install in reverse order of removal, observing the following:

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Note

Renew oil seas.

– Check heater slot for dirt with heat exchanger removed.

– If necessary, remove any dirt and coolant residue.
– Vehicles with TDI engine: With auxiliary air heater element
removed, check heating element slot for dirt and clean if
necessary.
– Check connection -3- of heat exchanger and connection -2-
of coolant pipes for damage or contamination.

– Clean and smooth sealing surface for seals.

– Moisten new seals -4- with coolant (or lubricate lightly with
silicone grease) and fit them to coolant pipe -1-.
– Carefully slide heat exchanger into heater and air condition‐
ing unit as far as stop.

Note

When sliding in the heat exchanger, make sure not to damage

the connections and coolant pipes.

– Push coolant pipes into heat exchanger as far as stop.

NOTICE
Risk of heat exchanger malfunction due to defective seals and
leaks.
– Never pinch seals.
– Never tilt coolant pipes.
– Slide on coolant pipes completely.

– Fit new clip -5- or screw-type clip -2- onto joint of coolant
pipe and heat exchanger.

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– Tighten bolt -3- ⇒ o5.2 verview – heater and air conditioning

unit”, page 116 .
– Check clip and screw-type clip for proper seating on connec‐
tions of heat exchanger and coolant pipes. They should not
be in contact with air distribution housing or any other com‐
ponents.
Vehicles with petrol engine (1.8 and 2.0 l, 4 V, EA 888 gen 3,
turbocharger, chain drive)
– Check cooling system for irregularities listed in section
“Flushing cooling system”, flush cooling system if necessary
⇒ Rep. gr. 19; Cooling system/coolant; Flushing cooling sys‐
tem.
Vehicles with diesel engine (1.6 and 2.0 l, 4 V, turbocharger, EA
288)
Procedure for installing new heat exchanger:
– Flush cooling system ⇒ Rep. gr. 19; Cooling system, cool‐
ant; Flushing cooling system.
Procedure if old heat exchanger is to remain installed:
– Check cooling system for irregularities listed in section
“Flushing cooling system”, flush cooling system if necessary
⇒ Rep. gr. 19; Cooling system/coolant; Flushing cooling sys‐
tem.
Continued for all vehicles
– Fill up with coolant ⇒ Rep. gr. 19; Cooling system/coolant;
Draining and filling coolant.
– As a final step, check operation of heater and air conditioner.
Specified torques
♦ ⇒ o5.2 verview – heater and air conditioning unit”, page 116
♦ Turbocharger; Assembly overview - turbocharger ⇒ Rep.
gr. 21; Turbocharger; Assembly overview - turbocharger.
♦ Centre console; Assembly overview – centre console ⇒ Gen‐
eral body repairs, interior; Rep. gr. 68; Centre console; As‐
sembly overview – centre console

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♦ Compartments/covers; Assembly overview - glove compart‐

ment ⇒ General body repairs, interior; Rep. gr. 68; Compart‐
ments/covers; Assembly overview - glove compartment.

5.14.3 Removing and installing Denso heat

exchanger, left-hand drive vehicles
Special tools and workshop equipment required
♦ Hose clamps to 25 mm -3094-

♦ Engine bung set -VAS 6122-

♦ Drip tray for workshop hoist -VAS 6208-

♦ Compressed air gun

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Removing
Vehicles with TDI engine

– Press release tabs on crankcase breather hose -1- and dis‐

connect hose from cylinder head cover.
– Move clear vacuum hoses at air pipe -arrows-.
– Release hose clip -3-.
– Remove bolt -2-, swivel air pipe and connection to rear and
detach from turbocharger.
Vehicles with 1.5 l or 2.0 l engine
– Remove throttle valve module -GX3- ⇒ Rep. gr. 24; Intake
manifold; Removing and installing throttle valve module
GX3.
Continued for all vehicles

– Mark installation position of coolant hoses -1- and -4-.

Note

The heat exchanger is designed for a certain direction of cool‐

ant flow. Therefore, the coolant hoses must be connected to the
correct sides.

– Clamp off coolant hoses -1- and -4- using hose clamps for
hoses up to 25 mm -3094-.
– Lift retaining clips -2- and -3-.
– Disconnect coolant hoses -1- and -4- from heat exchanger
for heater.
– Push a suitable hose -A- onto upper connection of heat ex‐
changer.

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– Hold suitable container -B- under lower connection leading

to heat exchanger -C-.
– Carefully blow out the remaining coolant into the container
-B- through the hose from the heat exchanger using a pneu‐
matic gun -A-.
– Seal off open lines and connections with clean plugs from
engine bung set -VAS 6122-.
– Remove centre console ⇒ General body repairs, interior;
Rep. gr. 68; Centre console; Removing and installing centre
console.
Vehicles with auxiliary air heater element -Z35-
– Remove auxiliary air heater element -Z35- ⇒ page 120 .
Continued for all vehicles
– Cover area beneath connections for coolant hoses in ple‐
num chamber as well as airbag control unit -J234- with, for
example, impermeable sheeting and absorbent paper.
– Remove bolts -2- and detach screw-type clamps -3-.

– Separate coolant pipes.

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Note

♦ If the coolant pipes cannot be separated because the seals

are gummed up, cut through them at the marked locations
-arrows- using pliers -T40147-.
♦ Pull the cut coolant pipes -4- and -7- of heat exchanger off
coolant pipes -1- and -11- leading to the engine.

– Remove bolt -10- and detach heat exchanger bracket -9-.

– Pull out heat exchanger -6- to left.
– Seal off open lines and connections with clean plugs from
engine bung set -VAS 6122-.
Installing
Install in reverse order of removal, observing the following:

Note

Renew oil seas.

– Check heater slot for dirt with heat exchanger removed.

– If necessary, remove any dirt and coolant residue.
– Vehicles with TDI engine: With auxiliary air heater element
removed, check heating element slot for dirt and clean if
necessary.
– Check foam seals -2- attached to heat exchanger -1- for
damage and replace if necessary.

Note

♦ If the foam seal is not properly bonded in, it may roll up

when the heat exchanger is fitted.
♦ If the foam seal is damaged or improperly fitted, cold air can
flow past the heat exchanger.

– Check connection -3- of heat exchanger and connection of

coolant pipes -1- for damage or dirt.

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– Clean and smooth sealing surface for seals.

– Moisten new seals -1- with coolant (or lubricate lightly with
silicone grease) and fit them to coolant pipe.
– Carefully slide heat exchanger into heater and air condition‐
ing unit as far as stop.

