Heating and ventilation system components in passenger compartment, servicing Стр.

1 из 19

80 - 2

Heating and ventilation system components in

passenger compartment, servicing
Fresh Air Blower V2 , removing and installing

Removing

Fresh Air Blower V2 is accessible from footwell on front

passengers side.

- Remove partition from heating and ventilation unit.

Partition

- Unscrew plastic screws - 2 - and remove partition - 1 -

.

- Disconnect harness connector - A - from Fresh Air

Blower V2 .

- Unscrew bolts - B - for Fresh Air Blower V2 (1 Nm).

- Release catch - 2 - and rotate Fresh Air Blower V2 in -

direction of arrow - .

- Remove Fresh Air Blower V2 from heating and

ventilation unit.
Heating and ventilation system components in passenger compartment, servicing Стр. 2 из 19

Installing

Install in reverse order.

Fresh Air Blower Series Resistor With Fuse N24 ,

removing and installing

Removing

Warning!

There is a danger of burning.

Fresh Air Blower Series Resistor With Fuse N24 may

be hot.

Let Fresh Air Blower Series Resistor With Fuse N24

cool off before removing.

First perform the following work:

- Remove partition from heating and ventilation unit 80-

2, Partition

- Disconnect harness connector - 1 - from Fresh Air

Blower Series Resistor With Fuse N24 .

- Press catch in - direction of arrow - and remove Fresh

Air Blower Series Resistor With Fuse N24 from heating
and ventilation unit.

Installing

Install in reverse order.

Dust and pollen filter, removing and installing

Removing
Heating and ventilation system components in passenger compartment, servicing Стр. 3 из 19

- Remove footwell trim - 1 - on front passengers side

Repair Manual, Body Interior, Repair Group 68,

- Remove partition - 2 - from heating and ventilation unit

80-2, Partition

- Release cover - 3 - in - direction of arrow - .

- Remove dust and pollen filter downward out of heating

and ventilation unit.

Installing

Install in reverse order.

Note:

„ Note installation position of dust and pollen filter

element.

Vents, removing

Center vents, removing

Heating and ventilation system components in passenger compartment, servicing Стр. 4 из 19

- Remove radio unit

Repair Manual, Electrical Equipment, Repair Group 91,

- Remove bolts - 1 - .

- Disconnect harness connectors on center vents.

- Remove center vents from instrument panel in direction

of arrow - A - .

Driver or front passengers side vent, removing

Note:

„ Vent removal on both sides is identical.

Removing

- Remove side instrument panel cover

Repair Manual, Body Interior, Repair Group 68,

.
Heating and ventilation system components in passenger compartment, servicing Стр. 5 из 19

- Reach sideways into instrument panel and unclip vent -

1 - in direction of - arrow A - from instrument panel.

Installing

Install in reverse order.

Rear footwell channel, removing and installing

Note:

„ Removal of rear channels on both sides is identical.

- Remove driver or front passenger seat

Repair Manual, Body Interior, Repair Group 72,

- Remove center console

Repair Manual, Body Interior, Repair Group 68,

- Lift floor carpet, unclip rear channel from floor and pull off
from heating and ventilation unit.

Installing

Install in reverse order.

Note:
Heating and ventilation system components in passenger compartment, servicing Стр. 6 из 19

„ When installing the rear channel, make sure that

rear channel is first slid onto heating and ventilation
unit - arrow - and then clipped in to floor.

Right footwell vent, removing and installing

- Remove glove compartment

Repair Manual, Body Interior, Repair Group 68,

- Unscrew securing bolt - 2 - and remove right footwell

vent - 1 - .

Installing

Install in reverse order.

Note:

„ In vehicles with glove compartment cooling system,

make sure cooling hose is correctly seated.

Left footwell vent, removing and installing

- Remove drivers side storage compartment

Heating and ventilation system components in passenger compartment, servicing Стр. 7 из 19

Repair Manual, Body Interior, Repair Group 68,

- Unscrew securing bolt - 2 - and remove left footwell vent

- 1 - .

Installing

Install in reverse order.

