Skoda Octavia Mk1 04 Heating Air Conditioning

SKODA OCTAVIA
MK1
Heating
Air conditioning
HEATING, AIR CONDITIONING............................................................................................ 4
HEATING.......................................................................................................................... 4
REPAIRING HEATING SYSTEM,........................................................................................................................ 4
Dash panel vent and air guides......................................................................................................... 4
Removing and installing the right dash panel vent...........................................................................5
Removing and installing the centre and left dash panel vent............................................................5
Check ventilation frame.................................................................................................................... 6
Remove and install air guide duct to defroster vents........................................................................6
Heating, heater control and air guides.............................................................................................. 7
Removing and installing heater control........................................................................................... 10
Remove and install Bowden cables from the heater control............................................................10
Connection diagram for the Bowden cables on the heater control..................................................10
Connection diagram for the Bowden cables on the heating............................................................11
Remove Bowden cables on the heater, install and adjust................................................................11
Replace bulb for heater control....................................................................................................... 13
Removing and installing fresh air blower -V2-.................................................................................14
Removing and installing series resistor for fresh air blower -N24 -..................................................15
Removing and installing control motor of fresh air flap and re-circulating air flap - V154-..............15
Check the function of the fresh air flap and re-circulating air flap control motor -V154- and the
switch -E159-................................................................................................................................... 16
Remove and install footwell vent.................................................................................................... 19
Removing and installing dust pollen filter.......................................................................................19
Remove and install coolant shut-off valve of heating system..........................................................20
2 way valve for coolant shut-off valve -N147-.................................................................................21
REMOVING AND INSTALLING HEATER UNIT...................................................................................................... 23
Removing and installing heat exchanger........................................................................................25
AIR CONDITIONER........................................................................................................... 27
SAFETY MEASURES WHEN WORKING ON VEHICLES WITH AIR CONDITIONING AND WHEN USING REFRIGERANT R 134A. . .27
DESCRIPTION AND COMPONENTS OF THE AIR CONDITIONING SYSTEM, CHECKS AS WELL AS REPAIR WORK, FILLING
CONTENTS.............................................................................................................................................. 28
Operation of the air conditioning system........................................................................................28
Structure of the refrigerant circuit................................................................................................... 28
Parts of the refrigerant circuit......................................................................................................... 30
Connection for the quick-coupling adapter on the refrigerant circuit..............................................32
Parts for securing the refrigerant circuit.......................................................................................... 33
Switch for refrigerant circuit............................................................................................................ 34
Contents.......................................................................................................................................... 35
SUMMARY OF COMPONENTS FOR AIR CONDITIONING AND HEATING - ENGINE COMPARTMENT (MANUAL CONTROL).........37
Air conditioner pressure switch -F129-............................................................................................ 40
High pressure sensor for air conditioning system -G65-..................................................................42
Removing and installing extractor and filler valves.........................................................................43
Remove and install the heat-protection insulation for the expansion valve....................................44
Removing and installing the refrigerant lines on the expansion valve............................................44
Removing and installing the expansion valve.................................................................................45
Check condensation water drain, remove and install valve.............................................................45
Inspecting the pressure relief valve on the compressor..................................................................46
Removing and installing the compressor from/on the holder..........................................................47
Removing and installing the refrigerant lines of the compressor....................................................48
Removing and installing the compressor......................................................................................... 48
Removing and installing fluid reservoir........................................................................................... 49
Removing and installing the condenser........................................................................................... 49
REPAIR MAGNETIC COUPLING -N25- (MANUAL CONTROL AND CLIMATRONIC).........................................................51
REPAIR AIR CONDITIONING SYSTEM AND HEATING - PASSENGER COMPARTMENT (MANUAL CONTROL)..........................56
2
REMOVING AND INSTALLING THE AIR CONDITIONING UNIT (MANUAL CONTROL)......................................................60
Removing and installing the heat exchanger of the air conditioning unit........................................63
DISASSEMBLING AND ASSEMBLING THE AIR CONDITIONING UNIT (MANUAL CONTROL).............................................65
DISASSEMBLING AND ASSEMBLING THE EVAPORATOR HOUSING (MANUAL CONTROL)...............................................68
CLIMATRONIC (AIR CONDITIONER WITH AUTOMATIC REGULATION) - SELF-DIAGNOSIS..............................................72
Operation........................................................................................................................................ 72
Technical data of self-diagnosis....................................................................................................... 72
Test preconditions for self-diagnosis................................................................................................ 73
Connect vehicle system tester V.A.G 1552 and select climatronic control unit...............................73
Overview of selectable functions..................................................................................................... 74
Interrogating fault memory............................................................................................................. 75
Fault table....................................................................................................................................... 75
Actuator diagnosis........................................................................................................................... 88
Initiating basic setting..................................................................................................................... 89
Erasing fault memory...................................................................................................................... 90
Ending output.................................................................................................................................. 91
Code climatronic control unit.......................................................................................................... 91
Reading measured value block....................................................................................................... 92
CLIMATRONIC - AIR CONDITIONER WITH AUTOMATIC REGULATION)......................................................................99
Function of the Control and display unit for air conditioner, Climatronic -E87-................................99
Climatronic - Passenger compartment.......................................................................................... 101
Removing and installing Control and display unit for air conditioner, Climatronic -E87- with
Climatronic control unit -J255-....................................................................................................... 108
Replacing the air conditioning control motors...............................................................................109
Removing and installing the control motor of air flow flap -V71-.................................................................110
Removing and installing the control motor of temperature flap -V68-.........................................................111
Removing and installing the control motor of central flap -V70-.................................................................112
Removing and installing the footwell flap and defroster flap control motor -V85-.......................................113
Removing and installing air conditioning unit................................................................................114
Middle vent temperature sender -G191-.......................................................................................114
Evaporator vent temperature sender -G263-................................................................................115
Disassembling and assembling the evaporator housing................................................................115
Climatronic - engine compartment................................................................................................ 119
3
Heating, Air conditioning
Heating
Repairing heating system,
Dash panel vent and air guides
Note
The ventilation of the passenger compartment occurs via the 2 ventilation frames (in the
luggage compartment on the right in the area of the bumper) → Chapter.
1- Dash panel
q with integrated air guide ducts for defroster vents and dash panel vents
q removing and installing → Body Work; Rep. Gr.70
2- Defroster vent side window
q clipped into place
3- Right dash panel vent
q removing and installing → Chapter
4- Centre right dash panel vent
4
5- Trim for dash panel insert
q removing and installing → Body Work; Rep. Gr.70
6- Left and centre left dash panel vent
7- Defroster vent windscreen
8- Air guide duct to the dash panel vents
q screwed to the heating, locked on the top
9- Air guide duct to the defroster vents
Removing and installing the right dash panel vent
– Remove glove compartment and right trim from dash panel → Body work; Rep. Gr.70
Press on fixing clamps -arrows- by hand

–
or with a screwdriver.
Removing and installing the centre and left dash panel vent
– Removing the trim for the dash panel insert → Body work; Rep. Gr.70.
5
– Loosen the catches -arrows-.
– Pull out the dash panel vent.
Note
Only the left and centre left dash panel

vent are the same.
Installation is carried out in the reverse

–
order.
Check ventilation frame
The sealing lips -B- in the ventilation frame

– -A- must operate freely and close
independently.
Note
This figure shows the ventilation frame with

t
removed rear bumper.
Two ventilation frames are installed for
t
compulsive ventilation (only right).
For perfect functioning of the ventilation for
the passenger compartment, the air guides
t
formed by the covering of the luggage
compartment must not be covered.
Remove and install air guide duct to defroster vents
– Removing the dash panel → Body Work; Rep. Gr.70
6
– Remove air guide duct -A- to the top.
Installation is carried out in the

–
reverse order.
Heating, heater control and air guides
Note
t The fresh air is sucked in via a dust and pollen filter; remove and install → Chapter
The illumination of the rotary switches is performed by way of a bulb at the start of
t
production. At a later stage it must be converted to LEDs, which can no longer be replaced.
7
1- Heater control
q Remove and install Bowden cables → Chapter
q Adjust Bowden cables → Chapter
q Connection diagram for the Bowden cables → Chapter
q Replace light bulb → Chapter
2- Switch for fresh air and re-circulating air flap - E159-
q Inspect proper operation → Chapter
Note
t The switch is firmly attached to the heater control.
t During the “defrosting operation” no re-circulating air operation is possible (approx. 15°
before the rotary switch for air distribution reaches the final setting “air guide to front
8
windscreen”, the re-circulating air operation is switched off).
3- Footwell vent front passenger side
4- Rear duct
5- Connecting piece to rear duct
6- Left cover for footwell vent
7- Footwell vent
8- Heater unit
q Remove Bowden cables on the heater, install and adjust → Chapter
q Connection diagram for the Bowden cables → Chapter
9- Heat exchanger
only for vehicles with mapped cooling on the basis of higher temperatures in an all-metal
q
version
10 - Air guide duct to the defroster vents
11 - Fresh air flap and re-circulating air flap control motor -V154-
q Inspect proper operation → Chapter
12 - Fresh air blower series resistor - N24-
13 - Fresh air blower -V2-
Removing and installing heater control
– Removing the centre console → Body Work; Rep. Gr.68
9
Remove trim for the dash panel centre
–
part -A-.
– Remove screws -B-.
– Disconnect plug connections.
Take out heater control -C- towards the

–
bottom.

–
order.
Remove and install Bowden cables from the heater control
– Remove the heater control.
– Unclip Bowden cable support bearing -A-.

– Detach Bowden cable.
– Installation is carried out in the reverse order.
Note
Check Bowden cables before installation,

t replace damaged Bowden cables or Bowden
cables showing a resistance.
Insert the wire cable -B- on the correct side
t
(bottom coil).
Connection diagram for the Bowden cables on the heater control
10
– Bowden cable -A- to footwell/defroster flap.
Colour: green
– Bowden cable -B- to the central flap.
Colour: yellow
– Bowden cable -C- to the temperature flap.
Colour: beige
Connection diagram for the Bowden cables on the heating
– Bowden cable -A- to footwell/defroster flap.

Colour: green
– Bowden cable -B- to the central flap.
Colour: yellow
– Bowden cable -C- to the temperature flap.
Colour: beige
Remove Bowden cables on the heater, install and adjust
Remove Bowden cables
– Remove footwell vent → Chapter
11
– Lever off anchoring clip -A-.
Carefully remove Bowden cable from the

–
lever arm -B-.
Note
Check Bowden cables before installation,

t replace damaged Bowden cables or
Bowden cables showing a resistance.
After installing the Bowden cable, turn

t the rotary switch between the end stops
(must reach both end stops).
Install and adjust Bowden cable to

temperature flap
Turn rotary switch for temperature flap up

to the stop in position “cold”.
Insert Bowden cable at lever to

–
temperature flap -B-.
Slightly press lever for temperature flap

–
-B- in -direction of arrow-.
Fix Bowden cable cover with anchoring

–
clip -A-.
Turn rotary switch for temperature flap

–
between the end stops (must reach both
end stops).
Install and adjust Bowden cable to central

flap
Turn rotary switch for air distribution up

–
to the stop in position “air distribution to
front windscreen”.
12
Insert Bowden cable at lever to central
–
flap -C-.
Slightly press lever for central flap -C- in

–
-direction of arrow-.

–
clip -A-.
Turn rotary switch for air distribution

–
end stops).
Install and adjust Bowden cable to

footwell/defroster flap

–
Insert Bowden cable at lever for

–
footwell/defroster flap -B-.
Slightly press lever for footwell/defroster

–
flap -B- in -direction of arrow-.

–
clip -A-.
Turn rotary switch for air distribution

–
end stops).
Replace bulb for heater control
Note
In order to avoid damage to the rotary knob, i.e use a thick cloth between the rotary knob and the jaws of
t
the pliers or use pliers with plastic or rubber jaws.
The illumination of the rotary switches is performed by way of a bulb at the start of production. At a later
t
stage it must be converted to LEDs, which can no longer be replaced.
13
Detach rotary knob -A- with pliers from the
–
rotary switch for the fresh air blower.
Detach bulb from its fixture -B- e. g. using a
–
set of pointed pliers or a bulb extractor.
Removing and installing fresh air blower -V2-
– Remove series resistor - N24- → Chapter.
Pull fresh air blower -B- towards the

–
bottom out of the heating.
Remove the connector -A- from the fresh

–
air blower.
Seperate fresh air blower -V2- and base

plate
– Screw out screw -A-.

–
-B-.
Note
t After installing the fresh air blower, check

14
for correct positioning in the heating.
Removing and installing series resistor for fresh air blower -N24 -
– Remove screw clip for foam cover.
– Swing foam cover -C- to the side.

Remove the connector -A- from the series
–
resistor.
– Release screws -B- and remove resistor carrier.
Remove series resistor from the resistor carrier
– Bore out or break off attachments -A-.