Note

When sliding in the heat exchanger, make sure not to damage

the connections and coolant pipes.

– Push coolant pipes into heat exchanger as far as stop.

NOTICE
Risk of heat exchanger malfunction due to defective seals and
leaks.
– Never pinch seals.
– Never tilt coolant pipes.
– Slide on coolant pipes completely.

– Fit heat exchanger bracket -3- on air distribution housing

and tighten bolt -4- to specified torque.

– Fit new clip -2- to joint between coolant pipe and heat ex‐
changer.

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– Tighten bolt -1- ⇒ o5.2 verview – heater and air conditioning

unit”, page 116 .
– Check clip and screw-type clip for proper seating on connec‐
tions of heat exchanger and coolant pipes. They should not
be in contact with air distribution housing or any other com‐
ponents.
Vehicles with petrol engine (1.8 and 2.0 l, 4 V, EA 888 gen 3,
turbocharger, chain drive)
– Check cooling system for irregularities listed in section
“Flushing cooling system”, flush cooling system if necessary
⇒ Rep. gr. 19; Cooling system/coolant; Flushing cooling sys‐
tem.
Vehicles with diesel engine (1.6 and 2.0 l, 4 V, turbocharger, EA
288)
Procedure for installing new heat exchanger:
– Flush cooling system ⇒ Rep. gr. 19; Cooling system, cool‐
ant; Flushing cooling system.
Procedure if old heat exchanger is to remain installed:
– Check cooling system for irregularities listed in section
“Flushing cooling system”, flush cooling system if necessary
⇒ Rep. gr. 19; Cooling system/coolant; Flushing cooling sys‐
tem.
Continued for all vehicles
– Fill up with coolant ⇒ Rep. gr. 19; Cooling system/coolant;
Draining and filling coolant.
– As a final step, check operation of heater and air conditioner.
Specified torques
♦ ⇒ o5.2 verview – heater and air conditioning unit”, page 116
♦ Turbocharger; Assembly overview - turbocharger ⇒ Rep.
gr. 21; Turbocharger; Assembly overview - turbocharger.
♦ Centre console; Assembly overview – centre console ⇒ Gen‐
eral body repairs, interior; Rep. gr. 68; Centre console; As‐
sembly overview – centre console

5.14.4 Removing and installing Denso heat

exchanger, right-hand drive vehicles
Special tools and workshop equipment required
♦ Hose clamps to 25 mm -3094-

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♦ Engine bung set -VAS 6122-

♦ Drip tray for workshop hoist -VAS 6208-

♦ Compressed air gun

Removing
Vehicles with TDI engine

– Press release tabs on crankcase breather hose -1- and dis‐

connect hose from cylinder head cover.
– Move clear vacuum hoses at air pipe -arrows-.
– Release hose clip -3-.
– Remove bolt -2-, swivel air pipe and connection to rear and
detach from turbocharger.
Vehicles with 1.5 l or 2.0 l engine
– Remove throttle valve module -GX3- ⇒ Rep. gr. 24; Intake
manifold; Removing and installing throttle valve module
GX3.

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Continued for all vehicles

– Mark installation position of coolant hoses -1- and -4-.

Note

The heat exchanger is designed for a certain direction of cool‐

ant flow. Therefore, the coolant hoses must be connected to the
correct sides.

– Clamp off coolant hoses -1- and -4- using hose clamps for
hoses up to 25 mm -3094-.
– Lift retaining clips -2- and -3-.
– Disconnect coolant hoses -1- and -4- from heat exchanger
for heater.
– Push a suitable hose -A- onto upper connection of heat ex‐
changer.

– Hold suitable container -B- under lower connection leading

to heat exchanger -C-.
– Carefully blow out the remaining coolant into the container
-B- through the hose from the heat exchanger using a pneu‐
matic gun -A-.
– Seal off open lines and connections with clean plugs from
engine bung set -VAS 6122-.
– Remove baffle plate ⇒ page 173 .
– Remove glove compartment ⇒ General body repairs, interi‐
or; Rep. gr. 68; Compartments/covers; Removing and instal‐
ling glove compartment.
– Remove footwell vent on front passenger side ⇒ page 176 .

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– Remove centre console ⇒ General body repairs, interior;

Rep. gr. 68; Centre console; Removing and installing centre
console.
Vehicles with auxiliary air heater element -Z35-
– Remove auxiliary air heater element -Z35- ⇒ page 120 .
Continued for all vehicles
– Cover area beneath connections for coolant hoses in ple‐
num chamber as well as airbag control unit -J234- with, for
example, impermeable sheeting and absorbent paper.
– Remove bolts -2- and detach screw-type clamps -3-.

– Separate coolant pipes.

Note

♦ If the coolant pipes cannot be separated because the seals

are gummed up, cut through them at the marked locations
-arrows- using pliers -T40147-.
♦ Pull the cut coolant pipes -4- and -7- of heat exchanger off
coolant pipes -1- and -11- leading to the engine.

– Remove bolt -10- and detach heat exchanger bracket -9-.

– Pull out heat exchanger -6- to left.
– Seal off open lines and connections with clean plugs from
engine bung set -VAS 6122-.
Installing
Install in reverse order of removal, observing the following:

Note

Renew oil seas.

– Check heater slot for dirt with heat exchanger removed.

– If necessary, remove any dirt and coolant residue.

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– Vehicles with TDI engine: With auxiliary air heater element

removed, check heating element slot for dirt and clean if
necessary.
– Check foam seals -2- attached to heat exchanger -1- for
damage and replace if necessary.

Note

♦ If the foam seal is not properly bonded in, it may roll up

when the heat exchanger is fitted.
♦ If the foam seal is damaged or improperly fitted, cold air can
flow past the heat exchanger.

– Check connection -3- of heat exchanger and connection of

coolant pipes -1- for damage or dirt.

– Clean and smooth sealing surface for seals.

– Moisten new seals -1- with coolant (or lubricate lightly with
silicone grease) and fit them to coolant pipe.
– Carefully slide heat exchanger into heater and air condition‐
ing unit as far as stop.

Note

When sliding in the heat exchanger, make sure not to damage

the connections and coolant pipes.

– Push coolant pipes into heat exchanger as far as stop.

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NOTICE
Risk of heat exchanger malfunction due to defective seals and
leaks.
– Never pinch seals.
– Never tilt coolant pipes.
– Slide on coolant pipes completely.

– Fit heat exchanger bracket -3- on air distribution housing

and tighten bolt -4- to specified torque.

