Heating, Ventilation: Other Volkswagen Eos I

DUST AND POLLEN FILTER WITH ACTIVATED CHARCOAL INSERT

1. A dust and pollen filter with additional activated charcoal filter insert is installed together with the Air quality sensor -G238-.
2. The filter with activated charcoal insert continues to work as a dust and pollen filter. It can also filter out gaseous pollutants such as ozone, benzene, nitrogen, etc. from the air coming into the vehicle.
3. The activated charcoal is designed to absorb the gaseous pollutants in the air flow until the fresh-air door is closed and the air conditioner is operating in recirculated-air mode. The change over from fresh to recirculating mode occurs via the Climatronic Control Module -J255-, as soon as the air quality sensor detects gaseous pollutants in the ambient air (the "automatic recirculating" mode must be selected).
4. The activated charcoal layer in the dust and pollen filter reacts differently to various pollutants in the air.

Certain pollutants bond permanently in the active-carbon layer.

Others are converted into noxious bonds like in a catalytic converter.

For the rest the activated charcoal works as a condenser (capacitor). With increasing load pollutants are absorbed, until a certain saturation is reached. If the amount of pollutants decreases, the activated charcoal layer continuously releases the absorbed particles.

1. Under the following operating conditions the dust and pollen filter must be replaced earlier than required, because a certain amount of pollutant particles are permanently bonded to the activated charcoal layer.

If the vehicle is driven in areas with heavy air pollution.

If vehicle is predominantly driven with the "automatic recirculating air mode" mode switched off.

On vehicles without air quality sensor and therefore without "automatic recirculating" mode.

1. If possible, vehicles with climate control using the air quality sensor should always be operated in "automatic recirculating" mode. However, if it is desired or necessary to switch this mode off, the following must be observed

The active carbon layer in the dust and pollen filter is saturated after a certain time.

A saturated filter can no longer absorb pollutants and the pollutants can flow through freely.

1. The most important task of the dust and pollen filter and air quality sensor is keep the load peaks out from the passenger compartment. For this the following must be observed

If a vehicle is driven in an area with relatively clean air (with little air pollution), the system will switch from fresh air mode to recirculation mode occurs at a different point in time than when in an area with heavy air pollution (such as an industrial area).

The switch from fresh to recirculating mode always occurs when the level of pollutants increases, regardless of what the level originally was (for example, when driving through an exhaust cloud).

1. The filter with activated charcoal can be installed in all vehicle types (also vehicles without air quality sensor). The same limitations apply to these vehicles as on climate control systems with the "automatic recirculation" mode switched off.

VENTILATION, CHECKING

Note. The stale air escapes through the vent openings in the luggage compartment trim. If the ventilation is to function properly, the ventilation openings must not be covered. Ventilation frames are located in rear side panels, behind bumper cover.

Checking

Remove the rear bumper cover. Refer to Removal and Installation .

Scheme 1

The sealing lips -1- in the ventilation frame on both sides of vehicle must be free to move and close automatically.

Observe installed position

AIR DISTRIBUTION DOOR ADJUSTER

Removal

Remove the left footwell vent. Refer to LEFT FOOTWELL VENT .

Unclip flexible shaft from adapter for controls. Refer to FLEXIBLE SHAFT, THROUGH 18 MAY 2008 .

Scheme 2

Unscrew bolts -1- and remove adjusting unit for air distribution doors.

Installation

The arrows on the gears must align.

Position adjusting unit for air distribution doors and tighten bolts -1-.

Clip in the flexible shaft to adapter for controls. Refer to FLEXIBLE SHAFT, THROUGH 18 MAY 2008 .

Note. When installing flexible shaft, adapter and air distribution rotary switch on controls for hot air and fresh air must have a specific position to each other, otherwise it will malfunction. After installing, function of air distribution door must be checked.

Checking Flexible shaft for adjusting unit of air distribution doors

Let fresh air blower run on highest speed. If air flows out of defroster vents in the "Defrost" position and no air flows out of footwell vents, installation of flexible shaft is correct. If this is not the case, remove flexible shaft from adapter. Place controls for heating and A/C system, Climatic onto adapter and rotate rotary knob for air distribution 1 / 2 rotation (180°). Then re-connect flexible shaft. Repeat test.

AIR INTAKE HOUSING

Removal

Remove the instrument panel. Refer to Removal and Installation .

Loosen the heater and A/C unit on the right side.

Disconnect the connector from the motor.

Loosen the bolts -1-.