– Press back -C- catches.
– Remove series resistor -B-.
– Installation is carried out in the reverse order.
Note
When installing, fix series resistor with sheet

metal screw -D- of 3.2x10 mm.
Removing and installing control motor of fresh air flap and re-circulating air flap - V154-
Removing
– Remove glove compartment → Body Work; Rep. Gr.70
– Position (if possible) fresh air and re-circulating air flap “re-circulating air”.
15
– Pull out connector -A-.
– Remove screw -B-.
Press control motor towards the bottom

– until the catch -D- is no longer in the slot
-E- and press control motor to the outside
in -direction of arrow-.
Install
Manually set fresh air and re-circulating

–
air flap “fresh air”.
– Connect plug -A-.
By operating the switch for fresh air and

re-circulating air flap and switching on
–
and off the ignition, position the lever -F-
at the control motor in the centre
position -direction of arrow-.
Incline the control motor approx. 45° to

–
the bottom and install.
Check the function of the fresh air flap and re-circulating air flap control motor -V154- and
the switch -E159-
Note
In order for the steam to quickly fade from the steamed-up windows, no re-circulating air
t operation is possible at “air distribution to front windscreen”. (Switch -E159- is
mechanically locked via the rotary switch).
Otherwise it could arise that the window panes steam up during the re-circulating air
t operation (the humidity of the air in the passenger compartment increases and then
condenses on the window panes).
Check the function of the switch -E159- and the fresh air flap and re-circulating air flap
control motor -V154-
– Switch on ignition.
– Position rotary switch -A- for the fresh air

16
blower -V2- on speed 3.
Turn rotary switch -B- for air distribution

–
in position “air distribution to the dash
panel vents”.
Do not operate switch -C- for fresh air

–
and re-circulating air flap -E159-.
The air is sucked in via the dust and pollen

filter (fresh-air operation, warning light in
the switch must not light up).
Operate switch -C- (re-circulating air

– operation, warning light in the switch
must light up).
The air is sucked out of the front passenger

footwell area (re-circulating air operation).
Turn rotary switch -B- for air distribution

–
up to the stop in position “air distribution
to front windscreen”.
The warning light in the switch -C- must go

out, the fresh air and re-circulating air flap
goes into position fresh air operation
(operation of the switch -C- via the rotary
switch -B-).
Note
If the function is OK however the window

t
panes steam up:
Check dust and pollen filter for

t contamination → Chapter and compulsive
ventilation → Chapter
If the function is N.O.K., check switch

t
-E159-.
Check the function of the switch -E159-
Remove glove compartment → Body

–
Work; Rep. Gr.70
17
Remove connector -A- from the fresh air
–
flap and re-circulating air flap control
motor -V154-.
Turn rotary switch for air distribution in

–
position “air distribution to the dash
panel vents”.
Do not operate switch -E159- (not

–
pressed in).
Fresh air operation, the warning light in the

switch must not light up.
Connect voltage tester -V.A.G1527B-

–
between the contacts -1- and -3- of the
plug connection -A-.
The warning light in the voltage tester

must light up.
– Operate switch -E159- (press).
Re-circulating air operation, the warning

light in the switch must light up.

must go out.
Connect voltage tester between the

– contacts -2- and -3- of the plug
connection -A-.

must light up.

–
The warning light in the switch as well as in

the voltage tester must go out.
Note
If no fault is found during this test:

however the vehicle window panes steam
up, check -fresh air- and re-circulating air
t
flap for smooth operation or replace fresh
air flap and re-circulating air flap control
motor -VI54-.
t If the function is N.O.K.:
18
Check wiring between -El59- and -VI54-
–
for interruption and short-circuit.
Check voltage supply and earth

–
connection to the switch -El59-.
– Replace heater control.
Remove and install footwell vent
– Removing the centre console → Body Work; Rep. Gr.68
– Remove left cover below the dash panel.
Remove left cover for footwell vent -E- (2

–
plastic spreader clips, 2-part).
– Remove support -D-.
Remove connecting piece -C- between

–
footwell vent and rear duct.
Press footwell vent -B- out of the catches

–
-A- towards the bottom and remove in
Removing and installing dust pollen filter
19
1- Surround
2- Filter insert
3- Plastic nut
4- Filter housing with seal
Removing
Remove right plenum chamber cover

–
→ Body Work; Rep. Gr.66.
Press catches of the filter housing in

–
direction of arrow -B- and take out filter
element with frame.
Install
The frame must grip into the first plate of

–
the filter element -arrow A-.
Remove and install coolant shut-off valve of heating system
Vehicles with mapped cooling
Removing
The coolant shut-off valve -arrow- is

located in the engine compartment in the
area of the heat exchanger flange.
– Remove intake hose.
Reduce pressure in the coolant circuit by

–
opening the cap on the coolant
expansion reservoir.
Disconnect coolant hoses before and

–
after the coolant shut-off valve with hose
clamps -MP 7-602-.
Detach vacuum hose from the coolant

–
shut-off valve.
Position collecting vessel under the shut-

–
off valve and detach coolant hoses from
the valve.
Install
20
order.
After installing, fill up with coolant

–
according to specification →
2 way valve for coolant shut-off valve -N147-
Inspection
Disconnect the connector from the valve

–
-arrow-.
Measure the resistence between the

–
contacts of the valve using a multimeter.
Specified value: 31...39 Ω
If the specified value is not reached:
– Replace valve.
If the specified value is reached:
Inspect wiring according to the current

– flow diagram and repair if necessary
→ Current flow diagrams and Fitting
locations.
If wiring is o.k.:
Vehicles without air conditioning system

and vehicles with air conditioning system
with manual control.
Check heater control → Current flow

– diagrams and Fitting locations,
→ Chapter.
Vehicles with Climatronic
Check climatronic control unit → Chapter;

–
replace if necessary → Chapter.
Removing
21
Disconnect the connector from the valve
–
-arrow-.
– Remove vacuum hoses from the valve.
– Unlock and take out valve.
Install

order.
Removing and installing heater unit
Removing
– Removing dust and pollen filter with housing → Chapter.
– Determine the code for radio sets fitted with anti-theft coding.
– Disconnect battery.
Reduce pressure in the coolant circuit by opening the cap on the coolant expansion
–
reservoir.
Disconnect both coolant hoses to heat

–
exchanger of the heater with hose
clamps (e. g. - V.A.G 3094-).
Note
Connect the coolant hoses the right way

round: - Coolant hose -A- Feed from the
t
cylinder head, coolant hose -B- Return
flow to the water pump.
Bleed the refrigerant circuit → Engine,

t
Mechanics; Rep. Gr.19.
22
Position the reservoir under the
connection for the hose -B- and via the
–
connection for the hose -A- carefully blow
the coolant out of the heat exchanger
(with compressed air).
Slightly raise the pre-type punched points

-A- of the heat protection matting and
–
remove the hexagon nuts with washer -B-
located behind them (tightening torque
15 Nm).
– Remove hexagon nut with washer -C-.
Note
A gasket must be present at the washers of

the hexagon nuts for sealing.
Removing the dash panel → Body

–
Work; Rep. Gr.70
– Remove right footwell vent → Chapter.
Removing passenger-side airbag unit

–
→ Electrical System; Rep. Gr.96.
All opened connectors and the air guides

–
of the heater unit must be covered to
prevent any swarf from penetrating.
23
Bore out the support for the dash panel
–
at the points marked (connection points)
with -A- using a 7 mm drill Ø.
Bend part -B- to the side at the

–
predetermined breaking point -C- in
Note
After installing the heater unit, bend the

part -B- back in its original position and
screw the molded part drawn with
interrupted lines to the bores -A- (e. g. with
screws M6x10).
Disconnect electrical connection between

–
vehicle and heater unit (plug connection
and bolted earth cable to -A- pillar.
Remove heater unit in -direction of the

–
arrow-.
Install
Installation is performed in the reverse

order, pay attention to the following points:
Note
Check all the gaskets at the heater unit

t for damage before installing, replace
damaged gaskets.
Before inserting the heater unit, check

t the gasket at the suction channel as it
must touch the body.
24
Replace gasket -A- at the heat exchanger
t and check for correct fitting at the
contact surface -C-.
At the connection to the heat exchanger,

t the flow direction of the coolant is
indicated (-arrow B-).
All the cable binders which must be

removed for removing the heater unit
t
must be fitted again at the same point
after the assembly.
Removing and installing heat exchanger
– Remove heater unit → Chapter.
Press back catch pegs -B- and pull the

–
heat exchanger -A- out of the heater unit.
Install

Note
If the heat exchanger does not lock when

installed in the heater flap box, it must
t
be fixed with 2 suitable screws -C- (e. g.
sheet metal screws 3.2x20 mm).
Pay attention to correct fitting of gasket

t
-D-, it must not be visible after installing.
25
Replace gasket -A- and check for correct
t
fitting at the contact surface -C-.

indicated (-arrow -B--).
26
Air conditioner
Safety measures when working on vehicles with air conditioning and when using refrigerant R
134a
The assemblies and the line system of the air conditioning system are filled with refrigerant R
134a.
Safety measures must be observed for refrigerant R 134a (additional directives may apply in
individual countries):
Refrigerant must not be released into the environment, it must be drained off from the
refrigerant circuit using an exhaust system or service position. The drained off refrigerant is
processed on site or is returned to the manufacturer for ecological disposal (different or
additional directives may apply in certain countries).
If during repairs on the vehicle it is necessary to drain the refrigerant circuit, these tasks must
be carried out in a specialist service centre which has suitably trained personnel and is fitted
out for working on the refrigerant circuit!
Reasons:
Only the service centres have suitable service positions and properly trained personnel where
the refrigerant can be drained off professionally.
The Commission Regulation (EC) No 307/2008 of 2.4.2008, stipulates the qualification

requirements of the employees who carry out the recovery of fluorinated greenhouse gases
from air conditioning systems for vehicles.
Only employees with a training certificate, as mentioned in the Article 3 of the given
regulation (as of the dates in the regulation), are recognised as skilled workers who can
pursue the activities mentioned in the preceding paragraph.
Alternative or additional regulations may be valid in certain countries.
Note
All the safety measures when working on vehicles with air conditioning system, when using
the refrigerant as well as to the below-mentioned chapters can be found in the Workshop
Manual “Air conditioning system with refrigerant R134a” → Air conditioning system with
refrigerant R134a; Rep. Gr.00 technical data.
t General notes on the air conditioning system
t General instructions for refrigerant circuit
t Legal texts and legal regulations
t Refrigerant circuit
27
t Working with the service position of the air conditioning systems
t Detecting leaks in the refrigerant circuit
t Removing contaminants from the refrigerant circuit
t Complaints
Check the pressure in the refrigerant circuit (with the service position of the air conditioning
t
systems)
t Replacing components of the refrigerant circuit
Description and components of the air conditioning system, checks as well as repair work,
filling contents
Note
Detailed description of the function of the air conditioning system, checks as well as repair
work can be found in the Workshop Manual “Air conditioning system with refrigerant R134a”
→ Air conditioning system with refrigerant R134a; Rep. Gr.00 technical data.
Operation of the air conditioning system
The temperature in the passenger compartment is influenced by radiant heat through the window and by the
contact heat emitted by metallic parts. In order to provide agreeable temperatures for the passengers on very
hot days, some of the ambient heat must be evacuated.
As it is a well known fact that heat spreads towards colder temperatures, an aggregate that generates lower
temperatures has been fitted to the vehicle, i.e. the evaporator. Liquid refrigerant is continuously evaporated
in this aggregate. The heat required for this operation is drawn from the air flowing through the evaporator.
The refrigerant gas together with the absorbed heat is pumped out of the evaporator by the compressor. The
compressor's compression work increases the heat content and the temperature of the refrigerant. It is now
considerably higher than the ambient air temperature.
The high-temperature refrigerant and its heat content flow to the condenser. There, because of the
temperature difference between the refrigerant and the ambient air, the refrigerant releases heat into the
ambient air via the condenser and liquifies.
The refrigerant is also a heat conveyor. As it will be re-used, it is again pumped to the evaporator.
Structure of the refrigerant circuit
Note
All air conditioning components marked * as well as all refrigerant hoses and refrigerant lines must be
repaired or replaced in service centres, as the refrigerant must first be drained off at a service position.
HP = High-pressure side
LP = Low-pressure side
28
1- Oil drain plug*
2- Magnetic coupling -N25-
3- Compressor*
4- Pressure relief valve*
5- Condenser*
6- Fluid container with desiccator*
7- Exhaust, filler and measurement valve*
Note
High-pressure side
8- Cap
9- Connection with valve*
10 - Air conditioner pressure switch -F129- or high pressure sensor -G65-
11 - Expansion valve*
12 - Evaporator*
13 - Cap
14 - Exhaust, filler and measurement valve*
q Low-pressure side
15 - Pre-cubic contents*
29
Parts of the refrigerant circuit
Compressor
The compressor is driven by the ribbed V-belt of
the vehicle engine.
A magnetic coupling -N25- fitted to the
compressor generates the shaft grip between the
belt pulley and compressor shaft when the air
conditioning system is on.
The compressor sucks refrigerant gas from the
evaporator, compresses it and transfers it to the
condenser.
Note
The compressor contains refrigerant oil, which

can be mixed with the -R 134a- refrigerant at all
temperatures.
Condenser
The condenser dissipates heat from the
compressed refrigerant gas into the ambient air.
During this process the refrigerant gas condenses
and liquifies.
Fluid reservoir
The fluid reservoir gathers the liquid drops and
conveys them to the expansion valve in a constant
flow. Humidity, that has penetrated into the
refrigerant circuit during assembly, is bound by a
dessicator integrated in the fluid reservoir.
30
Expansion valve
The expansion valve atomizes incoming
refrigerant and controls the flow in accordance
with the different pressures in such a way that,
depending on the heat transport, the vapour only
becomes gaseous at the outlet of the evaporator.
Evaporator
The liquid refrigerant evaporates in the
evaporator. The heat required for this operation is
drawn from the air flowing through the
evaporator fins. This cools down the evaporator.
The refrigerant evaporates and is sucked in with
the absorbed heat as gas by the compressor.
Tubes and hoses of the refrigerant circuit
The mixture of refrigerant oil and refrigerant -R
134a- corrodes certain metals (e.g. copper) and
alloys and dissolves certain hose materials.
Therefore only original spare parts may be used.
“O”-ring seals
These rings seal off the connection points
between the individual components of the
refrigerant circuit.
Only use “O”-rings that are resistant to
refrigerant -R 134a- and related refrigerant oils.
Original spare parts offer this guarantee.
“O”-ring seals:
t Only use once, replace.
t Pay attention to correct diameter -a- and -b-.
t Moisten with refrigerant oil before inserting.
Connection for the quick-coupling adapter on the refrigerant circuit
t Only use valves and connections that are resistant to refrigerant -R 134a- and related refrigerant oils.
Different connections (outside diameter) for high-pressure and low-pressure side guarantee that the
t
connections are not interchanged.
31
t After disconnecting the quick-coupling adapter tighten the caps to prevent any dirt from penetrating.
Connection to high-pressure valve
1- Base with inside thread