– Fit new clip -2- to joint between coolant pipe and heat ex‐
changer.
– Tighten bolt -1- ⇒ o5.2 verview – heater and air conditioning
unit”, page 116 .
– Check clip and screw-type clip for proper seating on connec‐
tions of heat exchanger and coolant pipes. They should not
be in contact with air distribution housing or any other com‐
ponents.
Vehicles with petrol engine (1.8 and 2.0 l, 4 V, EA 888 gen 3,
turbocharger, chain drive)
– Check cooling system for irregularities listed in section
“Flushing cooling system”, flush cooling system if necessary
⇒ Rep. gr. 19; Cooling system/coolant; Flushing cooling sys‐
tem.
Vehicles with diesel engine (1.6 and 2.0 l, 4 V, turbocharger, EA
288)
Procedure for installing new heat exchanger:
– Flush cooling system ⇒ Rep. gr. 19; Cooling system, cool‐
ant; Flushing cooling system.
Procedure if old heat exchanger is to remain installed:
– Check cooling system for irregularities listed in section
“Flushing cooling system”, flush cooling system if necessary
⇒ Rep. gr. 19; Cooling system/coolant; Flushing cooling sys‐
tem.

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Continued for all vehicles

– Fill up with coolant ⇒ Rep. gr. 19; Cooling system/coolant;
Draining and filling coolant.
– As a final step, check operation of heater and air conditioner.
Specified torques
♦ ⇒ o5.2 verview – heater and air conditioning unit”, page 116
♦ Turbocharger; Assembly overview - turbocharger ⇒ Rep.
gr. 21; Turbocharger; Assembly overview - turbocharger.
♦ Centre console; Assembly overview – centre console ⇒ Gen‐
eral body repairs, interior; Rep. gr. 68; Centre console; As‐
sembly overview – centre console
♦ Compartments/covers; Assembly overview - glove compart‐
ment ⇒ General body repairs, interior; Rep. gr. 68; Compart‐
ments/covers; Assembly overview - glove compartment.

5.15 Removing and installing coolant pipes

on heat exchanger
⇒ a5.15.1 nd installing coolant pipes at heat exchanger (Va‐
leo)”, page 164
⇒ a5.15.2 nd installing coolant pipes at heat exchanger (Den‐
so)”, page 166

5.15.1 Removing and installing coolant pipes

at heat exchanger (Valeo)
Special tools and workshop equipment required
♦ Torque screwdriver -VAS 6494-

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Removing

– Remove heater and air conditioning unit ⇒ page 123 .

– Pull off sealing boot -3-.
– Unscrew bolt -2-.
– Remove retainer -4-.
– Detach the foam -1-.
– Lift locking element -7- in -direction of arrow- and pull off clip
-6-
– Pull coolant pipe -5- off heat exchanger.
– Unscrew bolt -8-.
– Remove screw-type clip -9- and pull coolant pipe -10- off
heat exchanger.
– Detach coolant pipes.
Installing

Install in reverse order of removal, observing the following:

– Check coolant pipe connections -1- and connections of heat
exchanger -3- for damage and contamination. Clean or re‐
new damaged components as necessary ⇒ Electronic parts
catalogue (ETKA).
– Clean and smooth sealing surfaces -2- for seals -4-.

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– Moisten new seals -4- with coolant, and slide them onto
coolant pipes -1-.

NOTICE
Risk of heat exchanger malfunction due to defective seals and
leaks.
– Never pinch seals.
– Never tilt coolant pipes.
– Slide on coolant pipes completely.

– Push coolant pipe connections -1- into heat exchanger con‐

nections -3- as far as stop.
Specified torques
♦ ⇒ o5.2 verview – heater and air conditioning unit”, page 116

5.15.2 Removing and installing coolant pipes

at heat exchanger (Denso)
Special tools and workshop equipment required
♦ Torque screwdriver -VAS 6494-

Removing

– Remove heater and air conditioning unit ⇒ page 123 .

– Pull off sealing boot -1-.
– Unscrew bolt -2-.

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– Remove retainer -3-.

– Detach the foam -4-.
– Unscrew bolts -arrows-.
– Remove clamps -5-.
– Pull off coolant hoses -6- from heat exchanger.
Installing

Install in reverse order of removal, observing the following:

– Check coolant pipe connections -1- and heat exchanger
connections -4- for damage and contamination. Clean or re‐
new damaged components as necessary ⇒ Electronic parts
catalogue (ETKA) or ⇒ webMANTIS for MAN TGE.
– Clean and smooth sealing surfaces -2- for seals -3-.
– Moisten new seals -3- with coolant, and slide them onto
coolant pipes -1-.

NOTICE
Risk of heat exchanger malfunction due to defective seals and
leaks.
– Never pinch seals.
– Never tilt coolant pipes.
– Slide on coolant pipes completely.

– Push coolant pipe connections -1- into heat exchanger con‐

nections -4- as far as stop.
Specified torques
♦ ⇒ o5.2 verview – heater and air conditioning unit”, page 116

5.16 Removing and installing evaporator

temperature sensor -G308-
Special tools and workshop equipment required

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♦ Removal wedge -3409-

Removing
– Remove footwell vent on front passenger side ⇒ page 176 .
Right-hand drive vehicles
– Remove footwell vent on driver side ⇒ page 175 .
Continued for all vehicles

– Disconnect electrical connector -1-.

Note

Levering with removal wedge -3409- causes both retaining tabs

-arrows- to be pushed together.

– Lever evaporator temperature sensor -G308- -2- out of

evaporator housing using removal wedge -3409-.
Installing
Install in reverse order of removal, observing the following:
– Check locking lugs -arrows- for damage; renew component if
necessary ⇒ Electronic parts catalogue (ETKA).
– Check operation of heater and air conditioning system.

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5.17 Removing and installing condensation

drain
⇒ a5.17.1 nd installing condensation drain, left-hand drive vehi‐
cles”, page 169
⇒ a5.17.2 nd installing condensation drain, right-hand drive ve‐
hicles”, page 171

5.17.1 Removing and installing condensation

drain, left-hand drive vehicles
Removing
– Remove centre console ⇒ General body repairs, interior;
Rep. gr. 68; Centre console; Removing and installing centre
console.

NOTICE
Risk of damage to airbag control unit. Connectors may cor‐
rode if moisture enters.
– After disconnecting, cover or seal off electrical connectors
of the control unit to prevent the ingress of moisture.

Note

Disregard position -2-.

– Disconnect electrical connector -6- from airbag control unit

-J234-.

– Separate cable ties -3- if fitted.

