Page 3 Heating & Air Conditioning 80 - Heating, Ventilation Heating and ventilation system Heating and ventilation system, assembly Heating and ventilation unit, assembly Heating and ventilation cables, installing and adjusting Heating and ventilation controls, assembly 87 - Air conditioning A/C refrigerant system, notes Safety measures A/C refrigerant R-134a, properties Basics when working on A/C refrigerant system R-134a...
Page 4 A/C refrigerant system, troubleshooting Compressor noisy A/C refrigerant system pressures, checking A/C refrigerant system cooling performance, checking A/C refrigerant system, checking for leaks A/C refrigerant system, capacities Refrigerant R-134a, capacity Refrigerant (PAG) oil R-134a, capacity Refrigerant (PAG) oil R-134a, identification Refrigerant (PAG) oil R-134a, distribution...
Page 5 Heating and ventilation system Page 1 of 21 80-1 Heating and ventilation system Heating and ventilation system, assembly CAUTION! Obtain the anti-theft radio security code. Switch the ignition off. Disconnect the battery Ground (GND) strap. After reconnecting battery, re-code and check operation of anti-theft radio.
Page 6 Heating and ventilation system Page 2 of 21 80-2 5 - Fresh Air Blower Series Resistance with Fuse -N24- Removing and installing Fig. 1 6 - Fresh air blower -V2- Removing Fig. 2 7 - Footwell outlet Replacing: Remove shelf on drivers' and passenger side, center console, instrument panel bracket and...
Page 7 Heating and ventilation system Page 3 of 21 80-3 10 - Right air outlet Removing Fig. 8 11 - Grille For right air outlet 12 - Center air outlet Removing Fig. 7 13 - Control panel trim 14 - Grilles For center outlet 15 - Instrument panel trim Removing...
Page 8 Heating and ventilation system Page 4 of 21 80-4 18 - Rear duct Replacing: Remove console, instrument panel bracket, pedal cluster cover - 23 -, footwell outlet - 7 - 19 - Rear duct seal Replacing: Remove console, instrument panel bracket, pedal cluster cover - 23 -, footwell outlet - 7 - 20 - Instrument panel...
Page 9 Heating and ventilation system Page 5 of 21 80-5 23 - Pedal cluster cover 24 - Heating and ventilation cables Replacing: First remove pedal cluster cover - 23 - and foot well outlet - 7 - Removing and installing Page 80- 25 - Intermediate duct With gasket Replacing - remove...
Page 10: Table Of Contents
Heating and ventilation system Page 6 of 21 80-6 27 - Heater core Replacing Page 80- Always replace coolant after removal/replacement. 28 - Air duct with main shut-off flap Replacing: Remove instrument panel and items -22- to 28- Fig. 9 Installing: Page 80- 29 - Hex nut M6...
Page 11 Heating and ventilation system Page 7 of 21 80-7 Fig. 1 Fresh Air Blower Series Resistance with Fuse -N24-, removing Removing: - Remove shelf on passenger side - Pull off connections -2- - Press retainer -arrow- down and remove series resistor -1- Installing: - Seal surface between series resistor -1- and air...
Page 12 Heating and ventilation system Page 8 of 21 80-8 Fig. 3 Heating and ventilation controls, removing and installing Removing: - Heater control trim panel -3-, pull off - Central outlet -2- Fig. 7 , remove - Heater controls -1- with cables attached, pull out of instrument panel.
Page 13 Heating and ventilation system Page 9 of 21 80-9 Fig. 5 Dust and pollen filter, removing. 1 - Filter element 2 - Filter housing 3 - Gasket 4 - Clip 5 - Clip - Filter element, remove. - Press clips -4- and -5- in direction of arrow and remove filter housing.
Page 14 Heating and ventilation system Page 10 of 21 80-10 Fig. 7 Center air outlet, removing - Instrument panel trim Fig. 4 , remove. - Radio, remove. - Switch, remove. - Remove control panel trim. - Control -2-, remove - Center console -3-, loosen - Remove 2 screws -arrows- and take out central outlet -1-.
Page 15 Heating and ventilation system Page 11 of 21 80-11 Fig. 9 Heating and ventilation unit installing Note: Close evaporator connections to ensure that no coolant enters passenger compartment when removing. Installing: - Pre-assemble hex nuts on engine bulkhead. - Tighten hex nut with shank, in plenum chamber. - Tighten engine bulkhead Hex nuts.
Page 16: Heater Core
Heating and ventilation system Page 12 of 21 80-12 Heating and ventilation unit, assembly 1 - Gasket Replace 2 - Heater core Always replace coolant after removal/replacement Replacing: - Remove instrument panel. Repair Manual, Body- Interior, Repair Group 70 - Carefully pinch off both coolant hoses to heater core and disconnect hoses.
Page 17: Air Duct With Main Shut-Off Flap
Heating and ventilation system Page 13 of 21 80-13 - Partially remove heating and ventilation unit. - Press retainer clips and remove heater core. Gaskets must be glued, free of gaps all around. If catches do not engage when installing, then secure heat exchanger with screws.
Page 18 Heating and ventilation system Page 14 of 21 80-14 8 - Air duct cover 9 - Plug 10 - Cables 11 - Fresh air and heated air controls 12 - Pedal cluster cover 13 - Footwell outlet 14 - Temperature flap lever 15 - Center flap lever 16 - Air distribution housing...