2- “O”-ring 10.8 mm; 1.8 mm
3- Valve with groove for “O”-ring and inside thread M8x1 for cap
4- “O”-ring 10.8 mm; 1.8 mm
5- Cap
Connection to low-pressure valve
1- Base with outside thread and groove for “O”-ring

2- “O”-ring 7.6 mm; 1.8 mm
3- Valve: Inside thread for cap M8x1
4- “O”-ring for cap: 7.6 mm; 1.8 mm
5- Cap
Parts for securing the refrigerant circuit
32
Pressure relief valve
The pressure relief valve is located on the
compressor and opens in the event of
overpressure. The refrigerant does not flow out
completely. A plastic washer glued to a valve
indicates if the valve was opened (it is pressed
off).
Opening pressure: 4 ± 0.4 MPa
Closing pressure: 3.25 MPa
Note
If the pressure relief valve was open, determine

the cause of the overpressure in the system and
adjust.
Coil for magnetic coupling -N25-

An overheating fuse is built into the solenoid
coil. The overheating fuse will cut out the
t solenoid coil as soon as (e.g. because of
compressor resistance) the magnetic coupling
starts overheating (approx. 180°C)
The solenoid coil also includes a protective
t diode (reduces voltage peaks that may occur
when disconnecting the magnetic coupling).
Switch for refrigerant circuit
Position A: Air conditioner pressure switch

-F129-
Switches off the magnetic coupling -N25- at an
t overpressure (3.2 MPa/32 bar overpressure) via
the radiator fan control unit -J293-.
Switches off the magnetic coupling -N25 - if
the pressure is too low (0.12 MPa/1.2 bar
t
overpressure) via the radiator fan control unit
-J293-, e.g. during loss of refrigerant.
Switches the radiator fan into the 2nd speed via
the radiator fan control unit at an overpressure
t
of 1.6 MPa (16 bar) (secures the optimal
working pressures of the refrigerant).
Position B: High pressure sensor -G65-
The high pressure sensor -G65- determines the
pressure in the refrigerant circuit and transmits
the determined values to the engine control unit.
This is performed via the radiator fan control unit
-J293- the required following steps:
33
Switches the radiator fan -V7- to the next speed
t in the event of a pressure rise in the refrigerant
circuit.
Switches off the magnetic coupling -N25- if the
t pressure is too high (for example at insufficient
engine cooling).
Switches off the magnetic coupling -N25- if the
t pressure is too low (for example loss of
refrigerant).
Radiator fan control unit -J293-

Via the control unit is switched:
t Magnetic coupling -N25-
t Radiator fan -V7- (1st and 2nd speed)
Control switch for coolant temperature too hot

-F14-
Switches off the magnetic coupling -N25- via the
radiator fan control unit at a coolant temperature
of 119°C and switches on again at a temperature
of 112°C (engine overheat protection)
34
Outside temperature switch -F38-
Switches off the magnetic coupling via the
radiator fan control unit at a temperature of 2°C
and switches on again at a temperature of 5°C
(evaporator icing protection).
Contents
Refrigerant circuit
750+50 g refrigerant R 134a
Note
When filling, always fill the refrigerant circuit up to the top tolerance limit (there will still be some
refrigerant in the filling hoses).
Refrigerant oil
For compressor firm Sanden or Zexel: 135+ 15 cm3 PAG oil (Order No. -G 052 154A2-).
Oil distribution
The oil, which before the first activation of the air conditioning system was located in the compressor's oil
pan, is distributed as follows in the refrigerant circuit:
Compressor approx. 50 %
Condensor approx. 10%
Suction hose approx. 10%
Pressure hose -
Evaporator approx. 20 %
Fluid reservoir approx. 10%
Summary of components for air conditioning and heating - engine compartment (manual
control)
Note
The parts marked with an * must only be repaired in specialist service centres which have
t
suitably trained personnel and are fitted out for working on the refrigerant circuit!
t Comply with the safety measures when working on vehicles with air conditioning system
and when using refrigerant R 134a and observe the instructions for working on the
refrigerant circuit → Air conditioning system with refrigerant R134a; Rep. Gr.00 technical
35
data.
1- Extractor and filling valve*
q High-pressure side
q for exhausting, filling and measuring
q always screw on cap with a gasket
2- Air conditioner pressure switch -F129- or high pressure sensor -G65-
for vehicles as of model year 99 with 1.6 ltr./74kW engine, the -G65- is installed instead of
q
the -F129 -
q on all vehicles is installed -G65- as of model year 00
q -F129- (4-pin plug connection) function, remove and install, check → Chapter
q -G65- (3-pin plug connection) function → Chapter, remove and install, check → Chapter
3- Expansion valve*
36
q Remove and install heat-protection insulation → Chapter
q Removing and installing the refrigerant lines → Chapter
4- Dust and pollen filter
q below the water box cover
5- Outside temperature switch -F38-
switches off the magnetic coupling -N25- if the ambient temperature is too low (off at 2°C -
q
is valid for vehicles up to model year 99, off at 0°C - is valid for vehicles as of model year
00, on at 5°C)
q clipped into the plenum chamber at the top
6- Valve for condensation water drain
q check, remove and install → Chapter
7- Control switch for coolant temperature too hot -F14-
q in the coolant circuit
q -F14- switches off the magnetic coupling -N25- if the coolant temperature is too high (off at
119°C, on at 112°C)
q 1.6 Itr./74 kW up to model year 1998 and all other vehicles as of model year 1999
8- Radiator fan control unit -J293-
q screwed on under the battery tray
q the magnetic coupling -N25- of the compressor is also switched via this control unit
9- Pressure relief valve*
q O-Ring: 8.6 mm; 1.8 mm
q Tightening torque: 10 Nm
q check → Chapter
10 - Oil drain plug*
q O-Ring: 8.8 mm; 1.5 mm
q Tightening torque: 15 Nm
Note
t To drain off refrigerant oil:
t Remove compressor:
t Remove oil drain plug.

37
Turn the compressor with the clutch disk of the magnetic coupling to speed up the
t
evacuation of the oil.
11 - Compressor*
q Remove and install compressor holder → Engine, Mechanics; Rep. Gr.13
q Removing and installing the compressor on the holder → Chapter
q Removing and installing the refrigerant lines → Chapter
q Removing and installing the compressor → Chapter
Note
t Remove and install V-ribbed belt → Engine, Mechanics; Rep. Gr.13
Mark the direction of rotation before removing the V-ribbed belt, the reversal of the direction
t
of rotation can lead to the damage of the belt.
The stroke of piston of the compressor is variable, it adjusts itself depending upon the
t
determined refrigerating capacity.
If a new compressor was installed or new refrigerant oil was filled into the compressor (e. g.
after blowing through the refrigerant circuit and emptying the compressor via the oil drain
t
plug), the compressor must be turned by hand approx. 10 turns after installing (in order to
avoid damage to the compressor before operation).
12 - Air conditioning system magnetic coupling -N25-
q repairing → Chapter
13 - Condenser*
14 - Fluid container with desiccator*
q replace after each opening of the refrigerant circuit
15 - Extractor and filling valve*
q Low-pressure side
q for exhausting, filling and measuring
q always use cap with gasket ring
Air conditioner pressure switch -F129-
38
Note
If the vehicle has been fitted with air conditioner with automatic regulation (Climatronic), the
pressure switch for the air conditioning system -F129 - is checked by the self-diagnosis
→ Chapter
Operation
The low/high pressure switch (switch

between the contacts 1 and 2) switches
t the compressor off when there is
underpressure or overpressure in the
refrigerant circuit.
Switching pressures (in bar overpressure):
Opens at 1.2 bar (compressor off) and

–
closes at 2.4 bar (compressor on).
Opens at 32 bar (compressor off) and

–
closes at 24 bar (compressor on)
High pressure switch (switch between the

t contacts 3 and 4) switches the radiator
fan V7 into the stage 2.
Switching pressures (in bar overpressure):
Closes at 16 bar (2nd fan stage switched

–
on).
Opens at 12.5 bar (2nd fan stage

–
switched off).
Removing and installing
Separate 4-pin plug connection and

–
remove pressure switch -B- (5 Nm).
Note
The refrigerant circuit remains closed,

connection to valve.
Replace -O--ring seal -A- (10.8 mm; 1.8

–
mm).
Inspect proper operation:
Test conditions
l AC not operating
Fresh air blower switch -E9- on position

l
“1”
39
Switch for air conditioning system -E35-
l
pressed (on)
Remove plug -B- from switch -A- and

– bridge the contacts 1 and 2 at the plug
-B-.
Note
If the magnetic coupling clicks when

switching the ignition on and off, either
t the pressure in the refrigerant circuit is
too low (refrigerant circuit empty) or the
switch is defective.
Entrust the vehicle to a service centre for

t checking the pressures in the refrigerant
circuit.
Test conditions
l AC operating
Fresh air blower switch -E9- on position

l
“1”
Switch for air conditioning system -E35-

l
pressed (on)
Remove pressure switch and connect

–
again to the wiring loom.
Note
In this condition the magnetic coupling

must not click, otherwise the pressure
switch is defective -F129- (although the air
conditioning system is operating).
High pressure sensor for air conditioning system -G65-
40
Separate 3-pin plug connection and
–
remove pressure switch -B- (5 Nm).
Replace -O--ring seal -A- (10.8 mm; 1.8

–
mm).

Note
The refrigerant circuit remains closed,

connection to valve.
Inspect proper operation:
The high pressure sensor -G65- is an

information transmitter for the radiator fan
control unit -J293- and for the engine
control unit. It can only be checked via self-
diagnosis of the engine control unit
→ Engine; Rep. Gr.01 self-diagnosis.
Removing and installing extractor and filler valves
Removing and installing extractor and filler

valves - low-pressure side
Special tools and workshop equipment required
t Octagon wrench socket -T10364/1-
Drain the refrigerant circuit with the aid of the
–
A/C service station.
– Release cap -5- with gasket ring -4-.
Use wrench -T10364/1- to release the valve -3-
–
from the pipe.
Screw in new valve (8 Nm) with new O-ring
–
-2- 7.6 mm; 1.8 mm.
– Again screw on cap with gasket ring.
41
Removing and installing extractor and filling
valve - high-pressure side
t Octagon wrench socket -T10364/2-
Drain the refrigerant circuit with the aid of the
–
A/C service station.
– Release cap -5- with gasket ring -4-.
Use wrench -T10364/2- to release the valve -3-
–
from the pipe.
Screw in new valve (8 Nm) with new O-ring
–
-2- 10.8 mm; 1.8 mm.
– Again screw on cap with gasket ring.
Remove and install the heat-protection insulation for the expansion valve
Press together both shells -A- and -B- of the

– heat-protection insulation until the existing
catches hook into position.
Note
If the heat-protection insulation is missing or not

correctly installed, it may result in a power
reduction of the air conditiong system (change of
the set control characteristic curve through heat
irradiation).
Removing and installing the refrigerant lines on the expansion valve
(Must only be performed in a service centre!)
– Drain refrigerant circuit.
– Remove heat-protection insulation -A- → Chapter.
42
Remove screw -B- (8 Nm) and remove
–
refrigerant lines -C- and -D-.

Note
Replace both “O”-ring seals -E- (16.7 mm;

t
1.8 mm) and -F- (7.6 mm; 1.8 mm).
Shut off open refrigerant lines and

t
expansion valve connections.
t Fit refrigerant lines stress free.
Removing and installing the expansion valve
(Must only be performed in a service centre!)
– Removing refrigerant lines from the expansion valve → Chapter.
– Release screws -A- (8 Nm).
Remove expansion valve -B- and

–
threaded plate -E-.