– Cover airbag control unit -J234- and electrical connector -6-
with waterproof sheet.
– Carefully push aside floor covering, and cover it in area un‐
der condensation drain hose -5- with waterproof sheet and
water absorbing paper.
– In area indicated by -arrow-, carefully pull condensation
drain hose -5- off heater and air conditioning unit -1- and
off body -4-.

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Installing
Install in reverse order of removal, observing the following:

Install in reverse order of removal, observing the following:

– Check condensation drain hose ⇒ page 173 .

Note

Condensation drain hose -1- can be pushed onto heater and air
conditioning unit only in one certain position -arrow-.

– Insert condensation drain hose -1- in bulkhead opening -2-

until it is heard to engage.

Note

Condensation drain hose -1- must be installed taut and above

bulkhead insulation -2-.

Specified torques
♦ Centre console; Assembly overview – centre console ⇒ Gen‐
eral body repairs, interior; Rep. gr. 68; Centre console; As‐
sembly overview – centre console

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5.17.2 Removing and installing condensation

drain, right-hand drive vehicles
Removing
– Remove centre console ⇒ General body repairs, interior;
Rep. gr. 68; Centre console; Removing and installing centre
console.
– Carefully push floor covering aside and cover it in area un‐
der condensation drain hose with impermeable sheeting and
water absorbing paper.
– Remove footrest ⇒ General body repairs, interior; Rep.
gr. 70; Trims, interior; Removing and installing footrest.

NOTICE
Risk of damage to airbag control unit. Connectors may cor‐
rode if moisture enters.
– After disconnecting, cover or seal off electrical connectors
of the control unit to prevent the ingress of moisture.

– Pull connector off airbag control unit -J234- -5-.

– Cover airbag control unit -J234- and connector -5- with im‐
permeable sheeting.

– Carefully push floor covering aside and cover it in area un‐

der condensation drain hose with impermeable sheeting and
water absorbing paper.
– Carefully pull condensation drain hose -3- off heater and air
conditioning unit -1- and off body -4-.
Installing
Install in reverse order of removal, observing the following:
• The condensation drain hose -3- can be properly pushed
onto heater and air conditioning unit -1- to stop in only one
position.

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• Lug -arrow- on connecting piece must engage in guide -2-.

• If a commercially available cable tie was installed to retain
the condensation drain -3-, renew it.
• The condensation drain hose must be routed below the wir‐
ing harness of the airbag control unit -J234- -5- in the figure.
• The bracket -1- for the condensation drain hose must be
properly clipped into the aperture in the body -2- under ten‐
sion.

• The sealing lip must not be loose on the body aperture.

• The retainer tabs -arrows- must be fully engaged.
• If the tension is insufficient, seal joint between body and
bracket using, e.g., silicon adhesive sealant ⇒ Electronic
parts catalogue (ETKA).

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Note

♦ Install the condensation drain hose so that it is not twisted or

pinched.
♦ When installing floor covering, ensure that the condensation
drain hose is not pinched by the floor covering.
♦ If the condensation drain hose is loose on the heater and
air conditioning unit connection, secure it e.g. with a hose
clip to prevent it from slipping. Hose clip ⇒ Electronic parts
catalogue (ETKA).

Specified torques
♦ Centre console; Assembly overview – centre console ⇒ Gen‐
eral body repairs, interior; Rep. gr. 68; Centre console; As‐
sembly overview – centre console

5.18 Checking condensation drain

Sequence of operations
– Remove condensate drain hose ⇒ page 169 .
– Check condensation drain hose for bottleneck, damage and
blockage; clean component if necessary or renew.

5.19 Removing and installing baffle plate

Removal and installation is described in ELSA, see ⇒ General
body repairs, interior; Rep. gr. 68; Compartments/covers; Re‐
moving and installing footwell cover on front passenger side.

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6 Air duct
⇒ o6.1 verview – air duct and air distribution in passenger com‐
partment”, page 174
⇒ a6.2 nd installing driver side footwell vents”, page 175
⇒ a6.3 nd installing front passenger side footwell vents”, page
176
⇒ a6.4 nd installing rear footwell vent”, page 178
⇒ a6.5 nd installing air ducts”, page 180
⇒ a6.6 nd installing forced ventilation for passenger compart‐
ment”, page 181
⇒ f6.7 orced ventilation for passenger compartment”, page 182
⇒ a6.8 nd installing fresh air intake”, page 183
⇒ a6.9 nd installing cover for fresh air intake”, page 184
⇒ a6.10 nd installing air intake duct”, page 185
⇒ a6.11 nd installing air duct for defroster vent”, page 185
⇒ a6.12 nd installing air duct for centre vent”, page 186

6.1 Assembly overview – air duct and air distribution in passenger compart‐
ment

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1 - Air duct
❑ For vent defrost func‐
tion
❑ Removing and instal‐
ling ⇒ page 185
2 - Air duct
❑ For centre vent
❑ Removing and instal‐
ling ⇒ page 186
3 - Footwell vent
❑ Front passenger side
❑ Removing and instal‐
ling ⇒ page 176
4 - Footwell vent
❑ Rear
❑ Removing and instal‐
ling ⇒ page 178
5 - Air duct
❑ For rear vent in centre
console
❑ Depending on equip‐
ment
❑ Removing and instal‐
ling ⇒ page 180
6 - Air duct
❑ For air duct for rear
vent in centre console
❑ Depending on equip‐
ment
❑ Removing and instal‐
ling ⇒ page 180
7 - Footwell vent
❑ Rear
❑ Removing and installing ⇒ page 178
8 - Footwell vent
❑ Driver side
❑ Removing and installing ⇒ page 175

6.2 Removing and installing driver side

footwell vents
Special tools and workshop equipment required

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♦ Torque wrench -VAS 6253A-

Removing

– Unscrew bolt -1-.