Page 19 Heating and ventilation system Page 15 of 21 80-15 Heating and ventilation cables, installing and adjusting Notes: Attach cables to removed controls first and then adjust on heater levers and secure. Ends of sleeves on cables, which are marked with a stripe of paint, must be secured to the controls.
Page 20: Fig. 1
Heating and ventilation system Page 16 of 21 80-16 1 - Main shut-off flap cable From blower rotary control to main shut-off flap Black sleeve, white marking Adjusting cable at main shut-off flap Fig. 1 2 - Temperature flap cable From temperature rotary control to temperature flap...
Page 21 Heating and ventilation system Page 17 of 21 80-17 3 - Footwell/defrost flap cable From air distribution rotary control to footwell/defrost flap Black sleeve, blue marking Adjusting cable at footwell/defrost flap Fig. 3 4 - Center flap cable From air distribution rotary control to center flap Black sleeve...
Page 22 Heating and ventilation system Page 18 of 21 80-18 Fig. 1 Main shut-off flap cable, adjusting - Install heated air and fresh air blower controls. - Turn blower rotary control onto stop at "0" position. - Push main shut-off flap lever onto stop (arrow) and secure cable sleeve.
Page 23 Heating and ventilation system Page 19 of 21 80-19 Fig. 3 Footwell/defrost flap cable, adjusting - Install heated air and fresh air blower controls. - Turn air distribution rotary control onto stop in defrost position. - Push footwell/defrost flap lever onto stop -arrow- and secure black cable sleeve.
Page 24 Heating and ventilation system Page 20 of 21 80-20 Fig. 5 Footwell/defrost flap cable, securing to control - Secure cable sleeve at blue marking -1- on control. - Secure inner cable to upper lever. - Adjusting cable at footwell/defrost flap Fig.
Page 25 Heating and ventilation system Page 21 of 21 80-21 Heating and ventilation controls, assembly 1 - Controls Including fresh air blower switch -E9- 2 - Fresh air control light bulb -L16- 3 - Light conductor 4 - Cap http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.HA01.80.1 12/7/2004...
Page 26 A/C refrigerant system, notes Page 1 of 15 87-1 A/C refrigerant system, notes Safety measures The subassemblies and lines of the air conditioner are filled with Tetrafluoroethane also known as refrigerant R-134a. Refrigerant R-134a replaces refrigerant R-12. R-134a and R-12 systems are similar in design but there are very important differences in the refrigerant, lubricating oils, service equipment and A/C system components.
Page 27 A/C refrigerant system, notes Page 2 of 15 87-2 WARNING! A/C system is filled with refrigerant gas which is under pressure. Always be careful that refrigerant does not come in contact with your skin. If liquid refrigerant has come in contact with your skin or eyes: do not rub skin or eyes immediately flush with cool water for 15...
Page 28 A/C refrigerant system, notes Page 3 of 15 87-3 WARNING! Keep refrigerant containers stored below 50 C (122 F) and never drop from high places. DO NOT warm refrigerant containers with an open flame. If refrigerant needs to be warmed, place bottom of tank in warm water. Keep refrigerant away from open flames because poisonous gas will be produced if it burns.
Page 29 A/C refrigerant system, notes Page 4 of 15 87-4 CAUTION! R-12 and R-134a refrigerant are NOT compatible. Never add R-12 refrigerant to an R-134a system or R-134a refrigerant to an R- 12 system. If the refrigerants are mixed, total system contamination will occur and compressor failure may result.
Page 30 A/C refrigerant system, notes Page 5 of 15 87-5 CAUTION! Always use separate refrigerant recovery/recycling/recharging servicing equipment for R-12 and R-134a systems. DO NOT use one piece of equipment for both R- 12 and R-134a systems. The residual traces of refrigerant will contaminate and damage the equipment.
Page 31: Installing
A/C refrigerant system, notes Page 6 of 15 87-6 CAUTION! Always replace damaged and/or leaking A/C system components. Do not attempt repair by soldering, brazing or welding. Work area must be extremely clean when working on A/C system components. Use only tools, equipment and parts specified for use with R-134a.
Page 32 A/C refrigerant system, notes Page 7 of 15 87-7 A/C refrigerant R-134a, properties Commercial designation Obtain R-134a refrigerant from a local A/C supplier under one of the following names: R-134a Tetrafluoroethane F CF H-FKW 134a SUVA TRANS A/C ARCTON 134a Note R-134a refrigerant is packaged in different containers.
Page 33 A/C refrigerant system, notes Page 8 of 15 87-8 Temperature/pressure relationship Similar to R-12 refrigerant, R-134a in an enclosed container will have a specific temperature/pressure relationship as follows: Temperature in C ( F) Pressure in bar (psi) -30 (-22) 0.0 (0.0) -20 (-4) 0.3 (4.4) -10 (14)
Page 34 A/C refrigerant system, notes Page 9 of 15 87-9 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.
Page 35 A/C refrigerant system, notes Page 10 of 15 87-10 Effects on metal In its pure state, refrigerant R-134a is chemically stable and will not attack iron or aluminum. However, the mixture of R-134a and PAG oil may deteriorate certain metals (copper) which could lead to blockage, leaks or deposits on the compressor piston.
Page 36 A/C refrigerant system, notes Page 11 of 15 87-11 Flammability R-134a refrigerant is not flammable. In fact, it tends to inhibit combustion and has a fire extinguishing effect. However, a flame or glowing hot surface, as well as ultraviolet light (from electric welding), will decompose the refrigerant into poisonous gases (hydrogen fluoride, carbonyl fluoride and fluorine).
