Heating, Ventilation Air Conditioning: Other Volkswagen Passat B5 рестайлинг

List of available functions

Note. Press HELP button to print out a complete list of available functions. This list indicates function capability of Scan Tool VAG 1551 only, and does not necessarily reflect function capability of vehicle systems equipped with OBD. For AC/Heating Electronics address word 08, do not attempt to select functions other than those listed above. After function is completed and forwarded with --> button, Scan Tool VAG 1551 returns to following start position

Indicated on display (select function, e.g.: 02 - check Diagnostic Trouble Code (DTC) memory)

Basic Setting (function 04)

Note. The following information applies to Passat with Climatronic models through 11.01 production only. OBD program functions on vehicles from 12.01 production must be performed using the Vehicle Diagnostic Testing and Information System VAS 5051 in mode "Guided Fault Finding".

Note. If the display flashes after switching ignition on even though no Diagnostic Trouble Code (DTC) are in memory (function 02), perform function 07 "Code control module" followed by function 04 "Basic setting".

1. Connect Scan Tool VAG 1551 , input address word 08 "AC/Heating electronics" and press --> until "Select function XX" appears in display --> «On Board Diagnostic (OBD), initiating checking control module versions»(ref-255355-S29515727232007053000000) .
2. Switch printer on by pressing PRINT button (warning lamp in button lights up).
3. Check Diagnostic Trouble Code (DTC) memory --> «Diagnostic Trouble Code (DTC) Memory, checking (function 02)»(ref-255355-S42276188482007053000000) and rectify all malfunctions shown.
4. Erase Diagnostic Trouble Code (DTC) memory --> «Diagnostic Trouble Code (DTC) Memory, erasing (function 05)»(ref-255355-S24623292282007053000000)

1. Check coding --> «Climatronic Control Module J255 , coding (function 07)»(ref-255355-S02682105982007053000000) and correct if necessary.

Indicated on display (select function)

1. Press buttons 0 and 4 to select function 04 "Basic setting".

Indicated on display

1. Press Q button to confirm input.

Indicated on display

1. Enter display group number 000
2. Press Q button to confirm input.

Note. The Climatronic Control Module J255 stores all flap motor position sensor (potentiometer) values when moving to their final positions and therefore takes on the basic setting of all flap motors.

Indicated on display

Note. The movement of the four flap motors can be followed on the display. The changes in the feedback values do not give an indication of a malfunctioning motor.

Indicated on display

The basic setting is completed when the display reads 0. malfunctions recognized by the system are stored in the Diagnostic Trouble Code (DTC) memory.

1. Press --> button.

Indicated on display (function selection)

1. Press buttons 0 and 2 to select function 02 "Check Diagnostic Trouble Code (DTC) memory".

Indicated on display

1. Press Q button to confirm input.

The number of stored DTCs or "No malfunction recognized" appears in the display.

1. Press --> button. Stored DTCs are displayed one after the other and printed out by pressing the print button.
2. When the last DTC has been displayed and printed out, eliminate malfunctions using DTC table --> «Diagnostic Trouble Code (DTC) table»(ref-255355-S22303384272007053000000)
3. Press --> button.

Indicated in display (select function, e.g.: 02 check Diagnostic Trouble Code (DTC) memory)

Prerequisites

1. DTC memory has been checked.

End Output (function 06)

Indicated on display

Note. If this appears in the display, the test sequence is faulty.

1. Follow test sequence precisely: first Check Diagnostic Trouble Code (DTC) memory, if necessary eliminate malfunctions, then erase.

1. Press buttons 0 and 6 to end output.

Indicated on display

Press Q button to confirm input.

Indicated on display

1. Switch off ignition.
2. Disconnect Scan Tool VAG 1551.

Climatronic Control Module J255 , coding (function 07)

Note. The following information applies to Passat with Climatronic models through 11.01 production only. OBD program functions on vehicles from 12.01 production must be performed using the Vehicle Diagnostic Testing and Information System VAS 5051 in mode "Guided Fault Finding". Each replacement Climatronic Control Module J255 must be coded after installing. Perform function 04, "Basic Setting" , after coding. If the appropriate vehicle code or the appropriate equipment level is not displayed, the control module must be coded as follows: The A/C Control Head E87 flashes for 15 seconds when the Climatronic Control Module J255 has not been coded.

1. Connect Scan Tool VAG 1551 , input address word 08 "AC/Heating electronics" and press --> until "Select function XX" appears in display --> «On Board Diagnostic (OBD), initiating checking control module versions»(ref-255355-S29515727232007053000000) .

Indicated on display

1. Press buttons 0 and 7 to select function 07 "Coding control module".

Indicated on display

1. Press Q button to confirm input.

Indicated on display

1. Using scan tool button pad, enter code number according to coding table and confirm entry with Q button.

CODING TABLE

CODING TABLE

1. Press Q button to confirm input.

The Scan Tool VAG 1551 display will show the control module coding and part number.

1. Press --> button.

Indicated on display

Note. The code entered and displayed will not be loaded into the Climatronic control module until the ignition has been switched off once.

1. End output (function 06) --> «End Output (function 06)»(ref-255355-S13522750942007053000000) .
2. Switch off ignition and disconnect Data Link Connector (DLC).

Read Measuring Value Block (function 08)

Note. The following information applies to Passat with Climatronic models through 11.01 production only. OBD program functions on vehicles from 12.01 production must be performed using the Vehicle Diagnostic Testing and Information System VAS 5051 in mode "Guided Fault Finding". During the function "Read measuring value block" the Climatronic regulation is in operation. 8 display group numbers display up to 4 measuring values each. To safely read measuring values while driving, an assistant is required.

1. Connect Scan Tool VAG 1551 and input address word 08 AC/Heating electronics and then press --> button, until "Select function XX" is shown in display --> «On Board Diagnostic (OBD), initiating checking control module versions»(ref-255355-S29515727232007053000000) .

Indicated on display (select function)

1. Press buttons 0 and 8 to select function 08 "Read measuring value block".

Indicated on display

1. Press Q button to confirm input.

Indicated on display

1. Enter desired display group number for component or system to be checked --> table, beginning on (for example, Display Group 001 covers various compressor switch-off conditions).

Indicated on display

1. Press Q button to confirm input.

Indicated on display

Note. Interpreting measured values in individual display fields --> table beginning on. With the printer switched on the information on the display will be printed-out. If measured value specifications are met in all display fields

1. Press --> button.

Indicated on display (select function)

Note. To change to another display group, proceed as follows

Table of selectable display group numbers

Display groups 009 - 013 for vehicles 10.00 --> only

Indicated on display (select function)

Note. After completing the function "Read measuring value block" Check Diagnostic Trouble Code (DTC) memory --> Diagnostic Trouble Code (DTC) Memory, checking (function 02)

Safety measures

The subassemblies and lines of the air conditioner are filled with Tetrafluoroethane also known as refrigerant R-134a.

A label on the lock carrier in the engine compartment indicates the refrigerant type and capacity.

Commercial designation

The following designations are used and appear on component labels and factor tags

1. R-134a
2. Tetrafluoroethane
3. CH 2 F CF 3
4. H-KW 134a

1. SUVA 134a
2. ARCTON 134a

Color

Refrigerant R-134a is colorless and is invisible as a gas. R-134a when viewed through the sight glass may appear milky due to the mixture of refrigerant and lubricating oil (PAG oil).

Temperature/pressure relationship

R-134a in an enclosed container will have a specific temperature/pressure relationship.

Refrigerant oil

A special Polyalkylene Glycol (PAG) synthetic oil is used in R-134a systems. This oil is NOT compatible with mineral based oils used in R-12 systems. See safety measures --> A/C Refrigerant System - General , for Warnings and Cautions regarding proper oil usage.

Airborne properties

Escaped refrigerant gases are heavier than air and will gather first in low places, like under the car. R-134a refrigerant gas displaces oxygen and may cause suffocation in low areas of poor air circulation.

Refrigerant R-134a is not poisonous in any state (liquid or gas) and is safe when used properly.

Affects on plastic

Refrigerant R-134a will deteriorate some plastics. Therefore, when making system repairs, use only genuine VW replacement parts which are specified for use with R-134a refrigerant.

Affects on metal

In its pure state, refrigerant R-134a is chemically stable and will not attack iron, copper, brass or aluminum. However, the mixture of R-134a and PAG oil may deteriorate certain metals (copper). Therefore, when making system repairs, use only genuine VW replacement parts which are specified for use with R-134a refrigerant.

Water solubility

Liquid R-134a refrigerant will absorb only very minute quantities of moisture. However, R-134a vapor can absorb large amounts of moisture.

Flammability

R-134a refrigerant is not flammable.

Refrigerant containers

DO NOT exceed maximum rated capacity of refrigerant container.

Leak detection

Use halogen leak detector Hitec HI400A-TEL or equivalent to check for R-134a system leaks. This tool can also be used to detect leaks in R-12 systems. Many currently available R-12 leak detectors cannot detect R-134a refrigerant leaks.

R-134a refrigerant oil

A special Polyalkylene Glycol (PAG) synthetic oil is used in R-134a systems. This oil is NOT compatible with mineral based oils used in R-12 systems.

Heating and A/C components in passenger compartment, servicing

Note. System components identified with * must only be serviced or replaced after discharging refrigerant system. Use Kent Moore ACR4 or equivalent. System components identified with ** must only be serviced or replaced after disconnecting vehicle battery. --> 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL

Scheme 22

1 - Clip

1. Lift out with screwdriver.

2 - Dust and pollen filter

1. Vehicles from 10.00, replacing --> «Dust and pollen filter from 10.00, removing and installing»(ref-255355-S33595325152007053000000) .

3 - Air intake housing

4 - Defroster air outlet

1. Removing and installing --> «70 - INTERIOR TRIM»(ref-255354-S40858316772007053000000) .

5 - Side window air outlets

1. Removing

6 - Heating and A/C controls

With

1. A/C Switch E30
2. Fresh Air Blower Switch E9
3. Fresh Air Blower/Recirculated Air Switch E184
4. Removing and installing --> «Heating and A/C controls, removing and installing»(ref-255355-S39739210152007053000000)

1. Assembly --> «Heating and A/C controls, assembly»(ref-255355-S36372482642007053000000)

7 - Air outlets

1. Center and side air outlets (early production), removing
2. Center air outlet (later production), removing
3. Side air outlets (later production), removing

8 - Instrument panel cross member **

1. Always follow installation instructions for bolt

9 - Defroster duct **

1. Replacing
2. Remove instrument panel --> «70 - INTERIOR TRIM»(ref-255354-S40858316772007053000000)

10 - Fresh/Recirculating Air Door Motor V154

1. Removing and installing

11 - Ambient Temperature Switch F38

1. Switches off A/C Clutch N25 at low ambient temperatures
2. Switching point: 5 ° C (41.5 ° F)
3. Replacing
4. Remove glove compartment --> «68 - INTERIOR EQUIPMENT»(ref-255354-S30068940822007053000000)

1. Reach behind heating and A/C unit from below and pull out switch.

12 - Gasket

1. Replace if damaged
2. Replacing
3. Remove Ambient Temperature Switch F38
4. Remove dust and pollen filter

1. Set fresh air/recirculation flap in "fresh air" position
2. Reach down into air intake housing and pull out gasket

Note. If unable to access and remove gasket as described, proceed as follows: Remove instrument panel --> 70 - INTERIOR TRIM Always follow installation instructions for bolt

13 - Evaporator water drain guide

1. Removing and installing

14 - Heating and A/C unit *, **

Contains

1. Heater core
2. Evaporator
3. Removing/assembly --> «Heating and A/C unit, assembly»(ref-255355-S06352040022007053000000) .