Note
Replace both “O”-ring seals -C- (14.0

t mm; 1.8 mm) and -D- (10.8 mm; 1.8
mm).
Shut off open connections on the

t
evaporator.
If the heat-protection insulation is

missing or not correctly installed, it may
result in a power reduction of the air
t
conditiong system (change of the set
control characteristic curve through heat
irradiation).
Check condensation water drain, remove and install valve
Inspection
43
l Version -I.-:
The condensation water drain valve -A- should
– not stick and must close, its drain opening must
be located at the bottom.
l Version -II.-:
Note: The water drain openings must not be
– blocked by contaminations and must be located
at the bottom.
Open the flap -D- of the heat-protection
– matting (at the pre-type punched points) and
remove the condensation water drain valve.
Note
Remove condensation water drain valve -A-

towards the bottom out of the floor plate, when
t
installing pay attention to the proper position in
the bulkhead -B-.
The condensation water drain valve must not
t rest against the flap of the heat-protection
matting in the installed position -D-.
The condensation water drain valve must not
t stick with wax or underbody sealant (version
-I-.) or it must not be blocked (version -II-).
If problems exist due to humidity in the
passenger compartment, check the
t condensation water drain -C- for correct fitting
position in the condensation water drain valve
-A-.
Only use valve version -II- when replacing
t
valve -A-.
Inspecting the pressure relief valve on the compressor
Operation: protects the refrigerant circuit from

t
excessive pressure.
The pressure relief valve indicates if the valve
was opened. An affixed small plate -arrow- is
then pressed out of its position. In this case, the
t vehicle must be repaired in a specialist service
centre which has suitably trained personnel and
is fitted out for working on the refrigerant
circuit.
44
Removing and installing the compressor from/on the holder
Note
After removal, attach the compressor e. g. with wire to the compressor holder and do not
t
suspend on the refrigerant lines.
t Do not drain refrigerant circuit, do not remove refrigerant lines from the compressor.
Mark the direction of rotation before removing the V-ribbed belt, the reversal of the
t
direction of rotation can lead to the damage of the belt.
– Remove V-ribbed belt → Engine, Mechanics; Rep. Gr.13
Remove bottom cover and separation between engine compartment and right wheel house
–
→ Body Work; Rep. Gr.66
– Remove vane pump for power-assisted steering from bracket → Chassis; Rep. Gr.48
Note
Only required for engines with the vane pump arranged at the bottom (e. g. 1.6 / 74 kW,
1.8 / 92 kW).
Release screws -A- (tightening torque 45

–
Nm).

Note
Slide the threaded bushing -B-

t completely into the hole of the
compressor before installing it.
Pay attention to the correct fitting

t position of the belt pulley when installing
the V-ribbed belt.
Removing and installing the refrigerant lines of the compressor
(Must only be performed in service centres!)

45
– Release screws -A- (tightening torque 20 Nm).
Replace both “O”-ring seals -B- (10.8 mm; 1.8
–
mm) and -D- (14.3 mm; 2.4 mm).
Installation is performed in the reverse order, pay
attention to the following points:
Note
t The refrigerant line -C- leads to the condenser.

The refrigerant line -E- comes from the
t
expansion valve.
Pay attention to the correct fitting position of
t the tensioning pins -F- when installing the
refrigerant lines.
Shut off open refrigerant lines and compressor
t
connections.
Removing and installing the compressor
– Removing refrigerant lines from the compressor → Chapter.
– Remove compressor from the bracket → Chapter.
Installation is performed in the reverse order, pay attention to the following points:
Note
Before the first operation of the compressor:
– Turn the compressor by hand approx. 10 turns
– Start engine with the compressor switched off.
– Wait until the idling speed has stabilised.
Only then the compressor is switched on and must run at idling speed for at least 10
–
minutes.
Removing and installing fluid reservoir

46
– Release screw -E- (tightening torque 15 Nm).
– Remove refrigerant lines -D-.
– Remove hexagon nut -C-.
– Remove screw -A- (tightening torque 15 Nm).
Pull fluid reservoir -G- towards the bottom out
–
of the support.
Installation is performed in the reverse order, pay
attention to the following points:
Note
Replace “O”-ring seals -F- and -B- (10.8 mm;

t
1.8 mm).
Keep the fluid reservoir closed as long as
possible and remove the caps just before
installing (a dessicator bag is located in the
t
fluid reservoir which saturates with humidity
over a short time and therefore becomes
unusable if the reservoir is opened).
Removing and installing the condenser
Remove condensor with radiator from the lock carrier → Body Work; Rep. Gr.50; replace
–
lock carrier.
– Remove fluid reservoir → Chapter.
Remove screw -D- (tightening torque 15

–
Nm).
– Remove refrigerant lines -B-.
Release screws -C- (tightening torque 8

–
Nm).

Note
Replace “O”-ring seal -A- (10.8 mm; 1.8

t
mm).
t Pay attention to the correct fitting

position of the tensioning pin -E- when
47
installing the refrigerant lines.
Repair magnetic coupling -N25- (manual control and climatronic)
Note
Remove the compressor from the bracket for repairing the magnetic coupling (do not open
t
the refrigerant circuit).
t Mark the direction of rotation before removing the V-ribbed belt.
t Counterholder -MP 9-601 -
t Flywheel type belt pulley fitting tool -MP 9-400-
48
1- Nut
t self-locking, replace
t Tightening torque: 15 Nm
t Screwing off and on → Fig.
2- Clutch disc
t remove → Fig.
3- Spacers
t to set the gap between the clutch disk and belt pulley
t Clearance: 0.4 up to 0.8 mm
t Testing and adjusting gap → Fig.
4- Circlip
t replace
t Fit on correct side (the smooth side points to the compressor).
t pay attention to correct fit in slot
5- Belt pulley
t with pressed-in bearing
t do not replace bearing
t remove → Fig.
t installing → Fig.
t clean sealing surface before installing
6- Circlip
t replace
t Fit on correct side (the smooth side points to the compressor).
t pay attention to correct fit in slot
7- Solenoid coil
t installing → Fig.
Note
An overheating fuse is built into the solenoid coil. The overheating fuse will cut out the
t solenoid coil as soon as (e.g. because of compressor resistance) the magnetic coupling
starts overheating (approx. 180°C)
t The solenoid coil also includes a protective diode (reduces voltage peaks that may occur
49
when disconnecting the magnetic coupling).
8- Bracket with screw
9- Support
10 - Support
11 - Screw
12 - Compressor
13 - Slide bush
t with thread
Screwing hexagon nut off and on
Tightening torque 15 Nm.
Note
t self-locking, replace
-MP 9-601- use with 6 mm pin

t
diameter
Remove clutch disk
Note
Carefully lever off a tightly fitted clutch

disc with two screwdrivers -A-.
50
Pull off belt pulley
Insert two-arm extractor -A- at the

–
shoulder -B- and pull off belt pulley.
Note
Pay attention to the correct position of

the extractor at the shoulder -B- so that
t
the belt pulley is not damaged when
removing.
t Clean contact surface before installing.
Install solenoid coil
Position naps -C- in the recess of the

–
solenoid coil -A-.
Pay attention the correct position of the

–
wiring -B- to the solenoid coil -A-.
Install belt pulley
Position belt pulley flat and install with

–
-MP 9-400-.
Note
Screw the screw of -MP 9-400- only by

hand onto the compressor shaft.
51
Testing and adjusting gap
Measure the dimention “1” between the

–
belt pulley and the clutch disk (-B- and
-C-) with depth gauge -A- (at 3 points).
Apply a voltage of 12 V to the 2-pin plug

–
-D- (pay attention to the correct polarity
of the voltage).
Measure the dimention “2” between the

–
belt pulley and the clutch disk (-B- and
-C-) with depth gauge -A- (at 3 points).
Gap (difference between dimension “1”

–
and “2”): 0.4 up to 0.8 mm.
Note
The gap must be within the tolerance

t
over the entire circumference.
The gap can also be measured with the

t
compressor fitted.
If the gap is outside the allowed range,

t remove the clutch disk and adjust the
gap by removing or inserting spacers.
Repair air conditioning system and heating - passenger compartment (manual control)
Note
t
Comply with the safety measures when working on vehicles with air conditioning system
t
data.
t The fresh air is sucked in via a dust and pollen filter; remove and install → Chapter.
The ventilation of the passenger compartment occurs via 2 ventilation frames (in the
t
luggage compartment on the right in the area of the bumper) → Chapter.
52
1- Dash panel
t Removing and installing → Body Work; Rep. Gr.70
2- Outer dash panel vent
t clipped into place
3- “Right” dash panel vent
t removing and installing → Chapter
4- “Centre, right” dash panel vent
t screwed to the heating, locked on the top
6- Fresh air flap and re-circulating air flap control motor -V154-
t Inspect proper operation → Chapter

53
7- Series resistor for fresh air blower with overheating fuse -N24-
8- Fresh air blower -V2-
9- Air conditioning unit*
t Remove Bowden cables, install and adjust → Chapter
t Connection diagram for the Bowden cables → Chapter
t disassembling and assembling → Chapter
10 - Heater control
t Remove and install Bowden cables → Chapter
t Adjust Bowden cables → Chapter
t Replace light bulb → Chapter
11 - Switch for fresh air and re-circulating air flap -E159-
Note
During the “defrosting operation” no re-circulating air operation is possible (approx. 15°
t before the rotary switch for air distribution reaches the final setting “air guide to front
windscreen”, the re-circulating air operation is switched off).
12 - Switch for air conditioning system -E35-
Note
t Perform the functional test according to the current flow diagram.
13 - Footwell vent front passenger side
14 - Rear duct
15 - Connecting piece to rear duct
54
16 - Left cover for footwell vent
17 - Footwell vent
18 - Heat exchanger*
for vehicles with mapped cooling on the basis of higher temperatures in an all-metal
t
version
20 - “Left” and “centre, left” dash panel vent
21 - Defroster vent "windscreen"
Removing and installing the air conditioning unit (manual control)
Only carry out in specialist service centres which have suitably trained personnel and are
fitted out for working on the refrigerant circuit see → Air conditioning system with refrigerant
R134a; Rep. Gr.00 technical data.
Removing
– Drain the refrigerant circuit with the aid of the A/C service station.
– Removing dust and pollen filter → Chapter.
– Disconnect battery earth strap → Electrical System; Rep. Gr.27.
Reduce pressure in the coolant circuit by opening the cap on the coolant expansion
–
reservoir.
55
Disconnect both coolant hoses to the
–
heat exchanger of the air conditioning
unit with hose clamps.
Note
Connect the coolant hoses the right way

round: - Coolant hose -A- Feed from the
t
cylinder head, coolant hose -B- Return
flow to the water pump
Bleed the refrigerant circuit → Engine,

t
Mechanics; Rep. Gr.19.
Position the reservoir under the

connection for the hose -B- and via the
–
connection for the hose -A- carefully blow
the coolant out of the heat exchanger
(with compressed air).
– Remove expansion valve → Chapter
Shut off refrigerant lines and open

– connections -A- and -B- on the
evaporator.
Remove two hexagon nuts with washer

–
-C- (tightening torque 15 Nm).
Note
A gasket must be present at the washers of

the hexagon nuts for sealing.
56
Slightly raise the pre-type punched points
-A- of the heat protection matting and
–
remove the hexagon nuts with washer -B-
located behind them (tightening torque
15 Nm).
Removing the dash panel → Body

–
Work; Rep. Gr.70
– Remove footwell vent → Chapter
Remove front passenger airbag → Body

–
work; Rep. Gr.69
All opened connectors and the air guides

– of the air conditioning unit must be
covered to prevent any swarf from
penetrating.
Bore out the support for the dash panel

–
at the points marked (connection points)
with -A- using a 7 mm drill Ø.
Bend part -B- to the side at the

–
predetermined breaking point -C- in
Note
After installing the heater unit, bend the

part -B- back in its original position and
screw the molded part drawn with
interrupted lines to the bores -A- (e. g. with
screws M6x10).
Disconnect electrical connection between

– vehicle and air conditioning unit (plug
connection and bolted earth cable to -A-
pillar).
57
Remove air conditioning unit in -direction
–
of arrow-.
Install

Note
Check all the gaskets at the air

t conditioning unit for damage before
installing, replace damaged gaskets.
Before inserting the air conditioning unit,

t check the gasket at the suction channel
as it must touch the vehicle body.
Replace gasket -A- at the heat exchanger

t and check for correct fitting at the
contact surface -C-.

indicated (-arrow B-).
All the cable binders which must be

removed for removing the air
t
conditioning unit must be fitted again at
the same point after the assembly.
Replace both “O”-ring seals for the

t
refrigerant lines and the expansion valve.
t Fit refrigerant lines stress free.
Check the correct fitting position of the

t condensation water drain and the
condensation water drain valve.
58
Replace the gasket -A- and pay attention
t to the correct fitting position of the
evaporator connection flange.
Pay attention to the sequence when

t connecting the battery → Electrical
System; Rep. Gr.27.
Removing and installing the heat exchanger of the air conditioning unit
– Remove air conditioning unit → Chapter.
Press back catch pegs -B- and pull the

–
heat exchanger -A- out of the air
conditioning unit.