Fresh/Recirculating Air Door Motor V154 , removing and

installing

Special tools, testers and auxiliary items required

„ Vehicle Diagnostic, Testing and Information System

VAS5051/5052

Removing

Note:

„ Fresh/Recirculating Air Door Motor V154 can only

be removed without difficulty in "fresh air mode stop"
and installed only in this position. If motor remains
stopped in a different position and can no longer be
moved electrically into "fresh air mode stop" position,
it can only be pulled off and removed with difficulty.
Heating and ventilation system components in passenger compartment, servicing Стр. 8 из 19

„ Position of fresh/recirculating air door must not be

changed.

- Switch on ignition and wait until Fresh/Recirculating Air

Door Motor V154 has reached its end position "fresh air
mode" .

- Switch off ignition.

- Remove glove compartment

Repair Manual, Body Interior, Repair Group 68,

- Disengage retaining lugs - B - and - C - for bracket - A

- on intake housing and remove bracket - A - .

- Disconnect harness connector from positioning motor - B

- .

- Remove Fresh/Recirculating Air Door Motor V154 - B -

(in - direction of arrow - ) from intake housing.

Note:

„ Connection between motor toothed gears and back

pressure flap is designed so that the motor can only
Heating and ventilation system components in passenger compartment, servicing Стр. 9 из 19

be removed in the "fresh air mode" position without

difficulty (intake opening for recirculating air mode is
sealed via the fresh/recirculating air door - A - ).

„ If motor is found in a different position and can no

longer be moved, motor cannot be simply pulled off,
rather it must be loosened first with great force from
mounting points - C - , ensure that toothed gear - D
- is not damaged when doing this.

Installing

Note:

„ Motor as replacement part is delivered in the "fresh

air mode" position, only when toothed gear - A -
contacts stop - B - can it then be connected onto
toothed gear of fresh/recirculating air door. If a motor
was removed in a different position or activated in
the removed state, it cannot be installed.

„ If toothed gear - A - of motor does not stand at stop

- B - "fresh air mode" , proceed as follows:

- Connect motor to vehicle wiring harness.

- Switch ignition on.

- Wait until toothed gear - A - of motor reaches stop - B -

"fresh air mode" .

- Switch ignition off

Heating and ventilation system components in passenger compartment, servicing Стр. 10 из 19

- Reach into intake opening for recirculating air mode and

bring fresh/recirculating air door - A - into "fresh air mode"
position (intake opening for recirculating air mode is
closed).

- Pull toothed gear - D - slightly from shaft.

- Insert motor - B - into mounts - C - in opposite -

direction of arrow - and onto toothed gear - D - .

Note:

„ So that toothed gear - B - on motor - A - can be

slid on toothed gear of fresh/recirculating air door,
short tooth - C - of motor toothed gear must align
with short tooth interval - D - of toothed gear on
shaft of fresh air/recirculating air door.
Heating and ventilation system components in passenger compartment, servicing Стр. 11 из 19

- After assembling actuator motor, press toothed gear - 1 -

again on to shaft of fresh/recirculating air door.

- Install the wiring harness so that it cannot come in

contact with any moving parts (e.g. the actuating arm of the
control motor).

- Install bracket - A - , take special care when doing this,

that the bracket guide - D - is inserted correctly into intake
housing mount - E - and bracket is engaged in both
retaining lugs - B - and - C - .

Note:

„ Position of motor (and of flap) is no longer visible

with glove compartment installed, therefore it is
recommended to check its function before installing
glove compartment.

„ When both toothed gears are assembled in the

incorrect position, this can be detected by
fresh/recirculating air door not reaching its two end
positions or motor does not run cleanly and without
hitching.

- Install all removed components in reverse order.

Note:

„ After installing Fresh/Recirculating Air Door Motor

V154 , check recirculating air door function.

- Checking: Vehicle Diagnostic, Testing and Information

System VAS5051/5052

- Replacing: Initiate Basic Setting using Vehicle

Diagnostic, Testing and Information System
VAS5051/5052 87-3, Components, checking and
adjusting using Vehicle Diagnostic, Testing and Information
System VAS5051/5052 .
Heating and ventilation system components in passenger compartment, servicing Стр. 12 из 19

Heater core, removing and installing

Special tools, testers and auxiliary items required

„ Drip tray V.A.G 1306

„ Hose Clamps, Up to 40 mm. 3093

„ Compressed air gun, standard

Removing

- Remove facing wall in plenum chamber

Repair Manual, Body Exterior, Repair Group 50,

- Place Drip tray V.A.G 1306 under the engine.

Warning!

There is a danger of scalding.