Page 37 A/C refrigerant system, notes Page 12 of 15 87-12 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. CAUTION! Refrigerant oils used for the R-134a system and R-12 system are NOT compatible.
Page 38 A/C refrigerant system, notes Page 13 of 15 87-13 Basics when working on A/C refrigerant system R-134a CAUTION! Keep work area and all tools clean. Use only tools, equipment and parts specified for use with R-134a. Always wear protectiveglasses and gloves when working on A/C refrigerant system.
Page 39 A/C refrigerant system, notes Page 14 of 15 87-14 CAUTION! Always replace O-rings, DO NOT reuse. Use only the correct size and type of O-rings specified for use with R-134a refrigerant. Lubricate O-ring with refrigerant oil before installing. Use only the specified PAG oil from a sealed container and ALWAYS reseal oil container immediately after use.
Page 40 A/C refrigerant system, notes Page 15 of 15 87-15 Note: For information on A/C wiring see applicable wiring diagram. See also A/C refrigerant system safety precautions starting Page 87-1 Green label in engine compartment indicates A/C system is charged with refrigerant R-134a. Only a high pressure service valve is used for A/C system servicing.
Page 41 Manual A/C Page 1 of 36 87-16 Manual A/C Heating and A/C components in passenger compartment, servicing CAUTION! Obtain the anti-theft radio security code. Switch the ignition off. Disconnect the battery Ground (GND) strap. After reconnecting battery, re-code and check operation of anti-theft radio.
Page 42 Manual A/C Page 2 of 36 87-17 2 - Heater core* Gaskets must be bonded gap-free all around. If retaining tabs do not engage when assembling, secure heat exchanger with screws. Always replace coolant after replacement. Removing Page 87- (Heating and A/C unit, assembly) 3 - Connecting duct With gasket...
Page 43 Manual A/C Page 3 of 36 87-18 7 - Vacuum unit for fresh/recirculating air flap* Ventilated: Fresh air operation 8 - Fresh air blower switch -E9- 9 - A/C switch -E35- With switch for fresh/recirculating air flap -E159- With control light for lighting - Air conditioner switch - L43-...
Page 44 Manual A/C Page 4 of 36 87-19 12 - Evaporator housing cover Replacing: First remove instrument panel and footwell outlets - 31 - 13 - Retaining strap Replacing: First remove instrument panel and footwell outlets - 31 - 14 - Right air duct 15 - Air distributor Replacing: Remove center console,...
Page 45 Manual A/C Page 5 of 36 87-20 17 - Grille For right vent 18 - Center air outlet Removing Page 80- Fig. 7 19 - Control panel trim 20 - Grilles For center vent 21 - Instrument panel trim Removing Page 80- Fig.
Page 46 Manual A/C Page 6 of 36 87-21 24 - Rear heater duct Replacing: First remove center console, instrument panel bracket, pedal cluster cover - 33 -, footwell outlet - 31 -, seats and carpet 25 - Gasket 26 - Instrument panel Removing and installing Repair Manual, Body...
Page 47 Manual A/C Page 7 of 36 87-22 29 - A/C clutch cut-off relay -J246- Only on vehicles with automatic transmission Behind the center console Control number 135 30 - Heating and A/C controls With A/C switch -E35- Installing and adjusting cables Page 87-26 Removing and...
Page 48 Manual A/C Page 8 of 36 87-23 32 - Heating and A/C cables Replacing: First remove pedal cluster cover - 33 - and footwell outlet - 31 - Installing and adjusting Page 87-26 33 - Pedal cluster cover 34 - Air distribution housing* With temperature flap With center flap...
Page 49 Manual A/C Page 9 of 36 87-24 Fig. 1 A/C switch -E35-, removing Press the switch unit (at the four locating points) against the controls and at the same time toward the buttons. Fig. 2 Fresh air blower series resistance with fuse -N24-, replacing - Remove shelf on passenger side - Remove glove box.
Page 50 Manual A/C Page 10 of 36 87-25 Fig. 3 Fresh air blower -V2-, removing and installing - Remove right side shelf. - Remove glove box. - Disconnect electrical connection -1-. - Remove clamp -3-. - Remove screws -arrows- and remove fresh air blower -2- downward.
Page 51 Manual A/C Page 11 of 36 87-26 Heating and A/C cables, installing and adjusting Notes: First connect cables to removed controls then adjust and secure cables to levers on air conditioner. Sleeve ends of cables which are marked with a colored line are attached to the controls.
Page 52 Manual A/C Page 12 of 36 87-27 1 - Footwell/defrost flap cable From air distribution rotary control knob to footwell/defrost flap Black sleeve Adjusting cable at footwell/defrost flap Fig. 1 2 - Cable for center flap From air distribution rotary control knob to center flap Black sleeve Adjusting cable at...
Page 53 Manual A/C Page 13 of 36 87-28 Fig. 1 Footwell/defrost flap cable, adjusting - Install warm and fresh air controls. - Turn air distribution rotary control knob to stop at "defrost" position. - Press footwell/defrost flap lever onto stop -arrow- and secure black cable sleeve.
Page 54 Manual A/C Page 14 of 36 87-29 Fig. 3 Temperature flap cable, adjusting - Install warm and fresh air blower controls. - Turn temperature rotary control knob to stop at "cold" position. - Press temperature flap lever onto stop -arrow- and secure blue cable sleeve.
