Service

Workshop Manual
Sharan 2016 ➤
Heating, air conditioner
Edition 02.2019

Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
80 - Heating
87 - Air conditioning system

Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
 Sharan 2016 ➤
Heating, air conditioner - Edition 02.2019

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on air conditioning systems . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety precautions when handling refrigerants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 2
1.4 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Notes concerning odours in air conditioned vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Notes for vehicles with start-stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Type plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Working on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Refrigerant circuit seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Checking cooling output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.5 Notes on control motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.1 Refrigerant capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 Refrigerant oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3 Oil distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

80 - Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1 Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

87 - Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1 Overview of fitting locations - air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.1 Overview of fitting locations - components not located in passenger compartment . . . . . . 17
1.2 Overview of fitting locations - components located in front section of passenger
compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.3 Overview of fitting locations - components located in rear section of passenger
compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2 Refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.1 System overview - refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2 Assembly overview - condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3 Removing and installing high-pressure sender G65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4 Removing and installing expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.5 Removing and installing condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.6 Removing and installing desiccant bag or cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.7 Removing and installing evacuating and charging valves on low and high-pressure side
........................................................................ 40
2.8 Removing and installing refrigerant line between condenser and expansion valve . . . . . . 43
2.9 Removing and installing refrigerant line between condenser and air conditioner
compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.10 Removing and installing refrigerant line between air conditioner compressor and expansion
valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.11 Removing and installing refrigerant line to second heater unit, high-pressure section . . . . 50
2.12 Removing and installing refrigerant line to second heater unit, low-pressure section . . . . 52
2.13 Removing and installing refrigerant line from second heater unit . . . . . . . . . . . . . . . . . . . . 54
3 Air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.1 Assembly overview - drive unit of air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . 58
3.2 Assembly overview - pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.3 Removing air conditioning compressor from and installing on bracket . . . . . . . . . . . . . . . . 62
3.4 Removing and installing air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

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3.5 Checking high-pressure safety valve on air conditioner compressor . . . . . . . . . . . . . . . . . . 69

3.6 Removing and installing pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4 Control motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.1 Overview of fitting locations - front control motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.2 Removing and installing temperature flap control motor V68 . . . . . . . . . . . . . . . . . . . . . . 74
4.3 Removing and installing defroster flap control motor V107 . . . . . . . . . . . . . . . . . . . . . . . . 76
4.4 Removing and installing air recirculation flap control motor V113 . . . . . . . . . . . . . . . . . . . . 78
4.5 Removing and installing rear temperature flap control motor V137 . . . . . . . . . . . . . . . . . . 79
4.6 Removing and installing left temperature flap control motor V158 . . . . . . . . . . . . . . . . . . 80
4.7 Removing and installing right temperature flap control motor V159 . . . . . . . . . . . . . . . . . . 82
4.8 Removing and installing fresh air/air recirculation, air flow flap control motor V425 . . . . . . 83
4.9 Removing and installing front air distribution flap control motor V426 . . . . . . . . . . . . . . . . 84
4.10 Removing and installing rear air distribution flap control motor V427 with potentiometer for
rear air distribution flap control motor G643 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.11 Removing and installing air distribution flap control motor V428 . . . . . . . . . . . . . . . . . . . . 86
5 Front heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.1 Assembly overview - heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.2 Removing and installing auxiliary air heater element Z35 . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.3 Removing and installing heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.4 Dismantling and assembling heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . 97
5.5 Assembly overview - evaporator housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.6 Removing and installing evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.7 Removing and installing dust and pollen filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.8 Removing and installing fresh air blower V2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.9 Removing and installing heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.10 Removing and installing evaporator temperature sensor G308 . . . . . . . . . . . . . . . . . . . . 107
5.11 Removing and installing condensation drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5.12 Checking condensation drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5.13 Removing and installing fresh air blower series resistor with overheating fuse N24 . . . . . . 109
5.14 Removing and installing glove box cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6 Rear heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
6.1 Assembly overview - heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
6.2 Removing and installing heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . 114
6.3 Dismantling and assembling heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . 118
6.4 Removing and installing rear fresh air blower V80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.5 Removing and installing rear fresh air blower control unit J391 . . . . . . . . . . . . . . . . . . . . 120
6.6 Removing and installing heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
7 Air duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
7.1 Assembly overview - air duct and air distribution in passenger compartment . . . . . . . . . . 125
7.2 Removing and installing air ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
7.3 Removing and installing forced ventilation for passenger compartment . . . . . . . . . . . . . . 131
7.4 Checking forced ventilation for passenger compartment . . . . . . . . . . . . . . . . . . . . . . . . . . 132
7.5 Removing and installing fresh air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
7.6 Removing and installing driver side footwell vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
7.7 Removing and installing front passenger side footwell vents . . . . . . . . . . . . . . . . . . . . . . . . 134
7.8 Removing and installing long rear vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
7.9 Removing and installing short rear vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
7.10 Removing and installing footwell vents for 3rd row of seats . . . . . . . . . . . . . . . . . . . . . . . . 136
8 Coolant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
8.1 Checking 2nd heat exchanger switch-off valve N317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
8.2 Removing and installing 2nd heat exchanger switch-off valve N317 . . . . . . . . . . . . . . . . 139
9 Operating and display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
9.1 Overview of operating and display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
9.2 Removing and installing operating and display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
10 Other controlling and regulating components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