Scheme 3

Lift air intake housing -in direction of arrow A-.

Scheme 4

Unhook the air intake housing -in direction of arrow B- from the anchoring.

Installation

Install in reverse order of removal. Make sure the housing fits correctly with the mounts -1- in the hooks -2-.

Scheme 5

Note. After installing, function of recirculation door must be checked. Initiate Basic Setting function on the motor with Vehicle Diagnostic Tester. Refer to CHECKING AND ADJUSTING COMPONENTS .

DUST AND POLLEN FILTER

Note. With or without EVAP canister, refer to DUST AND POLLEN FILTER WITH ACTIVATED CHARCOAL INSERT . Different versions depending on the vehicle version and equipment level. Follow the replacement intervals. Refer to "Maintenance Intervals" under: 03 MAINTENANCE, DIAGNOSIS .

Removal

Remove the plastic screws -2- and the partition -1-.

Scheme 6

Release cover -1- in direction of arrow.

Scheme 7

Remove dust and pollen filter downward out of heater.

Installation

Install in reverse order of removal.

Scheme 8

Note. Note installation position of dust and pollen filter.

FRESH AIR BLOWER -V2

Removal

The Fresh Air Blower is accessible from footwell on front passenger side.

Remove the partition from the heater.

PARTITION

Remove the plastic screws -2- and the partition -1-.

Disconnect harness connector -A- from fresh air blower.

Scheme 9

Remove the bolts -B- (1 Nm) from the fresh air blower.

Release the retainer -2- and turn the fresh air blower in -direction of arrow-.

Remove the fresh air blower from the heater.

Installation

Install in reverse order of removal.

FRESH AIR BLOWER SERIES RESISTOR WITH FUSE -N24

Removal

Contact with a hot exhaust system can cause severe burns.

Perform the following work first

Remove the partition from the heater. Refer to PARTITION .

Scheme 10

Disconnect harness connector -1- from fresh air blower series resistor with fuse.

Push the retainer in direction of arrow and remove the fresh air blower series resistor with fuse from the heater.

Installation

Install in reverse order of removal.

FRESH/RECIRCULATING AIR DOOR MOTOR -V154

Special tools and workshop equipment required

1. Vehicle Diagnosis, Testing and Information System -VAS 5051B- (or succeeding model).

Removal

Note. The Fresh/Recirculating Air Door Motor can only be removed without difficulty in "fresh air mode stop" and installed only in this position. If motor remains standing in a different position and can no longer be moved electrically into "fresh air mode stop" position, it can only be pulled off and removed with difficulty. Position of fresh/recirculating air door must not be changed.

Turn on the ignition and wait until the fresh/recirculating air door motor has reached its end position "fresh air mode".

Switch off the ignition.

Remove the glove compartment. Refer to Removal and Installation .

Scheme 11

Loosen the tabs -B- and -C- and remove the air intake shroud bracket -A-.

Scheme 12

Disconnect the connector from the motor -B-.

Remove the fresh/recirculating air door motor -B- (in direction of arrow) from the air intake shroud.

Note. Connection between motor toothed gears and back pressure door is designed so that the motor can only be removed in the "fresh air mode" position without difficulty (intake opening for recirculating air mode is sealed via the fresh/recirculating air door -A-). If motor is found in a different position and can no longer be moved, motor cannot be simply pulled off, rather it must be loosened first with great force from mounting points -C-, ensure that toothed gear -D- is not damaged when doing this.

Installation

Note. Motor as replacement part is delivered in the "fresh air mode" position, only when toothed gear -A- contacts stop -B- can it then be connected onto toothed gear of fresh/recirculating air door. If a motor was removed in a different position or activated in the removed state, it cannot be installed. If toothed gear -A- of motor does not stand at stop -B- "fresh air mode", proceed as follows

Connect the motor to the vehicle wiring harness.

Switch on the ignition.

Scheme 13

Wait until the toothed gear -A- on the motor reaches the stop -B- "fresh air mode".

Switch off the ignition.

Reach into intake opening for recirculating air mode and move the fresh/recirculating air door -A- into the "fresh air mode" position (intake opening for recirculating air mode is closed).

Pull the toothed gear -D- slightly off the shaft.

Insert the motor -B- into mounts -C- in opposite direction of arrow and onto toothed gear -D-.

Scheme 14

Note. So that toothed gear -B- on motor -A- can be slid on toothed gear of fresh/recirculating air door, short tooth -C- of motor toothed gear must align with short tooth interval -D- of toothed gear on shaft of fresh air/recirculating air door -D-.