Page 55 Manual A/C Page 15 of 36 87-30 Heating and A/C components in engine compartment, servicing CAUTION! Obtain the anti-theft radio security code. Switch the ignition off. Disconnect the battery Ground (GND) strap. After reconnecting battery, re-code and check operation of anti-theft radio.
Page 56 Manual A/C Page 16 of 36 87-31 4 - A/C pressure switch - F129- Testing Fig. 2 Removing and installing: - Tightening torque 8 Nm (70 in lb) - Replace O ring seal (note Part No.). 5 - Ambient temperature switch -F38- Switches off A/C clutch -N25- at low ambient...
Page 57 Manual A/C Page 17 of 36 87-32 8 - Plenum chamber cover 9 - Evaporator water drain valve Behind bulkhead insulation Removing and installing Fig. 3 Valve mating surfaces must be clean and dry 10 - Heat exchanger and vacuum hose guide 11 - Vacuum reservoir Insertion depth for vacuum hose: 30 mm...
Page 58 Manual A/C Page 18 of 36 87-33 14 - Fresh air/recirculating flap two-way valve - N63- Open when electrically completed Vacuum hose connection diagram Page 87-40 Installing Fig. 5 15 - Coolant FC (Fan Control) Control Module -J293- 16 - A/C cut-out thermal switch -F163- and third speed coolant fan control (FC) thermal...
Page 59 Manual A/C Page 19 of 36 87-34 17 - Condenser* 18 - Pressure relief valve* Checking Fig. 8 19 - A/C clutch -N25-* 20 - Receiver drier* http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.HA01.87.2 12/7/2004...
Page 60 Manual A/C Page 20 of 36 87-35 Fig. 1 A/C cut-out thermal switch -F163- and third speed coolant fan control (FC) thermal switch -F165- (engine code AAA), removing and installing WARNING! Cooling system is pressurized when engine is warm. Wear gloves and other protection and carefully release system pressure if necessary, before performing repairs.
Page 61 Manual A/C Page 21 of 36 87-36 Fig. 2 A/C pressure switch -F129-, checking Visual check: Ensure that O-ring (color: red) 10.8 mm x 1.8 mm is seated in groove Switch part between contacts -T4a/1- and -T4a/2 of connector housing switches magnetic coupling -N25- off when refrigerant system insufficiently filled or pressure too high.
Page 62 Manual A/C Page 22 of 36 87-37 Fig. 3 Evaporator water drain valve, removing and installing 1 - Bulkhead 2 - Evaporator housing 3 - Valve flap, shown raised 4 - Water drain valve 5 - Hex key 14 mm Removing: - Turn valve 45 with hex key -5- and pull out.
Page 63 Manual A/C Page 23 of 36 87-38 Fig. 5 Fresh air/recirculating air flap two-way valve -N63-, installing 1 - Cap Check air passage slot 2 - Two-way valve (other designs possible) Fig. 6 Expansion valve insulation piece, checking 1 - Insulator 2 - Expansion valve The insulator prevents drop in air conditioner efficiency caused by increasing temperatures...
Page 64 Manual A/C Page 24 of 36 87-39 Fig. 7 Vacuum reservoir, removing and installing 1 - Plastic line Installation depth: 30mm 2 - Rubber seal 3 - Vacuum reservoir 4 - Nut 5 - Wheel housing liner Wheel housing liner, removing and installing Repair Manual, Body Exterior, Interior, Repair Group 66;...
Page 65 Manual A/C Page 25 of 36 87-40 Vacuum hose layout Note: Insertion depth of vacuum hose in vacuum reservoir: 30 mm. Overlap of vacuum hose on plastic line: onto stop (approx. 15 mm) 1 - Fresh air/recirculating air flap vacuum unit 2 - Reduction hose 3 - Hose 3.5 x 2 x 90 mm...
Page 66 Manual A/C Page 26 of 36 87-41 5 - Plastic line 4 x 1 x 1030 mm 6 - Foam line 7 - Plastic line 4 x 1 x 490 mm 8 - Vacuum reservoir 9 - Cable tie 10 - Non-return valve Direction of suction indicated by arrow 11 - Hose...
Page 67 Manual A/C Page 27 of 36 87-42 14 - Hose 3.5 x 2 x 350 mm 15 - Hose 3.5 x 2 x 245 mm 16 - Hose 3.5 x 2 x 116 mm 17 - Hose 3.5 x 2 x 116 mm 18 - Non-return valve http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.HA01.87.2 12/7/2004...
Page 68 Manual A/C Page 28 of 36 87-43 A/C clutch -N25- (Sanden), servicing (compressor removed) Special tools, testers, measuring instruments and auxiliary items required 3212 Pin wrench VW 401 Thrust plate VW 402 Thrust plate VW 412 Thrust disc VW 432 Arbor (50 mm) VW 441 Base block Not shown Two-arm puller with...
Page 69 Manual A/C Page 29 of 36 87-44 VAG 1616 Retainer (for clutch plate) VAG 1616/1 Puller (for A/C clutch) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.HA01.87.2 12/7/2004...
Page 70 Manual A/C Page 30 of 36 87-45 First do the following: - Discharge A/C refrigerant system Page 87-96 - Disconnect electrical connection for A/C clutch -N25-. - Remove compressor from bracket, 4-cylinder gasoline engine page Page 87-54 4-cylinder TDI engine page Page 87-57 6-cylinder engine page...
Page 71 Manual A/C Page 31 of 36 87-46 3 - Circlip Always replace Install correctly: Flat side faces compressor Ensure correct seating in groove 4 - Ribbed belt pulley Removing Fig. 3 Installing Fig. 6 5 - Bearing Removing Fig. 4 Installing Fig.