15 - Fresh Air Blower V2

1. Removing and installing

16 - Fresh Air Blower Series Resistor With Fuse N24

1. Replacing

17 - Center air outlet duct **

18 - Control panel trim

1. Unclip using screwdriver

19 - Center trim

20 - Heating and A/C cables

1. Installing --> «Heating and A/C cables, installing»(ref-255355-S37321658942007053000000)

21 - Heater core *, **

1. Removing and installing.
2. Always use new coolant after replacement

22 - Left rear duct

23 - Lower duct

24 - Upper duct

25 - Footwell air outlet **

1. Replacing
2. Remove instrument panel --> «70 - INTERIOR TRIM»(ref-255354-S40858316772007053000000)
3. Remove instrument panel cross member - 8 -.
4. Always follow installation instruction for bolt

1. Remove all upper ducts.
2. Carefully lift heating and A/C unit.
3. Remove footwell air outlet.

26 - Instrument panel cross member, left side member securing bolt

1. Always follow installation instruction for bolt

27 - Relay

Coolant Fan control (FC) Relay J26

1. Control number 214

First Speed Engine Coolant (EC) Fan Control (FC) Relay (V7, V35) J279

1. Vehicles through 09.00: Control number 214
2. Vehicles from 10.00: Control number 373

Second Speed Coolant Fan Control (FC) Relay (V7) J280

1. Vehicles through 09.00: Control number 213
2. Vehicles from 10.00: Control number 370

Radiator Fan Afterrun Relay J397

1. TDI - PD only (where applicable)
2. Control number 373

Component locations --> Electrical Wiring Diagrams, Troubleshooting and Component Locations.

28 - A/C Cut-Off Control Module J314

1. Control number 384 --> Electrical Wiring Diagrams Component Locations.

29 - Instrument panel **

1. Removing: --> «70 - INTERIOR TRIM»(ref-255354-S40858316772007053000000)

Removing air outlets

1. Center and side air outlets (early production), removing
2. Center air outlet (later production), removing
3. Side air outlets (later production), removing

Scheme 23

1. Carefully pull out using needle-nose pliers.

Scheme 24

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

Scheme 25

1. 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.

1. Grip center vent - 1 - at point - C - which has been raised up slightly from instrument panel opening by action of pushing down.

Scheme 26

1. Push center vent in direction - D - to release locking lugs and pull it outward slightly.

Scheme 27

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

Side air outlets (later production), removing

Note. Removal of both sides is identical.

Scheme 28

1. Unclip and remove instrument panel side cover - 1 - using screwdriver.
2. Guide a flat screwdriver between vent and seal alternately into side openings - A - and - B -.

Scheme 29

1. Pry vent - 2 - in direction - C - alternately through these openings.

Scheme 30

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

Fresh Air Blower Series Resistor With Fuse N24 , replacing

1. Remove glove compartment. --> «68 - INTERIOR EQUIPMENT»(ref-255354-S30068940822007053000000) .

Scheme 31

1. Disconnect electrical connector and remove bolt - arrow -.
2. Seal surface between series resistance - 1 - and air duct before installing with AMV 176 000 05 (or equivalent).

Fresh Air Blower V2 , removing and installing

Removing

1. Remove glove compartment --> «68 - INTERIOR EQUIPMENT»(ref-255354-S30068940822007053000000) .
2. Disconnect electrical connector - 1 -.

Scheme 32

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

Installing

1. Install in reverse order of removal.

Scheme 33

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

Fresh/Recirculating Air Door Motor V154 , removing and installing

Removing

1. Remove glove compartment. --> «68 - INTERIOR EQUIPMENT»(ref-255354-S30068940822007053000000)
2. From the front passenger side, use a mirror to look behind heating and A/C unit.

Scheme 34

1. Remove screws (TORX T15 ) - arrows -.
2. Unclip lever for fresh/recirculated air flap.
3. Pull off connector.
4. Pull out motor downwards.

Installing

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

Scheme 35

1. Carefully remove trim panel by depressing locating lugs - arrows - with a covered screwdriver. Do not damage instrument panel.

1. Remove instrument panel screws - arrows
2. Remove center trim panel (19) with screws. See «Heating And A/C Components In Passenger Compartment, Servicing»(ref-255355-S36765835422007053000000) and (Scheme 22).
3. Pull controls with cables attached from instrument panel.
4. Release cables on controls.

1. Disconnect electrical connector.

Installing

Note. 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.

Scheme 36

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

Scheme 37

1. 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

Scheme 38

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

Temperature flap cable sleeve marking: Red

Scheme 39

1 - Heating and A/C controls

With

1. A/C Switch E30
2. Fresh Air Blower Switch E9
3. Fresh Air Blower/Recirculated Air Switch E184
4. Removing and installing --> «Heating and A/C controls, removing and installing»(ref-255355-S39739210152007053000000)

2 - Illumination filter

3 - Trim panel

4 - Fresh Air Control Illumination L16

1. 12V, 1.2W
2. Removing
3. Unclip trim panel - 7 - and rotary control - 5
4. Remove bulb (if necessary, slide a short piece fuel hose over bulb and pull out).

5 - Rotary control

1. For blower speed
2. To remove: Use pliers with suitable plastic or rubber protection on jaws

6 - Rotary control

1. For air distribution
2. To remove: Use pliers with suitable plastic or rubber protection on jaws

7 - Trim panel

8 - Rotary control

1. For interior temperature
2. To remove: Use pliers with suitable plastic or rubber protection on jaws

Heating and A/C cables, installing

Note. 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.

Scheme 40

1 - Central flap cable

1. From air distribution rotary control to central flap
2. Cable sleeve marking: Black
3. Removing and installing --> «Temperature and central flap cables, removing and installing»(ref-255355-S33405926022007053000000)

2 - Footwell/defrost flap cable

1. From air distribution rotary control to footwell/defrost flap
2. Cable sleeve marking: White
3. Replacing
4. Remove controls for heating and A/C system --> «Heating and A/C controls, removing and installing»(ref-255355-S39739210152007053000000)

1. Remove driver side shelf --> «68 - INTERIOR EQUIPMENT»(ref-255354-S30068940822007053000000)
2. Unclip cable at heating and A/C unit.
3. When installing, attach cable to heating and A/C unit first.

3 - Heating and A/C controls

1. Removing --> «Heating and A/C controls, removing and installing»(ref-255355-S39739210152007053000000)

4 - Temperature flap cable

1. From temperature rotary control to temperature flap
2. Cable sleeve marking: Red
3. Removing and installing --> «Temperature and central flap cables, removing and installing»(ref-255355-S33405926022007053000000)

Temperature and central flap cables, removing and installing

Note. 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

1. Remove heating and A/C controls --> «Heating and A/C controls, removing and installing»(ref-255355-S39739210152007053000000)
2. Remove instrument panel --> «70 - INTERIOR TRIM»(ref-255354-S40858316772007053000000)
3. Remove footwell air outlet.
4. Disconnect cable for central flap or temperature flap on heating and A/C unit.

Scheme 41

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 not press end of wire - arrow - against lever.

Heating and A/C components in engine compartment, servicing

Note. System components identified with * must only be serviced or replaced after discharging refrigerant system. Use Kent Moore ACR4 or equivalent. Illustration shows vehicle with engine code AHA.

Scheme 42

1 - Accumulator *

2 - Refrigerant hose *

1. Between evaporator and accumulator

3 - Refrigerant hose *

1. Between evaporator and condenser

4 - Low pressure service valve *

5 - *

6 - Dust and pollen filter

1. Vehicles from 10.00, replacing --> «Dust and pollen filter from 10.00, removing and installing»(ref-255355-S33595325152007053000000)
2. Ambient Temperature Switch F38 located below dust and pollen filter in lower air intake housing.

7 - Evaporator *

1. In heating and A/C unit.
2. Removing/assembly --> «Heating and A/C unit, assembly»(ref-255355-S06352040022007053000000) .

8 - Evaporator water drain valve

1. Checking.

9 - Pressure relief valve *

1. Zexel compressor illustrated
2. Checking, Zexel compressor
3. Checking, Denso compressor

10 - A/C compressor *

1. A/C compressor and bracket removing/assembly --> «A/C Compressor and Bracket»(ref-255355-S29259358342007053000000) .

11 - A/C Clutch N25

1. Servicing: Zexel --> «A/C Clutch N25 - Zexel, servicing»(ref-255355-S37723751872007053000000)
2. Servicing: Denso --> «A/C Clutch N25 - Denso, servicing»(ref-255355-S11827342122007053000000)

12 - Condenser*

1. Removing/assembly --> «Condenser, assembly»(ref-255355-S04106266752007053000000) .

13 - A/C Pressure Switch F129

1. Tightening torque 8 Nm (71 in lb)
2. Replace O-ring (note Part No.).

Function

1. Switches Coolant Fan V7 to next highest speed when pressure increases in refrigerant circuit.
2. Switches off A/C Clutch N25 when refrigerant pressure is excessive (e.g.: insufficient engine cooling).
3. Switches off A/C Clutch N25 when refrigerant pressure is too low (e.g.: refrigerant loss).
4. Electrical checking

1. Functional checks
2. Removing and installing through 09.00
3. Removing and installing from 10.00.

14 - Refrigerant hose *

1. Between compressor and condenser

15 - Refrigerant hose *

1. Between compressor and accumulator.

1. Lift front hood. Remove air intake plenum cover.

Scheme 43

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

1. Install in reverse order of removal.

Scheme 44

1 - Filter housing

2 - Dust and pollen filter

3 - Nut (2Nm)

Ventilation system, checking

Note. 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

1. Remove rear bumper cover --> «63 BUMPER»(ref-255352-S24259318442007053000000)

Scheme 45

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

Scheme 46

Special tools, testers and auxiliary items required

1. Two Hole Pin Wrench VAG 3212
2. A/C Clutch set VAG 1719
3. Adapter VAG 1719/1
4. Adapter VAG 1719/2

Not illustrated

1. Torque wrench (5 - 50 Nm)
2. Locally available two-arm puller (e.g. Kukko 20-10) with fixtures for a depth of 100 mm.
3. Feeler gauge

Note. 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 --> A/C refrigerant system, discharging and remove compressor from compressor bracket.

Scheme 47

1 - Hex head combination bolt

1. 15 Nm (11 ft lb)
2. Removing and installing

2 - Clutch plate

1. Removing
2. Checking clutch plate gap

3 - Shims

1. Used to adjust gap between clutch plate and pulley
2. Gap: 0.3 - 0.6 mm (0.011 - 0.023 in)

4 - Circlip

1. Always replace
2. Install correctly: thick side faces compressor
3. Ensure correct seating in groove

5 - Clutch pulley

1. Removing and installing

6 - Circlip

1. Always replace
2. Install correctly: Flat side faces compressor
3. Ensure correct seating in groove

7 - Clutch coil

1. Installing

Note. A thermofuse 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 - Felt ring

1. Always replace

9 - Bolt

10 - Compressor

1. Manufacturer: Zexel

Scheme 48

1. Remove bolt.

1. 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.

Clutch plate, removing

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

Scheme 49

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

Clutch pulley, removing and installing

Removing

1. Remove felt ring.
2. Fit adapter VAG 1719/1 (or equivalent) as illustrated.

Scheme 50

1. Fit locally available 2 arm puller - B - on shoulder - A - and extract pulley.

Installing

Scheme 51

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

Clutch coil, installing

1. Install coil on compressor.

Scheme 52

1. Position pin - A - in recess.

Clutch plate gap, checking

1. Check gap with feeler gauge.

Scheme 53

1. Gap: 0.3 - 0.6 mm (0.011 - 0.023 in)

Note. 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.

Tools

Not illustrated

Special tools, testers and auxiliary items required

1. Torque wrench VAG 1331 (or 5 - 50 Nm equivalent)
2. Locally available two-arm puller (e.g. Kukko 20-10) with fixtures for a depth of 100 mm.
3. Locally available strap wrench
4. Depth Gauge

Note. 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 --> A/C refrigerant system, discharging and remove compressor from compressor bracket.

Scheme 54

1 - Hex head combination bolt

1. 15 Nm (11 ft lb)
2. Removing and installing

2 - Clutch plate

1. Removing
2. Checking clutch plate gap

3 - Shims

1. Used to adjust gap between clutch plate and pulley
2. Gap: 0.4 - 0.6 mm (0.015 - 0.023 in)

4 - Circlip

1. Always replace
2. Install correctly: Thick side faces compressor.
3. Ensure correct seating in groove.

5 - Clutch pulley

1. Remove with locally available 2 or 3 arm puller.

Ensure puller is seated correctly to prevent damage to pulley.

6 - Circlip

1. Always replace
2. Install correctly: Flat side faces compressor.
3. Ensure correct seating in groove.

7 - Clutch coil

1. Installing

Note. A thermofuse 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

1. Manufacturer: Denso

Scheme 55

1. Remove bolt.

1. Tightening torque: 15 Nm (11 ft lb)

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

1. Pry off clutch plate carefully with two large screwdrivers.

Scheme 56

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

1. Install coil on compressor.

Scheme 57

1. Locate locking pin - A - in recess - B -.

Scheme 58

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

Note. In order to check gap with compressor installed in vehicle

1. Bring front end assembly (lock carrier) into service position. --> «50 BODY, FRONT»(ref-255352-S40424905372007053000000) .

