87-11

Manual A/C
Heating and A/C components in passenger
compartment, servicing

CAUTION!

Before beginning repairs on the electrical system:

Obtain the anti-theft radio security code.

Switch the ignition off.
Disconnect the battery Ground (GND) strap.
After reconnecting battery, re-code and check
operation of anti-theft radio. Also check operation of
clock and power windows according to Repair Manual
and/or Owner's Manual.

Note:

System components identified with an * must only be

serviced or replaced after discharging refrigerant system.
Use Kent Moore ACR4 or equivalent.
 87-12

1 - Clip
Lift out with screwdriver.
2 - Dust and pollen filter
Vehicles 10.00 , replacing Page 87-41 .
3 - Air intake housing
4 - Defroster air outlet
Removing and installing

Repair Manual, Body Interior, Repair Group 70.

5 - Side window air outlet

Removing Fig. 1
 87-13

6 - Heating and A/C controls

With:
A/C switch -E35-
Fresh air blower switch -E9-
Switch for fresh air blower and recirculated air -
E184-
Removing and installing Page 87-27
Assembly Page 87-30
7 - Air outlets
Center and side air outlets, removing (early prod.)
Fig. 2
Center air outlet, removing (later prod.) removing
Fig. 3
Side air outlets, removing (later prod.) Fig. 4
8 - Instrument panel cross member
Always follow installation instructions for bolt Fig.
7
 87-14

9 - Defroster duct
Replacing:
- Remove instrument panel

Repair Manual, Body Interior, Repair Group 70

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

Removing and installing Page 87-26
11 - Ambient temperature switch -F38-
Switches off A/C clutch -N25- at low ambient
temperatures
Switching point: 5 C (41.5 F)
Replacing:
- Remove glove box

Repair Manual, Body Interior, Repair Group 68

- Reach behind heating and A/C unit from below

and pull out switch.
 87-15

12 - Gasket
Replace if damaged
Replacing:
- Remove ambient temperature switch -F38-
- Remove dust and pollen filter
- Set fresh air/recirculation flap in "fresh air" position
- Reach down into air intake housing and pull out
gasket

CAUTION!

Area around dust and pollen filter and air intake housing
must be free from debris, leaves etc. before reaching
into housing. Debris entering heating and A/C unit will
block evaporator water drain and cause subsequent
(water) damage.

Note:

If unable to access and remove gasket as described,

proceed as follows:

- Remove instrument panel

Repair Manual, Body Interior, Repair Group 70

- Loosen cross member - 10 - .
Always follow installation instructions for bolt Fig.
7
 87-16

13 - Evaporator water drain guide

Removing and installing Page 87-25
14 - Heating and A/C unit*
Contains:
Heater core
Evaporator
Removing/assembly Page 87-164 .
15 - Fresh air blower -V2-
Removing and installing Fig. 6
16 - Fresh air blower series resistance with fuse -N24-
Replacing Fig. 5
17 - Center air outlet duct
18 - Control panel trim
Unclip using screwdriver
19 - Center trim
 87-17

20 - Heating and A/C cables

Installing Page 87-32
21 - Heater core*
Always use new coolant after replacement
22 - Left rear duct
23 - Lower duct
24 - Upper duct
25 - Footwell air outlet
26 - Instrument panel cross member and left side
member securing bolt
Always follow installation instruction for bolt Fig.
7
 87-18

27 - Relay
Coolant Fan Control (FC) Relay -J26-
Control number 214
First Speed Coolant Fan Control (FC) relay -J279-
Vehicles 10.00: Control number 214
Vehicles 10.00 : Control number 373
Second Speed Coolant Fan Control (FC) Relay -
J280-
Vehicles 10.00: Control number 213
Vehicles 10.00 : Control number 370
Component locations Electrical Wiring Diagrams,
Troubleshooting and Component Locations.
28 - A/C cut-off control module -J314-
Control number 384
Component location Electrical Wiring Diagrams,
Troubleshooting and Component Locations.
 87-19

Fig. 1 Side window air outlet, removing

- Carefully pull out using needle-nose pliers.

