87-11

Manual A/C
Heating and A/C components in passenger compartment, servicing
CAUTION! Before beginning repairs on the electrical system: Obtain the anti-theft radio security code. Switch the ignition off. Disconnect the battery Ground (GND) strap. After reconnecting battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows according to Repair Manual and/or Owner's Manual. Note: System components identified with an * must only be serviced or replaced after discharging refrigerant system. Use Kent Moore ACR4 or equivalent.

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1 - Clip Lift out with screwdriver. 2 - Dust and pollen filter Vehicles 10.00 , replacing Page 87-41 .

3 - Air intake housing 4 - Defroster air outlet Removing and installing Repair Manual, Body Interior, Repair Group 70. 5 - Side window air outlet Removing Fig. 1

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6 - Heating and A/C controls With: A/C switch -E35Fresh air blower switch -E9Switch for fresh air blower and recirculated air E184Removing and installing Assembly 7 - Air outlets Center and side air outlets, removing (early prod.) Fig. 2 Center air outlet, removing (later prod.) removing Fig. 3 Side air outlets, removing (later prod.) 8 - Instrument panel cross member Always follow installation instructions for bolt 7 Fig. Fig. 4 Page 87-30 Page 87-27

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9 - Defroster duct Replacing: - Remove instrument panel Repair Manual, Body Interior, Repair Group 70 10 - Servo motor for fresh/recirculating air door -V154Removing and installing Page 87-26

11 - Ambient temperature switch -F38Switches off A/C clutch -N25- at low ambient temperatures Switching point: 5 C (41.5 F) Replacing: - Remove glove box Repair Manual, Body Interior, Repair Group 68 - Reach behind heating and A/C unit from below and pull out switch.

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12 - Gasket Replace if damaged Replacing: - Remove ambient temperature switch -F38- Remove dust and pollen filter - Set fresh air/recirculation flap in "fresh air" position - Reach down into air intake housing and pull out gasket CAUTION! Area around dust and pollen filter and air intake housing must be free from debris, leaves etc. before reaching into housing. Debris entering heating and A/C unit will block evaporator water drain and cause subsequent (water) damage. Note: If unable to access and remove gasket as described, proceed as follows: - Remove instrument panel Repair Manual, Body Interior, Repair Group 70

- Loosen cross member - 10 - . Always follow installation instructions for bolt 7 Fig.

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13 - Evaporator water drain guide Removing and installing 14 - Heating and A/C unit* Contains: Heater core Evaporator Removing/assembly 15 - Fresh air blower -V2Removing and installing Fig. 6 Page 87-164 . Page 87-25

16 - Fresh air blower series resistance with fuse -N24Replacing Fig. 5

17 - Center air outlet duct 18 - Control panel trim Unclip using screwdriver 19 - Center trim

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20 - Heating and A/C cables Installing 21 - Heater core* Always use new coolant after replacement 22 - Left rear duct 23 - Lower duct 24 - Upper duct 25 - Footwell air outlet 26 - Instrument panel cross member and left side member securing bolt Always follow installation instruction for bolt 7 Fig. Page 87-32

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27 - Relay Coolant Fan Control (FC) Relay -J26Control number 214 First Speed Coolant Fan Control (FC) relay -J279Vehicles 10.00: Control number 214 : Control number 373

Vehicles 10.00

Second Speed Coolant Fan Control (FC) Relay J280Vehicles 10.00: Control number 213 : Control number 370

Vehicles 10.00

Component locations Electrical Wiring Diagrams, Troubleshooting and Component Locations. 28 - A/C cut-off control module -J314Control number 384 Component location Electrical Wiring Diagrams, Troubleshooting and Component Locations.

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Fig. 1

Side window air outlet, removing

- Carefully pull out using needle-nose pliers.

Fig. 2

Center and side air outlets, removing (early prod.)

- With flashlight, locate the two retaining tabs inside housing, lift tabs with two small screwdrivers and carefully pull outlet from instrument panel.

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Fig. 3

Center air outlet, removing (later production)

- Insert fingers of both hands into lower row of grille -A- and push center vent -1down suing force until locking lugs -B- are released from their mounts. Note: Sit between front seats to apply the force required. If outer locking lugs -B- will not release, grip at this point and push center vent down while simultaneously pulling out slightly.

- Grip center vent -1- at point -C- which has been raised up slightly from instrument panel opening by action of pushing down. - Push center vent in direction -D- to release locking lugs and pull it outward slightly.

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- Disconnect electrical connectors -2- from center vent before removing in direction of -arrow-.

Fig. 4 Note:

Side air outlet, removing (later prod.)

Removal of both sides is identical. - Unclip and remove instrument panel side cover -1- using screwdriver.

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- Guide a flat screwdriver between vent and seal alternately into side openings -Aand -B-. - Pry vent -2- in direction -C- alternately through these openings.