Determine "Dimension 1"

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

Determine "Dimension 2"

1. If compressor is installed in vehicle, disconnect compressor electrical connector - A - from vehicle wiring harness.
2. 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.
3. With clutch energized, measure gap between belt pulley and clutch plate with depth gauge - C

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

Note. 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.

Climate control options

1. Automatic temperature and fan speed mode
2. Manual temperature and fan speed mode
3. Manual selection of air recirculation mode
4. Manual selection of air flow to instrument panel vents

1. Manual selection of air flow to footwell vents
2. Manual selection of air flow to windshield defroster

Note. Pressing the button AUTO overrides any manually input settings. In ECON operation, only the compressor is switched off. Heating and A/C operation continues to be controlled electronically. Manually selected settings remain stored in memory after switching the ignition off and will be recalled on subsequent restart. Only the function "Air recirculation" is erased after 20 minutes. Climatronic, manual operation --> Owners Manual. A malfunction is present if all display symbols on A/C Control Head E87 flash. In this case check the Diagnostic Trouble Code (DTC) memory first --> Climatronic through 11.01 - On Board Diagnostic (OBD) .

A/C Control Head E87 , functions

Scheme 59

1 - Windshield defrost button

2 - Blower speed display

3 - Ambient (outside) temperature display

1. Display will not change when road speed is below 15 km/h (9.5 mph) and coolant temperature is above 70 ° C (158 ° F). Under these conditions, the actual measured value is not displayed because engine heat will adversely affect reading.

4 - Windshield defrost display

5 - Air recirculation display

6 - Air distribution display

7 - Selected temperature display

1. To change display from Celsius to Fahrenheit and vice versa
2. Temp. scale appears in display.

8 - Operating mode display

"AUTO" : Automatic mode

1. In automatic mode, the Climatronic maintains the selected interior temperature automatically. With this setting, the air outlet temperature, blower speed and air distribution are controlled automatically.

"ECON" : A/C system off

1. In ECON mode only the compressor is switched off. Heating and A/C operation continues to be controlled automatically.

"OFF" : Complete system is switched off

1. Select by pressing and holding "decrease blower speed" button - 17 - until "OFF" appears in display.
2. In this mode, all air flaps remain in the last set position before switching off. (Setting should only be used in the case of a malfunction).

9 - Automatic operation button

10 - Instrument Panel Interior Temperature Sensor (006785-3211) G56 and Interior Temperature Sensor Fan V42

1. Installation location on right-hand drive vehicles.

11 - ECON button

1. In ECON mode only the compressor is switched off. Heating and A/C operation continues to be controlled automatically.

12 - Warmer button

13 - Cooler button

14 - "Air flow to footwell" button

15 - "Air flow to upper body" button

16 - "Increase blower speed" button

17 - "Decrease blower speed" button

1. To switch off A/C system, press and hold button until "OFF" appears in display.
2. In this mode, all air flaps remain in the last set position before switching off. (Setting should only be used in the case of a malfunction).

18 - Recirculating air button

19 - Instrument Panel Interior Temperature Sensor (006785-3211) G56 and Interior Temperature Sensor Fan V42

1. Installation location on left-hand drive vehicles.

Scheme 60

12-pin multi-connector - A - (black -T12/-)

1 - Data Link Connector (DLC) K-wire

2 - Motronic Engine Control Module (ECM) J220 (idle speed control)

3 - A/C readiness

4 - Open

5 - Terminal 58d (instrument illumination - dimmer)

7 - Fresh Air Intake Duct Temperature Sensor G89

8 - Outside Air Temperature Sensor G17

9 - Ground signal (sensors - motors)

10 - Open

11 - Engine Coolant Temperature (ECT) warning lamp (where applicable*)

12 - Ground signal (sensors - motors)

20-pin multi-connector housing - B - (red -T20/-)

1 - Outside temperature signal from instrument cluster (where applicable*)

2 - CAN Bus - high (where applicable*)

3 - CAN Bus - low (where applicable*)

4 - CAN Bus - shielding (where applicable*)

5 - Footwell Outlet Temperature Sensor G192

6 - Center Outlet Temperature Sensor G191

7 - Evaporator Vent Temperature Sensor G263

8 - Temperature Regulator Flap Motor Position Sensor G92

9 - Central Flap Motor Position Sensor G112

10 - Footwell/Defrost Flap Motor Position Sensor G114

13 - Standing time - instrument cluster (where applicable*)

14 - Temperature increase off/PTC off (P/N 3B1/2 907 044 F only - where applicable*)

15 - Engine Coolant Shut-Off Two-Way Vacuum Valve Relay J585 (where applicable*)

17 - Back Pressure Flap Motor Position Sensor G113

18 - Sunlight Photo Sensor (3241) G107

* Confirm using applicable wiring diagram

16-pin multi-connector housing - C - (brown -T16b/-)

1 - - Kickdown (where applicable*)

2 - A/C Pressure Switch F129 pin 2 (diagnosis 2/32 bar - high pressure side)

3 - Compressor voltage (where applicable*)

4 - Speedometer signal (where applicable*)

5 - Open

6 - Engine Speed (RPM) signal (where applicable*)

7 - - Terminal 58 (instrument illumination) (where applicable*)

8 - Reference voltage 5V (10 mA) for flap motors

9 - Fresh air blower control signal (-)

10 - 11 Open

12 - Motronic Engine Control Module (ECM) (engine electronics - bi-directional)

13 - Open

14 - Fresh air blower control signal (+)

15 - Wiring control (internal)

16 - Fresh Air Blower Control Module J126

* Confirm using applicable wiring diagram

16-pin multi- connector - D - (black -T16a/-)

1 - Open

2 - Temperature Regulator Flap Motor V68

3 - Footwell/Defroster Flap Motor V85

4 - Central Air Flap Motor V70

5 - Air Flow Flap Motor V71

6 - A/C Clutch Relay J44 or A/C Compressor Regulator Valve N280 (where applicable*)

7 - Terminal 30 (where applicable*)

8 - A/C Clutch Relay J44 (where applicable*)

9 - Terminal 15

10 - Temperature Regulator Flap Motor V68

11 - Footwell/Defroster Flap Motor V85

12 - Central Air Flap Motor V70

13 - Air Flow Flap Motor V71

14 - Terminal 31 (Ground - where applicable*)

15 - Terminal 31 (Ground)

16 - Coolant Fan Control (FC) Control Module J293 or First Speed Engine Coolant (EC) Fan Control (FC) Relay (V7, V35) J279 (where applicable**)

* Confirm using applicable wiring diagram

* Engine dependent - confirm using applicable wiring diagram

Climatronic components in passenger compartment, servicing

Note. System components identified with * must only be serviced or replaced after discharging refrigerant system. Use Kent Moore ACR4 or equivalent. System components identified with ** must only be serviced or replaced after disconnecting vehicle battery. --> 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL

Scheme 61

1 - Clip

1. Lift out with screwdriver

2 - Dust and pollen filter

1. Vehicles from 10.00, replacing --> «Dust and pollen filter from 10.00, removing and installing»(ref-255355-S33595325152007053000000) .

3 - Air intake housing

4 - Sunlight Photo Sensor G107

1. Function: Controls temperature flap and fresh air blower speed depending on light intensity
2. In event of failure: Climatronic Control Module J255 assumes fixed value
3. Checking through 11.00, use Scan Tool VAG 1551 or VAG 1552 or Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 or Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Vehicle Self Diagnosis" --> «Climatronic through 11.01 - On Board Diagnostic (OBD)»(ref-255355-S42715121132007053000000) .
4. Checking from 12.00, use Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Guided Fault Finding".

1. Removing and installing

5 - Defroster air outlet

1. Removing and installing: --> «70 - INTERIOR TRIM»(ref-255354-S40858316772007053000000) .

6 - Side window air outlet

1. Removing

7 - Instrument Panel Interior Temperature Sensor G56 with Interior Temperature Sensor Fan V42

1. Climatronic Control Module J255 , A/C Control Head E87 and Instrument Panel Interior Temperature Sensor (006785-3211) G56 with Interior Temperature Sensor Fan V42 are integrated into a single unit and cannot be serviced separately.
2. Function: Temperature sensor controls temperature flap and fresh air blower speed dependent on temperature measurement of interior air.
3. In event of Instrument Panel Interior Temperature Sensor (006785-3211) G56 malfunction, operation continues using assumed value of 24 ° C (75 ° F)
4. Checking through 11.00, use Scan Tool VAG 1551 or VAG 1552 or Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 or Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Vehicle Self Diagnosis" --> «Climatronic through 11.01 - On Board Diagnostic (OBD)»(ref-255355-S42715121132007053000000) .

1. Checking from 12.00, use Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Guided Fault Finding".
2. Replacing and adjusting: Code Climatronic Control Module J255 , function 07 and then set Basic Setting, function 04 (through 11.00 --> «Climatronic through 11.01 - On Board Diagnostic (OBD)»(ref-255355-S42715121132007053000000) , from 12.00 ).

8 - A/C Control Head E87

1. Climatronic Control Module J255 , A/C Control Head E87 and Instrument Panel Interior Temperature Sensor (006785-3211) G56 with Interior Temperature Sensor Fan V42 are integrated into a single unit and cannot be serviced separately.
2. Functions --> «A/C Control Head E87 , functions»(ref-255355-S04123288442007053000000)
3. Checking through 11.00, use Scan Tool VAG 1551 or VAG 1552 or Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 or Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Vehicle Self Diagnosis" --> «Climatronic through 11.01 - On Board Diagnostic (OBD)»(ref-255355-S42715121132007053000000) .
4. Checking from 12.00, use Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Guided Fault Finding".

1. Removing and installing --> «A/C Control Head E87 with Climatronic Control Module J255 , removing and installing»(ref-255355-S32550648252007053000000)

9 - Air outlets

1. Center and side air outlets (early production), removing
2. Center air outlet (later production), removing
3. Side air outlets (later production), removing

10 - Instrument panel cross member **

1. Always follow installation instructions for bolt

11 - Defroster duct **

1. Replacing
2. Remove instrument panel --> «70 - INTERIOR TRIM»(ref-255354-S40858316772007053000000) .
3. Always follow installation instructions for bolt

12 - Evaporator water drain guide

1. Removing and installing.

13 - Fresh Air Intake Duct Temperature Sensor G89

1. Function: Temperature sensor controls temperature flap and fresh air blower speed dependent on temperature measurement of intake air.
2. Outside Air Temperature Sensor G17 value is used if Fresh Air Intake Duct Temperature Sensor G89 malfunctions.
3. Checking through 11.00, use Scan Tool VAG 1551 or VAG 1552 or Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 or Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Vehicle Self Diagnosis" --> «Climatronic through 11.01 - On Board Diagnostic (OBD)»(ref-255355-S42715121132007053000000) .
4. Checking from 12.00, use Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Guided Fault Finding".

1. Replacing
2. Remove glove compartment --> «68 - INTERIOR EQUIPMENT»(ref-255354-S30068940822007053000000)
3. Reach behind heat/A/C unit from below.
4. Turn sensor 90 ° and pull out.

Note. If unable to access and remove sensor as described above, proceed as follows: Remove instrument panel --> 70 - INTERIOR TRIM Always follow installation instructions for bolt

14 - Evaporator Vent Temperature Sensor G263

1. Vehicles from 10.00 only
2. Checking through 11.00, use Scan Tool VAG 1551 or VAG 1552 or Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 or Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Vehicle Self Diagnosis" --> «Climatronic through 11.01 - On Board Diagnostic (OBD)»(ref-255355-S42715121132007053000000) .
3. Checking from 12.00, use Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Guided Fault Finding".
4. Replacing

1. Remove glove compartment --> «68 - INTERIOR EQUIPMENT»(ref-255354-S30068940822007053000000)
2. Reach behind heating and A/C unit from below.
3. Turn sensor 90 ° and pull out.