Page 72 Manual A/C Page 32 of 36 87-47 7 - Circlip Always replace Install correctly: Flat side faces compressor Ensure correct seating in groove 8 - Clutch coil Secured with fitted pin and circlip -7- Note: A thermo-fuse is incorporated into the clutch coil. Current to the clutch coil is interrupted in the event of compressor overheating (E.g.: a binding...
Page 73 Manual A/C Page 33 of 36 87-48 A/C Clutch -N25-, removing and installing Fig. 1 Self-locking nut, removing - Counter-hold clutch plate using pin wrench 3212 or VAG 1616 and remove nut. Fig. 2 Clutch plate, removing - Use puller VAG 1616/1. Note: Three retaining bolts on VAG 1616/1 have 1/4"thread.
Page 74 Manual A/C Page 34 of 36 87-49 Fig. 3 Ribbed-belt pulley, removing - Remove circlip Page 87-46 , key 3 . - Use locally available two-arm puller with 100 mm span depth (E.g.: Kukko 20-10 or equivalent). - Place puller arm under pulley as illustrated -arrow-. CAUTION! Place puller arms under pulley only far enough so as to not damage clutch coil upon removal.
Page 75 Manual A/C Page 35 of 36 87-50 Fig. 5 Bearing, installing Fig. 6 Ribbed-belt pulley, installing CAUTION! In order to prevent pulley deformation while pressing, ensure compressor remains flat at all times. - Displace threaded bushing -1-. - Install circlip Page 87-46 , key 3 .
Page 76 Manual A/C Page 36 of 36 87-51 Fig. 7 Clutch plate, checking/adjusting clearance - With compressor grounded, repeatedly apply 12V to clutch coil terminal connection. - Measure clearance between clutch plate and pulley around entire circumference. Specification: 0.4..0.8 mm Notes: Clearance must be within tolerance around entire circumference.
Page 77 Compressor bracket, removing and installing Page 1 of 11 87-52 Compressor bracket, removing and installing 4-cyl. gasoline engine Note: The compressor bracket and related components can be removed and installed without having to open the refrigerant system 1 - Generator (GEN) and compressor bracket Generator, removing and installing...
Page 78 Compressor bracket, removing and installing Page 2 of 11 87-53 4 - Compressor bracket Installing: - Insert bolts - 5 - and - 6 - 2 to 5 turns. - Screw in bolt -6- until bracket contacts threaded bushing - 7 -. - First tighten bolt - 5 - to 45 Nm (4 to 33 ft.
Page 79 Compressor bracket, removing and installing Page 3 of 11 87-54 9 - Compressor Removing: - Loosen hex bolt - 11 - two turns and knock-back threaded sleeve - 7 - from compressor. Then remove hex bolts. 10 - Ribbed belt Removing and installing Repair Manual, 2.0 Liter 4-...
Page 80 Compressor bracket, removing and installing Page 4 of 11 87-55 4-cyl. TDI engine Note: The compressor bracket and related components can be removed and installed without having to open the refrigerant system 1 - Hex bolt M8x22 25 Nm (18 ft. lb) 2 - Generator (GEN) and compressor bracket Removing: first...
Page 81 Compressor bracket, removing and installing Page 5 of 11 87-56 4 - Generator (GEN) Removing: Repair Manual, Electrical Equipment, Repair Group 27 5 - Tensioning element for tensioner roller 6 - Hex socket bolt M8x22 25 Nm (18 ft. lb) Qty.: 3 7 - Hex nut M8 30 Nm (22 ft.
Page 82 Compressor bracket, removing and installing Page 6 of 11 87-57 9 - Compressor Removing: - Loosen hex bolt - 11 - two turns and knock-back threaded sleeve from compressor. Then remove hex bolts. 10 - Ribbed belt Removing and installing Repair Manual, 1.9 Liter 4- Cyl.
Page 83 Compressor bracket, removing and installing Page 7 of 11 87-58 6-cyl. engine Note: Compressor and related parts can be removed and installed without having to open refrigerant system 1 - Generator (GEN), compressor and power steering pump bracket Removing: - First remove generator (GEN), compressor - 8 - and Power steering...
Page 84 Compressor bracket, removing and installing Page 8 of 11 87-59 2 - Washer 8.4x16x1.6 3 - Fitting bolt M8x28 25 Nm (18 ft. lb) 4 - Socket head bolt M8x30 25 Nm (18 ft. lb) 5 - Socket head bolt M8x30 25 Nm (18 ft.
Page 85 Compressor bracket, removing and installing Page 9 of 11 87-60 7 - Refrigerant hoses 8 - Compressor Removing: - First discharge refrigerant circuit Page 87-96 - Remove front bumper Repair Manual, Body Exterior, Interior, Repair Group - Loosen hood lock carrier and pull forward.
Page 86 Compressor bracket, removing and installing Page 10 of 11 back threaded sleeves from compressor. Then remove hex bolts. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.HA01.87.3 12/7/2004...
Page 87 Compressor bracket, removing and installing Page 11 of 11 87-61 9 - Ribbed belts Removal and installing Repair Manual, 2.8 Liter VR6 2V Engine Mechanical, Engine Code(s): AAA, Repair Group 13 10 - Hex bolt M10x112 45 Nm (33 ft. lb) 11 - Socket head combi- bolt M8x30 25 Nm (18 ft.