Fig. 2 Center and side air outlets, removing (early prod.)

- With flashlight, locate the two retaining tabs inside housing, lift tabs with two
small screwdrivers and carefully pull outlet from instrument panel.
 87-20

Fig. 3 Center air outlet, removing (later production)

- Insert fingers of both hands into lower row of grille -A- and push center vent -1-
down suing force until locking lugs -B- are released from their mounts.

Note:
Sit between front seats to apply the force required.
If outer locking lugs -B- will not release, grip at this point and push center vent
down while simultaneously pulling out slightly.

- Grip center vent -1- at point -C- which has been raised up slightly from
instrument panel opening by action of pushing down.
- Push center vent in direction -D- to release locking lugs and pull it outward
slightly.
 87-21

- Disconnect electrical connectors -2- from center vent before removing in

direction of -arrow-.

Fig. 4 Side air outlet, removing (later prod.)

Note:

Removal of both sides is identical.

- Unclip and remove instrument panel side cover -1- using screwdriver.
 87-22

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

- Disconnect electrical connector -3- when removing vent -2- in direction -C-.
7
 87-23

Fig. 5 Fresh air blower series resistance with fuse -N24- , replacing
- Remove glove box.

Repair Manual, Body Interior, Repair Group 68.

- Disconnect electrical connector and remove bolt -arrow-.

- Seal surface between series resistance -1- and air duct before installing with
AMV 176 000 05 (or equivalent).

Fig. 6 Fresh air blower -V2-, removing and installing

- Remove glove box

Repair Manual, Body Interior, Repair Group 68.

- Disconnect electrical connector -1-.

- Remove three screws -arrows- and remove fresh air blower -2- downwards.
 87-24

Fig. 7 Instrument panel cross member and left side member securing bolt,
installation note:

To avoid damage to instrument panel wiring harness -2-, ensure that the protective
cap -1- is installed on the securing bolt for upper instrument panel cross member -
4- at left side member -3-.
 87-25

Evaporator water drain guide, removing and

installing

Removing

- Remove instrument panel

Repair Manual, Body Interior, Repair Group

70.

- Release instrument panel cross member from

bulkhead Page 87-13 .

For the next step, an assistant must lift and hold

the heating and A/Cunit.

- Remove nuts -1- (2.5 Nm / 23 in lb) and remove guide -2- from bulkhead.

Installing

When installing, ensure water drain valve -3- sealing lip completely encloses the
guide -2-. If necessary, lubricate to aid installation.

Water drain valve, checking Page 87-40 , Fig. 1

 87-26

Servo motor for fresh/recirculated air door -

V154-, removing and installing

Removing

- Remove glove box.

Repair Manual, Body Interior, Repair Group 68

- From the front passenger side, use a mirror to

look behind heating and A/C unit.

- Remove screws (TORX T15) -arrows-.

- Un-clip lever for fresh/recirculated air flap.
- Pull off connector.
- Pull out motor downwards.

Installing

Position fresh/recirculated air flap lever by hand dependent on position of servo

motor.
 87-27

Heating and A/C controls, removing and

installing

Removing

- Carefully remove trim panel by depressing

locating lugs -arrows-with a covered screwdriver.
Do not damage instrument panel.

- Remove instrument panel screws -arrows-.

- Remove center trim panel Page 87-16 .
- Pull controls with cables attached from instrument panel.
- Release cables on controls.
- Disconnect electrical connector.
 87-28

Installing

Notes:

Cable sleeve ends are color coded.

Check cables before installing and replace

binding or damaged cables.

All air flaps must audibly move onto end stops

when turning controls.

- Mount eyelet on end of cable -1- onto control - arrow 2-.

- Press footwell/defrost or central flap cable -1- into mount -2- until it engages.