Note
If the heat exchanger does not lock when

installed in the heater flap box, it must
t
be fixed with 2 suitable screws -C- (e. g.
sheet metal screws 3.2x20 mm).
Pay attention to correct fitting of gasket

t
-D-, it must not be visible after installing.
59
Replace gasket -A- and check for correct
t
fitting at the contact surface -C-.

indicated (-arrow B-)
Disassembling and assembling the air conditioning unit (manual control)
60
1- Evaporator housing
t disassembling and assembling → Chapter
2- Tensioning strap
t pay attention to the correct routing → Fig.
3- Wiring loom air conditioning system
4- Cover
fixed with the tensioning strap -Pos. 2- and both screw clips -Pos. 5- on the evaporator
t
housing
5- Screw clip
6- Heater control
t Remove and install Bowden cables → Chapter
t Adjust Bowden cables → Chapter
61
t Replace light bulb → Chapter
7- Heater flap box
t do not disassemble
t Remove Bowden cables, install and adjust → Chapter
8- Heat exchanger
for vehicles with mapped cooling on the basis of higher temperatures in an all-metal
t
version
t screwed to the air conditioning unit, locked on the top
10 - Screw
11 - Retaining clip
t release with a screwdriver
12 - Gasket
t install on the evaporator housing → Fig.
Lay tensioning strap
Note
Pay attention to the correct routing of the

t tensioning strap -A- around the
evaporator housing.
The tensioning strap holds the cover on

t
the evaporator housing.
62
Install the gasket on the evaporator
housing
Note
The gasket -A- must be inserted all around

in the groove of the evaporator housing.
Disassembling and assembling the evaporator housing (manual control)
– Disassembling and assembling the air conditioning unit → Chapter
63
1- Top part evaporator housing
t Assembling the evaporator housing → Fig.
Check the gasket at the suction channel, replace if damaged (it seals the suction channel to
t
the passenger compartment)
2- Fresh air flap and re-circulating air flap control motor -V154-
3- Screw
4- Fresh/re-circulating air flap
5- Evaporator housing - bottom part
t Assembling the evaporator housing → Fig.
64
7- Fresh air blower series resistor - N24-
8- Evaporator
t Install seal on the refrigerant lines of the evaporator → Fig.
t Installing the seal on the evaporator → Fig.
9- Seal
10 - Seal
t replace
t Installing the seal on the evaporator housing → Fig.
t seals the connecting area of the refrigerant lines to the engine compartment
11 - “O”-ring seal
12 - “O”-ring seal
13 - Threaded plate
14 - Expansion valve
t Removing and installing the refrigerant lines → Chapter
t Remove and install heat-protection insulation → Chapter
15 - Screw
65
Assembling the evaporator housing
Both housing halves must be screwed

–
together at the provided screw points -B-
with suitable screws -A-.
Note
The provided screw points -B- are over the

entire circumference.
Install seal on the refrigerant lines of the

evaporator
The refrigerant lines -C- must be sealed

– with the seal -A- on both housing halves
-B-.
Installing the seal on the evaporator
The evaporator -A- must be sealed at the

–
top and on both sides with the gasket -B-
of the evaporator housing.
Note
No gasket must be present on the bottom

side of the evaporator (so that the
condensation water can drain off).

housing
– Replace the gasket -A- and pay attention

to the correct fitting of the evaporator
66
connection flange.
67
Climatronic (Air conditioner with automatic regulation) - Self-diagnosis
Note
Some of the components and functions of the climatronic are not checked by the self-diagnosis (for example
the temperature sensor blower V42). If in spite of a problem no fault has been recognized after interrogating
the fault memory, the further test must be carried out with reference to the problem.
Operation
The climatronic control unit receives information from the electrical and electronic
components (information transmitters), which are processed by the control unit in compliance
with the nominal values. The output signals of the control unit control the electrical
components (actuators).
The Climatronic control unit -J255- is located behind the control and display unit for air
conditioner, Climatronic -E87-. Both components form a unit that must not be disassembled.
In order to rapidly determine the cause of the fault in the event of the failure of a component
or a line interruption, the control unit is fitted with a fault memory that can be read with the
vehicle system tester -V.A.G1552-, or → Vehicle diagnosis, testing and information system VAS
5051.
If malfunctions occur in the monitored sensors or components, they are stored in the fault
memory with indication of the fault type.
If a fault of a component is stored, which has a lasting effect on the operation of the
Climatronic, the display of the control and display unit for air conditioner, Climatronic -E87-
flashes after switching on the ignition for approx. 15 seconds. The climatronic control unit can
maintain the operation, which has been canceled, in the emergency running mode for all
occuring faults.
Initiate the self-diagnosis at the start of fault finding and retrieve the stored information using
the vehicle system tester -V.A.G1552-, or → Vehicle diagnosis, testing and information system
VAS 5051.
The displayed fault information refers to a fault table including indications on the possible
causes as well as targeted repairs.
The vehicle system tester -V.A.G1551-, or → Vehicle diagnosis, testing and information system
VAS 5051 is used for the self-diagnosis. The following description only relates to the vehicle
system tester -V.A.G1552-.
Technical data of self-diagnosis
Memory: Permanent memory

Data output: Vehicle system test
01 Interrogate control unit version: yes
02 Interrogate fault memory: yes
03 Actuator diagnosis: yes
04 Basic setting: yes
05 Erase fault memory: yes
68
06 End output: yes
07 Coding control unit: yes
08 Read measured value block: yes
Test preconditions for self-diagnosis
l All fuses must be OK in compliance with the current flow diagram.

l Battery voltage at least 9 V.
l Check whether negative terminal of battery is properly connected.
Connect vehicle system tester V.A.G 1552 and select climatronic control unit
t Vehicle system tester -V.A.G 1552 -
t Diagnostic cable -V.A.G 1551/3 -
Connect vehicle system tester

– -V.A.G 1552- with diagnostic cable
-V.A.G 1551/3-.
Readout on display:
Note
Vehicle system test

HELP
If there is nothing on the display: → Operating Select function XX
instructions of vehicle system tester
Readout on display:
Vehicle system test
Enter 08 for the address word “heating/air conditioning HELP
– Enter address word XX
electronics” and confirm entry with the Q key.
The control unit identification appears in the display, 1J1907044 CLIMATRONIC

SXX
e.g.:
Coding 01000 WSC
69
t 1J1907044 = Part no. of the control unit
t Climatronic = System designation
t SXX = Software version
t Coding: 01000
t WSC = Workshop code XXXXX
If the code does not match the corresponding version

of the vehicle: → Chapter.
Note
Vehicle system test

If one of the adjacent error messages appears on the display, HELP
the possible fault causes can be printed via the HELP button. The control unit does not
respond!
(The ignition must be on!) Vehicle system test HELP
C cable does not connect to pos. term.!
Vehicle system test
Malfunctions occurred at the start of or during the program ->
t
(external sources of interference?). No signal from the control
unit!
Check diagnostic cables as well as voltage supply and
–
earth connection.
Vehicle system test
After removing the possible fault causes re-enter address Fault in communication build-
– up ->
word 08 “heating/air conditioning electronics” and confirm
entry with Q key.
The control unit identification number is

displayed. 1J1907044 CLIMATRONIC HELP
Coding 01000 WSC XXXXX
– Press → key.
Vehicle system test

Readout on display: HELP
The control unit does not
Note respond!
Vehicle system test
->
No signal from the control unit!
After pressing the HELP button an overview of the
Vehicle system test
possible functions is displayed: HELP
Select function XX
Overview of selectable functions
Page
01 Interrogate control unit version → Chapter
02 Interrogate fault memory → Chapter
03 Actuator diagnosis → Chapter
70
04 Basic setting → Chapter
05 Erase fault memory → Chapter
06 End output → Chapter
07 Coding control unit → Chapter
08 Read measured value block → Chapter
If the → key is pressed, the programme of the vehicle system tester -V.A.G 1552- returns to
the initial position.
Interrogating fault memory
Connect the vehicle system tester -V.A.G 1552- and select the address word 08 for the
– climatronic control unit. (Connect the vehicle system tester and select the climatronic
control unit → Chapter.)
Readout on display:
Vehicle system test
Enter 02 for the function “Interrogate fault memory” and HELP
– Select function XX
confirm entry with the Q key.
The number of stored faults or “No fault recognised!” appears in the

display.
If no fault is stored:
X faults detected!
– Press → key.
If one or several faults are stored:
The stored faults are displayed in sequence.
Subsequently the following readout appears in the

display: Vehicle system test
HELP
Search for displayed faults according to fault table Select function XX
–
and rectify → Chapter.
Fault table
Note
All the possible faults which can be detected by the Climatronic control unit -J255- and can
t
be displayed by -V.A.G 1552- are listed below according to the fault code.
t If faults only occur occasionally, these faults are displayed as “sporadic faults” (“SP”).
t The fault table may also display the fault type.
71
After repair always erase the fault memory again using vehicle system tester -V.A.G 1552 -
t
and interrogate again.
If in spite of a problem with the climatronic no fault is detected, the function “final control
diagnosis 03” → Chapter or the function “read measured value block 08” → Chapter must
be performed. If the display flashes, although no fault was detected, the function “coding
t
control unit 07” and the function “basic setting 04” must be initiated → Chapter in
sequence. If applicable problem-related fault finding without self-diagnosis must be
performed.
Readout on Possible cause of fault Rectifying fault

-V.A.G 1552-
00000 If after repair “No fault detected” is displayed, the self-diagnosis is completed.
no fault If nevertheless the display still flashes, the following functions must be selected
detected in sequence:
07 - Coding control unit → Chapter
04 - Initiate basic setting → Chapter
00281
Vehicle speed
sender -G68-
1)
Short-circuit or open circuit on wiring or Check speed signal in measured

–
plug connections for the speed signal of value block 001 → Chapter.
the engine control unit to the climatronic
control unit Check wiring and plug
– connections to the control unit
according to the current flow
diagram.
Speedometer sender -G22- defective (only – Check speedometer display.

if speedometer -G21- is also not
operational)
cannot be
This display only appears if a final control diagnosis was carried out before
tested at
interrogating the fault memory. This fault is erased in the fault memory of the
present
control unit after switching off the ignition. -G68- is defective, if the fault
reappears when driving.
00532
Supply
voltage
Signal too AC generator defective Check supply voltage (voltage at

high – terminal 15) with “read
measured value block 08”
→ Chapter.
– Inspect AC generator: → Current

flow diagrams and Fitting
72
locations
Signal too Wiring or plug connections to the Check supply voltage (voltage at
low climatronic control unit -J255 - defective – terminal 15) with “read
measured value block 08”
→ Chapter.
Repair wiring and plug

–
connections according to current
flow diagram.
Inspect AC generator: → Current

–
flow diagrams and Fitting
locations
1)
A fault is detected by the speedometer sender -G22- and not by the vehicle speed sender
-G68 -. The fault is only recognized if during the 5 driving cycles (start, drive more than 15
km/h, switch off) within 4 minutes after engine start, a speed signal cannot be measured.
Display Possible cause of fault Rectifying fault

-V.A.G 155
2-
00538
Reference
voltage
Signal too Short-circuit or open circuit on wiring or plug Check wiring and plug
great connections – connections to the climatronic
Signal too control unit -J255- according to
small the current flow diagram.
Check function of the air

– conditioning control motors by 03
“final control diagnosis”
→ Chapter.
Potentiometer for control motor of the Detach the plug connections of

temperature flap -G92- or potentiometer for the specified components in
–
control motor of the central flap -G112 - or sequence, erase fault memory
potentiometer for control motor of the air → Chapter and interrogate again
flow flap -G113- or potentiometer for footwell → Chapter.
and defroster flap control motor -G114-
defective
– If the fault “reference voltage” is
73
no longer detected, replace the
corresponding control motor
causing the fault once the
connector is plugged into the plug
housing.
Climatronic control unit -J255- defective If necessary replace climatronic

control unit -J255-, subsequently
– select the following functions in
sequence: 07 “coding control
unit” → Chapter. 04 initiate basic
setting → Chapter.
1)
00576
Terminal
15
Signal too Voltage regulator on AC generator defective Inspect AC generator → Current

high – flow diagrams and Fitting
locations
Wiring or plug connections to the climatronic Check wiring and plug

control unit -J255 - defective – connections to the climatronic
control unit according to the
current flow diagram.
Signal too Battery discharged Check battery → Electrical

–
low System; Rep. Gr.27
AC generator defective Inspect AC generator → Current

– flow diagrams and Fitting
locations
Wiring or plug connections to the climatronic Check wiring and plug

control unit -J255 - defective – connections to the climatronic
control unit according to the
1)
valid for vehicles as of 08.00
Readout on Possible cause of fault Rectifying fault

-V.A.G 1552-
00603
Footwell/defroster
flap control motor
74
-V85-1)
Short-circuit or open circuit on Performing actuator diagnosis

–
wiring or plug connections to the → Chapter.
footwell/defroster flap control
motor -V85-
Check -V85- with the function 08

–
“read measured value block”
→ Chapter.
Test wiring and plug connections

–
according to current flow
diagram.
-V85- defective – -V85- replace → Chapter.
Subsequently carry out the

– function 04 basic setting
→ Chapter.
006062)
2 way valve for
coolant shutoff
valve. -N147-
Short-circuit to earth Short-circuit or open circuit on Test wiring and plug connections
–
wiring or plug connections 2 way according to current flow
Open circuit/short- valve for coolant shut-off valve diagram.
circuit to positive -N147-
Climatronic control unit -J255- not – Code the control unit → Chapter.
at all or incorrectly coded
-N147- defective – -N147- replace → Chapter.
007052)
Radiator fan relay

stage 1
Short circuit to Short-circuit to positive on wiring Check wiring and plug

positive or plug connections to the radiator – connections to the radiator fan
fan control unit -J293- control unit -J293- according to
the current flow diagram.
-J293- defective -J293- replace. → Current flow

–
diagrams and Fitting locations
Open circuit/short- Open circuit or short-circuit to – Check wiring and plug

circuit to earth earth on wiring or plug connections connections to the radiator fan
to the radiator fan control unit control unit -J293- according to
75
-J293- the current flow diagram.
-J293- defective -J293- replace → Current flow

–
diagrams and Fitting locations
007062)
Radiator fan relay see fault code 00705

stage 2
1)
This fault is recognized in the basic setting 04, final control diagnosis 03 and in normal
operation. Both end stops must be reached.
2)
1) This fault is detected in the basic setting 04, final control diagnosis 03 and in normal
2)
Display -V.A.G 1552- Possible cause of fault Rectifying fault
00779
Outside
temperature sensor
-G17 -
Open circuit/short Short-circuit to positive or open circuit on Check -G17- with 08 “read
–
circuit to positive wiring or plug connections to the measured value block”
ambient temperature sensor -G17- → Chapter.
Test wiring and plug

–
connections according to
Short circuit to earth Short-circuit to earth on wiring or plug Check -G17- with the
–
connections to the ambient temperature function 08 “read measured
sensor -G17- value block” → Chapter.