After installing the control motor, install the toothed gear -1- onto the fresh/recirculation air door shaft again.

Install the wiring harness so that it cannot come in contact with any moving parts (for example, the lever on the motor).

Install the bracket -A-. When doing this, make sure the guide -D- fits correctly into the mount -E- and the bracket locks with the two retainers -B- and -C-.

Note. Position of motor (and of door) is no longer visible with glove compartment installed, therefore it is sensible to check its function before installing glove compartment. If both toothed gears are assembled in incorrect position, fresh/recirculating air door does not reach its two end positions or motor does not run cleanly and without hitching.

Install the removed parts in the opposite order.

Note. After installing the fresh/recirculating air door motor, the function of the recirculating air door must be checked.

Checking: use the Vehicle Diagnostic Tester.

Replace: initiate Basic Setting function using the Vehicle Diagnostic Tester. Refer to CHECKING AND ADJUSTING COMPONENTS .

HEATER CORE

Special tools and workshop equipment required

1. Drip Tray For Shop Crane -VAS 6208
2. Hose Clamps Up To Diameter 40 mm -VAS 3093
3. Compressed Air Gun, Commercially Available

Removal

Remove the bulkhead in the plenum chamber. Refer to Removal and Installation .

Place -VAS 6208- under the engine.

Scheme 15

Clamp the coolant hoses -1- using the -VAS 3093- and remove the coolant hoses from the heater core.

Scheme 16

Connect a section of hose -A- to the upper connection on the heater core.

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

Using a compressed air gun, carefully clear out any coolant still inside the heater core into the container -B-.

Scheme 17

Loosen the bolt -1- (do not remove it completely) from the connection flange between the heater core connections.

Note. This allows the coolant pipes to move for removing the heater core.

Remove the footwell trim on the driver side. Refer to Removal and Installation .

Remove the left footwell vent. Refer to LEFT FOOTWELL VENT .

Scheme 18

Remove the bolts -1- and remove the heater core trim.

Cover the carpet the in area under heater core with waterproof foil and water absorbing paper.

Scheme 19

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

Remove the heater core from the heater housing.

Installation

Installation is carried out in the reverse order while noting the following

Scheme 20

Check the seals -A- and -B- on the heater core for damage.

Note. An incorrectly glued seal can roll up into heater housing when sliding in the heater core. Cold air may flow past heater core if seal is damaged or not properly fitted.

Check the heater housing (while the heater core is removed) through the heater core opening -A-, for dirt.

Scheme 21

Remove any dirt or coolant which has leaked out of the heater (for example, after removing a leaking heater core).

Install the heater core into the heater housing.

Coat sealing rings -1- with coolant before installing.

Scheme 22

Install the seals -1- into the coolant pipe connections.

Note. If hose clamps are deformed, replace them.

Connect the coolant pipes.

Hose clamps -A- must be able to be twisted slightly when installing onto the coolant pipes.

Tighten hose clamps -A- to 2.0 Nm.

Check seating of both clamps -A- after tightening bolts, clamps must enclose the flange on coolant pipe completely and must not touch other components.

Tighten the connection flange bolt -1- between the heater core connections to 2 Nm.

Make sure the grommet -C- fits correctly inside the plenum chamber bulkhead.

Scheme 23

Seal flange for coolant pipes to heater core -A- and for expansion valve (to evaporator, only in vehicles with A/C system) -B- at pass-through of grommet -C- with silicon adhesive sealant if necessary (to prevent water from penetrating).

Note. Replace the seals. If hose clamps are deformed, replace them. Replace all the coolant after replacing the heater core. Refer to DRAINING AND FILLING . Check coolant circuit for leaks, pay particular attention to the connection between coolant hoses and heater core. Refer to COOLING SYSTEM, CHECKING FOR LEAKS .

HEATER AND A/C UNIT

Special tools and workshop equipment required

1. Drip Tray For Shop Crane -VAS 6208
2. Hose Clamps Up To Diameter 40 mm -VAS 3093
3. Torque Wrench -V.A.G 1331
4. Compressed Air Gun, Commercially Available

Removal

Note. To improve accessibility, additional components, for example, engine cover must be removed (depending on engine version). Refer to ENGINE COVER/UPPER AIR FILTER HOUSING .

Remove the instrument panel. Refer to Removal and Installation .

If the vehicle has a steel subframe, then remove the subframe. Refer to Removal and Installation . The tunnel support is welded to the steel tube on these vehicles.