Footwell/defrost flap cable sleeve marking: White

Central flap cable sleeve marking: Black
 87-29

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

Temperature flap cable sleeve marking: Red

 87-30

Heating and A/C controls, assembly

1 - Heating and A/C controls

With:
A/C switch -E35-
Fresh air blower switch -E9-
Switch for fresh air blower and recirculated air -
E184-
Removing and installing Page 87-27
2 - Illumination filter
3 - Trim panel
4 - Fresh air control lever light -L16-
12V, 1.2W
Removing:
- Un-clip trim panel - 7 - and rotary control - 5 -.
- Remove bulb (if necessary, slide a short piece fuel
hose over bulb and pull out).
5 - Rotary control
For blower speed

To remove: Use pliers with suitable plastic or rubber

protection on jaws
 87-31

6 - Rotary control
For air distribution
To remove: Use pliers with suitable plastic or rubber
protection on jaws
7 - Trim panel
8 - Rotary control
For interior temperature
To remove: Use pliers with suitable plastic or rubber
protection on jaws
 87-32

Heating and A/C cables, installing

Notes:
Cable sleeve ends are color coded.
Check cables before installing and replace binding or
damaged cables.
All air flaps must audibly move onto end stops when
turning controls.
1 - Central flap cable
From air distribution rotary control to central flap
Cable sleeve marking: Black
Removing and installing Page 87-34
 87-33

2 - Footwell/defrost flap cable

From air distribution rotary control to footwell/defrost
flap
Cable sleeve marking: White
Replacing:
- Remove controls for heating and A/C system
Page 87-27
- Remove driver side shelf

Repair Manual, Body Interior, Repair Group 68

- Unclip cable at heating and A/C unit.

- When installing, attach cable to heating and A/C
unit first.
3 - Heating and A/C controls
Removing Page 87-27
4 - Temperature flap cable
From temperature rotary control to temperature flap
Cable sleeve marking: Red
Removing and installing Page 87-34
 87-34

Temperature and central flap cables,

removing and installing

Notes:

Cable sleeve ends are color coded.

When installing secure cable to heating and

A/C unit first.

Check cables before installing and replace

binding or damaged cables.

Removing

- Remove heating and A/C controls Page 87-

27

- Remove instrument panel

Repair Manual, Body Interior, Repair Group 70

- Remove footwell air outlet Page 87-17 .

- Disconnect cable for central flap or temperature
flap on heating and A/C unit.
 87-35

Installing

Illustration shows right-hand drive version.

1- Central flap cable, sleeve marking: Black
2- Temperature flap cable, sleeve marking: Red
3- When attaching inner cable note: Do not press end of wire (arrow) against lever.
 87-36

Heating and A/C components in engine

compartment, servicing

CAUTION!

Before beginning repairs on the electrical system:

Obtain the anti-theft radio security code.

Switch the ignition off.
Disconnect the battery Ground (GND) strap.
After reconnecting battery, re-code and check
operation of anti-theft radio. Also check operation of
clock and power windows according to Repair Manual
and/or Owner's Manual.

Notes:
System components identified with an * must only be
serviced or replaced after discharging refrigerant system.
Use Kent Moore ACR4 or equivalent.
Illustration shows vehicle with engine code AHA.
 87-37

1 - Accumulator*
2 - Refrigerant hose*
Between evaporator and accumulator
3 - Refrigerant hose*
Between evaporator and condenser
4 - Low pressure service valve*
5 - High pressure service valve*
6 - Dust and pollen filter
Vehicles 10.00 , replacing Page 87-41
Ambient temperature switch -F38- located below
dust and pollen filter in lower air intake housing.
7 - Evaporator*
In heating and A/C unit.
 87-38

8 - Evaporator water drain valve

Checking Fig. 1.
9 - Pressure relief valve*
Zexel compressor illustrated
Checking, Zexel compressor Page 87-159
Checking, Denso compressor Page 87-160
10 - Compressor*
11 - A/C clutch -N25-
Servicing: Zexel Page 87-43
Servicing: Denso Page 87-49
12 - Condenser*
 87-39