–
-G17- defective -G17- replace. → Electrical

–
System; Rep. Gr.90
00787
Temperature sensor
- Fresh air intake
76
duct -G89-
–
circuit to positive wiring or plug connections to the fresh air measured value block”
intake duct temperature sensor -G89- → Chapter.

–
Short circuit to earth Short-circuit to earth on wiring or plug Check -G89- with 08 “read
–
connections to the fresh air intake duct measured value block”
temperature sensor -G89- → Chapter.

–
-G89- defective – -G89- replace → Chapter.

-V.A.G 1552-
00792 Check -F129- with 08 “read

–
Air conditioner measured value block” → Chapter.
pressure switch
-F129-1)
Short-circuit or open circuit on wiring Test wiring and plug connections

–
or plug connections to the air according to current flow diagram.
conditioner pressure switch -F129 -
Incorrect filling of the refrigerant Entrust the vehicle to a service

–
circuit centre.
Poor engine cooling Check engine cooling. → Engine,

–
Mechanics; Rep. Gr.19
-F129- defective – -F129- replace → Chapter.
cannot be This display only appears if a final control diagnosis was carried out before
tested at interrogating the fault memory and the pressure switch could not be checked
present (e.g. if the measured ambient temperature is below 12°C). This fault is
erased in the fault memory of the control unit after switching off the ignition.
00797
Sunlight
penetration
77
photosensor
-G107-
Open Short-circuit to positive or open circuit Check sunlight penetration
–
circuit/short on wiring or plug connections to the photosensor -G107- with 08 “read
circuit to sunlight penetration photosensor measured value block” → Chapter.
positive -G107-

–
according to current flow diagram.
Check -G107- with the function 08

– “read measured value block”
→ Chapter
Short circuit to Short-circuit to earth on wiring or plug Test wiring and plug connections
–
earth connections to the sunlight according to current flow diagram.
penetration photosensor -G107-
-G107- defective – -G107- replace → Fig.
1)
This fault cannot be detected at an ambient temperature below 12°C or in the event that
-G17- and -G89- fails. The switch is a 3-position-switch. The 0.2 MPa (2 bar)/3.2 MPa (32 bar)
switch part is checked, the 1.6 MPa (16 bar) switch part is not checked.

-V.A.G 1552-
00818
Evaporator
vent
temperature
sender
Open Short-circuit to positive or open Test wiring and plug connections

–
circuit/short circuit on wiring or plug connections according to current flow diagram.
circuit to to the vent temperature sender
positive evaporator -G263-
Short circuit to Short-circuit to earth on wiring or Test wiring and plug connections
–
earth plug connections to the vent according to current flow diagram.
temperature sender evaporator
-G263-
00819
High-pressure
78
sender -G65-
Short circuit to Short-circuit to positive terminal or Check wiring and plug connections
positive plug connections to the high pressure – to the high pressure sender -G65- in
sender -G65- accordance with the current flow
diagram
Open Short-circuit to earth or open circuit Check wiring and plug connections
circuit/short- on wiring or plug connections to the – to the high pressure sender -G65- in
circuit to earth high pressure sensor -G65- accordance with the current flow
diagram
Open circuit or short-circuit to Check wiring and plug connections

positive or earth on wiring or plug – to the high pressure sender -G65- in
connections between the -G65- and accordance with the current flow
the climatronic control unit -J255- diagram
Climatronic control unit -J255- Replace climatronic control unit

–
defective -J255- → Chapter.
Subsequently select the following

– functions in sequence: 07 “coding
control unit” → Chapter, 04 initiate
basic setting → Chapter.

-V.A.G 1552-
01044
Control unit
wrongly coded
Climatronic control unit -J255- – Code the control unit → Chapter.

not at all or incorrectly coded
01087
Basic setting
not performed
Basic setting was not or Perform function 04 “basic setting”

–
incorrectly performed → Chapter.
79
01206
Immobilization
time signal 1)
Dash panel insert defective Check dash panel insert and replace if
–
necessary.
Short-circuit or open circuit on Check immobilization time signal by 08

–
wiring or plug connections to “read measured value block” → Chapter
the climatronic control unit
-J255-
Test wiring and plug connections according

–
to current flow diagram.
Climatronic control unit -J255- Replace climatronic control unit -J255-

–
defective → Chapter.
Subsequently select the following

– functions in sequence: 07 “coding control
unit” → Chapter, 04 initiate basic setting
→ Chapter.
1)
The permanent immobilization time signal is received from the dash panel insert. The
climatronic control unit -J255- utilises the time measurement after the engine has been
switched off in order to replace the measured values of the ambient temperature sensor
-G17- and the fresh air intake duct temperature sensor -G89- with the temperatures used
during the last operation after the vehicle has stopped (ignition off) and a restart has occured.
The measured values are otherwise inaccurate through the radiant heat while the engine is in
idle. The immobilization time signal occurs only after the start.

-V.A.G 1552-
01271
Temperature flap
control motor
-V68-1)
Short-circuit or open circuit on Check -V68- with 08 “read

–
wiring or plug connections to the measured value block” → Chapter.
temperature flap control motor
-V68-

–
80
-V68- was installed, without the use Check final setting of the
of function 04 “basic setting” – temperature flap control motor
-V68- in the installed position
→ Chapter.
-V68- is blocked Perform function 03 “final control

–
diagnosis” → Chapter.
-V68- defective Replace -V68- → Chapter and

–
perform function 04 “Initiate basic
setting” → Chapter.
01272
Central flap
control motor
-V70-1)
Short-circuit or open circuit on Check -V70- with 08 “read

–
wiring or plug connections to the measured value block” → Chapter.
central flap control motor -V70-

–
-V70- was installed, without the use Check final setting of the central
–
of function 04 “basic setting” flap control motor -V70- in the
installed position → Chapter.
-V70- is blocked Perform function 03 “final control

–
diagnosis” → Chapter.

–
perform function 04 “Initiate basic
setting” → Chapter.
1)

-V.A.G 1552-
01273
Fresh air blower
-V2-
Short-circuit or open circuit on wiring or – Check with 08 “read measured

plug connections to the fresh air blower
81
-V2- value block” → Chapter.

–
diagram.
Fresh air blower control unit -J126- or Perform function 03 “final

–
fresh air blower -V2- defective control diagnosis” → Chapter.
-J126- → Chapter or -V2-

–
→ Chapter replace.
01274
Air flow flap
control motor
-V71-1)
Short-circuit or open circuit on wiring or Check -V71- with 08 “read

plug connections to the air flow flap – measured value block”
control motor -V71- → Chapter.

–
diagram.
-V71- is blocked Perform function 03 “final

–
control diagnosis” → Chapter.

–
perform function “basic setting”
→ Chapter.
1)

-V.A.G 1552-
012961)
Middle vent
temperature
sender -G191-
–
circuit to positive wiring or plug connections to the middle measured value block”
vent temperature sender -G191- → Chapter.
82
–
Short circuit to Short-circuit to earth on wiring or plug Check -G191- with 08 “read
–
earth connections to the middle vent measured value block”
temperature sender -G191- → Chapter.

–
-G191- defective -G191- replace → Chapter.
01297
Footwell vent
temperature
sender -G192-
–
circuit to positive wiring or plug connections to the footwell measured value block”
vent temperature sender -G192- → Chapter.

–
Short circuit to Short-circuit to earth on wiring or plug Check -G192- with 08 “read
–
earth connections to the footwell vent measured value block”
temperature sender -G192- → Chapter.

–
1)
Only applies for vehicles with mapped cooling.

-V.A.G 1552
-
65535
Control unit
defective
83
Wiring or plug Test wiring and plug connections according to
–
connections to the current flow diagram.
climatronic control unit
-J255- defective
Climatronic control unit Check Climatronic control unit -J255- with 08 “read
–
defective measured value block” → Chapter
Replace climatronic control unit -J255-.

– Subsequently select the following functions in
sequence: 07 “coding control unit” → Chapter, 04
“initiate basic setting” → Chapter.
Actuator diagnosis
Note
The final control diagnosis must be carried out when the engine is not running, the ignition is
switched on and the climatronic is switched off (push-button for “blower slower” → Chapter.
To receive accurate information, the final control diagnosis should be performed at an

t
ambient temperature of at least 12°C shown on the display of the control and display unit.
t During the final control diagnosis a control of the climatronic is not performed.
t This final control diagnosis may be repeated a number of times if necessary.
Readout on display:
Vehicle system test
Enter 03 for the function “final control diagnosis” and HELP
Readout
The on display:
following tests are performed:
t All sensors are checked.

84
After approx. 30 seconds the adjustment is completed.
Readout on display:
If “function unknown or cannot be carried out at the moment”

–
is shown in the display, the final control diagnosis is ended.
– Press → key.
Function is unknown or
Note cannot ->
be carried out at the
moment
Interrogate the fault memory page → Chapter after completing
the final control diagnosis.
Check readout of the display of the Control and display unit for
air conditioner, Climatronic -E87-
Complete read-out on the display
Note
All the segments of the display appear

during the duration of the final control
diagnosis 03. Otherwise the Climatronic
control unit -J255- must be replaced.
Initiating basic setting
Note
“interrogate fault memory” the function 07 “coding control unit” and subsequently the
function 04 “basic setting” must be performed.
– Check coding → Chapter and in this case correct.

85
Read-out on display (function selection):
Vehicle system test
Enter 04 for the function “basic setting” and confirm HELP
entry with the Q key.
Readout on display:
Enter 000 for the display group number and confirm entry with the Q
–
key.
Note Basic setting

Enter display
group number XXX
When extending all the control motors until they reach the final setting,
the climatronic control unit -J255- stores the values of the potentiometer
and takes over the basic settings of the control motors.
Readout on display:
Note
System in basic setting
0
XXX XXX
The motions of the four control motors can be monitored on the XXX XXX
display. The changes in the feedback values do not indicate a
possibly faulty control motor.
Readout on display:
Basic setting Q
– Confirm entry with key Q. Enter display group number 000
Readout on display:
Basic setting 0
Display 0 indicates that the basic setting is completed. Faults ->
detected by the system are stored in the fault memory. 0 0
0 0
– Press → key.
Readout on display:
Vehicle system test
Enter function 02 “interrogate fault memory” and HELP
The number of stored faults or “No fault recognised” appears in the

display.
– Press → key.
X faults
The stored faults are displayed in sequence. detected!
After the display of the last fault, the faults must be eliminated
–
according to the fault table → Chapter.
– Press → key.
Readout on display: Vehicle system test HELP

Select function XX
86
Erasing fault memory
Precondition:
l Fault memory was interrogated.
Erasing fault memory
Readout on display: Vehicle system test
Enter function 05 “erase fault memory” and confirm entry with HELP
the Q key.
Readout on display: Vehicle system test HELP
– Press → key. Fault memory erased! ->
Vehicle system test HELP
Readout on display: Select function XX
Ending output
Readout on display: Vehicle system test

Enter function 06 “end output” and confirm entry with the HELP
Q key.
Readout on display:
Vehicle system test
– Switch off ignition. HELP
Disconnect plug connections from vehicle system tester Enter address word XX
–
-V.A.G 1552-.
Code climatronic control unit
Note
t Each spare part climatronic control unit J255 -J255- must be coded after installing.
t After each coding the function 04 “basic setting” must be performed.
If the code displayed does not match the vehicle or the equipment, the climatronic control
t
unit must be coded.
The display of the Control and display unit for air conditioner, Climatronic -E87 - flashes for
t
15 seconds if the Climatronic control unit -J255- was not coded.
Readout on display:
Vehicle system test
Select function 07 “Code control unit” and confirm HELP
entry with the Q key.
Readout on display:
Code control unit Q
Enter code number in accordance with the table Enter code number XXXX (0–
– 32000)
and confirm with Q.
Code number Vehicles
87
01000 up to model year 2000 all countries
11000 as of model year 2001 all engines except 1.6ltr./75kW
11010 as of model year 2001 with 1.6 Itr./75 kW engine
On the display is shown the control unit coding and

1J1907044
the spare part number. SXX ->
Coding 01000 WSC
– Press → key. XXXXX
Readout on display:
Note
Vehicle system test
HELP
Select function XX
The climatronic control unit uses the entered and displayed
coding only after the ignition has been switched off once.
Reading measured value block
Note
During the function “read measured value block” the control of the climatronic is operative.
Connect the vehicle system tester -V.A.G 1552- and select the “address word” 08 for the
–
climatronic control unit → Chapter.
Readout on display:
Vehicle system test
Select function 08 “Read measured value block” and HELP
confirm the entry with the Q key.
Readout on display:
– Enter desired display group number. Enter display group number XXX
Readout on display:
– Confirm entry with key Q. Enter display group number 001
Readout on display: Reading measured value block 1