Coolant temperature can be above 100 C with a

warm engine. Cooling system is under pressure.
Heating and ventilation system components in passenger compartment, servicing Стр. 13 из 19

If necessary, reduce pressure and temperature before

repairs.

- Clamp off coolant hoses - 1 - using Hose Clamps, Up to

40 mm. 3093 and disconnect coolant hoses to heater
core.

- Connect a section of hose - A - onto upper connection of

heater core.

- Hold a container - B - under the lower connection - C -

.

- Using a compressed air gun, carefully blow coolant out of

heater core into container - B - .

- Loosen (do not unscrew completely) bolt (6 mm socket

Heating and ventilation system components in passenger compartment, servicing Стр. 14 из 19

head) - 1 - out of connection flange between heater core

connections.

Note:

„ This allows the coolant pipes to move when

removing the heater core.

- Remove drivers side footwell trim

Repair Manual, Body Interior, Repair Group 68,

- Remove left footwell vent 80-2, Left footwell vent,

removing and installing

- Remove screws - 1 - and remove heater core trim.

- Cover floor carpet in area below heater core with leak-

proof foil and absorbent paper.

- Open hose clamps - A - and disconnect coolant pipes.

- Remove heater core from heating and ventilation unit.

Installing

Installation is the reverse of removal, noting the following:

Heating and ventilation system components in passenger compartment, servicing Стр. 15 из 19

- Check seals - A - and - B - installed on heater core,

only install a heater core with undamaged seals.

Note:

„ An incorrectly glued seal can roll up into heating and

ventilation unit when sliding in the heater core.

„ If seal is damaged or installed incorrectly, cold air

can flow past the heater core.

- With the heater core removed, check heating and

ventilation unit for soiling (via heater core opening - A - ).

- If necessary, remove dirt or coolant from heating and

ventilation unit, for example after removing leaky heater
core.

- Push heater core into the heating and ventilation unit.

Heating and ventilation system components in passenger compartment, servicing Стр. 16 из 19

- Coat sealing rings - 1 - with coolant before installing.

- Insert sealing rings - 1 - into connection on coolant

pipe.

Note:

„ If hose clamps are deformed, replace them.

- Connect coolant pipes.

- Hose clamps - A - must be able to be twisted slightly

when installing onto the coolant pipes.

- Tighten hose clamps - A - to 2.0 Nm.

- Check seating of both clamps - A - after tightening bolts,

clamps must enclose the flange on coolant pipe completely
and must not touch other components.
Heating and ventilation system components in passenger compartment, servicing Стр. 17 из 19

- Tighten bolt (6 mm socket head) - 1 - of connection

flange between heater core connections to 2.0 Nm.

- Check position of grommet - C - in bulkhead for proper

seating.

- Seal the flange for coolant pipes to heater core - A - and

for expansion valve (to evaporator, only in vehicles with
A/C system) - B - at pass-throughs of grommet - C - with
silicon adhesive sealant if necessary (to prevent water from
penetrating).

Note:

„ Sealing rings must always be replaced.

„ If hose clamps are deformed, replace them.

„ After replacing heater core, coolant must be

replaced completely

Repair Manual, 2.0 Liter 4-Cyl. 4V Turbo Engine

Mechanical, Fuel Injection Ignition, Engine Code(s): BPY,
Repair Group 19,

.
Heating and ventilation system components in passenger compartment, servicing Стр. 18 из 19

„ Check coolant circuit for leaks, pay particular

attention between coolant pipes and heater core.

Ventilation system, checking

Note:

„ The stale air escapes via ventilation openings in the

luggage compartment trim.

„ If the ventilation is to function properly the ventilation

openings must not be covered.

„ Ventilation frames are located in rear side panels,

behind bumper cover.

Checking

- Remove rear bumper cover

Repair Manual, Body Exterior, Repair Group 63,

- The sealing lips - 1 - in the ventilation frame on both

sides of vehicle must be free to move and close
automatically.

- Note installation position.

Intake air grille, removing and installing

Removing

- Remove plenum chamber cover and the lying beneath in

area of air intake grille
Heating and ventilation system components in passenger compartment, servicing Стр. 19 из 19

Repair Manual, Body Exterior, Repair Group 64,

- Unscrew mounting nuts - arrows - and remove intake air

grille upward.

Installing

Install in reverse order.

Note:

„ Make sure seal on air intake grille is seated

correctly.