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10.1 Removing and installing sunlight penetration photosensor G107 . . . . . . . . . . . . . . . . . . . . 148

10.2 Principle of operation of air quality sensor G238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
10.3 Removing and installing air quality sensor G238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
10.4 Removing and installing ambient temperature sensor G17 . . . . . . . . . . . . . . . . . . . . . . . . 151
10.5 Removing and installing left vent temperature sender G150 . . . . . . . . . . . . . . . . . . . . . . 151
10.6 Removing and installing right vent temperature sender G151 . . . . . . . . . . . . . . . . . . . . . . 152
10.7 Removing and installing left footwell vent temperature sender G261 . . . . . . . . . . . . . . . . 152
10.8 Removing and installing right footwell vent temperature sender G262 . . . . . . . . . . . . . . . . 153
10.9 Removing and installing rear vent temperature sender G174 . . . . . . . . . . . . . . . . . . . . . . 153

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Heating, air conditioner - Edition 02.2019

00 – Technical data
1 Safety information
(VRL012664; Edition 02.2019)
⇒ “1.1 Safety precautions when working on air conditioning sys‐
tems”, page 1
⇒ “1.2 Safety precautions when handling refrigerants”,
page 1
⇒ “1.3 Safety measures when working on vehicles with a start/
stop system”, page 2
⇒ “1.4 Safety precautions when working on the cooling system”,
page 2

1.1 Safety precautions when working on air conditioning systems

Risk of fatal injury and explosion from sources of ignition
Risk of fatal injury and explosion from sources of ignition in the
vicinity of air conditioning systems and refrigerant tanks. Escap‐
ing refrigerant could ignite and cause an explosion. Risk of ex‐
plosion leading to loss of life or serious injuries.
– Never bring sources of ignition close to air conditioning sys‐
tems and refrigerant tanks.
– Avoid electrostatic discharge, sparks from tools striking sur‐
faces and hot surfaces.

Risk of damage to refrigerant lines

There is a risk of damage to the refrigerant lines due to rupture of
the inner foil.
– Never bend refrigerant lines to a radius less than 100 mm.

1.2 Safety precautions when handling refrigerants

Risk of suffocation and poisoning from refrigerant
Coughing and nausea leading to suffocation and poisoning from
refrigerant vapours possible.
– Never inhale refrigerant vapours.
– Only work on the refrigerant circuit and refrigerant tanks in well
ventilated areas.
– Never work in or near cellars or other low lying areas.
– Switch on the extraction system.