– Swivel down driver-side footwell vent -2- off air distribution
housing.
Installing
Install in reverse order of removal, observing the following:
Specified torques
Component Specified torque
Bolt -1- 1.5 Nm

6.3 Removing and installing front passen‐

ger side footwell vents
⇒ a6.3.1 nd installing front passenger side footwell vents, left-
hand drive vehicles”, page 176
⇒ a6.3.2 nd installing front passenger side footwell vents, right-
hand drive vehicles”, page 177

6.3.1 Removing and installing front passen‐

ger side footwell vents, left-hand drive
vehicles
Special tools and workshop equipment required

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♦ Torque wrench -VAS 6253A-

Removing

– Remove glove compartment ⇒ General body repairs, interi‐

or; Rep. gr. 68; Compartments/covers; Removing and instal‐
ling glove compartment.
– Unscrew bolt -2-.
– Unscrew bolts -3-.
– Pull dash panel frame towards front. While doing this, pull
front-passenger side footwell vent -1- off air distribution
housing.
Installing
Install in reverse order of removal, observing the following:
Specified torques
♦ Compartments/covers; Assembly overview - glove compart‐
ment ⇒ General body repairs, interior; Rep. gr. 68; Compart‐
ments/covers; Assembly overview - glove compartment.
Component Specified torque
Bolt -2- 1.5 Nm

6.3.2 Removing and installing front passen‐

ger side footwell vents, right-hand drive
vehicles
Special tools and workshop equipment required

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♦ Torque wrench -VAS 6253A-

Removing

– Remove glove compartment ⇒ General body repairs, interi‐

or; Rep. gr. 68; Compartments/covers; Removing and instal‐
ling glove compartment.
– Unscrew bolt -2-.
– Unscrew bolts -4-.
– Release locking lug -3-.
– Pull dash panel frame towards front. While doing this, pull
front-passenger side footwell vent -1- off air distribution
housing.
Installing
Install in reverse order of removal, observing the following:
Specified torques
♦ Compartments/covers; Assembly overview - glove compart‐
ment ⇒ General body repairs, interior; Rep. gr. 68; Compart‐
ments/covers; Assembly overview - glove compartment.
Component Specified torque
Bolt -2- 1.5 Nm

6.4 Removing and installing rear footwell

vent
Removing
– Remove sill panel trim ⇒ General body repairs, interior; Rep.
gr. 70; Trims, interior; Removing and installing sill panel trim.
– Remove the front seat ⇒ General body repairs, interior; Rep.
gr. 72; Front seats; Removing and installing front seat.

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– Remove centre console ⇒ General body repairs, interior;

Rep. gr. 68; Centre console; Removing and installing centre
console.
– Raise floor covering in area of rear footwell vent.

Note

Disregard position -4-.

– Prise off the cable clip -3-.

– Lift rear footwell vent -1- in direction of -arrows B-. Pull off
in direction of -arrow A- from heater and air conditioning unit
-2- when doing this.
Installing

Install in reverse order of removal, observing the following:

– Check the cable clip -1- for damage before pressing on at
footwell vent -2-.

Note

A loose cable clip or damaged seal can lead to flow noise.

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6.5 Removing and installing air ducts

⇒ a6.5.1 nd installing air duct, for air duct for rear vent in centre
console”, page 180
⇒ a6.5.2 nd installing air duct, for rear vent in centre console”,
page 180

6.5.1 Removing and installing air duct, for air

duct for rear vent in centre console
Removing
– Remove centre console ⇒ General body repairs, interior;
Rep. gr. 68; Centre console; Removing and installing centre
console.

Note

If the vehicle is not provided with rear vents, a cap -1- is fitted
on the air distribution housing. Cap -1- is removed in the direc‐
tion of -arrow A-.

– Swing air duct -2- in direction of -arrow B-. At the same time,
pull it out of fastener on air distribution housing in direction of
-arrow C-.
Installing
Install in reverse order of removal.

6.5.2 Removing and installing air duct, for

rear vent in centre console
Special tools and workshop equipment required

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♦ Removal wedge -3409-

Removing

– Remove trim for rear centre console ⇒ General body repairs,

interior; Rep. gr. 68; Centre console; Removing and instal‐
ling trim for rear centre console.
– Release air duct for rear vent -1- in area indicated by
-arrows-. While doing this, pull it off air duct for rear vent
in centre console.
Installing
Install in reverse order of removal.

6.6 Removing and installing forced ventila‐

tion for passenger compartment
Special tools and workshop equipment required
♦ Removal wedge -3409-

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Removing

– Remove rear bumper cover ⇒ General body repairs, exte‐

rior; Rep. gr. 63; Rear bumper; Removing and installing
bumper cover.
– Release locking lugs -arrows- using removal wedge -3409-.
– Remove vent frames -1- from side panel.
Installing
Install in reverse order of removal, observing the following:
– Check forced ventilation for passenger compartment ⇒ page
182 .
Specified torques
♦ Rear bumper; Assembly overview - rear bumper ⇒ General
body repairs, exterior; Rep. gr. 63; Rear bumper; Assembly
overview - bumper cover.

6.7 Checking forced ventilation for passen‐

ger compartment

Note

♦ The stale air escapes via ventilation outlets in the luggage

compartment trim.
♦ If the ventilation is to work properly, the vent openings must
not be covered.
♦ The ventilation frames are located in the rear side panels
behind the bumper.

The ventilation can be checked through the luggage compart‐

ment.
Depending on vehicle equipment, additional fittings must be
removed.
– Remove luggage compartment side trim ⇒ General body
repairs, interior; Rep. gr. 70; Luggage compartment trims;
Overview of fitting locations- luggage compartment side trim.

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– Sealing lips in ventilation frames on both sides of vehicle

must be free to move and close by themselves.

6.8 Removing and installing fresh air in‐

take
Removing

– Remove cover for fresh air intake ⇒ page 184 .

Vehicles with Climatronic
– Remove air quality sensor -G238- ⇒ page 196 .
Continued for all vehicles
– Unscrew nuts -arrows-.
– Remove fresh air intake duct -1-.
Installing
Install in reverse order of removal, observing the following:

Note

♦ Inspect seal -2- to ensure it is seated correctly and not

damaged; renew if necessary ⇒ Electronic parts catalogue
(ETKA).
♦ Check fresh air intake duct of bonnet -1- for contamination
(e.g. foliage) and clean if necessary.

Specified torques
Component Specified torque
Nuts -arrows- 3 Nm

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6.9 Removing and installing cover for fresh

air intake
Removing
– Remove right plenum chamber cover ⇒ General body re‐
pairs, exterior; Rep. gr. 50; Plenum chamber bulkhead; Re‐
moving and installing plenum chamber cover.
Right-hand drive vehicles
– Remove left plenum chamber cover ⇒ General body repairs,
exterior; Rep. gr. 50; Bulkhead; Removing and installing ple‐
num chamber cover.
Continued for all vehicles

Note

♦ Illustration shows left-hand drive vehicle.

♦ Removal on right-hand drive vehicles is the same.

– Remove cover for fresh air intake duct -1-.

Installing
Install in reverse order of removal, observing the following:
– Check cover for fresh air intake duct -1- for damage; renew
component if necessary ⇒ Electronic parts catalogue (ET‐
KA).