Remove the right and left footwell channels (on vehicles where it is not necessary to remove the subframe). Refer to REAR FOOTWELL CHANNEL .

Place -VAS 6208- under the engine.

Mark the coolant hoses -1-.

Clamp the coolant hoses -1- using the -VAS 3093- and remove the coolant hoses from the heater core.

Connect a section of hose -A- to the upper connection.

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

Using a compressed air gun, carefully blow residual coolant out of heater core at heater core connection.

Cover the carpet inside the passenger compartment with waterproof foil and water absorbing paper.

Note. When removing the bolts, make note of the lengths and allocation.

Scheme 24

1. Screw 4.5 ± 0.7 Nm On the lower right side on the cable bracket for the heater and air conditioner near the plenum chamber bulkhead.
2. Screws 4 ± 0.7 Nm Quantity 2
3. Cable Bracket
4. Heating and A/C Unit Removing -- Remove the condensation water hose from the heater and air conditioner. Refer to «CONDENSATION WATER DRAIN HOSE, CHECKING»(ref-475571-S23748702042012052300000) . -- Disconnect the connectors from the heater and air conditioner. NOTE: All cable ties opened or cut during removal must be reinstalled at the same locations during installation. The air conditioning wiring harness is removed with the heater and air conditioner. -- Remove the bolts -7- and -5-. -- Remove the supports -8- and -9-. Assembly carrier bolts 9 ± 1.3 Nm. Tunnel bolts 20 ± 3 Nm. If the vehicle has a steel subframe, then remove the subframe. Refer to «Removal and Installation»(ref-475594-S08016081942012052300000) . The supports -8- and -9- are welded to the steel pipe on these vehicles. -- Remove the bolts -10- and -12- and bracket -11-. -- Remove the bolts -1- and -2- from the cable bracket -3-. NOTE: Pull the heater and A/C unit slightly from the bulkhead on the front passenger side in order to be able to access the bolt -1-. When removing heat unit, make sure the two coolant pipes of the heater core do not get caught and bent or damaged on plenum chamber or noise insulation pan. Observe wiring harness, individual electrical wiring connections may get damaged when pulling on harness. -- Remove heating and A/C unit. Installing Installation is carried out in the reverse order while noting the following: NOTE: A second technician is necessary to install the heater. Tighten the bolts on the subframe first when installing the supports -8- and -9-. -- When inserting heater core, have the second technician guide both coolant pipes to heater core through the seal (from engine compartment). Refer to «SEAL FOR HEATING AND A/C UNIT / ENGINE COMPARTMENT»(ref-475552-S36268177292012052300000) . -- Fill the coolant. Refer to «DRAINING AND FILLING»(ref-475529-S03789025912012052300000) .
5. Bracket
6. Subframe NOTE: There are two types of subframes (aluminum and steel). The steel supports are welded to the steel pipe.
7. Screws 9 ± 1.3 Nm
8. Right Support
9. Left Support
10. Screws 9 ± 1.3 Nm Quantity 2
11. Bracket
12. Screws 9 ±1.3 Nm Quantity: 2

Scheme 25

Note. Make sure the seal -A- is installed correctly.

Installation

Install in reverse order of removal.

INTAKE AIR GRILLE

Removal

Remove the plenum chamber cover. Refer to Removal and Installation .

Remove the cover -1- from the plenum chamber.

Scheme 26

Note. Beginning 25 May 2008, vehicles with Climatronic have a bracket with an Air quality sensor -G238- installed on the intake air grille. Air quality sensor function, refer to AIR QUALITY SENSOR -G238 .

Turn the air quality sensor -1- to the right and remove it.

Scheme 27

Remove the flange nuts -arrows- (2.5 ± 0.4 Nm) and the intake air grille.

Scheme 28

Installation

Install in reverse order of removal.

Note. The seal must fit correctly in the intake air grille.

Assembly sequence

Align the air grille on the flange.

Hold the intake air grille and install the side flange nuts (2.5 ± -0.4 Nm) and then the center flange nut.

OUTSIDE AIR TEMPERATURE SENSOR -G17

Note. The outside air temperature sensor is located behind the air grille in the center. Remove it through the center of the air grille.

Removal

Unhook the tab -arrow A- from the bracket.

Scheme 29

Remove the outside air temperature sensor -1- from the bracket in -direction of arrow-.

Remove the outside air temperature sensor forward through the center of the air grille and disconnect the connector.