->
Note 1 2 3
4
The breakdown of the values in the individual display

t
fields page → Anchor.
t Interrogate the fault memory after ending the function
88
“Reading measured value block” → Chapter
t If the nominal values are reached in all display fields:
– Press → key.
Readout on display:
Note
Vehicle system test HELP
Select function XX
To switch to another display group proceed as
follows:
Display group V.A.G1552
higher Press ↑ key
lower Press ↓ key
skip Press the key C
Overview of the selectable display group numbers
Display Display Denomination

group field
number
001 1 The AC compressor, the air conditioner magnetic coupling -N25- (code No.
1 to 17 gives the reason for the deactivation)
code:0
-N25- is not deactivated.
Code: 1
-N25- is deactivated by the air conditioner pressure switch -F129- because
of excessive pressure in the refrigerant circuit
code: 2
-N25- is deactivated, because the fresh air blower -V2- or the fresh air
blower control unit -J126- is defective.
Code: 3
-N25- is deactivated by the air conditioner pressure switch -F129- because
of a too low pressure in the refrigerant circuit.
Code: 4
Is not displayed.
Code: 5
-N25- is deactivated for 4 seconds (no defect).
Code 5 is displayed for only 5 seconds. If still indicating, check speed
signal.
Code: 6
-N25- is deactivated, “ECON” mode (no defect).
Code: 7
-N25- is deactivated, because the output of the fresh air blower was
switched off (no defect) by the button “fan”.
Code: 8
89
-N25- is deactivated because the ambient temperature is below 3 °C
(against icing, no defect). It may be necessary to check the ambient
temperature sensor -G17- and the fresh air intake duct temperature
sensor -G89-.
Code: 9
Is not displayed.
Code: 10
-N25- is deactivated because the voltage in the vehicle voltage system is
below 9.5 V.
Code: 11
-N25- is deactivated because the coolant temperature is above 118°C
(protection of the engine against overheating).
Code: 12
-N25- is deactivated by the automatic gearbox control unit or the engine
control unit via the climatronic control unit -J255-.
Display group Display Denomination

number field
001 2 Engine speed signal detected

(code 0 - no)
(code 1 - yes)
Possibly:
on
off
3 Vehicle speed
(Value 0 up to 255 km/h)
4 Immobilization time
(code 0 up to 240 - time for “ignition off” in minutes)
(code 250 - battery was disconnected)
(code 255 - incorrect transmittance)
002 1 Temperature flap control motor -V68-
90
(code of the measured value: 0 up to 255)
(allowed deviation from the nominal value ±2)
2 Temperature flap control motor -V68-

(Nominal value: 0 up to 255)

flap stop: cold
(code 0 up to 149 -V68-defective)
(code 150 up to 250 -V68- is in order, on condition that the
function 04
basic setting was performed)
(code 251 up to 255 -V68- defective)

flap stop: warm
function 04
003 1 Central flap control motor -V70-

2 Central flap control motor -V70-


flap stop: air to the dash panel vents
function 04

flap stop: air to the footwell/defrost vents
function 04
Display Displa Denomination

group y field
number
004 1 Footwell/defroster flap control motor -V85 -
91
2 Footwell/defroster flap control motor -V85 -

3 Footwell/defroster flap control motor -V85-

flap stop: air to the footwell
(code 0 up to 149 - V85- defective)
(code 150 up to 250 - V85- is in order, on condition that the function 04
4 Footwell/defroster flap control motor -V85-

flap stop: air to the front windscreen
(code 5 up to 100 - V85- is in order, on condition that the function 04
005 1 Control motor of air flow flap -V71-

2 Air flow flap control motor -V71- (Nominal value: 0 up to 255)
3 Air flow flap control motor -V71-

flap stop: fresh air to the passenger compartment
(code 150 up to 250 -V71- is in order, on condition that the function 04
4 Air flow flap control motor -V71-

flap stop: re-circulating air to the passenger compartment
(code 5 up to 100 -V71- is in order, on condition that the function 04
006 1 The value in °C determined by the Climatronic control unit -J255- which is
shown in the display of the Control and display unit for air conditioner,
Climatronic -E87-. The value is calculated from the temperature
measurements of the fresh air intake duct temperature sensor -G89- and the
ambient temperature sensor -G17-. The value is lower than the measured
values indicated by the -G17- and -G89- if the vehicle is parked.
If the measured values of the -G17- and the -G89- indicate the actual value,
no fault is present. The values equalize during a long drive. -G17- or -G89- is
incorrect if the value is greatly abnormal.
2 Fresh air intake duct temperature sensor -G89-

(actual measured value in °C)
3 Ambient temperature sensor -G17-

92
4 Sunlight penetration photosensor -G107-

(measured value in %, from 0 up to 120)
Display group Display Denomination

number field
1)
007 1 Middle vent temperature sender -G191-
2 Footwell vent temperature sender -G192-

3 Dash panel temperature sensor -G56-

1)
4 Evaporator vent temperature sender -G263-
008 1 Fresh air blower -V2-

nominal value in V)
Off: 0 V
ein blower beam: 3.6 V
seven blower beams: 12 V
2 Fresh air blower -V2-

(actual value, measured in V)
permissible deviation from the nominal value ± 0.8 V
3 Terminal 15
(measured value: voltage in V)
4 Is not displayed.
4)
009 1 2 way valve for coolant shut-off valve -N147-
-(on/off) 2)
2 Is not displayed.
3 Is not displayed.
4 Is not displayed.
3)4)
010 1 Position of the switch for the temperature flap
(off/on)
2 Heating
(off/on)
3 Windscreen wipers
93
(off/on)
4 Coolant temperature gauge
0114) 1 Display illumination (depending on the position of the regulator for

switch and instrument lighting rheostat -E20-)
measured value in %, from 0 up to 100)
2 Demand for the engine speed increase

(off/on)
3 Is not displayed.
4 Is not displayed.
1)
Only for vehicles with mapped cooling.
2)
In the position "on" the valve -N147 - is closed.
3)
Do not pay attention to the values at present.
4)
Valid for vehicles as of MY 2001.
Note
Interrogate the fault memory after ending the function “Reading measured value block”
→ Chapter.
94
Climatronic - Air conditioner with automatic regulation)
Note
By pressing the “AUTO” button all deviating settings from automatic operation are
t
cancelled.
In “ECON” operation only the compressor is disconnected, the heating and ventilation
t
operation continues to be controlled electronically.
If automatic operation is cancelled before switching off the ignition; the selected functions
t will remain stored. Only the function “re-circulating air operation” is erased 20 minutes after
switching off the ignition.
t Deviations from automatic operation → operating instructions.
If after switching on the ignition all symbols in the display field of the Control and display
t unit for air conditioner, Climatronic -E87- flash, there is a system failure. In this case the
fault memory must first be interrogated → Chapter.
The components, i.e the Climatronic control unit -J255-, the Control and display unit for air
t conditioner, Climatronic -E87- and the dash panel temperature sensor -G56- with the
temperature sensor blower -V42- cannot be disassembled.
Function of the Control and display unit for air conditioner, Climatronic -E87-
95
1- Push-button for defrosting the windscreen
2- Display of blower stage
t In automatic mode -8- independently of the actual blower speed, a medium blower stage is displayed.
3- Display of ambient temperature
If the driving speed drops below 15 km/hr and if the refrigerant temperature exceeds 70°C, the displayed
t value will not change. Thus the actually measured ambient temperature is not displayed as it could be
negatively influenced at low speed by the stored heat of the engine.
4- Display for defrosting the windscreen

5- Display for re-circulating air operation
6- Display for air flow direction
t If the push-button -14- is pressed the display for the footwell air flow will light up or go out.
t If the push-button -15- is pressed the display for the upper body air flow will light up or go out.
7- Display of the selected interior temperature
Transition from Celsius to Fahrenheit degrees and back: Press and hold the push-button -11- and then
t
press the push-button -9-. The display will show the corresponding temperature unit.
8- Display
“AUTO”: for automatic mode
In automatic mode the Climatronic maintains the selected interior temperature for the vehicle fully
t automatically. To this end the temperature of the expelled air, the blower speed and the air distribution are
automatically changed.
96
“ECON”: for cooling system off
In “ECON” operation only the compressor is disconnected, the heating and ventilation operation
t
continues to be controlled automatically.
“OFF”: for complete system switched off
t switch off with push-button -17-
9- Push-button for “automatic mode”
10 - Dash panel temperature sensor -G56- and Temperature sensor blower -V42-
t Fitting location for RHD vehicles
11 - Push-button for “ECON”
In “ECON” operation only the compressor is disconnected, the heating and ventilation operation
t
continues to be controlled automatically.
12 - Push-button for “warmer”
13 - Push-button for “colder”
14 - Push-button for “footwell air flow”
15 - Push-button for “upper body air flow”
16 - Push-button for “blower faster”
17 - Push-button for “blower slower”
To switch off the air conditioning: keep the push-button pressed until the indication “OFF” is displayed
t
(blower speed: 0).
18 - Push-button for “fresh air/re-circulation”
19 - Dash panel temperature sensor -G56- and Temperature sensor blower -V42-
t Fitting location for LHD vehicles
Climatronic - Passenger compartment
WARNING
Disconnect the earth strap from the battery before commencing work on the electrical
system → Electrical System; Rep. Gr.27.
Note
Pay attention to the sequence when connecting the battery → Electrical System; Rep.
t
Gr.27.
t
97
1- Defroster vent - side window
t remove: carefully lever out
2- Outer dash panel vent
t remove: carefully lever out
3- Defroster vent - windscreen
t remove: carefully lever out, remove plug of sunlight penetration photosensor -G107-
4- Sunlight penetration photosensor -G107-
Function: depending on the intensity of the sunlight controls the temperature flap and the
t
fresh air blower
Emergency operation in the event of failure: Climatronic control unit -J255- adopts fixed
t
value
t check: by the self-diagnosis
t removing and installing → Fig.
98
5- Centre dash panel vent
t Unit with warning light switch
t remove: carefully lever out, remove plug from warning light switch
6 - Dash panel temperature sensor -G56- with Temperature sensor blower -V42-
the components, i.e the Climatronic control unit -J255-, the Control and display unit for air
temperature sensor blower -V42- cannot be disassembled
Function: the temperature sensor controls the temperature flap and the fresh air blower
t
according to the temperature
Emergency operation in the event -G56- fails: System keeps running at an assumed value
t
of + 24°C
after replacing: function 07 “code control unit” → Chapter and subsequently perform
t
function 04 “basic setting” → Chapter
7- Control and display unit -E87-
t Control and operation → Chapter
after replacing: function 07 “code control unit” → Chapter and subsequently perform
t
function 04 “basic setting” → Chapter
8- Intermediate piece for centre dash panel vent
t only for climatronic
t is fitted in the air guide duct for the dash panel vent
t removing and installing with the dash panel
9- Middle vent temperature sender -G191-
t Vehicles with mapped cooling
t remove and install and test → Chapter
10 - Air guide duct for the dash panel vent
t screwed on the distributor box, locked on the top
11 - Fresh air intake duct temperature sensor -G89-
t
99
Emergency operation in the event of failure: The Ambient temperature sensor -G17-
t
performs the task
t replace:
Remove the glove compartment → Body Work; Rep. Gr.70
– Rotate the temperature sensor 90° and pull out
– when fitting moisten the rubber seal with oil
12 - Air flow flap control motor -V71 -
t operated simultaneously with the fresh air and re-circulating air flap
t replace → Chapter
t adjust: Perform function 04 “basic setting” → Chapter
13 - Fresh air blower -V2-
t removing → Fig.
14 - Fresh air blower control unit -J126-
Function: smoothly controls the output of the fresh air blower in accordance with the
t
voltage values
t replace → Fig.
15 - Air conditioning unit*
t with heat exchanger
t with evaporator
16 - Control motor for temperature flap -V68-
17 - Control motor for centre flap -V70-
100
18 - Centre part of dash panel
t removing and installing → Body Work; Rep. Gr.70
19 - Climatronic control unit -J255-
replace: function 07 “code control unit” → Chapter and subsequently perform function 04
t
“basic setting” → Chapter
20 - Footwell vent
t only passenger side
21 - Rear duct
22 - Connecting piece to rear duct
23 - Footwell vent
24 - Footwell vent temperature sender -G192-
Function: controls the defrost/footwell air distribution and the output of the fresh air blower
t
in accordance with the vent temperature
Emergency operation in the event of failure: System keeps running at an assumed value of
t
+80°C coolant temperature
25 - Footwell flap and defroster flap control motor -V85-
26 - Heat exchanger*
t after removing the coolant must be completely replaced
27 - Gasket heat exchanger/bulkhead*
t check fitting position → Chapter
101
29 - Evaporator vent temperature sender -G263-*
t Vehicles as of 03.01
t remove and install, test → Chapter
Removing and installing sunlight

penetration photosensor -G107-
– Carefully lever off cover -A-.
– Remove screw -B-.
– Disconnect plug, take out photosensor.
Install

order.
Remove fresh air blower -V2-
Remove the glove compartment → Body

–
Work; Rep. Gr.70
Remove the swing foam cover -3- below

–
the air conditioning unit.
– Unscrew bolts -1-.
– Remove cover -2-.
102
Disconnect the plug connection -2- at the
–
fresh air blower.
– Remove wiring loom from holder -3-.
Pull out the fresh air blower -1- towards

–
the bottom in the -direction of the arrow-.
Replace fresh air blower control unit -J126-
Remove the glove compartment → Body

–
Work; Rep. Gr.70
Disconnect plug connection -1- and

–
screw out screw -2- (locked at the top).
Removing and installing the Footwell vent

temperature sender -G192-
Removing
Remove bottom part of dash panel on

–
the left → Body Work; Rep. Gr.70
Disconnect plug on the footwell vent

–
temperature sender -G192-
Turn footwell vent temperature sender

–
-1- by 90° and remove from housing -2-.
Install
When fitting moisten the rubber seal with

oil on the footwell vent temperature sender
-G192-.
Removing and installing Control and display unit for air conditioner, Climatronic -E87- with
103
Climatronic control unit -J255-
Note
The climatronic control unit and the control and display unit for air conditioner cannot be
disassembled.
Removing
– Switch off the ignition and all electrical components.
Unclip trim -1- using a screwdriver.