15 - Gasket

1. Lubricate with oil when installing.

16 - Air Flow Flap Motor V71 **

1. Also operates fresh and recirculating air flap
2. Checking through 11.00, use Scan Tool VAG 1551 or VAG 1552 or Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 or Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Vehicle Self Diagnosis" --> «Climatronic through 11.01 - On Board Diagnostic (OBD)»(ref-255355-S42715121132007053000000) .
3. Checking from 12.00, use Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Guided Fault Finding".
4. Removing --> «Air flap motors (for climate control regulation), removing and installing»(ref-255355-S16816600302007053000000)

1. Replacing and adjusting
2. Initiate Basic Setting, function 04 (through 11.00 --> «Climatronic through 11.01 - On Board Diagnostic (OBD)»(ref-255355-S42715121132007053000000) , from 12.00 ).

17 - Fresh Air Blower V2

1. Checking through 11.00, use Scan Tool VAG 1551 or VAG 1552 or Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 or Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Vehicle Self Diagnosis" --> «Climatronic through 11.01 - On Board Diagnostic (OBD)»(ref-255355-S42715121132007053000000) .
2. Checking from 12.00, use Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Guided Fault Finding".
3. Removing and installing --> «Fresh Air Blower V2 with Fresh Air Blower Control Module J126 , removing and installing»(ref-255355-S18539821132007053000000)

18 - Fresh Air Blower Control Module J126

1. Function: Controls fresh air blower speed with variable voltage signal.
2. Checking through 11.00, use Scan Tool VAG 1551 or VAG 1552 or Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 or Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Vehicle Self Diagnosis" --> «Climatronic through 11.01 - On Board Diagnostic (OBD)»(ref-255355-S42715121132007053000000) .
3. Checking from 12.00, use Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Guided Fault Finding".
4. Removing and installing --> «Fresh Air Blower V2 with Fresh Air Blower Control Module J126 , removing and installing»(ref-255355-S18539821132007053000000)

19 - Air outlet for glove compartment

1. Removing and installing

20 - Temperature Regulator Flap Motor V68

1. Checking through 11.00, use Scan Tool VAG 1551 or VAG 1552 or Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 or Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Vehicle Self Diagnosis" --> «Climatronic through 11.01 - On Board Diagnostic (OBD)»(ref-255355-S42715121132007053000000) .
2. Checking from 12.00, use Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Guided Fault Finding".
3. Removing --> «Air flap motors (for climate control regulation), removing and installing»(ref-255355-S16816600302007053000000)
4. Replacing and adjusting

1. Initiate Basic Setting, function 04 (through 11.00 --> «Climatronic through 11.01 - On Board Diagnostic (OBD)»(ref-255355-S42715121132007053000000) , from 12.00 ).

21 - Central Air Flap Motor V70

1. Checking through 11.00, use Scan Tool VAG 1551 or VAG 1552 or Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 or Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Vehicle Self Diagnosis" --> «Climatronic through 11.01 - On Board Diagnostic (OBD)»(ref-255355-S42715121132007053000000) .
2. Checking from 12.00, use Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Guided Fault Finding".
3. Removing, installing and adjusting --> «Air flap motors (for climate control regulation), removing and installing»(ref-255355-S16816600302007053000000)
4. Replacing and adjusting

1. Initiate Basic Setting, function 04 (through 11.00 --> «Climatronic through 11.01 - On Board Diagnostic (OBD)»(ref-255355-S42715121132007053000000) , from 12.00 ).

Note. A modified flap (with cut-out at top) was introduced 11.98. This design allows air flow to footwell to be blocked.

22 - Climatronic Control Module J255

1. Climatronic Control Module J255 , A/C Control Head E87 and Instrument Panel Interior Temperature Sensor (006785-3211) G56 with Interior Temperature Sensor Fan V42 are integrated into a single unit and cannot be serviced separately.
2. Checking through 11.00, use Scan Tool VAG 1551 or VAG 1552 or Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 or Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Vehicle Self Diagnosis" --> «Climatronic through 11.01 - On Board Diagnostic (OBD)»(ref-255355-S42715121132007053000000) .
3. Checking from 12.00, use Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Guided Fault Finding".
4. Removing and installing --> «A/C Control Head E87 with Climatronic Control Module J255 , removing and installing»(ref-255355-S32550648252007053000000)

23 - Climatronic Control Module J255 , A/C Control Head trim

24 - Center trim

25 - Center Outlet Temperature Sensor G191

1. Function: Controls center air distribution and fresh air blower speed, dependent on air outlet temperature measurement.
2. Checking through 11.00, use Scan Tool VAG 1551 or VAG 1552 or Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 or Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Vehicle Self Diagnosis" --> «Climatronic through 11.01 - On Board Diagnostic (OBD)»(ref-255355-S42715121132007053000000) .
3. Checking from 12.00, use Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Guided Fault Finding".
4. Removing and installing

26 - Center air outlet duct **

27 - Heating and A/C unit *, **

Contains

1. Heater core
2. Evaporator
3. Removing/assembly --> «Heating and A/C unit, assembly»(ref-255355-S06352040022007053000000) .

28 - Footwell Outlet Temperature Sensor G192

1. Function: Controls air distribution to defrost/footwell and fresh air blower speed dependent on outlet temperature measurement.
2. In event of malfunction, operation continues using assumed value of 80 ° C (176 ° F)
3. Checking through 11.00, use Scan Tool VAG 1551 or VAG 1552 or Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 or Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Vehicle Self Diagnosis" --> «Climatronic through 11.01 - On Board Diagnostic (OBD)»(ref-255355-S42715121132007053000000) .
4. Checking from 12.00, use Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Guided Fault Finding".

1. Removing and installing

29 - Footwell/Defroster Flap Motor V85 **

1. Checking through 11.00, use Scan Tool VAG 1551 or VAG 1552 or Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 or Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Vehicle Self Diagnosis" --> «Climatronic through 11.01 - On Board Diagnostic (OBD)»(ref-255355-S42715121132007053000000) .
2. Checking from 12.00, use Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Guided Fault Finding".
3. Removing --> «Air flap motors (for climate control regulation), removing and installing»(ref-255355-S16816600302007053000000)
4. Replacing and adjusting

1. Initiate Basic Setting, function 04 (through 11.00 --> «Climatronic through 11.01 - On Board Diagnostic (OBD)»(ref-255355-S42715121132007053000000) , from 12.00 ).

30 - Heater core *, **

1. Removing and installing, heating and A/C unit assembly --> «Heating and A/C unit, assembly»(ref-255355-S06352040022007053000000) .
2. Always use new coolant after replacement

31 - Left rear duct

1. Right is mirror image

32 - Lower duct

33 - Upper duct

34 - Footwell air outlet **

1. Replacing
2. Remove instrument panel --> «70 - INTERIOR TRIM»(ref-255354-S40858316772007053000000) .
3. Remove instrument panel cross member - 10 -.
4. Always follow installation instructions for bolt

1. Remove upper duct.
2. Carefully lift heating and A/C unit.
3. Remove footwell air outlet.

35 - Instrument panel cross member left side support securing bolt

1. Always follow installation instructions for bolt

36 - Relay

First Speed Engine Coolant (EC) Fan Control (FC) Relay (V7, V35) J279

1. Vehicles through 09.00: Control number 214
2. Vehicles from 10.00: Control number 373

Second Speed Coolant Fan Control (FC) Relay (V7) J280

1. Vehicles through 09.00: Control number 213
2. Vehicles from 10.00: Control number 370

Radiator Fan Afterrun Relay J397

1. TDI - PD only (where applicable)
2. Control number 373

Component locations --> Electrical Wiring Diagrams Component Locations.

37 - A/C Clutch Relay J44

1. For A/C Clutch N25
2. Not for W8 engine
3. Control number 267

Component locations --> Electrical Wiring Diagrams Component Locations.

38 - Instrument panel **

1. Removing and installing: --> «70 - INTERIOR TRIM»(ref-255354-S40858316772007053000000) .

Footwell Outlet Temperature Sensor G192, removing and installing

Removing

1. Remove driver side shelf --> «68 - INTERIOR EQUIPMENT»(ref-255354-S30068940822007053000000) .
2. Disconnect electrical connector from Footwell Outlet Temperature Sensor G192.

Scheme 62

1. Rotate sender - 2 - , 90 ° - arrow - and remove from housing - 1 -.

Installing

Lubricate rubber seal on Footwell Outlet Temperature Sensor G192 with oil when installing.

Air outlet for glove compartment, removing and installing

Removing

1. Remove glove compartment --> «68 - INTERIOR EQUIPMENT»(ref-255354-S30068940822007053000000)

Scheme 63

1. Remove securing screw - 5 -.
2. Pull air outlet - 4 - out from guides on heating and A/C unit - 2 -.
3. Pull off hose - 1 -.

Installing

1. Replace seal - 3 - if damaged.

When installing, ensure that locking lugs engage in guides on heating and A/C unit - arrows -.

Center Outlet Temperature Sensor G191, removing and installing

Removing

1. Remove radio --> «91 RADIO, TELEPHONE, NAVIGATION, TRIP COMPUTER»(ref-255359-S25491043142007053000000) .
2. Remove Climatronic Control Module J255 --> «A/C Control Head E87 with Climatronic Control Module J255 , removing and installing»(ref-255355-S32550648252007053000000)
3. Remove center trim

Scheme 64

1. Disconnect electrical connector - 2 - from sender G191.
2. Rotate sender - 1 - , 90 ° - arrow A - and remove from housing - 3 -.

Installing

1. Install in reverse order of removal, being sure to coat seal lightly with oil.

Sunlight Photo Sensor G107 , removing and installing

Removing

Scheme 65

1. Carefully lift sender - 1 - at side with small screwdriver.

Installing

1. Install in reverse order of removal.

A/C Control Head E87 with Climatronic Control Module J255 , removing and installing

Special tools, testers and auxiliary items required

1. Through 11.00 Scan Tool VAG 1551 or Scan Tool VAG 1551
2. From 12.00 Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052.

Note. Climatronic Control Module J255 and A/C Control Head E87 are integrated into a single unit and cannot be serviced separately.

Scheme 66

1. Using a screwdriver with a protected tip, carefully unclip control head trim at locations indicated by - arrows -.

Scheme 67

1. Remove instrument panel screws - arrows -.
2. Pull A/C control head/control unit from instrument panel opening.
3. Disconnect electrical connections on rear of unit.
4. Remove A/C control head with control unit.

1. Install in reverse order of removal.
2. Code Control Module (function 07) and then initiate Basic Setting, function 04 (through 11.00 --> «Climatronic through 11.01 - On Board Diagnostic (OBD)»(ref-255355-S42715121132007053000000) , from 12.00.

1. Remove glove compartment --> «68 - INTERIOR EQUIPMENT»(ref-255354-S30068940822007053000000) .

Scheme 68

1. Remove screws - arrows -.
2. Remove blower with blower control unit - 2 - from housing - 1 -.

Scheme 69

1. Remove screws - arrows -.

Scheme 70

1. Lift control module - 3 - and pull out forwards - arrow B -.
2. Disconnect electrical connector - 1 -.

Observe following when inserting Fresh Air Blower Control Module J126

1. Pull both components carefully apart in direction of - arrow A - to provide a slight clearance between fresh air blower wheel - 2 - and housing - 4 -.
2. Insert control module - 3 - into housing - 4 - and secure.

1. Insert fresh air blower with blower control unit - 2 - into housing - 1 - and secure with screws - arrows -.

Air flap motors (for climate control regulation), removing and installing

Special tools, testers and auxiliary items required

1. Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052

Note. After installing any new flap motor, always use Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Guided Fault Finding" to initiate Basic Setting, function 04.

Air Flow Flap Motor V71

Temperature Regulator Flap Motor V68

Central Air Flap Motor V70

Footwell/Defroster Flap Motor V85

Air Flow Flap Motor V71 , removing and installing

Note. The air flow flap motor also operates the fresh/recirculating air flap.

Removing

1. Disconnect battery --> «27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(ref-255357-S00731330752007053000000) .
2. Remove instrument panel --> «70 - INTERIOR TRIM»(ref-255354-S40858316772007053000000) .
3. Loosen instrument panel cross member.

For the next step, an assistant must lift and hold the heating and A/C unit.

1. Look behind heating and A/C unit using a mirror from front passengers side.

Scheme 71

1. Remove bolts (TORX T15 ) - arrows A -.
2. Disconnect electrical connector.
3. Pull out motor downwards.

Installing and adjusting

Scheme 72

Observe correct orientation of flap levers to drive cam when installing flap motor.

1 - Air Flow Flap Motor V71

2 - Guide for plastic lever

3 - Guide for metal lever

1. Connect connector.

1. Insert flap motor - 1 - into guide - arrow B -.

Position air flow flap and recirculated air flap levers -2 and 3- by hand according to position of flap motor.