13 - A/C pressure switch -F129-

- Tightening torque 8 Nm (71 in lb)
- Replace O-ring (note Part No.).
Function:
Switches coolant fan -V7- to next highest speed
when pressure increases in refrigerant circuit.
Switches off A/C clutch -N25- when refrigerant
pressure is excessive (e.g.: insufficient engine
cooling).
Switches off A/C clutch -N25- when refrigerant
pressure is too low (e.g.: refrigerant loss).
Checking Page 87-154
Replacing, 10.00 Page 87-156, Fig. 4 .
Replacing, 10.00 Page 87-157, Fig. 5 .
14 - Refrigerant hose*
Between compressor and condensor
15 - Refrigerant hose*
Between compressor and accumulator.
 87-40

Fig. 1 Evaporator water drain valve, checking

Check drain valve as follows:

- Remove nuts -arrows- on right catalytic converter heat shield -1-.

- Remove catalytic converter heat shield.

Note:

Catalytic converter heat shield from 10.00 differs from illustration.

Check valve as follows to ensure proper function:

The valve must not be stuck together.

The opening in the sealing cap of the valve must point downwards.
The right catalytic converter heat shield plate must not be deformed or
damaged in the area of the valve.

- Remove valve -1- from bulkhead -2-.

The valve sealing lip -1- must cover the water drain guide outlet completely
Page 87-25 .
 87-41

Dust and pollen filter 10.00 , removing

and installing

Removing

- Lift front hood. Remove air intake plenum

cover.

- Unclip spring -1-. Remove dust and pollen filter upwards from housing.

Installing

- Installation in reverse order of removal.

Filter housing, assembly

1 - Filter housing
2 - Dust and pollen filter
3 - Nut (2Nm)
 87-42

Ventilation system, checking

Notes:

Passenger compartment air is vented to the

outside trough openings in the luggage
compartment trim.

In order for the ventilation system to work

properly, these openings must not be blocked.

Vent frames are located in both rear quarter

panels, behind the bumper cover.

Checking

- Remove rear bumper cover

Repair Manual, Body Exterior, Repair Group

63

- Sealing lips -1- in vent frame -2- must move and close freely.
 87-43

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

Special tools, workshop equipment, test and measuring

appliances and auxiliary items required

3212 Two hole pin wrench

VAG 1719 A/C Clutch set
VAG 1719/1 Adapter
VAG 1719/2 Adapter

Not illustrated:

Torque wrench (5 - 50 Nm)

Locally available two-arm puller (e.g. Kukko 20-10) with
fixtures for a depth of 100 mm.
Feeler gauge
 87-44

Notes:
Refrigerant circuit does not need to be opened to service
A/C clutch.
If unable to service A/C clutch on compressor installed in
vehicle, discharge refrigerant Page 87-173 and
remove compressor from compressor bracket.
1 - Hex head combination bolt
15 Nm (11 ft lb)
Removing and installing Fig. 1
2 - Clutch plate
Removing Fig. 2
Checking clutch plate gap Fig. 6
3 - 45Shims
Used to adjust gap between clutch plate and pulley
Gap: 0.3 - 0.6 mm (0.011 - 0.023 in)
6 - Circlip
Always replace
- Install correctly: thick side faces compressor
Ensure correct seating in groove
 87-45

7 - Clutch pulley
Removing Fig. 3
Installing Fig. 4
8 - Circlip
Always replace
- Install correctly: Flat side faces compressor
Ensure correct seating in groove
9 - Clutch coil
Installing Fig. 5

Note:

A thermo-fuse is incorporated into the clutch coil. Current to

the clutch coil is interrupted in the event of compressor
overheating (e.g. a binding compressor).

10 - Felt ring
Always replace
11 - Bolt
12 - Compressor
Manufacturer: Zexel
 87-46

Fig. 1 Combination bolt for clutch plate, removing and installing

- Remove bolt.
Tightening torque: 15 Nm (11 ft lb)

When removing and installing bolt, counter-hold with 2 hole pin wrench -A- (3212 or
equivalent) with pin diameter: 4 mm.