Page 88 A/C refrigerant system Page 1 of 7 87-62 A/C refrigerant system A/C refrigerant system, identification Note: Before carrying out any work on the A/C refrigerant system, refer to A/C system safety measures Page 87-1 A/C refrigerant systems on Passat models are charged with refrigerant R-134a.
Page 89 A/C refrigerant system Page 2 of 7 87-63 A/C refrigerant system, component overview Compressor The compressor is driven via a belt on the engine when power is applied to the the A/C clutch -N25- (A/C "ON"). Low-pressure refrigerant gas from the evaporator is compressed by the compressor.
Page 90 A/C refrigerant system Page 3 of 7 87-64 Condenser The condenser transfers heat from the compressed refrigerant gas to the outside air which causes the refrigerant to change state from a gas to a liquid. Expansion valve The expansion valve restricts and controls refrigerant flow to the evaporator thus lowering refrigerant temperature and pressure.
Page 91 A/C refrigerant system Page 4 of 7 87-65 Evaporator Liquid refrigerant entering the evaporator absorbs heat from air passing through the evaporator fins and cools the air. As the refrigerant absorbs heat it turns to vapor and then is suctioned by the compressor. A/C system hoses and lines The mixture of refrigerant oil (PAG oil) and refrigerant R-134a attacks some metals and alloys (for example,...
Page 92 A/C refrigerant system Page 5 of 7 87-66 Receiver drier The receiver drier accumulator acts as a refrigerant reservoir for the system. Any moisture in the refrigerant system is absorbed by drier desiccantr. Note: Replace the receiver drier each time the refrigerant circuit is opened.
Page 93 A/C refrigerant system Page 6 of 7 87-67 O-rings O-rings seal connections between A/C system components. Notes: 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.
Page 94 A/C refrigerant system Page 7 of 7 87-68 A/C pressure switch -F129- 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. 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 .
Page 95 A/C refrigerant system, servicing Page 1 of 35 87-69 A/C refrigerant system, servicing Notes: Before carrying out any work on the A/C refrigerant system, refer to A/C refrigerant system safety measures Page 87-1 Service refrigerant system using Kent More ACR 4 or equivalent.
Page 96 A/C refrigerant system, servicing Page 2 of 35 87-70 4 - O-ring 17.7 mm; 1.8mm 5 - Expansion valve In engine compartment at bulkhead, right Must be sealed against water spray. Removing Page 87- 6 - O-ring 14 mm; 1.8mm 7 - O-ring 10.8 mm;...
Page 97 A/C refrigerant system, servicing Page 3 of 35 87-71 11 - A/C pressure switch - F129-* Checking -F129- Fig. 3 Removing and installing - tightening torque: 8 Nm (71 in. lb.) Component can be removed without discharging refrigerant system 12 - Bolt 7 Nm (62 in.
Page 98 A/C refrigerant system, servicing Page 4 of 35 87-72 19 - Condenser Removing and installing Page 87- 20 - Coupling Thread 5/8" - 18 UNF 15 Nm (11 ft. lb.) 21 - O-ring 7.6 mm; 1.8mm 22 - Pressure relief valve On compressor Checking Fig.
Page 99: Compressor
A/C refrigerant system, servicing Page 5 of 35 87-73 26 - O-ring 7.6 mm; 1.8mm 27 - Coupling Thread 5/8" - 18 UNF 15 Nm (11 ft. lb.) 28 - Compressor Sanden SD7-V16 29 - A/C clutch -N25-* Clutch assembly can be serviced without discharging refrigerant system.
Page 100 A/C refrigerant system, servicing Page 6 of 35 87-74 31 - O-ring 14 mm; 1.8mm 32 - O-ring 10.8 mm; 1.8mm 33 - High pressure service valve Only use Kent Moore ACR4 or equivalent Removing and installing Fig. 1 Refrigerant system capacity Page 87- 34 - Cap*...
Page 101 A/C refrigerant system, servicing Page 7 of 35 87-75 Fig. 1 High pressure service valve, removing - Discharge refrigerant system Page 87-96 - Unscrew and remove high pressure service valve - 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;...
Page 102 A/C refrigerant system, servicing Page 8 of 35 87-76 Fig. 3 A/C pressure switch -F129-, checking 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...
Page 103 A/C refrigerant system, servicing Page 9 of 35 87-77 Checking: - With the engine running, briefly bridge terminal 1 and 2 of connector. If the A/C clutch -N25- engages, the refrigerant circuit is empty. -F129- functional checks To determine proper A/C system performance, perform the following functional checks with the switch installed and connected.
Page 104 A/C refrigerant system, servicing Page 10 of 35 87-78 Fig. 4 Pressure relief valve, checking Function: Protects the refrigerant circuit from over-pressure. Refrigerant oil deposited on rear of compressor indicates pressure relief valve has opened to release pressure -arrow-. An adhesive plate is pushed out.
Page 105: Removing
A/C refrigerant system, servicing Page 11 of 35 87-79 Expansion valve, removing Notes: Before carrying out any work on the A/C refrigerant system, refer to A/C refrigerant system safety measures Page 87-1 Service refrigerant system using Kent More ACR 4 or equivalent.
Page 106: First Discharge Refrigerant Circuit
A/C refrigerant system, servicing Page 12 of 35 87-80 6 - Refrigerant hose From expansion valve to compressor With dampener 7 - O-ring 16.7 mm; 1.8mm 8 - Expansion valve In engine compartment at bulkhead, right Must be sealed against water spray. Checking insulation piece for expansion valve...