Risk of freezing injury from refrigerant

When working on the air conditioning system, there is a risk of
highly pressurised refrigerant escaping from the system. There is
a risk of injury to the skin and parts of the body due to freezing.

1. Safety information 1
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– Wear protective gloves.

– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immediately
afterwards.
– If more than 10 minutes have passed since the refrigerant was
extracted, repeat the extraction process before opening the
refrigerant circuit. Pressure could build up in the refrigerant
circuit from continued evaporation.

1.3 Safety measures when working on vehicles with a start/stop system

Risk of injury due to unexpected motor start
If the vehicle’s start/stop system is activated, the engine can start
unexpectedly. A message in the dash panel insert indicates
whether the start/stop system is activated.
– Deactivate start/stop system by switching off the ignition.

1.4 Safety precautions when working on the cooling system

Danger of scalding by hot coolant
On a warm engine, the cooling system is under high pressure.
Danger of scalding by steam and hot coolant.
– Wear protective gloves.
– Wear protective goggles.
– Reduce excess pressure by covering cap of coolant expan‐
sion tank with cloths and opening it carefully.

2 Rep. gr.00 - Technical data

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2 General information
⇒ “2.1 Notes concerning odours in air conditioned vehicles”, page
3
⇒ “2.2 Notes for vehicles with start-stop system”, page 3
⇒ “2.3 Type plates”, page 4

2.1 Notes concerning odours in air condi‐

tioned vehicles
♦ If the evaporator emits unpleasant odours, clean the evapo‐
rator.
♦ Volkswagen has tested and approved the ultrasound A/C
cleaner - VAS 6189A- as well as the suction feed spray-gun -
V.A.G 1538- with the appropriate spray probe.
♦ Instructions on cleaning the evaporator are supplied with the
equipment.
♦ As soon as Volkswagen releases new procedures, corre‐
sponding information is found in the workshop manual ⇒ Air
conditioning systems with refrigerant R1234yf - General infor‐
mation; Rep. gr. 87 ; Refrigerant circuit; Possible complaints
or ⇒ Air conditioning system with refrigerant R134a; Rep. gr.
00 ; Complaints; Odours from heater and air conditioner unit

2.2 Notes for vehicles with start-stop system

The following abort conditions deactivate the start-stop-function:
♦ The start-stop system has been switched off via the start-stop
mode button.
♦ The charge status of the battery - - is insufficient to restart the
engine (starting voltage prediction).
♦ The defrost function is active.
♦ The windscreen heater function is active.
♦ The temperature set on the operating and display unit varies
by more than 8°C from the actual interior temperature.
♦ The engine speed is greater than 1200 rpm.
♦ The alternator - C- is defective, i.e. poly V-belt broken.
♦ The coolant temperature is not within specifications of 25°C -
100°C.
♦ Blower speed increase by more than 4 stages.

2. General information 3
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2.3 Type plates

⇒ “2.3.1 Identification plates, refrigerant R1234yf”, page 4
⇒ “2.3.2 Identification plates, refrigerant R134a”, page 4

2.3.1 Identification plates, refrigerant R1234yf

Identification plate with capacities for refrigerant R1234yf and re‐
frigerant oil
1- Designation of refrigerant oil
2- Name of refrigerant
3- Refrigerant capacity

Note

♦ A tolerance of ± 15 g is permissible although not indicated on

the identification plate.
♦ Capacities for refrigerant R1234yf and refrigerant oil
⇒ “4 Technical data”, page 13 .

2.3.2 Identification plates, refrigerant R134a

Identification plate with capacities for refrigerant R134a and re‐
frigerant oil
1- Name of refrigerant
2- Refrigerant capacity
3- Designation of refrigerant oil

Note

♦ A tolerance of ± 15 g is permissible although not indicated on

the identification plate.
♦ Capacities for refrigerant R134a and refrigerant oil
⇒ “4 Technical data”, page 13 .