- Disconnect electrical connector -3- when removing vent -2- in direction -C-. 7

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Fig. 5

Fresh air blower series resistance with fuse -N24- , replacing

- Remove glove box. Repair Manual, Body Interior, Repair Group 68. - Disconnect electrical connector and remove bolt -arrow-. - Seal surface between series resistance -1- and air duct before installing with AMV 176 000 05 (or equivalent).

Fig. 6

Fresh air blower -V2-, removing and installing

- Remove glove box Repair Manual, Body Interior, Repair Group 68. - Disconnect electrical connector -1-. - Remove three screws -arrows- and remove fresh air blower -2- downwards.

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Fig. 7

Instrument panel cross member and left side member securing bolt, installation note:

To avoid damage to instrument panel wiring harness -2-, ensure that the protective cap -1- is installed on the securing bolt for upper instrument panel cross member 4- at left side member -3-.

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Evaporator water drain guide, removing and installing Removing - Remove instrument panel

Repair Manual, Body Interior, Repair Group 70. - Release instrument panel cross member from bulkhead Page 87-13 . For the next step, an assistant must lift and hold the heating and A/Cunit. - Remove nuts -1- (2.5 Nm / 23 in lb) and remove guide -2- from bulkhead. Installing When installing, ensure water drain valve -3- sealing lip completely encloses the guide -2-. If necessary, lubricate to aid installation. Water drain valve, checking Page 87-40 , Fig. 1

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Servo motor for fresh/recirculated air door V154-, removing and installing Removing - Remove glove box.

Repair Manual, Body Interior, Repair Group 68

- From the front passenger side, use a mirror to look behind heating and A/C unit. - Remove screws (TORX T15) -arrows-. - Un-clip lever for fresh/recirculated air flap. - Pull off connector. - Pull out motor downwards. Installing Position fresh/recirculated air flap lever by hand dependent on position of servo motor.

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Heating and A/C controls, removing and installing

Removing - Carefully remove trim panel by depressing locating lugs -arrows-with a covered screwdriver. Do not damage instrument panel. - Remove instrument panel screws -arrows-. - Remove center trim panel Page 87-16 .

- Pull controls with cables attached from instrument panel. - Release cables on controls. - Disconnect electrical connector.

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Installing Notes: Cable sleeve ends are color coded. Check cables before installing and replace binding or damaged cables. All air flaps must audibly move onto end stops when turning controls. - Mount eyelet on end of cable -1- onto control - arrow 2-.

- Press footwell/defrost or central flap cable -1- into mount -2- until it engages. Footwell/defrost flap cable sleeve marking: White

Central flap cable sleeve marking: Black

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- Insert temperature flap cable -1- into mount opening -arrow B-. - Turn -arrow A- temperature flap cable -1- until it engages into air distributor housing -2-. Temperature flap cable sleeve marking: Red

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Heating and A/C controls, assembly

1 - Heating and A/C controls With: A/C switch -E35Fresh air blower switch -E9Switch for fresh air blower and recirculated air E184Removing and installing 2 - Illumination filter 3 - Trim panel 4 - Fresh air control lever light -L1612V, 1.2W Removing: - Un-clip trim panel - 7 - and rotary control - 5 -. - Remove bulb (if necessary, slide a short piece fuel hose over bulb and pull out). 5 - Rotary control For blower speed To remove: Use pliers with suitable plastic or rubber Page 87-27

protection on jaws

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6 - Rotary control For air distribution To remove: Use pliers with suitable plastic or rubber protection on jaws 7 - Trim panel 8 - Rotary control For interior temperature To remove: Use pliers with suitable plastic or rubber protection on jaws

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Heating and A/C cables, installing

Notes: Cable sleeve ends are color coded. Check cables before installing and replace binding or damaged cables. All air flaps must audibly move onto end stops when turning controls. 1 - Central flap cable From air distribution rotary control to central flap Cable sleeve marking: Black Removing and installing Page 87-34

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2 - Footwell/defrost flap cable From air distribution rotary control to footwell/defrost flap Cable sleeve marking: White Replacing: - Remove controls for heating and A/C system Page 87-27 - Remove driver side shelf Repair Manual, Body Interior, Repair Group 68 - Unclip cable at heating and A/C unit. - When installing, attach cable to heating and A/C unit first. 3 - Heating and A/C controls Removing Page 87-27

4 - Temperature flap cable From temperature rotary control to temperature flap Cable sleeve marking: Red Removing and installing Page 87-34

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Temperature and central flap cables, removing and installing

Notes: Cable sleeve ends are color coded. When installing secure cable to heating and A/C unit first. Check cables before installing and replace binding or damaged cables. Removing - Remove heating and A/C controls 27 - Remove instrument panel Page 87-

Repair Manual, Body Interior, Repair Group 70

- Remove footwell air outlet

Page 87-17 .