1. Insert flap levers - 2 - and - 3 - into drive cam guides.

1. Plastic lever, position - 2
2. Metal lever, position - 3

Remaining installation is in reverse order of removal.

1. Use Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Guided Fault Finding" to initiate Basic Setting, function 04.

Temperature Regulator Flap Motor V68 , removing and installing

The temperature flap lever and operating rod are color coded "Red".

Removing

1. Disconnect battery --> «27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(ref-255357-S00731330752007053000000) .
2. Remove instrument panel --> «70 - INTERIOR TRIM»(ref-255354-S40858316772007053000000)
3. Remove dust and pollen filter.
4. Loosen instrument panel cross member.

For the next steps, an assistant must lift and hold the heating and A/C unit.

1. Remove footwell air outlet
2. Remove air flow flap motor.

Scheme 73

1. Remove bolts (TORX T15 ) -arrows A-.
2. Carefully unclip operating rod - 1 - from lever - arrow B - using a screwdriver.

1. Turn operating rod - 1 - - arrow C - and remove motor - 2 -.
2. Disconnect electrical connector.
3. Remove flap motor.

Installing and adjusting

Install in reverse order of removal.

1. Use Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Guided Fault Finding" to initiate Basic Setting, function 04.

Central Air Flap Motor V70 , removing and installing

The temperature flap lever and operating rod are color coded "Blue".

Removing

1. Disconnect battery --> «27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(ref-255357-S00731330752007053000000) .
2. Remove instrument panel --> «70 - INTERIOR TRIM»(ref-255354-S40858316772007053000000)
3. Loosen instrument panel cross member.

For the next steps, an assistant must carefully lift and hold the heating and A/C unit.

1. Remove footwell air outlet.

Scheme 74

1. Remove bolts (TORX T15 ) - arrow A -.
2. Carefully unclip operating rod - 2 - from lever - arrow B - using a screwdriver.

1. Turn operating rod - 2 - - arrow C - and remove motor - 1 -.
2. Disconnect electrical connector.
3. Remove motor.

Installing and adjusting

Install in reverse order of removal.

1. Use Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Guided Fault Finding" to initiate Basic Setting, function 04.

Footwell/Defroster Flap Motor V85 , removing and installing

Removing

1. Disconnect battery --> «27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(ref-255357-S00731330752007053000000) .
2. Remove Instrument panel --> «70 - INTERIOR TRIM»(ref-255354-S40858316772007053000000) .
3. Loosen Instrument panel cross member.

For the next steps, an assistant must lift and hold the heating and A/C unit.

Scheme 75

1. Remove bolts (TORX T15 ) - arrows A -.
2. Remove motor - 3 - from housing.

Scheme 76

1. Disconnect electrical connector - 1 -.
2. Turn motor - 3 - and remove operating rod - 2 -.

Installing and adjusting

Install in reverse order of removal.

1. Use Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Guided Fault Finding" to initiate Basic Setting, function 04.

Climatronic components in engine compartment, servicing

Note. System components identified with * must only be serviced or replaced after discharging refrigerant system. Use Kent Moore ACR4 or equivalent. Before carrying out any work on the A/C refrigerant system, refer to all CAUTIONS and WARNINGS in A/C refrigerant system safety measures --> A/C Refrigerant System - General Illustration shows vehicle with engine code AHA.

Scheme 77

1 - Accumulator*

2 - Refrigerant hose*

1. Between evaporator and accumulator

3 - Refrigerant hose*

1. Between evaporator and condenser

4 - Low pressure service valve*

5 - High pressure service valve*

6 - Dust and pollen filter

1. Vehicles from 10.00, replacing --> «Dust and pollen filter from 10.00, removing and installing»(ref-255355-S33595325152007053000000)

7 - Evaporator*

1. In heating and A/C unit
2. Removing/assembly --> «Heating and A/C unit, assembly»(ref-255355-S06352040022007053000000) .

8 - Engine Coolant (EC) Switch-Off Valve (heater) N279

1. 8-cylinder engine only
2. Checking, use Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Guided Fault Finding".

9 - Evaporator water drain valve

1. Checking.

10 - Pressure relief valve*

1. Checking, Zexel compressor
2. Checking, Denso compressor

11 - Coolant Fan Control (FC) Control Module J293

1. 6-cylinder engine, code ATQ
2. 8-cylinder engine, code BDP

12 - Compressor*

1. A/C Clutch N25 on 4 6 cylinder engines.
2. Externally regulated compressor without A/C clutch N25 on 8-cylinder engine
3. A/C compressor and bracket removing/assembly --> «A/C Compressor and Bracket»(ref-255355-S29259358342007053000000) .

13 - A/C Clutch N25

1. Servicing: Zexel --> «A/C Clutch N25 - Zexel, servicing»(ref-255355-S37723751872007053000000)
2. Servicing: Denso --> «A/C Clutch N25 - Denso, servicing»(ref-255355-S11827342122007053000000)
3. Not for 8-cylinder engine

14 - Condenser*

1. Removing/assembly --> «Condenser, assembly»(ref-255355-S04106266752007053000000) .

15 - Outside Air Temperature Sensor G17

1. Function: Temperature sensor controls temperature flap and fresh air blower speed dependent of temperature measurement.
2. In event of sensor malfunction, Fresh Air Intake Duct Temperature Sensor G89 measurement value is used instead. If both sensors malfunction, operation continues with default value of 10 ° C (50 ° F). Air recirculation not possible. A/C Control Head E87 display indicates: "--"
3. Checking, use Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Guided Fault Finding".

16 - A/C Pressure Switch F129 or High Pressure Sensor G65

Note. Application is engine dependent. Always confirm system use of A/C Pressure Switch F129 or High Pressure Sensor G65 and applicable wiring circuit using applicable "Engine" and "Climatronic" wiring diagrams. A/C Pressure Switch F129 , electrical checking A/C Pressure Switch F129 , functional checks

1. A/C Pressure Switch F129 , removing and installing through 09.00
2. A/C Pressure Switch F129 , removing and installing from 10.00
3. High Pressure Sensor G65 checking, use Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Guided Fault Finding"..
4. High Pressure Sensor G65 , removing and installing

1. Switch or sensor can be removed without discharging refrigerant system.
2. Tightening torque 8 Nm (71 in lb)
3. Always replace O-ring (note Part No.).

17 - Refrigerant hose*

1. Between compressor and accumulator.

18 - Refrigerant hose*

1. Between compressor and condenser.

Special tools, testers and auxiliary items required

Scheme 78

1. VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

1. Bring front end assembly (lock carrier) into service position. --> «50 BODY, FRONT»(ref-255352-S40424905372007053000000) .

Scheme 79

1. Loosen ribbed belt tensioner securing bolts - arrows - and remove ribbed belt.

1. Install and route ribbed belt over compressor and vibration dampener pulleys.

Scheme 80

1. Fit torque wrench to tensioner at the 7 o'clock position and rotate clockwise - arrow - until tension of 25 Nm (18 ft lb) is reached.
2. Hold torque wrench in place and tighten securing bolts - A - to 20 Nm (15 ft lb).

Special tools, testers and auxiliary items required

1. VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

1. Bring front end assembly (lock carrier) into service position. --> «50 BODY, FRONT»(ref-255352-S40424905372007053000000) .

1. Loosen ribbed belt tensioner securing bolts - arrows - and remove ribbed belt.

1. Install and route ribbed belt over compressor and vibration dampener pulleys.

1. Fit torque wrench to tensioner at the 7 o'clock position and rotate clockwise - arrow - until tension of 25 Nm (18 ft lb) is reached.
2. Hold torque wrench in place and tighten securing bolts - A - to 20 Nm (15 ft lb).

Note. Before carrying out any work on the A/C refrigerant system, refer to all CAUTIONS and WARNINGS in A/C refrigerant system safety measures --> A/C Refrigerant System - General Service refrigerant system using Kent More ACR 4 or equivalent

Special tools, testers and auxiliary items required

1. VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

1. Refrigerant Charging/Recycling/Recovery unit Kent Moore ACR 4 or equivalent

1. If replacing compressor, discharge refrigerant system --> «A/C refrigerant system, discharging»(ref-255355-S09682864072007053000000) .

1. Drain engine coolant --> «19 - ENGINE - COOLING SYSTEM»(ref-255333-S22135423832007053000000) .
2. Bring front end assembly (lock carrier) into service position. --> «50 BODY, FRONT»(ref-255352-S40424905372007053000000) .
3. Remove ribbed belt --> «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-255333-S26720497122007053000000) .
4. Remove viscous coupling --> «19 - ENGINE - COOLING SYSTEM»(ref-255333-S22135423832007053000000) .

Scheme 81

1. Remove resistor for radiator fan - 2 - from left longitudinal member - 1 -.

1. Nut tightening torque: 8 Nm (71 in lb)

1. Remove oil filter. --> «17 - ENGINE - LUBRICATION»(ref-255333-S01518588622007053000000) .

Scheme 82

1. Loosen coolant pipe securing bolts - arrows - on oil pan and remove coolant hoses from oil cooler.

1. Bolt tightening torque: 10 Nm (69 in lb).

1. Remove oil cooler. --> «17 - ENGINE - LUBRICATION»(ref-255333-S01518588622007053000000) .

Scheme 83

1. Loosen nut - arrow - on bracket - 1 - for refrigerant pipes.

1. Nut tightening torque: 8 Nm (71 in lb).

1. Remove bolts for compressor , key number.
2. Remove compressor from bracket
3. Disconnect electrical connectors and wiring as necessary.

1. Swing compressor downward (leaving refrigerant hoses connected) and secure compressor to lower frame member with suitable wire (e.g.: welding rod or similar) as illustrated.

1. If replacing compressor, remove socket head bolts from refrigerant line retainer at compressor, and remove refrigerant lines --> «A/C Refrigerant System Servicing»(ref-255355-S31794454622007053000000) .

1. Install in reverse order of removal, noting the following

Note. If installing replacement compressor, always use new seals at compressor refrigerant lines. Compressor refrigerant line hex socket bolts M8 - tightening torque: 25 Nm (18 ft. lb.) Ribbed belt, routing Evacuate and recharge refrigerant system --> A/C refrigerant system, evacuating and recharging .

1. Perform leak test --> «A/C refrigerant system, checking for leaks»(ref-255355-S20366386002007053000000) .

Scheme 84

1 - Generator (GEN)

2 - Ribbed belt

3 - Power steering pump

4 - Viscous fan

5 - A/C compressor

6 - Crankshaft pulley

7 - Tensioner pulley

Note. When installing belt ensure it is correctly seated in pulley.

Note. Before carrying out any work on the A/C refrigerant system, refer to all CAUTIONS and WARNINGS in A/C refrigerant system safety measures --> A/C Refrigerant System - General Service refrigerant system using Kent More ACR 4 or equivalent During servicing, all couplings, fittings and related fasteners must be torqued to specifications --> 8-cylinder engine, assembly and --> A/C Refrigerant System Servicing .

Special tools, testers and auxiliary items required

1. VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)
2. Refrigerant Charging/Recycling/Recovery unit Kent-Moore ACR4 (or equivalent)

1. VAS 5532 Socket set

1. Discharge refrigerant system --> «A/C refrigerant system, discharging»(ref-255355-S09682864072007053000000) .
2. Remove ribbed belt: --> «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-255331-S25837766742007053000000) .

Scheme 85

1. Remove refrigerant line retainers from oil pan.
2. Remove windshield washer reservoir.
3. Remove power steering pump from bracket and lay to side; hoses remain connected. --> «48 STEERING»(ref-255349-S09926923282007053000000)
4. Remove power steering pump bracket.

Scheme 86

1. Remove both front stabilizer bar brackets - 2 - and pull stabilizer bar downwards. --> «40 FRONT SUSPENSION»(ref-255349-S18466171542007053000000)

Note. Before removing engine mount, support subframe from below.

1. Remove left-engine mount carrier from subframe. --> «40 FRONT SUSPENSION»(ref-255349-S18466171542007053000000)
2. Remove left hydraulic engine mount from carrier and engine mount support.

Scheme 87

1. Remove both fasteners - arrows - from cooling fan control module and remove.

1. Tightening torque: 8 Nm

1. Disconnect electrical connectors and wiring as necessary.
2. Remove securing bolts from compressor (leave refrigerant lines on bracket).
3. Remove refrigerant lines from compressor and pull compressor out downwards.