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6.10 Removing and installing air intake duct

Removing

– Remove central tube for dash panel ⇒ General body repairs,

interior; Rep. gr. 70; Central tube for dash panel; Removing
and installing central tube for dash panel.
– Remove dust and pollen filter ⇒ page 132 .
– Separate electrical connector -1- and lay wiring harness on
intake duct -2- to one side.
– Release locking lugs -3-.
– Swivel intake duct -2- in direction of -arrow- out of mountings
-4-.
Installing
Install in reverse order of removal, observing the following:
– Check locking lugs -3- for damage; renew component if nec‐
essary ⇒ Electronic parts catalogue (ETKA).

6.11 Removing and installing air duct for de‐

froster vent
Removing

– Remove dash panel ⇒ General body repairs, interior; Rep.

gr. 70; Dash panel; Removing and installing dash panel.
– Remove spreader rivets -2-.

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– Release locking lugs -arrows-. While doing this, detach air

duct for defroster vent -1-.
Installing
Install in reverse order of removal, observing the following:
– Inspect seal of air duct for defroster vent -1- to ensure it
is seated correctly and not damaged; renew if necessary
⇒ Electronic parts catalogue (ETKA).
– Check locking lugs -arrows- for damage; renew component if
necessary ⇒ Electronic parts catalogue (ETKA).
Specified torques
♦ Dash panel; Assembly overview - dash panel ⇒ General
body repairs, interior; Rep. gr. 70; Dash panel; Assembly
overview - dash panel.

6.12 Removing and installing air duct for

centre vent
Removing

– Remove air duct for defrost function vent ⇒ page 185 .

– Release locking lugs -arrows-. While doing this, detach air
duct for centre vent -1-.
Installing
Install in reverse order of removal, observing the following:
– Check air duct for centre vent -1- to ensure it is seated
correctly and not damaged; renew if necessary ⇒ Electronic
parts catalogue (ETKA).
– Check locking lugs -arrows- for damage; renew component if
necessary ⇒ Electronic parts catalogue (ETKA).
Specified torques
♦ Dash panel; Assembly overview - dash panel ⇒ General
body repairs, interior; Rep. gr. 70; Dash panel; Assembly
overview - dash panel.

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7 Operating and display unit

⇒ o7.1 f operating and display unit”, page 187
⇒ a7.2 nd installing operating and display unit”, page 191

7.1 Overview of operating and display unit

⇒ -7.1.1 operating and display unit, air conditioning system”,
page 187
⇒ -7.1.2 operating and display unit, Climatronic”, page 189

7.1.1 Overview - operating and display unit, air conditioning system

Note

♦ Additional display and operating unit 1 -E857- with air conditioning system control unit -J301-
♦ A warning lamp in the instrument panel controls will indicate that the selected function is active.

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1 - Button for left seat heating

-E653-
❑ Depending on equip‐
ment
❑ Seat heating can be
set in 3 stages; current
setting is displayed via
LED
2 - A/C button
❑ If the A/C button is de‐
activated, the air condi‐
tioner compressor will
be set to almost zero
delivery.
3 - Heated rear window button
❑ Works only while en‐
gine is running and
switches off automati‐
cally after 10 minutes at
the latest
4 - Air recirculation button
❑ Pressing the air recir‐
culation button will pre‐
vent polluted air from
entering the interior.
5 - OFF button
❑ Switches off the heat‐
ing and ventilation
mode
6 - Button for right seat heat‐
ing -E654-
❑ Depending on equip‐
ment
❑ Seat heating can be set
in 3 stages; current set‐
ting is displayed via LED
7 - Rotary knob for setting air distribution
8 - Display for air distribution
9 - Rotary knob for setting blower speed
❑ Anticlockwise: reduces blower speed
❑ Clockwise: increases speed
10 - Display for blower speed
11 - Rotary knob for setting temperature
❑ Anticlockwise: lowers temperature
❑ Clockwise: increases temperature
12 - Temperature setting display

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7.1.2 Overview - operating and display unit, Climatronic

Note

♦ Additional display and operating unit 1 -E857- with Climatronic control unit -J255-
♦ A warning lamp in the instrument panel controls will indicate that the selected function is active.

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1 - Left temperature indicator

❑ Indicates temperature
setting on driver side.
2 - Button for left seat heating
-E653-
❑ Depending on equip‐
ment
❑ Seat heating can be
set in 3 stages; current
setting is displayed via
LED
3 - Button to regulate wind‐
screen air distribution
4 - Button for centre air distri‐
bution
❑ Air distributed to upper
body via middle vents
5 - Button for bottom air distri‐
bution
❑ Air distribution to foot‐
well
6 - Air recirculation button
❑ Pressing the air recir‐
culation button will pre‐
vent polluted air from
entering the interior.
7 - Button for right seat heat‐
ing -E654-
❑ Depending on equip‐
ment
❑ Seat heating can be
set in 3 stages; current
setting is displayed via
LED
8 - Right temperature indicator
❑ Indicates temperature setting on front passenger side.
9 - A/C button
❑ Air conditioning system is operated with maximum cooling output
10 - A/C button
❑ If the A/C button is deactivated, the air conditioner compressor will be set to almost zero delivery.
11 - Rotary knob for setting right temperature
❑ Set temperature is indicated in display.
12 - SYNC button
❑ Synchronisation of climate zones to driver value
13 - Reduce blower speed
❑ Display only, no function
14 - Rotary knob for fan speed adjustment
❑ Turning the rotary knob enables individual adjustment of the fan speed
❑ If the fan speed is changed individually, the AUTO function is deactivated automatically.
15 - MENU button
❑ Displays the menu for setting e.g. recirculation mode etc.

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16 - AUTO function button

❑ In automatic mode, the Climatronic maintains the selected interior temperature automatically
17 - Increase blower speed
❑ Display only, no function
18 - OFF button
❑ Switches off the heating and ventilation mode
19 - Rotary knob for setting left temperature
❑ Set temperature is indicated in display.
20 - Heated rear window button
❑ Works only while engine is running and switches off automatically after 10 minutes at the latest
21 - Max. defrost function button
❑ Air drawn in from outside is channelled to windscreen, and, if activated, air recirculation mode is
automatically switched off
❑ To demist windscreen as quickly as possible, air is dried at temperatures above +1.5°C.
❑ Air conditioner compressor is switched on and blower is set to a high speed

7.2 Removing and installing operating and

display unit
Special tools and workshop equipment required
♦ Vehicle diagnostic tester

Note

If a new Climatronic control unit -J255- or air conditioning sys‐

tem control unit -J301- is installed, the function "Renew control
unit", the basic setting and an adaptation (“Compressor first
run”) must be carried out in the "Guided fault finding" or in the
"Guided functions".