Fig. 2 Clutch plate, removing

- Mount VAG 1719 and turn in center bolt to extract clutch plate.

When removing, counter-hold with 2 hole pin wrench -A- (3212 or equivalent).
 87-47

Fig. 3 Clutch pulley, removing

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

Fig. 4 Clutch pulley, installing

- Drive on belt pulley with plastic head hammer and VAG 1719/2 (or equivalent).
 87-48

Fig. 5 Clutch coil, installing

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

Fig. 6 Clutch plate gap, checking

- Check gap with feeler gauge.
Gap: 0.3 - 0.6 mm (0.011 - 0.023 in)

Notes:
Gap must be within tolerance around entire circumference.
If gap is outside tolerance range, remove clutch plate and adjust gap by adding
or removing shims Page 87-44 .
 87-49

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

Special tools, workshop equipment, test and measuring

appliances and auxiliary items required

Not illustrated:

Torque wrench (5 - 50 Nm)

Locally available two-arm puller (e.g. Kukko 20-10) with
fixtures for a depth of 100 mm.
Locally available strap wrench
Depth gauge
 87-50

Notes:
Refrigerant circuit does not need to be opened to service
the A/C clutch.
If unable to service A/C clutch on compressor installed in
vehicle, discharge refrigerant Page 87-173 and
remove compressor from compressor bracket.
1 - Hex head combination bolt
15 Nm (11 ft lb)
Removing and installing Fig. 1
2 - Clutch plate
Removing Fig. 2
Checking clutch plate gap Fig. 4
3 - Shims
Used to adjust gap between clutch plate and pulley
Gap: 0.4 - 0.6 mm (0.015 - 0.023 in)
4 - Circlip
Always replace
- Install correctly: Thick side faces compressor.
Ensure correct seating in groove.
 87-51

5 - Clutch pulley
- Remove with locally available 2 or 3 arm puller.
Ensure puller is seated correctly to prevent damage to
pulley.
6 - Circlip
Always replace
- Install correctly: Flat side faces compressor.
Ensure correct seating in groove.
7 - Clutch coil
Installing Fig. 3

Note:

A thermo-fuse is incorporated into the clutch coil. Current to

the clutch coil is interrupted in the event of compressor
overheating (e.g. a binding compressor).

8 - Screw
9 - Compressor
Manufacturer: Denso
 87-52

Fig. 1 Combination bolt for clutch plate, removing and installing

- Remove bolt.
Tightening torque: 15 Nm (11 ft lb)

When removing and installing bolt, counter-hold with locally available strap wrench
-A-.

Fig. 2 Clutch plate, removing

- Pry off clutch plate carefully with two large screwdrivers.

Use locally available 2 or 3 arm puller if plate is securely seated (difficult to

remove).
 87-53

Fig. 3 Clutch coil, installing

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

Fig. 4 Clutch plate gap, checking

Gap: 0.4 - 0.6 mm (0.015 - 0.023 in)

Note:
In order to check gap with compressor installed in vehicle:
- Bring front end assembly (lock carrier) into service position.

Repair Manual, Body Exterior, Repair Group 50.

Determine "Dimension 1"

- Using depth gauge -C-, measure gap between top of clutch plate and belt pulley
at three equally spaced locations (measurement must not deviate).
 87-54

Determine "Dimension 2"

- If compressor is installed in vehicle, disconnect compressor electrical connector -

A- from vehicle wiring harness.
- Using a jumper wire, energize clutch coil by applying 12V to connector -A-
(battery terminal B+). If compressor is removed from vehicle, compressor -B-
must be grounded.
- With clutch energized, measure gap between belt pulley and clutch plate with
depth gauge -C-:

The allowable gap (0.4 - 0.6 mm / 0.015 - 0.023 in) is the difference between
"Dimension 1" and "Dimension 2".

Notes:
Gap must be within tolerance around entire circumference.
If gap is outside the permitted tolerance range, remove clutch plate and adjust
gap by adding or removing shims Page 87-50 .