4 Rep. gr.00 - Technical data

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3 Repair instructions
⇒ “3.1 Working on refrigerant circuit”, page 5
⇒ “3.2 General repair instructions”, page 5
⇒ “3.3 Refrigerant circuit seals”, page 5
⇒ “3.4 Checking cooling output”, page 6
⇒ “3.5 Notes on control motors”, page 7

3.1 Working on refrigerant circuit

In some countries special qualifications are required for any work
for which the refrigerant circuit needs to be opened.
Additional information
♦ For notes on repair work on vehicles equipped with an air con‐
ditioning system and for handling refrigerant, refer to ⇒ Air
conditioning systems with refrigerant R1234yf - General infor‐
mation; Rep. gr. 00 ; Safety instructions or ⇒ Air conditioning
system with refrigerant R134a; Rep. gr. 00 ; General infor‐
mation on the air conditioning system; Safety precautions
when working on vehicles equipped with an air conditioning
system and for handling refrigerant R134a .
♦ For notes on working with air conditioner service station on
vehicles equipped with an air conditioning system, refer to ⇒
Air conditioning systems with refrigerant R1234yf - General
information; Rep. gr. 87 ; Working with air conditioner service
station or ⇒ Air conditioning system with refrigerant R134a;
Rep. gr. 00 ; Working with air conditioner service station .
♦ Conditions and procedure for flushing with refrigerant R1234yf
⇒ Air conditioning systems with refrigerant R1234yf - General
information; Rep. gr. 87 ; Refrigerant circuit; Cleaning refrig‐
erant circuit or ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00 ; Removing contamination from refrigerant
circuit; Flushing refrigerant circuit with refrigerant R134a
(cleaning) .
♦ Notes on testers and tools for repairs to vehicles with air con‐
ditioning can be found in ELSA under ⇒ Air conditioning
systems with refrigerant R1234yf - General information or ⇒
Air conditioning system with refrigerant R134a; Rep. gr. 00 ;
Testing equipment and tools .
♦ In some cases, it is no longer necessary on air conditioning
systems with refrigerant R1234yf to renew the desiccant bag
each time the refrigerant circuit is opened ⇒ Air conditioning
system with refrigerant R1234yf; Rep. gr. 87 ; Refrigerant cir‐
cuit; Renewing components .
♦ In some cases, it is no longer necessary on air conditioning
systems with R134a refrigerant to renew the desiccant bag
each time the refrigerant circuit is opened ⇒ Air conditioning
system with R134a refrigerant; Rep. gr. 00 ; Renewing com‐
ponents .

3.2 General repair instructions

Never attempt to repair any heating and air conditioning system
components. Defective components must be replaced with Gen‐
uine parts.

3.3 Refrigerant circuit seals

♦ Renew seals after removal.
♦ Moisten seals with refrigerant oil before installing.

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♦ Ensure proper seating of seals on the pipe or in the groove.

♦ Work in a completely clean environment. Even the smallest
contaminants, e.g. a hair, can cause leaks.
♦ Install only seals resistant to refrigerant R134a/R1234yf and
respective refrigerant oil ⇒ Electronic parts catalogue (ET‐
KA) .
The dimensions -a- and -b- depend on the fitting location of the
seal ⇒ Electronic parts catalogue (ETKA) .

3.4 Checking cooling output

Check
– Close bonnet.
– Measure ambient temperature.
– Close doors, windows and sunroof.
– Open all dash panel vents.
– Set air conditioning system temperature to coldest setting.
– Set air distribution to chest vents.
– Hold temperature gauge approx. 20 mm inside the middle of
the centre vent control.
– Switch on the air conditioning using the AC button.
– Start engine.

Note

Start time measurement (5 min.).

– Increase engine speed to approx. 2000 rpm and hold.