- Disconnect cable for central flap or temperature flap on heating and A/C unit.

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Installing Illustration shows right-hand drive version. 1- Central flap cable, sleeve marking: Black 2- Temperature flap cable, sleeve marking: Red 3- When attaching inner cable note: Do not press end of wire (arrow) against lever.

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Heating and A/C components in engine compartment, servicing

CAUTION! Before beginning repairs on the electrical system: Obtain the anti-theft radio security code. Switch the ignition off. Disconnect the battery Ground (GND) strap. After reconnecting battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows according to Repair Manual and/or Owner's Manual. Notes: System components identified with an * must only be serviced or replaced after discharging refrigerant system. Use Kent Moore ACR4 or equivalent. Illustration shows vehicle with engine code AHA.

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1 - Accumulator* 2 - Refrigerant hose* Between evaporator and accumulator 3 - Refrigerant hose* Between evaporator and condenser 4 - Low pressure service valve* 5 - High pressure service valve* 6 - Dust and pollen filter Vehicles 10.00 , replacing Page 87-41

Ambient temperature switch -F38- located below dust and pollen filter in lower air intake housing. 7 - Evaporator* In heating and A/C unit.

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8 - Evaporator water drain valve Checking Fig. 1.

9 - Pressure relief valve* Zexel compressor illustrated Checking, Zexel compressor Checking, Denso compressor 10 - Compressor* 11 - A/C clutch -N25Servicing: Zexel Servicing: Denso 12 - Condenser* Page 87-43 Page 87-49 Page 87-159 Page 87-160

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13 - A/C pressure switch -F129- Tightening torque 8 Nm (71 in lb) - Replace O-ring (note Part No.). Function: Switches coolant fan -V7- to next highest speed when pressure increases in refrigerant circuit. Switches off A/C clutch -N25- when refrigerant pressure is excessive (e.g.: insufficient engine cooling). Switches off A/C clutch -N25- when refrigerant pressure is too low (e.g.: refrigerant loss). Checking Replacing, Page 87-154 10.00 Page 87-156, Fig. 4 . Page 87-157, Fig. 5 .

Replacing, 10.00 14 - Refrigerant hose*

Between compressor and condensor 15 - Refrigerant hose* Between compressor and accumulator.

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Fig. 1

Evaporator water drain valve, checking

Check drain valve as follows: - Remove nuts -arrows- on right catalytic converter heat shield -1-. - Remove catalytic converter heat shield. Note: Catalytic converter heat shield from 10.00 differs from illustration.

Check valve as follows to ensure proper function: The valve must not be stuck together. The opening in the sealing cap of the valve must point downwards. The right catalytic converter heat shield plate must not be deformed or damaged in the area of the valve. - Remove valve -1- from bulkhead -2-. The valve sealing lip -1- must cover the water drain guide outlet completely Page 87-25 .

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Dust and pollen filter 10.00 and installing

Removing

, removing

- Lift front hood. Remove air intake plenum cover. - Unclip spring -1-. Remove dust and pollen filter upwards from housing. Installing - Installation in reverse order of removal.

Filter housing, assembly 1 - Filter housing 2 - Dust and pollen filter 3 - Nut (2Nm)

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Ventilation system, checking

Notes: Passenger compartment air is vented to the outside trough openings in the luggage compartment trim. In order for the ventilation system to work properly, these openings must not be blocked. Vent frames are located in both rear quarter panels, behind the bumper cover. Checking - Remove rear bumper cover

Repair Manual, Body Exterior, Repair Group 63 - Sealing lips -1- in vent frame -2- must move and close freely.

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A/C clutch -N25-, servicing (Zexel)

Special tools, workshop equipment, test and measuring appliances and auxiliary items required 3212 Two hole pin wrench VAG 1719 A/C Clutch set VAG 1719/1 Adapter VAG 1719/2 Adapter Not illustrated: Torque wrench (5 - 50 Nm) Locally available two-arm puller (e.g. Kukko 20-10) with fixtures for a depth of 100 mm. Feeler gauge

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Notes: Refrigerant circuit does not need to be opened to service A/C clutch. If unable to service A/C clutch on compressor installed in vehicle, discharge refrigerant Page 87-173 and remove compressor from compressor bracket. 1 - Hex head combination bolt 15 Nm (11 ft lb) Removing and installing 2 - Clutch plate Removing Fig. 2 6 Fig. 1

Checking clutch plate gap Fig. 3 - 45Shims

Used to adjust gap between clutch plate and pulley Gap: 0.3 - 0.6 mm (0.011 - 0.023 in) 6 - Circlip Always replace - Install correctly: thick side faces compressor Ensure correct seating in groove