Installation

Install the outside air temperature sensor in reverse order of removal.

CENTER VENT

Remove the radio. Refer to Removal and Installation .

Remove screws -1-.

Scheme 30

Disconnect the connectors from the center vents.

Remove the center vent from the instrument panel in direction of arrow -A-.

DRIVER AND PASSENGER SIDE VENTS

Note. Vent removal on both sides is identical.

Removal

Scheme 31

Remove the side instrument panel cover. Refer to Removal and Installation .

Reach into the instrument panel and unclip the vent from the instrument panel -1- in direction of -arrow A-.

Installation

Install in reverse order of removal.

LEFT FOOTWELL VENT

Removal

Remove the driver side storage compartment. Refer to Removal and Installation .

Scheme 32

Remove the screw -2- and the left footwell vent -1-.

Installation

Install in reverse order of removal.

RIGHT FOOTWELL VENT

Removal

Remove the glove compartment. Refer to Removal and Installation .

Scheme 33

Unscrew securing bolt -2- and remove right footwell vent -1-.

Installation

Install in reverse order of removal.

Note. If the vehicle has glove compartment cooling, check the coolant hose to make sure it is secure.

REAR FOOTWELL CHANNEL

Note. Removal of rear channels on both sides is identical.

Removal

Remove the front passenger or driver side. Refer to Removal and Installation .

Remove the center console. Refer to Removal and Installation .

Scheme 34

Lift floor carpet, unclip rear channel from floor and pull off from heater.

Installation

Install in reverse order of removal.

Note. When installing the rear channel, ensure the rear channel is first slid onto heater housing -arrow- and then clipped in to floor.

VENTILATION VENT FRAME

Special tools and workshop equipment required

1. Trim Removal Wedge -3409

Remove the rear bumper. Refer to Removal and Installation .

Release the tabs -2- using the -3409- -1- and remove the vent frame -3- from the side panel.

Scheme 35

Scheme 36

1. Bracket
2. Screws Bolts must be unscrewed to separate air distributor and evaporator housing.
3. Cover
4. Fresh/Recirculating Air Door Motor -V154- Checking: use Vehicle Diagnostic Tester. Removing and installing, refer to «FRESH/RECIRCULATING AIR DOOR MOTOR -V154»(ref-475552-S28213788292012052300000) .
5. Housing For Air Entry With air recirculation door. Removing and installing, refer to «AIR INTAKE HOUSING»(ref-475552-S11913518782012052300000) .
6. Upper Section Of Evaporator Housing Disassembling and assembling evaporator housing, refer to «EVAPORATOR HOUSING»(ref-475571-S07351290072012052300000) .
7. Lower Section Of Evaporator Housing Disassembling and assembling evaporator housing, refer to «EVAPORATOR HOUSING»(ref-475571-S07351290072012052300000) .
8. Fresh Air Blower Series Resistor With Fuse -N24- Removing and installing, refer to «FRESH AIR BLOWER SERIES RESISTOR WITH FUSE -N24»(ref-475552-S33171917912012052300000) .
9. Fresh Air Blower -V2- Removing and installing, refer to «FRESH AIR BLOWER -V2»(ref-475552-S17079984442012052300000) .
10. Dust and Pollen Filter Removing and installing, refer to «DUST AND POLLEN FILTER»(ref-475552-S19219546922012052300000) .
11. Cover For dust and pollen filter.
12. Heater Core Removing and installing, refer to «HEATER CORE»(ref-475552-S05136410682012052300000) .
13. Heater Core Trim
14. Auxiliary Heater Heating Element -Z35- Only installed on vehicles with Diesel engine.
15. Flexible Shaft For Air Distribution Door Removing and installing, refer to «FLEXIBLE SHAFT, THROUGH 18 MAY 2008»(ref-475571-S36679383542012052300000) .
16. Junction Box
17. Flexible Shaft For The Temperature Door Removing and installing, refer to «FLEXIBLE SHAFT, THROUGH 18 MAY 2008»(ref-475571-S36679383542012052300000) .

Scheme 37

Scheme 38

Scheme 39

Scheme 40

1. Trim Removal Wedge -3409
2. Torque Wrench -V.A.G 1331
3. Vehicle Diagnosis, Testing and Information System -VAS 5051B- (or succeeding model)
4. Drip Tray For Shop Crane -VAS 6208
5. Hose Clamps Up To Diameter 40 mm -VAS 3093
6. Compressed Air Gun, Commercially Available