Evaluation
After 5 minutes the temperature of the air blown out of the vents
on the “driver side” must lie within permitted tolerances depending
on the ambient temperature (see diagram).
A - Temperature of air blown out of dash panel vents on “driver
side”
B - Ambient temperature
C - Permitted tolerance range

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3.5 Notes on control motors

⇒ “3.5.1 Notes on control motors”, page 7
⇒ “3.5.2 Inserting link into the shaft of a control motor”,
page 9
⇒ “3.5.3 Activating control motor using adapter cable”,
page 11
⇒ “3.5.4 Locally manufacturing an adapter cable to activate con‐
trol motors”, page 12

3.5.1 Notes on control motors

Note

♦ Risk of malfunction of heater or air conditioning system caused

by improperly installed control motors or links.
♦ Mark the correct allocation of the connectors to the control
motors.
♦ Always install the appropriate links to the control motors.

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♦ There are different control motors installed on the air distribu‐

tion housing and air intake unit of the heater and air condi‐
tioning unit. These control motors differ in terms of electrical
values (defined by the travel which is determined by the links),
in terms of the links and in terms of the part number ⇒ Elec‐
tronic parts catalogue . Therefore, mark position of the control
motors accordingly before removing them (risk of interchang‐
ing the control motors).
♦ As of week 45/2013, gradual change of the control motors has
been introduced. The various links (levers, gears, etc.) for
connecting the control motors to the flaps in the heater and air
conditioning unit used to be different in colour. As of week
45/2013, the control motors are being used with links to the
various flaps of the heater and air conditioning unit in only one
colour (currently black). Thus, the links cannot be any longer
allocated via the colour. The illustration shows a temperature
flap control motor - V68- -A- with the respective link (lever)
-B-.
♦ Up to week 45/2013 there have been different control motors
available as a replacement part with pre-installed and colour-
marked links (e.g. lever -B- on a temperature flap control motor
- V68- -A-) and with different part numbers. As of week
45/2013, control motors without pre-installed link and a sepa‐
rate set of links (e.g. lever -B- for a temperature flap control
motor - V68- -A-) are being gradually introduced as replace‐
ment parts ⇒ Electronic parts catalogue . The required link
can be selected from this set (depending on the respective
heater and air conditioning unit and the fitting location of the
control motor), and it can be installed to the control motor shaft
⇒ page 9 .
♦ There are different versions of the control motors without pre-
installed links -B- which are being installed or have been made
available as a replacement part as of week 45/2013. The ver‐
sion which is installed as the air recirculation flap control motor
- V113- for a heater and fresh air ventilation system or an air
conditioning system with manual controls, for example, has no
potentiometer (but limit switches instead). The control motors
with potentiometer are available with different setting ranges
(max. setting range which can be evaluated electrically of ap‐
prox. 120° or 340°) ⇒ Electronic parts catalogue . Always
make sure that the appropriate version is allocated correctly.
If a control motor with an incorrect setting range has been in‐
stalled, this may cause problems during the basic setting of
the air conditioning system and/or the operation of the heater
and air conditioning system ⇒ Vehicle diagnostic tester.
♦ After the control motor has been installed, perform the basic
setting of the air conditioning system ⇒ Vehicle diagnostic
tester.
♦ The functions “Final control diagnosis” and “Basic setting” are
used to check the correct activation of the electric components
of the air conditioning system (e.g. for checking whether com‐
ponents have been interchanged); ⇒ Vehicle diagnostic tester
in “Guided Fault Finding” mode.
♦ Check the activation and operation of the control motor via the
operating and display unit.