–
Support the screwdriver accordingly.
Release screws -2- from the dash panel

–
middle part.
Pull out the control and display unit for

–
air conditioner with control unit -3-.
Release the plug connections -4- and pull

–
them off.
Install

–
order.
Enter function 07 “Code control unit”

– → Chapter and subsequently enter
function 04 “Initiate basic setting”
→ Chapter.
Replacing the air conditioning control motors
WARNING
Disconnect the earth strap from the battery before commencing work on the electrical
system → Electrical System; Rep. Gr.27.
Note
When installing the control motors, pay attention to the correct routing of the wiring looms.
t They must be fitted in such a way that they do not come in contact with moving parts (for
example the levers of the control motors).
t Pay attention to the sequence when connecting the battery → Electrical System; Rep. Gr.27.
t After installing a new control motor perform the function 04 “basic setting” → Chapter.
104
Removing and installing the control motor of air flow flap -V71-
Note
The fresh air and re-circulating air flap is also controlled by the control motor of air flow flap.
Removing
– Remove the glove compartment → Body Work; Rep. Gr.70
– Slacken the cover under the air conditioning unit.
Carefully unclip the actuator rod for the

–
air flow flap -1- from the lever -2- using a
screwdriver.
– Disconnect plug connection -1-.
– Release fixing screw -3-.
The control motor is guided into the

housing of the air conditioning unit. In
order to avoid any damage:
Fold the control motor downwards and

–
simultaneously detach from the shaft for
fresh/re-circulating air flap -2- (-arrow A-).
Install
A new control motor is supplied in position

"re-circulating air operation". To facilitate
installation of the control motor, carry out
the following work steps before installing:
105
– Fit plug -1- onto the control motor -2-.
Operate push-button for fresh air/re-

–
circulation.
When reaching the centre position,

– remove the plug -1- from the control
motor -2-.
Insert control motor into the shaft of the

–
fresh air/re-circulating flap -1-.
If the control motor cannot be inserted into

the shaft of the fresh air/re-circulating flap
-1-, remove the fresh air blower -V2-, → Fig.
and position the flap by hand.
Turn control motor in -direction of arrow

–
A- and tighten.
Clip on the actuator rod for the air flow

–
flap.
Initiate function 04 “basic setting”

–
→ Chapter.
Removing and installing the control motor of temperature flap -V68-
First carry out the following tasks:
Remove the glove compartment, the trim for the dash panel and the bottom part of dash
–
panel on the left → Body Work; Rep. Gr.70
– Remove centre console → Body Work; Rep. Gr.68
– Remove the dash panel middle part → Body Work; Rep. Gr.70
Removing
106
Carefully unclip the actuator rod -2- from
–
the lever -arrow A- using a screwdriver.
– Screw out the fixing screws -4-.
– Remove control motor -3-.
Install

–
order.

–
→ Chapter.
Removing and installing the control motor of central flap -V70-
First carry out the following tasks:
Remove the glove compartment, the trim for the dash panel and the bottom part of dash
–
panel on the left → Body Work; Rep. Gr.70
– Remove centre console → Body Work; Rep. Gr.68
– Remove the dash panel middle part → Body Work; Rep. Gr.70
Removing
– Unplug plug connection “1”.
Carefully unclip the actuator rod -2- from

–
the lever -arrow A- using a screwdriver.
Turn the actuator rod -2- and remove

–
from the control motor -4-.
– Remove control motor.
Install

–
order.

–
→ Chapter.
Removing and installing the footwell flap and defroster flap control motor -V85-
Removing
107
– Remove bottom part of dash panel on the left → Body Work; Rep. Gr.70
Remove control motor -4- from the

–
actuator rod -2- by rotating it.
Remove control motor -4- from the

–
housing.
Install

–
order.

–
→ Chapter.
108
Removing and installing air conditioning unit
Removing and installing the air conditioning unit climatronic corresponds essentially to that of
the air conditioning system with manual control → Chapter.
The difference exist only in the fact that instead of the heater control (control cables) the
control and display unit for air conditioner, climatronic -E87- must be removed.
– Initiate function 04 “basic setting” after installing the air conditioning unit → Chapter.
Middle vent temperature sender -G191-
Removing
– Remove the glove compartment → Body Work; Rep. Gr.70
– Disconnect plug.
Turn sender -1- by 90° -arrow- and take

–
out.
Install

order.
Inspection
Measure the resistence between the

– contacts of the sender using a
multimeter.
Nominal value at 25°C: 9.7... 10,3 kΩ
Replace middle vent temperature

–
sender.
Inspect wiring according to the current

– flow diagram and repair if necessary
→ Current flow diagrams and Fitting
locations.
If wiring is o.k.:
Check climatronic control unit → Chapter;

–
replace if necessary → Chapter.
Evaporator vent temperature sender -G263-
Vehicles as of 03.01
109
Removing
The evaporator vent temperature sender is located at the back of the evaporator housing.
– Disconnect plug.
– Turn sender by 90° and take out.
Install
Installation is carried out in the reverse order.
Inspection
– Check the resistence between the contacts of the sender using a multimeter.
Nominal value at 25°C: 960... 1056 Ω
– Replace evaporator vent temperature sender.
Inspect wiring according to the current flow diagram and repair if necessary → Current flow
–
diagrams and Fitting locations.
If wiring is o.k.:
– Check climatronic control unit → Chapter; replace if necessary → Chapter.
Disassembling and assembling the evaporator housing
Remove and install air conditioning unit → Chapter
110
1- Top part evaporator housing
t Disassembling and assembling the evaporator housing → Fig.
2- Tensioning strap for cover
t pay attention to the correct routing → Fig.
3- Seal
t replace
t Installing the seal on the evaporator housing → Fig.
4- Seal
5- Evaporator
t Install seal on the refrigerant lines of the evaporator
t Installing the seal on the evaporator → Fig.
6- Evaporator housing - bottom part

111
t Disassembling and assembling the evaporator housing → Fig.
8- Cover for fresh air blower -V2-
t screwed
9- Swing foam cover
t screwed and fixed with tensioning strap -2-
t must be positioned firmly at the evaporator housing
10 - Wiring loom of air conditioning unit
t when installing, make sure that there is clearance between the moving parts → Fig.
11 - Heat exchanger
t after replacing, the coolant must be completely replaced
12 - Evaporator vent temperature sender -G263-
t Vehicles as of 03.01
t remove and install, test → Chapter
Disassembling and assembling the

evaporator housing
Both housing halves must be screwed

–
together at the provided screw points -B-
with original screws -A-.
Note
The provided screw points -B- are over the

entire circumference.
112
Lay tensioning strap
Note
Pay attention to the correct routing of the

t tensioning strap -A- around the
evaporator housing.
The tensioning strap must firmly hold the

t
cover on the evaporator housing.
Install seal on the refrigerant lines of the

evaporator
The refrigerant lines -C- must be sealed

–
with the seal -A- on both housing halves
of the evaporator -B-.
The evaporator -A- must be sealed at the

–
top and on both sides with the gasket -B-
of the evaporator housing.
Note
No gasket must be present on the bottom

side of the evaporator (so that the
condensation water can drain off).
113
housing
Replace the gasket -A- and pay attention

–
to the correct fitting of the evaporator
connection flange.
Install wiring loom for air conditioning unit
Note
The wiring loom -A- must be installed in

such a way that it does not come in
t
contact with the moving components e.g.
lever -B- of the control motor).
Lay the wiring loom in such a way that it

t
does not clack.
Climatronic - engine compartment
Note
t
Comply with the safety measures when working on vehicles with air conditioning system
t
data.
114
1- Fluid container with desiccator*
t the fluid reservoir must be replaced after each opening of the refrigerant circuit
t Low-pressure side
t for exhausting, filling and measuring
t always screw on cap with gasket
t High-pressure side
t for exhausting, filling and measuring
t always screw on cap with gasket
4- Air conditioner pressure switch -F129- or high pressure sensor -G65-
t for vehicles as of model year 99 with 1.6 Itr./74 kW engine, the -G65- is installed instead of
115
the -F129 -
t on all vehicles is installed -G65- as of model year 00
t -F129- (4-pin plug connection), function, remove and install, check → Chapter
t -G65- (3-pin plug connection) function → Chapter, remove and install, check → Chapter
5- Expansion valve*
t Remove and install heat-protection insulation → Chapter
6- Dust and pollen filter
t below the water box cover
7- Valve for condensation water drain
t check, remove and install → Chapter
8- Control switch for coolant temperature too hot -F14-
t in the coolant circuit
-F14- switches off the magnetic coupling -N25- if the coolant temperature is too high (off at
t
119°C, on at 112°C)
t 1.6ltr./74 kW ?model year 98 and all vehicles ? model year 99
9- Radiator fan control unit -J293-
t screwed on under the battery tray
t the magnetic coupling -N25- of the compressor is also switched via this control unit
10 - Ambient temperature sensor -G17-
t
Emergency operation in the event of failure: Fresh air intake duct temperature sensor -G89-
performs the task. If both sensors are defective, the system keeps running at an assumed
t
value of +10°C; re-circulating air operation is not possible; readout in the display of the
Control and display unit for air conditioner, Climatronic -E87-: “-”
t screwed at front left frame side rail
11 - Pressure relief valve*
t “O”-ring seal 8.6 mm; 1.8 mm
116
t check → Chapter
12 - Oil drain plug*
t “O”-ring seal 8.8 mm; 1.5 mm
Note
To drain off refrigerant oil:
– Remove compressor:
– Remove oil drain plug.
Turn the compressor with the clutch disk of the magnetic coupling to speed up the
–
evacuation of the oil.
13 - Compressor*
t Remove and install compressor holder → Engine, Mechanics; Rep. Gr.13
t Removing and installing the compressor on the holder → Chapter
t Removing and installing the compressor → Chapter
Note
Mark the direction of rotation before removing the V-ribbed belt, the reversal of the direction
t
of rotation can lead to the damage of the belt.
The stroke of piston of the compressor is variable, it adjusts itself depending upon the
t
determined refrigerating capacity.
If a new compressor was installed or new refrigerant oil was filled into the compressor (e. g.
after blowing through the refrigerant circuit and emptying the compressor via the oil drain
t
plug), the compressor must be turned by hand approx. 10 turns after installing (in order to
avoid damage to the compressor before operation).
14 - Magnetic coupling -N25-
t repairing → Chapter
15 - Condenser*
117
118

Skoda Octavia Mk1 04 Heating Air Conditioning

Uploaded by

Document Information

Original Title

Copyright

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Skoda Octavia Mk1 04 Heating Air Conditioning

Uploaded by

Copyright:

SKODA OCTAVIA

Repairing heating system,

Dash panel vent and air guides

q removing and installing → Body Work; Rep. Gr.70

2- Defroster vent side window

q clipped into place

3- Right dash panel vent

q removing and installing → Chapter

4- Centre right dash panel vent

5- Trim for dash panel insert

q removing and installing → Body Work; Rep. Gr.70

6- Left and centre left dash panel vent

q removing and installing → Chapter

7- Defroster vent windscreen

8- Air guide duct to the dash panel vents

q screwed to the heating, locked on the top

9- Air guide duct to the defroster vents

q removing and installing → Chapter

Removing and installing the right dash panel vent

Press on fixing clamps -arrows- by hand

– Pull out the dash panel vent.

Only the left and centre left dash panel

Installation is carried out in the reverse

Check ventilation frame

The sealing lips -B- in the ventilation frame

This figure shows the ventilation frame with

Remove and install air guide duct to defroster vents

– Removing the dash panel → Body Work; Rep. Gr.70

Installation is carried out in the

Heating, heater control and air guides

q removing and installing → Chapter

q Remove and install Bowden cables → Chapter

q Adjust Bowden cables → Chapter

q Connection diagram for the Bowden cables → Chapter

q Replace light bulb → Chapter

2- Switch for fresh air and re-circulating air flap - E159-

q Inspect proper operation → Chapter

t The switch is firmly attached to the heater control.

3- Footwell vent front passenger side

5- Connecting piece to rear duct

6- Left cover for footwell vent

q removing and installing → Chapter

q removing and installing → Chapter

q Remove Bowden cables on the heater, install and adjust → Chapter

q Connection diagram for the Bowden cables → Chapter

q removing and installing → Chapter

10 - Air guide duct to the defroster vents

q removing and installing → Chapter

q Inspect proper operation → Chapter

q removing and installing → Chapter

12 - Fresh air blower series resistor - N24-

q removing and installing → Chapter

13 - Fresh air blower -V2-

q removing and installing → Chapter

Removing and installing heater control

– Removing the centre console → Body Work; Rep. Gr.68

– Remove screws -B-.

– Disconnect plug connections.

Take out heater control -C- towards the

Installation is carried out in the reverse

Remove and install Bowden cables from the heater control

– Remove the heater control.

– Unclip Bowden cable support bearing -A-.

Check Bowden cables before installation,

Connection diagram for the Bowden cables on the heater control

Connection diagram for the Bowden cables on the heating