Install in reverse order of removal, noting the following

Note. Always use new seals at compressor refrigerant lines. Compressor refrigerant line hex socket bolts M8 - tightening torque: 25 Nm (18 ft. lb.) Ribbed belt, routing Evacuate and recharge refrigerant system --> A/C refrigerant system, evacuating and recharging .

1. Perform leak test --> «A/C refrigerant system, checking for leaks»(ref-255355-S20366386002007053000000) .

1. Turn compressor 10 revolutions (clockwise) by hand.
2. Install ribbed belt --> «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-255331-S25837766742007053000000) .
3. Install hydraulic engine mount to mount carrier and engine mount support.

1. Tightening torque: 23 Nm

1. Install mount carrier to subframe. --> «40 FRONT SUSPENSION»(ref-255349-S18466171542007053000000)
2. Switch on ignition (do not start engine!)
3. Select "Econ" mode on Climatronic control head
4. Start engine and wait until idle speed stabilizes.

1. Open all instrument panel vents.
2. Select "Low" temperature setting on Climatronic control head.
3. Select "Auto" mode on Climatronic control head (compressor regulation activated) and allow engine to run for 5 minutes at idle.

If it is necessary to start engine with empty refrigerant circuit, proceed as follows

1. Refrigerant circuit must be fully assembled/closed.
2. At least 1/4 of the prescribed refrigerant oil must be in the compressor.
3. Engine speed must not exceed 2500 rpm.
4. Run engine only as long as absolutely necessary.

Scheme 88

Note. When installing belt ensure it is correctly seated in pulley.

A/C system hoses and lines

The mixture of refrigerant oil (PAG oil) and refrigerant R-134a attacks some metals and alloys (for example, copper) and breaks down certain hose material. Use only hoses and lines that are identified with a green mark (stripe) or the lettering "R-134a".

Hoses and lines are fastened together with threaded couplings/fittings and are retained (to bodywork or components) with specially isolated hose clamps.

Note. During servicing, all couplings, fittings and related fasteners must be torqued to specifications --> A/C Refrigerant System Servicing . Ensure that only special tools (as specified) are used while servicing.

Scheme 89

The accumulator traps the mixture of refrigerant vapor (liquid) and gas as coming from the evaporator. The accumulator acts as a refrigerant reservoir for the system and ensures that the compressor only suctions gaseous refrigerant. Any moisture in the refrigerant system is absorbed by drier desiccant in the accumulator.

Note. Replace the accumulator each time the refrigerant circuit is opened. Do not remove sealing caps - A - and - B - until just prior to installation. The drier desiccant in non sealed accumulators becomes saturated with moisture and therefore unusable.

Scheme 90

O-rings seal connections between A/C system components.

Note. Always use correct size O-rings (dimensions - a - and - b - ). Do not reuse O-rings, always replace. Use only new O-rings that are compatible with R-134a refrigerant and refrigerant (PAG) oil on R-134a systems. Lubricate O-rings with the appropriate refrigerant oil before installing (only use PAG oil).

Scheme 91

The pressure relief valve is mounted on the compressor or compressor inlet/outlet manifold. At pressures above 40 bar (580 psi), the pressure relief valve opens to vent excessive pressure. When the system pressure is reduced, the valve closes to prevent total refrigerant loss.

On some models, a cap on the pressure relief valve will pop out if the valve has opened.

A/C Pressure Switch F129

Where applicable, the A/C pressure switch is a combination switch (two switching components) that protects refrigerant circuit components from malfunctioning due to excessive or insufficient refrigerant system pressures.

1. Switch part between terminals - 1 - and - 2 - switches off the A/C Clutch N25 when the system pressure is too high or when there is not enough refrigerant in the system.

Scheme 92

1. Switch part between terminals - 3 - and - 4 - switches Coolant Fan V7 to the next higher fan speed when system pressures increase.

Note. Always confirm system use of A/C Pressure Switch F129 described above, and applicable wiring circuit using applicable "Engine" and "Climatronic" wiring diagrams.

Scheme 93

Where applicable, High Pressure Sensor G65 - B - is used instead of A/C Pressure Switch F129. High Pressure Sensor G65 transmits a square wave signal to the Climatronic Control Module J255 at a rate which varies according to the refrigerant system pressure. Climatronic Control Module J255 processes the signal/pulse rate from High Pressure Sensor G65 as follows

1. Confirms refrigerant system pressure is sufficient for A/C Compressor Regulator Valve N280 to be energized, and that compressor output regulation via A/C Compressor Regulator Valve N280 can begin.
2. Where excessive or insufficient refrigerant system pressure is present (E.g.: insufficient air flow over condenser or when overcharged), A/C Compressor Regulator Valve N280 will idle compressor internally.
3. When the refrigerant system pressure rises, the radiator fan(s) are switched to the second speed.

Where applicable, the signal generated by High Pressure Sensor G65 may also be input to the Motronic Engine Control Module (ECM). As the amount of torque needed to drive the A/C compressor varies according to the refrigerant system pressure, the ECM processes this signal in order to enhance engine performance.

Note. Always confirm system use of High Pressure Sensor G65 described above by referring to model specific Training (SSP) information, and confirm applicable wiring circuit using applicable "Engine" and "Climatronic" wiring diagrams.

A/C refrigerant system through 09.00, servicing

Note. Only system components identified with can be serviced or replaced without discharging refrigerant system. Before carrying out any work on the A/C refrigerant system, refer to all CAUTIONS and WARNINGS in A/C refrigerant system safety measures --> A/C Refrigerant System - General Service refrigerant system using Kent More ACR 4 or equivalent During servicing, all couplings, fittings and related fasteners must be torqued to specifications.

Scheme 94

1 - Refrigerant pipe/hose

1. Between accumulator and compressor

2 - Coupling

1. Thread 28 mm; pitch 1.5 mm
2. 40 Nm (30 ft lb)

3 - O-ring

1. 17.2 mm; 1.8 mm

4 - Refrigerant pipe/hose

1. Between evaporator and condenser

5 - Coupling

1. Thread 20 mm; pitch 1.5 mm
2. 15 Nm (11 ft lb)

6 - O-ring

1. 10.8 mm; 1.8 mm

7 - Restrictor

1. Removing and installing

8 - O-ring

1. 7.5 mm; 1.5 mm

9 - O-ring

1. 10.8 mm; 1.8 mm

10 - High pressure service valve

1. Only use Kent Moore ACR4 or equivalent.
2. Removing and installing
3. Refrigerant system capacities --> «A/C Refrigerant System Capacities»(ref-255355-S24739931452007053000000)

11 - Cap*

12 - O-ring

1. 10.8 mm; 1.8 mm

13 - O-ring

1. 17.2 mm; 1.8 mm

14 - Evaporator

1. In heating and A/C unit
2. Removing/assembly --> «Heating and A/C unit, assembly»(ref-255355-S06352040022007053000000) .

15 - Hex socket bolt(s)

1. At evaporator coupling
2. 10 Nm (7 ft lb)

16 - Cap*

17 - Low pressure service valve

1. Only use Kent Moore ACR4 or equivalent.
2. Removing
3. Refrigerant system capacities --> «A/C Refrigerant System Capacities»(ref-255355-S24739931452007053000000)

18 - O-ring

1. 7.6 mm; 1.8 mm

19 - Refrigerant hose

1. Between evaporator and accumulator

20 - Manifold bolts

1. 25 Nm (18 ft lb)

21 - O-ring

1. Compressor inlet
2. 11.1 mm; 1.8 mm

22 - O-ring

1. Compressor outlet
2. 23.8 mm; 2.4 mm

23 - Compressor

1. With A/C Clutch N25
2. Zexel DCW 17D
3. Compressor/engine applications --> «Compressor/engine applications»(ref-255355-S39011420692007053000000)

24 - Pressure relief valve

Checking

1. Zexel compressor
2. Denso compressor

25 - Compressor

1. With A/C Clutch N25
2. Denso 7SB-16C
3. Compressor/engine applications --> «Compressor/engine applications»(ref-255355-S39011420692007053000000)

26 - O-ring

1. Compressor outlet
2. 23.8 mm; 2.4 mm

27 - O-ring

1. Compressor inlet
2. 11.1 mm; 1.8 mm

28 - Manifold bolts

1. 25 Nm (18 ft lb)

29 - A/C Clutch N25 *

1. Repairing A/C clutch with compressor installed is not recommended.
2. Zexel, servicing --> «A/C Clutch N25 - Zexel, servicing»(ref-255355-S37723751872007053000000)
3. Denso, servicing --> «A/C Clutch N25 - Denso, servicing»(ref-255355-S11827342122007053000000)

30 - Condenser

1. Removing/assembly --> «Condenser, assembly»(ref-255355-S04106266752007053000000)

31 - Coupling

1. Thread 20 mm; pitch 1.5 mm

32 - Coupling

1. Thread 24 mm; pitch 1.5 mm

33 - O-ring

1. 14 mm; 1.8 mm

34 - Coupling

1. Thread 24 mm; pitch 1.5 mm

35 - O-ring

1. 10.8 mm; 1.8 mm

36 - Refrigerant pipe/hose

1. Between compressor and condenser

37 - Coupling

1. Thread 20 mm; pitch 1.5 mm

38 - O-ring

1. 7.6 mm; 1.8 mm

39 - A/C Pressure Switch F129 *

1. Electrical checking
2. Functional checks
3. Removing and installing
4. Inspect O-ring for damage and proper seating in recess of switch before installation.

1. 8 Nm (71 in lb)

40 - Accumulator

1. Always replace whenever refrigerant system has been opened

41 - Coupling

1. Thread 28 mm; pitch 1.5 mm

42 - O-ring

1. 17.2 mm; 1.8 mm

A/C refrigerant system from 10.00, servicing

Note. Before carrying out any work on the A/C refrigerant system, refer to all CAUTIONS and WARNINGS in A/C refrigerant system safety measures --> A/C Refrigerant System - General Service refrigerant system using Kent More ACR 4 or equivalent Only system components identified with can be serviced or replaced without discharging refrigerant system. During servicing, all couplings, fittings and related fasteners must be torqued to specifications.

Scheme 95

1 - Refrigerant pipe/hose

1. Between accumulator and compressor

2 - Hex socket bolt

1. M8x28
2. 15 Nm (11 ft. lb.)

3 - O-ring

1. 17.2 mm; 1.8 mm

4 - Refrigerant pipe/hose

1. Between evaporator and condenser

5 - Coupling

1. Thread 20 mm; pitch 1.5 mm
2. 15 Nm (11 ft. lb.)

6 - O-ring

1. 10.8 mm; 188 mm

7 - Restrictor

1. Removing and installing

8 - O-ring

1. 7.5 mm; 1.5 mm

9 - O-ring

1. 10.8 mm; 1.8 mm

10 - High pressure service valve

1. Only use Kent Moore ACR4 or equivalent.
2. Removing and installing
3. Refrigerant system capacities --> «A/C Refrigerant System Capacities»(ref-255355-S24739931452007053000000)

11 - Cap*

12 - O-ring

1. 10.8 mm; 1.8 mm

13 - O-ring

1. 17.2 mm; 1.8 mm

14 - Evaporator

1. In heating and A/C unit
2. Removing/assembly --> «Heating and A/C unit, assembly»(ref-255355-S06352040022007053000000) .

15 - Socket head bolt

1. 10 Nm (89 in. lb.)