Removing
– Remove trim for operating and display unit for front air condi‐
tioning system -E87- ⇒ General body repairs, interior; Rep.
gr. 68; Centre console; Removing and installing centre con‐
sole insert.

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– Pull out spreader rivets -1-.

– Detach operating and display unit for air conditioning system
at front -E87- -2- far enough for all of the electrical connec‐
tors to be disconnected.
Vehicles with Climatic

– Separate connectors -1-.

Vehicles with Climatronic
– Separate connectors -1-.
– Disconnect electrical connector -2-.
– Remove operating and display unit for air conditioning sys‐
tem at front -E87- -3-.
Installing
Install in reverse order of removal, observing the following:
Procedure for when renewing the operating and display unit for
air conditioning system at front -E87-
– If a new Climatronic control unit -J255- or air conditioning
system control unit -J301- is installed, the function "Renew

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control unit", the basic setting and an adaptation (“Compres‐

sor first run”) must be carried out in the "Guided fault finding"
or in the "Guided functions".
– Code using ⇒ Vehicle diagnostic tester.

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8 Other controlling and regulating

components
⇒ a8.1 nd installing sunlight penetration photosensorG107”,
page 194
⇒ p8.2 rinciples of air quality sensorG238”, page 195
⇒ a8.3 nd installing air quality sensorG238”, page 196
⇒ a8.4 nd installing ambient temperature sensorG17”, page 197
⇒ a8.5 nd installing humidity sender for air conditioning sys‐
temG260”, page 197
⇒ a8.6 nd installing left vent temperature senderG150”, page
198
⇒ a8.7 nd installing right vent temperature senderG151”, page
199
⇒ a8.8 nd installing footwell vent temperature senderG192”,
page 201

8.1 Removing and installing sunlight pene‐

tration photosensor -G107-

Note

Only on vehicles with Climatronic.

Special tools and workshop equipment required

♦ Removal wedge -3409-

Removing

– Release locking lugs by lifting sunlight penetration photosen‐

sor -G107- -1- with removal wedge -3409-.

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– Remove sunlight penetration photosensor -G107- -1- up‐

wards out of dash panel.
– Separate electrical connector.
Installing
Install in reverse order of removal, observing the following:
– Check locking lugs on sunlight penetration photosensor
-G107- -1- for damage; renew component if necessary
⇒ Electronic parts catalogue (ETKA).

8.2 Working principles of air quality sensor

-G238-
♦ The air quality sensor detects noxious substances in the
ambient air (primarily petrol and/or diesel fumes).
♦ The Climatronic control unit -J255- evaluates the signal from
the air quality sensor -G238-. The air conditioning system is
actuated depending on the degree and manner of ambient
air pollution.
♦ At an ambient temperature higher than approx. +2°C, air re‐
circulation is actuated even when there is a minimal increase
in noxious substances in the ambient air.
♦ At an ambient temperature between approx. +2°C and ap‐
prox. -5°C, air recirculation is not switched on until there is
a strong increase in noxious substances in the ambient air.
The air conditioner compressor is also switched on at the
same time.
♦ At an ambient temperature less than approx. -5°C, air recir‐
culation is not actuated until there is a strong increase in
noxious substances in the ambient air, but only for approx.
15 seconds (the air conditioner compressor is not actuated).
When the concentration decreases, the air conditioning sys‐
tem is switched back to fresh air mode.
♦ The automatic recirculation mode can be switched off at any
time. If the function is active, the air conditioner compressor
will be switched on even at an ambient temperature below
+2°C when automatic recirculation mode is required. Howev‐
er, even with this function, it is not possible to operate the air
conditioning compressor at temperatures below -5°C.
♦ On vehicles with automatic recirculation mode, the air condi‐
tioner compressor can also be switched on at temperatures
down to approx. –5 °C even if the air recirculation mode has
been activated manually.
♦ So that the air conditioning system does not operate con‐
tinually in air recirculation mode in areas with consistently
high levels of pollutants, the "intelligent" sensor adapts its
sensitivity to the prevailing environmental pollution.
♦ If the level of noxious substances in the ambient air remains
relatively high over a long period of time, the intelligent sen‐
sor starts to adapt to the change in environmental conditions
so that, generally, the demand for recirculated air lasts less
than 12 minutes in areas where the ambient air exhibits
a constant level of pollution. If a series of pollution peaks
occur, the air conditioning system may operate over a longer
period of time in air recirculation mode.
♦ A certain amount of time is required for repositioning of
the air conditioning system flaps. To prevent noxious sub‐
stances from entering the passenger compartment while the
flaps are closing (e.g. when driving through a cloud of diesel
smoke), a dust and pollen filter with an activated charcoal

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layer is installed. A saturated filter cannot perform this task

and should be renewed.
♦ To prevent frequent operation of the recirculation/fresh air
flap, the flap is not actuated immediately if there is a nominal
increase in harmful substances in the outside air. The sen‐
sor does not send a request to the Climatronic control unit
-J255-. The effect of the activated charcoal filter in the dust
and pollen filter is adequate for this.
♦ To prevent the air recirculation/fresh air flap from switching
too frequently, the sensor's request for automatic recircula‐
tion mode continues for at least 25 seconds (minimum wait‐
ing period) even if the air pollutants decrease to a level that
no longer requires air recirculation.
♦ If the air conditioner compressor is switched off ( A/C button
is deactivated), the maximum duration for automatic recircu‐
lation is limited to approx. 15 seconds by the Climatronic
control unit -J255- so that condensation does not develop on
the windows.
♦ To clear condensation from windows as quickly as possible,
the Climatronic control unit -J255- does not permit air recir‐
culation when the defrost function is activated.
♦ The air quality sensor -G238- requires approx. 30 seconds
to become operational once the ignition has been switched
on (warm-up period). During this time, the sensor can send
no request for automatic recirculation mode to the Climatron‐
ic control unit -J255-.
♦ The air quality sensor -G238- is a highly sensitive electron‐
ic component which direct contact with solvents, fuels and
certain chemical compositions could damage beyond repair.
For this reason, do not install sensors that may have come
into contact with these substances.

8.3 Removing and installing air quality sen‐

sor -G238-

Note

The air quality sensor -G238- is a highly sensitive electronic

component which could be destroyed by direct contact with
solvents, fuels and certain chemical compounds.

Removing

– Remove cover for fresh air intake ⇒ page 184 .

– Disconnect electrical connector -1-.

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– Release retaining tab -2- downwards. While doing this, push

air quality sensor -G238- -3- in direction of -arrow-.
Installing
Install in reverse order of removal.

