Heating and A/C Components In Passenger Compartment, Servicing
Heating And A/C Components In Passenger Compartment, Servicing
CAUTION:
Before beginning repairs on the electrical system:
- Obtain the anti-theft radio security code.
- Switch off all electrical consumers.
- Switch ignition off and remove ignition key.
- Disconnect negative (-) battery terminal.
- When disconnecting and reconnecting battery terminals, observe all applicable Notes and torque specifications, as well as instructions on performing OBD program and electrical system function checks.
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.
1. Clip
- Lift out with screwdriver.
2. Dust and pollen filter
- Vehicles from 10.00, replacing.
3. Air intake housing
4. Defroster air outlet
5. Side window air outlet
- Removing See Fig. 1
6. Heating and A/C controls
With:
- A/C switch -E35-
- Fresh air blower switch -E9-
- Switch for fresh air blower and recirculated air -E184-
- Assembly
7. Air outlets
- Center and side air outlets, removing (early prod.) See Fig. 2.
- Center air outlet, removing (later prod.) removing See Fig. 3.
- Side air outlets, removing (later prod.) See Fig. 4.
8. Inst. panel cross member **
- Always follow installation instructions for bolt See Fig. 7.
9. Defroster duct **
- Replacing:
- Remove instrument panel
10. Servo motor for fresh/recirculating air door -V154-
- Removing and installing See Fig. 9.
11. Ambient temperature switch -F38-
- Switches off A/C clutch -N25- at low ambient temperatures
- Switching point: 5 degrees C (41.5 degrees F)
- Replacing:
- Remove glove box
- Reach behind heating and A/C unit from below and pull out switch.
12. Gasket
- Replace if damaged
- Replacing:
- Remove ambient temperature switch -F38-
- Remove dust and pollen filter
- Set fresh air/recirculation flap in "fresh air" position
- Reach down into air intake housing and pull out gasket
CAUTION: Area around dust and pollen filter and air intake housing must be free from debris, leaves etc. before reaching into housing. Debris entering heating and A/C unit will block evaporator water drain and cause subsequent (water) damage.
NOTE: If unable to access and remove gasket as described, proceed as follows:
- Remove instrument panel
- Loosen cross member -10-.
- Always follow installation instructions for bolt See Fig. 7.
13. Evaporator water drain guide
- Removing and installing See Fig. 6.
14. Heating and A/C unit *, **
Contains:
- Heater core
- Evaporator
15. Fresh air blower -V2-
16. Fresh air blower series resistance with fuse -N24-
- Replacing See Fig. 5.
17. Center air outlet duct **
18. Control panel trim
- Unclip using screwdriver
19. Center trim
20. Heating and A/C cables
21. Heater core *,**
- Removing and installing, heating and A/C unit assembly.
- Always use new coolant after replacement
22. Left rear duct
23. Lower duct
24. Upper duct
25. Footwell air outlet **
- Replacing:
- Remove instrument panel
- Remove instrument panel cross member -8-.
- Always follow installation instruction for bolt See Fig. 7
- Remove all upper ducts.
- Carefully lift heating and A/C unit.
- Remove footwell air outlet.
26. Instrument panel cross member, left side member securing bolt
- Always follow installation instruction for bolt See Fig. 7.
27. Relay
Coolant Fan Control (FC) Relay -J26-
- Control number 214
First Speed Coolant Fan Control (FC) relay -J279-
- Vehicles from 10.00: Control number 373
Second Speed Coolant Fan Control (FC) Relay -J280-
- Vehicles from 10.00: Control number 370
Coolant Fan Afterrun Relay -J397-
- TDI - PD only (where applicable)
- Control number 373
Component locations
28. A/C cut-off control module -J314-
- Control number 384.
29. Instrument panel **
- Removing:
Removing air outlets:
- Center and side air outlets, removing (early prod.) See Fig. 2.
- Center air outlet, removing (later prod.) removing See Fig. 3.
- Side air outlets, removing (later prod.) See Fig. 4.
Fig. 1 Side window air outlet, removing
- Carefully pull out using needle-nose pliers.
Fig. 2 Center and side air outlets, removing (early prod.)
- With flashlight, locate the two retaining tabs inside housing, lift tabs with two small screwdrivers and carefully pull outlet from instrument panel.
Fig. 3 Center air outlet, removing (later production)
- Insert fingers of both hands into lower row of grille -A- and push center vent -1- down suing force until locking lugs -B- are released from their mounts.
NOTE:
- Sit between front seats to apply the force required.
- If outer locking lugs -B- will not release, grip at this point and push center vent down while simultaneously pulling out slightly.
- Grip center vent -1- at point -> which has been raised up slightly from instrument panel opening by action of pushing down.
- Push center vent in direction -D- to release locking lugs and pull it outward slightly.
- Disconnect electrical connectors -2- from center vent before removing in direction of -arrow-
Fig. 4 Side air outlet, removing (later prod.)
NOTE: Removal of both sides is identical.
- Unclip and remove instrument panel side cover -1- using screwdriver.
- Guide a flat screwdriver between vent and seal alternately into side openings -A- and -B-.
- Pry vent -2- in direction -C- alternately through these openings.
- Disconnect electrical connector -3- when removing vent -2- in direction -C-.
Fig. 5 Fresh air blower series resistance with fuse -N24-, replacing
- Remove glove box.
- Disconnect electrical connector and remove bolt -arrow-.
- Seal surface between series resistance -1- and air duct before installing with AMV 176 000 05 (or equivalent).
Fig. 6 Fresh air blower -V2-, removing and installing
- Remove glove box
- Disconnect electrical connector -1-
- Remove three screws -arrows- and remove fresh air blower -2- downwards.
Fig. 7 Instrument panel cross member and left side member securing bolt, installation Note:
To avoid damage to instrument panel wiring harness -2-, ensure that protective cap -1- is installed on securing bolt for upper instrument panel cross member -4- at left side member -3-.
Fig. 8 Evaporator water drain guide, removing and installing
Removing
- Remove instrument panel
- Release instrument panel cross member from bulkhead.
For the next step, an assistant must carefully lift and hold the heating and A/C unit.
- Remove nuts -1- (2.5 Nm, 23 in lb) and remove guide -2- from bulkhead.
Installing
When installing, ensure water drain valve -3- sealing lip completely encloses the guide -2- If necessary, lubricate to aid installation.
Water drain valve, checking, see Fig. 1.
Fig. 9 Servo motor for fresh/recirculated air door -V154-, removing and installing
Removing
- Remove glove box.
- From the front passenger side, use a mirror to look behind heating and A/C unit.
- Remove screws (TORX T15) -arrows-.
- Un-clip lever for fresh/recirculated air flap.
- Pull off connector.
- Pull out motor downwards.
Installing
Position fresh/recirculated air flap lever by hand dependent on position of servo motor.