Page 107 A/C refrigerant system, servicing Page 13 of 35 87-81 Condensor, removing CAUTION! Before beginning repairs on the electrical system: Obtain the anti-theft radio security code. Switch the ignition off. Disconnect the battery Ground (GND) strap. After reconnecting battery, re-code and check operation of anti-theft radio.
Page 108: Remove Front Bumper
A/C refrigerant system, servicing Page 14 of 35 87-82 - Discharge refrigerant system Page 87-96 - Remove front bumper Repair Manual, Body Exterior, Interior, Repair Group 63 - Bring front end assembly (lock carrier) into service position Repair Manual, Body Exterior, Interior, Repair Group 50 - Loosen and separate refrigerant pipes/couplings...
Page 109 A/C refrigerant system, servicing Page 15 of 35 87-83 4 - Foam gasket 480 mm long Secure with adhesive prior to installation 5 - Rubber grommet 6 - Air guide 7 - Screw Qty.: 4 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.HA01.87.5 12/7/2004...
Page 110 A/C refrigerant system, servicing Page 16 of 35 87-84 Heating and A/C unit, removing and assembly CAUTION! Before beginning repairs on the electrical system: Obtain the anti-theft radio security code. Switch the ignition off. Disconnect the battery Ground (GND) strap. After reconnecting battery, re-code and check operation of anti-theft...
Page 111 A/C refrigerant system, servicing Page 17 of 35 87-85 Removing - Discharge refrigerant system Page 87-96 - Drain cooling system Repair Manual, Engine Mechanical, Repair Group 19. CAUTION! The cooling system is pressurized when the engine is warm. Wear gloves and other protection and carefully release system pressure if necessary, before...
Page 112 A/C refrigerant system, servicing Page 18 of 35 87-86 - Remove instrument panel Repair Manual, Body Interior, Repair Group 70. - Locate and remove heating and A/C unit fasteners at bulkhead. - Remove heating and A/C unit. Assembly 1 - Housing, upper part Separate upper and lower housing sections by removing clips.
Page 113 A/C refrigerant system, servicing Page 19 of 35 87-87 8 - Housing, lower part Separate upper and lower housing sections by removing clips. Coat fitted surface of housing with AMV 176 000 06 (or equivalent) prior to assembly. 9 - A/C Evaporator Temperature Switch - E33- Ensure temperature...
Page 114 A/C refrigerant system, servicing Page 20 of 35 87-88 12 - Lower trim cover 13 - Evaporator water drain 14 - Gasket 15 - Air distribution housing Air flaps are not serviceable. 16 - Heater core Gaskets must be bonded gap-free all around.
Page 115 A/C refrigerant system, servicing Page 21 of 35 87-89 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.
Page 116 A/C refrigerant system, servicing Page 22 of 35 87-90 CAUTION! DO NOT flush R-134a refrigerant system with R-11. R-11 is not compatible with refrigerant R-134a and PAG oil and will cause total system contamination. 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...
Page 117 A/C refrigerant system, servicing Page 23 of 35 87-91 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.
Page 118 A/C refrigerant system, servicing Page 24 of 35 87-92 6 - Receiver drier 7 - Sight glass If equipped 8 - High pressure service valve 9 - Expansion valve http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.HA01.87.5 12/7/2004...
Page 119 A/C refrigerant system, servicing Page 25 of 35 87-93 Pressure and temperature specifications Refer to pages Page 87-91 Page 87-63 for component identification. Component Refrigerant Approximate pressure Approximate state (bar/psi) temperature 1 - Evaporator, inlet to Vapor to Gas -7 C (19 F) outlet 2 - Low pressure service 1.2 bar (17.4 psi)
Page 120 A/C refrigerant system, servicing Page 26 of 35 87-94 A/C refrigerant system, testing with pressure gauges Due to the constant temperature/pressure relationship of refrigerant R-134a, approximate high-side system temperature can be determined based on system pressure. Pressure gauges may have one or more temperature scales in addition to the pressure scale.
Page 121 A/C refrigerant system, servicing Page 27 of 35 87-95 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.
Page 122 A/C refrigerant system, servicing Page 28 of 35 87-96 A/C refrigerant system, discharging WARNING! Always use an Underwriter's Laboratory (UL) approved refrigerant recovery/recycling/recharging unit such as Kent-Moore ACR , or equivalent, whenever discharging an R-134a A/C system. Any person who services a motor vehicle air conditioner MUST, by law, be properly trained and certified and use approved refrigerant recycling equipment.
Page 123 A/C refrigerant system, servicing Page 29 of 35 87-97 CAUTION! Always use separate refrigerant recovery/recycling/recharging servicing equipment for R-12 and R-134a systems. DO NOT use one piece of equipment for both R- 12 and R-134a systems. The residual traces of refrigerant inside the equipment will contaminate and damage the equipment.
Page 124 A/C refrigerant system, servicing Page 30 of 35 87-98 Note: Make sure that initial set-up of the refrigerant recovery/recycling/recharging unit has been completed before discharging the A/C system. - Connect red high-pressure hose -A- of refrigerant recovery/recycling/recharging unit to high side fitting on vehicle and open coupler valve.
Page 125 A/C refrigerant system, servicing Page 31 of 35 87-99 A/C refrigerant system, flushing with compressed air and nitrogen CAUTION! When using compressed nitrogen always use a pressure regulator and the proper adaptor hoses and fittings (available locally). During flushing, use existing exhaust/ventilation systems to draw off the gas mixture escaping from the A/C system.