16 - Cap*

17 - Low pressure service valve

1. Only use Kent Moore ACR4 or equivalent.
2. Removing
3. Refrigerant system capacities --> «A/C Refrigerant System Capacities»(ref-255355-S24739931452007053000000)

18 - O-ring

1. 7.6 mm; 1.8 mm

19 - Refrigerant pipe/hose

1. Between accumulator and evaporator

20 - Compressor

1. Denso 7SB-16C
2. With A/C Clutch N25
3. Compressor/engine applications --> «Compressor/engine applications»(ref-255355-S39011420692007053000000)

21 - Pressure relief valve

1. Checking

22 - O-ring

1. 23.8 mm; 2.4 mm

23 - Socket head bolt

1. 25 Nm (18 ft. lb.)
2. Qty. 2

24 - O-ring

1. 11.1 mm; 1.8 mm

25 - A/C Clutch N25 *

1. Manufacturer: Denso
2. Repairing A/C clutch with compressor installed is not recommended.
3. Servicing --> «A/C Clutch N25 - Denso, servicing»(ref-255355-S11827342122007053000000)

26 - Compressor

1. 8-cylinder engine only
2. Denso 7SEU16
3. Without A/C clutch
4. Compressor/engine applications --> «Compressor/engine applications»(ref-255355-S39011420692007053000000)

27 - A/C Compressor Regulator Valve N280

1. Denso 7SEU16 only.

28 - O-ring

1. 23.8 mm; 2.4 mm

29 - Pressure relief valve

1. Zexel compressor
2. Denso compressor

30 - Socket head bolt

1. 25 Nm (18 ft. lb.)
2. Qty. 2

31 - O-ring

1. 11.1 mm; 1.82 mm

32 - Refrigerant pipe/hose

1. Between compressor and evaporator.

33 - Condenser

1. Removing/assembly --> «Condenser, assembly»(ref-255355-S04106266752007053000000)

34 - O-ring

1. 14 mm; 1.8 mm

35 - O-ring

1. 17.2 mm; 1.8 mm

36 - Hex socket bolt

1. 15 Nm (11 ft. lb.)

37 - O-ring

1. 4-cyl. 6-cyl. engine: 7.6 mm; 1.8 mm
2. 8-cyl. engine: 10.8 mm; 1.82 mm

38 - A/C Pressure Switch F129 or High Pressure Sensor G65

Note. Application is engine dependent. Always confirm system use of A/C Pressure Switch F129 or High Pressure Sensor G65 and applicable wiring circuit using applicable "Engine" and "Climatronic" wiring diagrams. A/C Pressure Switch F129 , electrical checking A/C Pressure Switch F129 , functional checks A/C Pressure Switch F129 removing and installing High Pressure Sensor G65 checking, use Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Guided Fault Finding".. High Pressure Sensor G65 , removing and installing Switch or sensor can be removed without discharging refrigerant system. Tightening torque 8 Nm (71 in lb) Always replace O-ring (note Part No.).

39 - Accumulator

1. Always replace whenever refrigerant system has been opened

40 - O-ring

1. 17.2 mm; 1.82 mm

High pressure service valve, removing

Note. Before carrying out any work on the A/C refrigerant system, refer to A/C system safety measures WARNINGS! and CAUTIONS! --> A/C Refrigerant System - General

1. Discharge refrigerant system --> «A/C refrigerant system, discharging»(ref-255355-S09682864072007053000000) .

Scheme 96

1. Unscrew and remove high pressure service valve - 3 -.

1 - Connection with internal thread

2 - O-ring, 10.8 mm; 1.8 mm

3 - High pressure service valve, with groove for O-ring and internal thread for cap

4 - O-ring, 10.8 mm; 1.8 mm

5 - Cap

Low pressure service valve, removing

Note. Before carrying out any work on the A/C refrigerant system, refer to A/C system safety measures WARNINGS! and CAUTIONS! --> A/C Refrigerant System - General

1. Discharge refrigerant system --> «A/C refrigerant system, discharging»(ref-255355-S09682864072007053000000) .

Scheme 97

1. Unscrew and remove low pressure service valve - 3 -.

1 - Connection with external thread and groove for O-ring

2 - O-ring, 7.6 mm; 1.8 mm

3 - Low pressure service valve

4 - O-ring, 7.6 mm; 1.8 mm

5 - Cap

A/C Pressure Switch F129 , electrical checking

Note. Before carrying out any work on the A/C refrigerant system, refer to A/C system safety measures WARNINGS! and CAUTIONS! --> A/C Refrigerant System - General The pressure switch can be removed without discharging refrigerant system. Visually check that O-ring 10,8 mm x 1,8 mm is positioned correctly in the groove.

Function

Switch part between terminals - 1 - and - 2 - switches off the A/C Clutch N25 when the system pressure is too high or when there is not enough refrigerant in the system.

1. Switch opens when the pressure is below 1.2 bar and closes again above 2.4 bar (switch point).
2. Switch opens above 32 bar and closes again below 24 bar (switch point).

Switch part between terminals - 3 - and - 4 - switches coolant fan V7 (via the Coolant Fan Control (FC) Control Module J293 ) to the next higher fan speed when system pressures increase.

1. Switch closes above 16 bar and opens again below 12.5 bar (switch point).

Quick check

1. With engine running, disconnect electrical connector from switch and briefly bridge connector terminals - 1 - and - 2 -. If the A/C Clutch N25 engages, the refrigerant circuit is empty.

A/C Pressure Switch F129 , functional checks

To determine proper A/C system performance, perform the following functional checks with the switch installed and connected.

1. Check refrigerant capacity (fill). If system pressure is too low (refrigerant leakage), A/C Pressure Switch F129 switches A/C Clutch N25 off.
2. Check cooling fan function. When system pressure increases, A/C Pressure Switch F129 causes Coolant Fan V7 to switch to next higher fan speed.
3. Check if A/C system switches off. At excessive system pressures (e.g.: caused by high ambient temperatures or if condenser is blocked), A/C Pressure Switch F129 switches A/C Clutch N25 off.

A/C Pressure Switch F129 through 09.00, removing and installing

Note. Before carrying out any work on the A/C refrigerant system, refer to A/C system safety measures WARNINGS! and CAUTIONS! --> A/C Refrigerant System - General

Scheme 98

Removing

1 - Connection

2 - A/C Pressure Switch F129 (8 Nm)

3 - Hex (to counter-hold)

4 - Condenser connection

5 - Lock carrier

6 - Cover

1. Remove right headlight --> «94 - LIGHTS, SWITCHES - EXTERIOR»(ref-255357-S32150885732007053000000) .
2. Remove bolt - arrow - (below cover - 6 - ) between lock carrier - 5 - and cover - 6 -.
3. Disconnect electrical connector - 1 -.

To prevent damage to condenser pipe connection - 4 - counter-hold hex fitting - 3 - with appropriate wrench when loosening switch.

1. Remove A/C pressure switch - 2 -.

Installing

1. Install in reverse order of removal.

A/C Pressure Switch F129 from 10.00 or High Pressure Sensor G65, removing and installing

Note. Before carrying out any work on the A/C refrigerant system, refer to A/C system safety measures WARNINGS! and CAUTIONS! --> A/C Refrigerant System - General

Scheme 99

Removing

1 - Connector

2 - Switch/sensor (8 Nm)

3 - Hex (to counter-hold)

4 - Condenser connection

1. Remove front bumper --> «63 BUMPER»(ref-255352-S24259318442007053000000)
2. Remove front bumper carrier --> «50 BODY, FRONT»(ref-255352-S40424905372007053000000)
3. Separate electrical connection - 1

To prevent damage to condenser pipe connection - 4 - counter-hold hex fitting - 3 - with appropriate wrench when loosening switch.

1. Remove switch/sensor - 2 -.

Installing

1. Install in reverse order of removal.

Restrictor, removing and installing

Note. Before carrying out any work on the A/C refrigerant system, refer to A/C system safety measures WARNINGS! and CAUTIONS! --> A/C Refrigerant System - General

Removing

1. Discharge refrigerant system --> «A/C refrigerant system, discharging»(ref-255355-S09682864072007053000000) .

Scheme 100

1. Loosen and separate coupling - A - on evaporator inlet pipe.

1. Tightening torque 15 Nm (11 ft lb)

1. Replace O-ring - D

1. O- ring - D - = 10.7 mm, 1.8 mm

1. Remove restrictor - B - using long nose pliers

Installing

Install in reverse order of removal, noting the following

1. Insert restrictor - B - into evaporator inlet pipe with arrow pointing in direction of refrigerant flow (towards evaporator).

Note. Ensure proper positioning of O-ring - C - Restrictor must fit tight in inlet pipe (push in as far as it will go) Assemble to allow stress free mounting of evaporator pipes

Pressure relief valve - Zexel compressor, checking

Note. Before carrying out any work on the A/C refrigerant system, refer to A/C system safety measures WARNINGS! and CAUTIONS! --> A/C Refrigerant System - General Function: Protects refrigerant circuit from excessive pressures.

Scheme 101

1. Refrigerant oil deposited on rear of compressor indicates pressure relief valve has opened to release pressure - arrow -. An adhesive plate is pushed out.

Pressure relief valve - Denso compressor, checking

Note. Before carrying out any work on the A/C refrigerant system, refer to A/C system safety measures WARNINGS! and CAUTIONS! --> A/C Refrigerant System - General Function: Protects refrigerant circuit from excessive pressures.

Scheme 102

1. Refrigerant oil deposited in area of compressor manifold indicates pressure relief valve has opened to release pressure - arrow -. An adhesive plate is pushed out.

Note. Before carrying out any work on the A/C refrigerant system, refer to all CAUTIONS and WARNINGS in A/C refrigerant system safety measures --> A/C Refrigerant System - General Service refrigerant system using Kent More ACR 4 or equivalent During servicing, all couplings, fittings and related fasteners must be torqued to specifications --> Condenser, assembly .

1. Discharge refrigerant system --> «A/C refrigerant system, discharging»(ref-255355-S09682864072007053000000) .
2. Bring front end assembly (lock carrier) into service position --> «50 BODY, FRONT»(ref-255352-S40424905372007053000000) .
3. Vehicles from 10.00: Remove front bumper carrier --> «50 BODY, FRONT»(ref-255352-S40424905372007053000000)
4. Loosen and separate refrigerant pipes/couplings from condenser.

1. Install in reverse order of removal, noting the following
2. Evacuate and recharge refrigerant system --> «A/C refrigerant system, evacuating and recharging»(ref-255355-S37221530752007053000000) .
3. Perform leak test --> «A/C refrigerant system, checking for leaks»(ref-255355-S20366386002007053000000) .

Scheme 103

1 - Heating and A/C unit

Contains

1. Heater core
2. Evaporator

2 - Screws

1. 12 Nm

3 - Screw

1. 3.5 Nm

4 - Instrument panel cross member

1. Always follow installation instructions for bolt

5 - Support

6 - Footwell vent assembly

Note. Before carrying out any work on the A/C refrigerant system, refer to all CAUTIONS and WARNINGS in A/C refrigerant system safety measures --> A/C Refrigerant System - General Service refrigerant system using Kent More ACR 4 or equivalent During servicing, all couplings, fittings and related fasteners must be torqued to specifications.

1. Discharge refrigerant system --> «A/C refrigerant system, discharging»(ref-255355-S09682864072007053000000) .
2. Drain engine coolant. Refer to applicable «19 ENGINE - COOLING SYSTEM»(ref-255332-S12390726352007053000000) for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AEB, ATW «19 COOLING SYSTEM»(ref-255335-S02869375882007053000000) for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AUG, AWM «19 COOLING SYSTEM»(ref-255334-S07009922742007053000000) for 2.0 LITER 4-CYL. 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BHW «19 - ENGINE - COOLING SYSTEM»(ref-255333-S22135423832007053000000) for 2.8 LITER V6 5V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AHA, ATQ «19 - ENGINE - COOLING SYSTEM»(ref-255331-S37852741602007053000000) for 4.0 LITER 8-CYL. 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): BDP .
3. Remove instrument panel --> «70 - INTERIOR TRIM»(ref-255354-S40858316772007053000000) .
4. Remove coolant hoses at heater core Coolant hoses at heater core, removing under «Coolant Hoses At Heater Core, Removing»(ref-255355-S18336163772007101900000) .

1. Seal off inlet and outlet at heater core to prevent coolant from escaping.
2. Remove refrigerant lines at evaporator Refrigerant lines at evaporator, removing under «Refrigerant Lines At Evaporator, Removing»(ref-255355-S17112672842007101900000) .
3. Remove Heating and A/C unit mounting screws - 2 - and - 3 -.
4. Remove footwell vent assembly - -.

1. Remove support - -.
2. Disconnect all electrical connections and wiring harness tie straps at heating and A/C unit.
3. Carefully pull out and remove complete housing - - from vehicle.
4. Loosen instrument panel cross member - - if necessary.

Heating and A/C unit, assembly --> Heating and A/C unit, assembly

Scheme 104

Coolant hoses at heater core, removing

1. Note Installation orientation of coolant hoses - A - (inlet and outlet) in engine compartment.
2. Clamp off both coolant hoses to heater core using 3094 hose clamps (or equivalent).
3. Release both coolant hose clamps using suitable pliers and pull hoses off from heater core inlet and outlet.

Scheme 105

1. Remove screw - 3 - (15 Nm).
2. Gently rock flange with refrigerant lines - 2 - up and down until they release from evaporator.