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7 - Clutch pulley Removing Installing 8 - Circlip Always replace - Install correctly: Flat side faces compressor Ensure correct seating in groove 9 - Clutch coil Installing Note: A thermo-fuse is incorporated into the clutch coil. Current to the clutch coil is interrupted in the event of compressor overheating (e.g. a binding compressor). 10 - Felt ring Always replace 11 - Bolt 12 - Compressor Manufacturer: Zexel Fig. 5 Fig. Fig. 4 3

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Fig. 1

Combination bolt for clutch plate, removing and installing

- Remove bolt. Tightening torque: 15 Nm (11 ft lb) When removing and installing bolt, counter-hold with 2 hole pin wrench -A- (3212 or equivalent) with pin diameter: 4 mm.

Fig. 2

Clutch plate, removing

- Mount VAG 1719 and turn in center bolt to extract clutch plate. When removing, counter-hold with 2 hole pin wrench -A- (3212 or equivalent).

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Fig. 3

Clutch pulley, removing

- Remove felt ring. - Fit adapter VAG 1719/1 (or equivalent). - Fit locally available 2 arm puller -B- on shoulder -A- and extract pulley.

Fig. 4

Clutch pulley, installing

- Drive on belt pulley with plastic head hammer and VAG 1719/2 (or equivalent).

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Fig. 5

Clutch coil, installing

- Install coil on compressor. - Position pin -A- in recess.

Fig. 6

Clutch plate gap, checking

- Check gap with feeler gauge. Gap: 0.3 - 0.6 mm (0.011 - 0.023 in) Notes: Gap must be within tolerance around entire circumference. If gap is outside tolerance range, remove clutch plate and adjust gap by adding or removing shims Page 87-44 .

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A/C clutch -N25-, servicing (Denso)

Special tools, workshop equipment, test and measuring appliances and auxiliary items required Not illustrated: Torque wrench (5 - 50 Nm) Locally available two-arm puller (e.g. Kukko 20-10) with fixtures for a depth of 100 mm. Locally available strap wrench Depth gauge

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Notes: Refrigerant circuit does not need to be opened to service the A/C clutch. If unable to service A/C clutch on compressor installed in vehicle, discharge refrigerant Page 87-173 and remove compressor from compressor bracket. 1 - Hex head combination bolt 15 Nm (11 ft lb) Removing and installing 2 - Clutch plate Removing Fig. 2 Fig. 4 Fig. 1

Checking clutch plate gap 3 - Shims

Used to adjust gap between clutch plate and pulley Gap: 0.4 - 0.6 mm (0.015 - 0.023 in) 4 - Circlip Always replace - Install correctly: Thick side faces compressor. Ensure correct seating in groove.

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5 - Clutch pulley - Remove with locally available 2 or 3 arm puller. Ensure puller is seated correctly to prevent damage to pulley. 6 - Circlip Always replace - Install correctly: Flat side faces compressor. Ensure correct seating in groove. 7 - Clutch coil Installing Note: A thermo-fuse is incorporated into the clutch coil. Current to the clutch coil is interrupted in the event of compressor overheating (e.g. a binding compressor). 8 - Screw 9 - Compressor Manufacturer: Denso Fig. 3

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Fig. 1

Combination bolt for clutch plate, removing and installing

- Remove bolt. Tightening torque: 15 Nm (11 ft lb) When removing and installing bolt, counter-hold with locally available strap wrench -A-.

Fig. 2

Clutch plate, removing

- Pry off clutch plate carefully with two large screwdrivers. Use locally available 2 or 3 arm puller if plate is securely seated (difficult to remove).

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Fig. 3

Clutch coil, installing

- Install coil on compressor. - Locate locking pin -A- in recess -B-.

Fig. 4

Clutch plate gap, checking Gap: 0.4 - 0.6 mm (0.015 - 0.023 in)

Note: In order to check gap with compressor installed in vehicle: - Bring front end assembly (lock carrier) into service position. Repair Manual, Body Exterior, Repair Group 50. Determine "Dimension 1" - Using depth gauge -C-, measure gap between top of clutch plate and belt pulley at three equally spaced locations (measurement must not deviate).

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Determine "Dimension 2" - If compressor is installed in vehicle, disconnect compressor electrical connector A- from vehicle wiring harness. - Using a jumper wire, energize clutch coil by applying 12V to connector -A(battery terminal B+). If compressor is removed from vehicle, compressor -Bmust be grounded. - With clutch energized, measure gap between belt pulley and clutch plate with depth gauge -C-: The allowable gap (0.4 - 0.6 mm / 0.015 - 0.023 in) is the difference between "Dimension 1" and "Dimension 2". Notes: Gap must be within tolerance around entire circumference. If gap is outside the permitted tolerance range, remove clutch plate and adjust gap by adding or removing shims Page 87-50 .