Page 126 A/C refrigerant system, servicing Page 32 of 35 87-100 Always flush components in opposite direction of refrigerant flow. Flush evaporator through the low-pressure line with the high-pressure line removed. If any component has dark thick deposits that cannot be removed with compressed air, replace component.
Page 127 A/C refrigerant system, servicing Page 33 of 35 87-101 Flush refrigerant system with compressed air and nitrogen if: Refrigerant oil is dark and viscous (thick) Too much refrigerant oil is in the system following compressor replacement Unclear or do not know how much refrigerant oil is in the system Moisture, dirt or other impurities have entered the refrigerant system (i.e.
Page 128 A/C refrigerant system, servicing Page 34 of 35 87-102 A/C refrigerant system, evacuating and recharging WARNING! Always use an Underwriter's Laboratory (UL) approved refrigerant recovery/ recycling/recharging unit such as Kent- Moore ACR , or equivalent, when evacuating and recharging an R-134a A/C system. Any person who services a motor vehicle air conditioner MUST, by law, be properly trained and certified and use approved...
Page 129 A/C refrigerant system, servicing Page 35 of 35 87-103 Notes: Refer to R-134a safety measures prior to discharging or charging A/C refrigerant system Page 87-1 Follow refrigerant recovery/recycling/recharging unit manufacturer's instructions for evacuating and recharging A/C system. Evacuate refrigerant system for a minimum of 30 minutes.
Page 130 A/C refrigerant system, troubleshooting Page 1 of 10 87-104 A/C refrigerant system, troubleshooting Requirements Electrical systems OK Air flow distribution systems (controls and cables) OK Correct and repair as necessary before proceeding. If any one of the following system conditions exists, check A/C refrigerant system pressures Page 87-106 A/C does not cool (cooling has stopped...
Page 131 A/C refrigerant system, troubleshooting Page 2 of 10 87-105 Compressor noisy - Tighten compressor and compressor bracket mounting bolts using torque wrench. - 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.
Page 132 A/C refrigerant system, troubleshooting Page 3 of 10 87-106 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...
Page 133 A/C refrigerant system, troubleshooting Page 4 of 10 87-107 Test 1: Air temperature drop from center instrument panel outlet, checking (A/C system cooling performance) - Start engine. - Set temperature control to maximum "cold". - Press "A/C" button and select second blower speed.
Page 134 A/C refrigerant system, troubleshooting Page 5 of 10 87-108 Test 2: A/C system high pressure, checking - Connect high- and low-pressure hoses of refrigerant recovery/ recycling/recharging unit Kent-Moore ACR or equivalent, to high- and low-pressure service valves. - Disconnect electrical connector from coolant fan.
Page 135 A/C refrigerant system, troubleshooting Page 6 of 10 87-109 Test 3: A/C system low pressure, checking - Connect high- and low-pressure hoses of refrigerant recovery/recycling/recharging unit Kent-Moore ACR , or equivalent, to high- and low-pressure service valves. - Start engine. - Set temperature control to maximum "cold".
Page 136 A/C refrigerant system, troubleshooting Page 7 of 10 87-110 Test 1 Test 2 Test 3 Possible causes of Corrective measures incorrect readings Temperature from High center air vent pressure pressure Normal Normal Normal None Too high Normal Normal Temperature flap Adjust temperature flap position incorrect cable...
Page 137 A/C refrigerant system, troubleshooting Page 8 of 10 87-111 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.
Page 138 A/C refrigerant system, troubleshooting Page 9 of 10 87-112 Checking - Start engine. - Set temperature control to maximum "cold". - Press A/C button and select second blower speed. - Adjust air distribution to instrument panel outlets. - Insert thermometer into center instrument panel outlet.
Page 139 A/C refrigerant system, troubleshooting Page 10 of 10 87-113 A/C refrigerant system, checking for leaks Use halogen leak detector, Hitec HI400A-TEL or equivalent, to check for refrigerant leaks, following the leak detector manufacturer's instructions. Refrigerant gas dissipates very quickly. To make the job easier, avoid drafty or windy areas when checking for leaks.
Page 140 Refrigerant R-134a, capacity Compressor Quantity Sanden SD7-V16 1150 g 50 g (40.5 oz 1.8 oz) (Passat 1995 - 1997) Obtain R-134a refrigerant from a local A/C supplier under one of the following names: R-134a Tetrafluoroethane F CF H-FKW 134a...
Page 141 A/C refrigerant system, capacities Page 2 of 4 87-115 Refrigerant (PAG) oil R-134a, capacity Model Total system capacity Passat from 1995 to 115 cc (4.6fl. oz.) 1997 Replacement A/C compressors supplied by the Parts Department are filled with 115 cc (fl. oz.) of refrigerant oil.
Page 142 A/C refrigerant system, capacities Page 3 of 4 87-116 Refrigerant (PAG) oil R-134a, identification Use only the correct type of refrigerant oil (PAG oil) specified for use with R-134a and compressor type. Compressor Refrigerant oil Part No. Sanden SD7-V16 G 052 154 A2 CAUTION! Part numbers are for reference only.
Page 143 A/C refrigerant system, capacities Page 4 of 4 87-117 Refrigerant (PAG) oil R-134a, distribution The total refrigerant oil quantity is distributed in the refrigerant circuit as follows: Compressor approx. 50% Condensor approx. 10% Suction pipe approx. 10% Discharge pipe -- Evaporator approx.

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