8.4 Removing and installing ambient tem‐

perature sensor -G17-
Removing

– Remove front bumper cover ⇒ General body repairs, exte‐

rior; Rep. gr. 63; Front bumper; Removing and installing
bumper cover.
– Unclip ambient temperature sensor -G17- -1- from bracket
-2-.
– Disconnect electrical connector -3-.
Installing
Install in reverse order of removal, observing the following:
– Check retaining tabs on ambient temperature sensor -G17-
-1- for damage. Renew component if necessary ⇒ Electronic
parts catalogue (ETKA).

8.5 Removing and installing humidity send‐

er for air conditioning system -G260-
The humidity sender for air conditioning system -G260- and
the light and rain sensor -G397- form one component and are
installed depending on vehicle equipment.
– Removal and installation procedure is described in ⇒ Electri‐
cal system; Rep. gr. 92; Windscreen wiper system; Remov‐
ing and installing rain and light sensor.

Note

Diagnosis is carried out via onboard supply control unit -J519-.

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8.6 Removing and installing left vent tem‐

perature sender -G150-
⇒ a8.6.1 nd installing left vent temperature senderG150, LHD
vehicles”, page 198
⇒ a8.6.2 nd installing left vent temperature senderG150, RHD
vehicles”, page 198

8.6.1 Removing and installing left vent tem‐

perature sender -G150-, LHD vehicles
Special tools and workshop equipment required
♦ Vehicle diagnostic tester

Note

♦ Only on vehicles with Climatronic.

♦ On vehicles with Climatic, apertures in air duct system are
sealed with plugs.

Removing

– Remove dash panel insert -KX2- ⇒ Electrical system; Rep.

gr. 90; Dash panel insert; Removing and installing dash pan‐
el insert -KX2-.
– Disconnect electrical connector -2-.
– Turn left vent temperature sender -G150- -1- 90° in direction
of -arrow-. While doing this, remove it from air duct.
Installing
Install in reverse order of removal, observing the following:
– Check seal -3- for damage; renew seal if necessary ⇒ Elec‐
tronic parts catalogue (ETKA).
– Read event memory and erase any entries displayed using
⇒ Vehicle diagnostic tester.
Specified torques
♦ Dash panel insert; Assembly overview - dash panel insert
⇒ Electrical system; Rep. gr. 90; Dash panel insert; Assem‐
bly overview - dash panel insert

8.6.2 Removing and installing left vent tem‐

perature sender -G150-, RHD vehicles
Special tools and workshop equipment required

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♦ Vehicle diagnostic tester

Note

♦ Only on vehicles with Climatronic.

♦ On vehicles with Climatic, apertures in air duct system are
sealed with plugs.

Removing

– Remove dash panel end cover ⇒ General body repairs, inte‐

rior; Rep. gr. 70; Dash panel: Removing and installing dash
panel end cover.
– Disconnect electrical connector -2-.
– Turn left vent temperature sender -G150- -1- 90° in direction
of -arrow-. While doing this, remove it from air duct.
Installing
Install in reverse order of removal, observing the following:
– Check seal -3- for damage; renew seal if necessary ⇒ Elec‐
tronic parts catalogue (ETKA).
– Read event memory and erase any entries displayed using
⇒ Vehicle diagnostic tester.

8.7 Removing and installing right vent tem‐

perature sender -G151-
⇒ a8.7.1 nd installing right vent temperature senderG151, LHD
vehicles”, page 199
⇒ a8.7.2 nd installing right vent temperature senderG151, RHD
vehicles”, page 200

8.7.1 Removing and installing right vent tem‐

perature sender -G151-, LHD vehicles
Special tools and workshop equipment required
♦ Vehicle diagnostic tester

Note

♦ Only on vehicles with Climatronic.

♦ On vehicles with Climatic, apertures in air duct system are
sealed with plugs.

8. Other controlling and regulating components 199

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Heating, air conditioner - Edition 03.2021

Removing

– Remove dash panel end cover ⇒ General body repairs, inte‐

rior; Rep. gr. 70; Dash panel: Removing and installing dash
panel end cover.
– Disconnect electrical connector -2-.
– Turn right vent temperature sender -G151- -1- by 90° in
direction of -arrow-. While doing this, remove it from air duct.
Installing
Install in reverse order of removal, observing the following:
– Check seal -3- for damage; renew seal if necessary ⇒ Elec‐
tronic parts catalogue (ETKA).
– Read event memory and erase any entries displayed using
⇒ Vehicle diagnostic tester.

8.7.2 Removing and installing right vent tem‐

perature sender -G151-, RHD vehicles
Special tools and workshop equipment required
♦ Vehicle diagnostic tester

Note

♦ Only on vehicles with Climatronic.

♦ On vehicles with Climatic, apertures in air duct system are
sealed with plugs.

Removing

– Remove dash panel insert -KX2- ⇒ Electrical system; Rep.

gr. 90; Dash panel insert; Removing and installing dash pan‐
el insert -KX2-.

200 Rep. gr.87 - Air conditioning system

 T-Roc 2018 ➤
Heating, air conditioner - Edition 03.2021

– Disconnect electrical connector -2-.

– Turn right vent temperature sender -G151- -1- by 90° in
direction of -arrow-. While doing this, remove it from air duct.
Installing
Install in reverse order of removal, observing the following:
– Check seal -3- for damage; renew seal if necessary ⇒ Elec‐
tronic parts catalogue (ETKA).
– Read event memory and erase any entries displayed using
⇒ Vehicle diagnostic tester.
Specified torques
♦ Dash panel insert; Assembly overview - dash panel insert
⇒ Electrical system; Rep. gr. 90; Dash panel insert; Assem‐
bly overview - dash panel insert

8.8 Removing and installing footwell vent

temperature sender -G192-

Note

♦ Only on vehicles with Climatronic.

♦ On vehicles with Climatic, apertures in air duct system are
sealed with plugs.

Special tools and workshop equipment required

♦ Removal wedge -3409-

Removing

– Remove footwell vent on driver side ⇒ page 175 .

– Disconnect electrical connector -1-.

8. Other controlling and regulating components 201

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Heating, air conditioner - Edition 03.2021

Note

Levering with removal wedge -3409- causes both retaining tabs

-arrows- to be pushed together.

– Lever footwell vent temperature sender -G192- -2- out of

evaporator housing using removal wedge -3409-.
Installing
Install in reverse order of removal, observing the following:
– Check locking lugs -arrows- for damage; renew component if
necessary ⇒ Electronic parts catalogue (ETKA).

202 Rep. gr.87 - Air conditioning system