Note. Always replace both O-rings - 1 -.

1. Install in reverse order of removal, noting the following

Note. Inspect all heating and A/C unit housing seals for damage and replace if necessary before installation. Evaporator inlet/outlet seal , Evaporator seal. Ensure all electrical harness tie straps are replaced and installed in their original locations. Replace both evaporator inlet/outlet O-rings. Ensure refrigerant pipes are reinstalled stress free. Ensure evaporator water drain and drain valve are installed and function properly. Evacuate and recharge refrigerant system --> A/C refrigerant system, evacuating and recharging . Perform leak test --> A/C refrigerant system, checking for leaks .

Heater core, removing and installing

Removing

1. Remove heating and A/C unit --> «Heating and A/C unit, removing and installing»(ref-255355-S05391094542007053000000) .

Scheme 106

1. Remove screws - 1 -.
2. Pull heater core up and out from housing - arrow -.

Installing

1. Install in reverse order of removal, noting the following

Note. Inspect all heating and A/C unit housing seals for damage and replace if necessary before installation. Evaporator inlet/outlet seal. Evaporator seal. Ensure all electrical harness tie straps are replaced and installed in their original locations. Replace both evaporator inlet/outlet O-rings. Ensure refrigerant pipes are reinstalled stress free. Ensure evaporator water drain and drain valve are installed and function properly. Evacuate and recharge refrigerant system --> A/C refrigerant system, evacuating and recharging . Perform leak test --> A/C refrigerant system, checking for leaks . Always use new coolant after replacement.

Evaporator, removing and installing

Removing

1. Remove heating and A/C unit --> «Heating and A/C unit, removing and installing»(ref-255355-S05391094542007053000000) .
2. Separate top and bottom sections of heating and A/C unit.
3. Remove evaporator from housing.

Installing

1. Install in reverse order of removal, noting the following

Note. Inspect all heating and A/C unit housing seals for damage and replace if necessary before installation. Evaporator inlet/outlet seal. Evaporator seal. Ensure all electrical harness tie straps are replaced and installed in their original locations. Replace both evaporator inlet/outlet O-rings. Ensure refrigerant pipes are reinstalled stress free. Ensure evaporator water drain and drain valve are installed and function properly. Evacuate and recharge refrigerant system --> A/C refrigerant system, evacuating and recharging . Perform leak test --> A/C refrigerant system, checking for leaks . Always use new coolant after replacement.

Scheme 107

1. Evaporator inlet - B - and outlet - A - pipes must be insulated between the halves of the housing with seal - C -.

Scheme 108

1. Foam seal - B - must be glued around circumference of evaporator - A -.
2. To allow evaporator water to drain, do not attach foam seal on evaporator in area - C -.

A/C refrigerant system, replacing components

Replacement A/C compressors, evaporators and condensers supplied by the Parts Dept. are filled with Nitrogen. If gas (Nitrogen) does not escape when component is first opened, the component may be faulty (leaking), do not install.

Replacement A/C compressors are filled with the total refrigerant oil quantity needed for the entire refrigerant system. When an additional, rear evaporator is present, additional compressor oil must be added after replacing the compressor.

Always replace the accumulator whenever the refrigerant system has been opened. Install immediately after opening to prevent moisture contamination of drier desiccant. Moreover, keep refrigerant system and other replacement components sealed for as long as possible to minimize the chance of dirt and moisture contamination.

Always plug open refrigerant line connections to prevent dirt and moisture contamination.

If the system has been discharged due to a damaged or leaking component (refrigerant hose/line, compressor, evaporator, condenser, etc.), flush the refrigerant system first with compressed air, then with nitrogen (available locally) and collect the oil that runs out. This will remove the refrigerant oil which may be saturated with moisture.

If the compressor is not replaced after flushing the system, fill compressor with the correct type and quantity of refrigerant oil as specified under A/C system capacities --> A/C Refrigerant System Capacities . Fill compressor with the total system oil capacity.

If the compressor is replaced, do not add any additional oil as the total amount of oil required is already in the compressor.

Dispose of contaminated refrigerant oil following laws governing hazardous waste disposal. Do not combine any refrigerant oil with any other old oils such as engine oil or transmission fluid.

Follow all applicable Warnings and Cautions when working on the A/C system.

A/C refrigerant system pressures and temperatures, checking

The pressures and temperatures in the A/C system will vary depending on engine speed (RPM), coolant fan speed, engine coolant temperature, A/C clutch engagement, outside temperature, humidity, etc.

Pressure and temperature specifications are based on the following

1. Engine speed (RPM) at 1500
2. Fresh air blower on high speed
3. A/C adjusted to Max. cooling

A = Low Pressure

B = High Pressure

1 - Compressor, high pressure side - B

2 - Condenser

3 - Restrictor

4 - Evaporator

5 - Accumulator

6 - Compressor, low pressure side - A

1) Low side pressure is maintained in the refrigerant system by the variable displacement compressor despite variables in temperature, load and engine speeds (RPM).

Note. On vehicles with A/C Compressor Regulator Valve N280 , low side pressures are regulated by the valve. Regulation depends on input signals received by the valve

Measuring pressure and temperature in a "switched-on" refrigerant system

Use the A/C refrigerant high-pressure gauge to measure high pressure between the compressor and restrictor (including condenser) with the A/C switched on.

Use the A/C refrigerant low-pressure gauge to measure low pressure between the restrictor and the compressor inlet (including evaporator) with the A/C switched on.

The temperature displays of the low- and high-pressure gauges apply only to a portion of the low- and high-pressure sides. The low-pressure gauge displays approximate temperature between the restrictor and evaporator outlet. The high-pressure gauge displays approximate temperature between the compressor outlet and restrictor.

Note. The temperature/pressure relationship only holds true when the refrigerant system contains liquid and vapor, but not when it contains only gas. In the gaseous state, the temperature is approx. 10-30 ° C (18-54 ° F) higher than indicated on the pressure gauge.

Measuring pressure and temperature in a closed container or "switched-off" refrigerant system

Due to the constant temperature/pressure relationship of R-12 and R-134a, approximate temperature in a closed container or in a switched-off A/C system can be determined based on its pressure.

If the temperature displayed on a gauge is lower than the actual temperature of the refrigerant, the refrigerant container or system is empty (discharged).

Note. The temperature/pressure relationship only holds true when the refrigerant system contains liquid and vapor, but not when it contains only gas. In the gaseous state, the temperature is approx. 10-30 ° C (18-54 ° F) higher than indicated on the pressure gauge.

A/C refrigerant system, discharging

Note. Refer to safety measures starting on --> A/C Refrigerant System - General prior to discharging or charging A/C refrigerant system.

Note. Make sure that initial set-up of the refrigerant recovery/recycling/recharging unit has been completed before discharging the A/C system.

1. Connect red high-pressure hose of refrigerant recovery/recycling/recharging unit to high side fitting on vehicle and open coupler valve.
2. Connect blue low-pressure hose of refrigerant recovery/recycling/recharging unit to low side fitting on vehicle and open coupler valve.

1. Following refrigerant recovery/recycling/recharging unit manufacturers instructions, discharge A/C system into refrigerant recovery/recycling/recharging unit.
2. Disconnect power supply from A/C clutch to prevent accidental compressor operation with A/C system discharged.

A/C refrigerant system, evacuating and recharging

Note. Refer to R-134a safety measures starting prior to discharging or charging A/C refrigerant system. Follow refrigerant recovery/recycling/recharging unit manufacturers instructions for evacuating and recharging A/C system. Evacuate refrigerant system for a minimum of 30 minutes. When recharging A/C system, add correct amount of refrigerant and PAG oil to system --> A/C Refrigerant System Capacities . After system recharge, manually rotate A/C compressor approx. 10 turns before starting engine. Start engine with A/C OFF. After idle speed has stabilized, switch A/C ON and let engine idle (compressor running) for a minimum of two minutes before raising engine speed.

Requirements

1. Electrical systems OK
2. Vacuum hoses and control systems OK
3. Air flow distribution systems OK

Correct and repair as necessary before proceeding.

If any one of the following system conditions exists, check A/C refrigerant system pressures --> A/C refrigerant system pressures, checking .

1. A/C does not cool (cooling has stopped completely)
2. Insufficient cooling during all driving speeds or engine speeds (RPM)
3. No cooling or insufficient cooling after a period of driving

Compressor noisy

1. Tighten compressor and compressor bracket mounting bolts using torque wrench.
2. Check routing of A/C refrigerant hoses and lines; hoses and lines must not contact other components and must be installed without tension or kinks, reposition or realign as necessary.

A/C compressor noisy immediately after switching A/C ON and/or when driving around corners or braking (refrigerant shock) - system overcharged

1. Discharge A/C refrigerant system --> «A/C refrigerant system, discharging»(ref-255355-S09682864072007053000000) , then evacuate and recharge --> «A/C refrigerant system, evacuating and recharging»(ref-255355-S37221530752007053000000) .

With an otherwise properly operating A/C system, water sprays out of instrument panel vents

1. Check evaporator drain pipe for proper routing (should not be kinked or pinched).
2. Check evaporator water drain valve.

1. Must not be plugged with wax, dirt or undercoating (clean if necessary)
2. Valve flap must open/close properly

1. Check plenum tray.

1. Must be properly installed and not damaged

A/C refrigerant system pressures, checking

Check A/C refrigerant system pressures using these three tests

1 - Air temperature drop from center instrument panel outlet (A/C system cooling performance)

2 - A/C system high pressure

3 - A/C system low pressure

The combined results of all three steps determine which part of the A/C system is causing the problem, see table SYSTEM PRESSURE TESTING .

A/C refrigerant system cooling performance, checking

Note. A/C Evaporator Temperature Switch E33 (if equipped) switches A/C compressor OFF only in special instances so evaporator does not ice up; variable displacement A/C compressor maintains temperature of 0 °C (32 °F) in evaporator. Cooling performance on Climatronic equipped vehicles can also be checked using Vehicle Diagnostic Testing and Information System VAS 5051 or VAS 5052 in mode "Guided Fault Finding".

Checking

1. Start engine.
2. Set temperature control to maximum "cold" (if Manual A/C) or "LO" (if Climatronic).
3. Manual A/C: press A/C button and select second blower speed.
4. Climatronic: Select minimum blower speed (manual override) by pressing "decrease blower speed" button (observe front "blower speed" display in control head).

1. Adjust air distribution to instrument panel outlets.
2. Insert thermometer into center instrument panel outlet.
3. Raise engine speed to approximately 1500 RPM.

Specified result

With normal humidity and outside (ambient) temperature between 20 ° - 25 °C (68 ° - 77 °F), system is sufficiently charged if air temperature from center instrument panel vent drops below 10 °C (50 °F) within one minute.

For higher ambient temperatures and/or higher humidity, specified air temperature from center instrument panel vent can be slightly higher.

Scheme 109

Use halogen leak detector, Hitec HI400A-TEL or equivalent, to check for refrigerant leaks, following the leak detector manufacturers instructions.

Refrigerant gas dissipates very quickly. To make the job easier, avoid drafty or windy areas when checking for leaks.

If the refrigerant system is discharged (empty), recharge the system with approx. 100 g (3.5 oz) of refrigerant in order to check for leaks.

Vehicles through 09.00

Vehicles from 10.00

Obtain R-134a refrigerant from a local A/C supplier under one of the following names

1. R-134a
2. Tetrafluoroethane
3. CH 2 F CF 3
4. H-FKW 134a

1. SUVA[ TRANS A/C
2. ARCTON[ 134a ]

Note. R-134a refrigerant is packaged in different containers. Some are used only for commercial applications which are sold in cylinders using a 1/4 flare fitting. This does not connect to the vehicle fittings and servicing equipment. Use only R-134a which come in containers having the correct type of service fitting.

PAG oil, distribution

Replacement A/C compressors supplied by the Parts Department are filled with 250 cc (fl. oz) of refrigerant oil. This is the total A/C system refrigerant oil capacity.

The total refrigerant oil quantity found in a new compressor is distributed in the refrigerant circuit the first time the compressor is engaged.

Before installation, all replacement refrigerant system components (except the compressor) should be filled with refrigerant (PAG) oil according to the system distribution (percentage) below

Compressor: approx. 50%

Condenser: approx. 10%

Suction pipe: approx. 10%

Evaporator: approx. 20%

Accumulator: approx. 10%