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3.5.2 Inserting link into the shaft of a control

motor

Note

♦ Up to week 45/2013 there have been different control motors

available as a replacement part with pre-installed and colour-
marked links (e.g. lever -B- on a temperature flap control motor
- V68- -A-) and with different part numbers. As of week
45/2013, various control motors without pre-installed link and
a separate set of links (e.g. lever -B- for a temperature flap
control motor - V68- -A-) are being introduced gradually as
replacement parts ⇒ Electronic parts catalogue . The required
link must be selected from this set, allocated correctly and in‐
serted in the new control motor.
♦ The link (e.g. lever -B-) can only be inserted and engaged in
the shaft -D- of the control motor -A- in one specific position.
♦ The links fitted in the control motors which have been installed
up to week 45/2013 (e.g. lever -B-), are engaged in shaft -D-
of the control motor. They can be levered out using, for ex‐
ample, two screwdrivers.
♦ To allow for inserting the respective link -B- into the shaft -D-
of the control motor, the shaft must be set to the position as
shown in the illustration.

Inserting link
– Remove link from removed control motor (lever it out using,
e.g., 2 screwdrivers), or select the required link from the set of
links ⇒ Electronic parts catalogue .

Note

♦ If a wrong link has been selected or installed, it may still be

possible to install the control motor. However, problems may
occur when the new control motor is adapted.
♦ The links may look quite similar in some cases. Therefore,
make sure to always select the correct version.
♦ Always insert a link which corresponds exactly to the removed
link in terms of shape.
♦ If the wrong link has been selected for a control motor, it may
still be possible to install the control motor together with the
link. However, problems may occur when the new control mo‐
tor is adapted.
♦ The various control motors all have the same shape. They can
only be distinguished by the part number. Therefore, always
make sure to use the correct version.
♦ Only install control motors which can be allocated correctly
without any doubt.

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Note

♦ The links which are available as a set are not colour-marked

⇒ Electronic parts catalogue .
♦ The achievable travel of a control motor is determined by the
shape of the link -B- and the stop -C- on the control motor. The
position of shaft -D- of the control motor is determined via the
integrated potentiometer (or a limit switch) by the respective
control unit.

– Check position of shaft -D- of control motor -A-. Only if the shaft
is in the illustrated position, shaft -F- of the link can be inserted
and engaged without any preload.

Note

♦ If the shaft -D- of the control motor -A- is not in the illustrated
position (only in this position the link can be fitted), activate the
removed control motor so that shaft -D- is moved to the illus‐
trated position ⇒ page 11 .
♦ The link -B- must only be fitted in a position in which it engages
by applying a minimum amount of force. To allow for better
locating the correct installation position, some of the links have
an embossed contour -E- which corresponds to the contour of
the shaft mounting of control motor -D-. If the link can only be
inserted with a preload, check control motor shaft -D-. It may
be turned by 180°.
♦ Do not reuse and always renew links which show signs of
wear.

– Insert shaft of removed link or of link selected from the supplied

set of links -F- into shaft of control motor -D-, and engage it.
– Make sure that link -B- is firmly seated in control motor -A-.
– Install control motor in the appropriate position on the heater
and air conditioning unit.

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3.5.3 Activating control motor using adapter

cable

Note

♦ To allow for inserting a link in shaft -D- of the control motor

-A-, the shaft must be set to a specific position. If shaft -D- is
in a different position than the one shown in the illustration, the
control motor can be activated to move the shaft to the appro‐
priate position.
♦ The control motor shaft -D- does not have a limit stop. Thus,
it will turn continuously on a control motor with integrated po‐
tentiometer, if a voltage is applied to contacts 5 and 6 of the
connector on the control motor. Therefore, voltage should only
be applied to a removed control motor, if the link -B- is fitted
or to move the shaft -D- to the appropriate position, if it is not
possible to fit the link.
♦ If the link -B- cannot be inserted in the control motor without
any preload, the shaft -D- may be in the wrong position.

Move control motor shaft to the appropriate position.

– Connect adapter cable ⇒ page 12 to control motor -A-.

Note

Instead of the adapter cable, a test lead from the auxiliary meas‐
uring set - V.A.G 1594/C- may also be used to connect contacts
“5” and “6” in the connector of control motor -A- via a 5-A fuse to
a 12-V battery.

– Connect one of the wires of the adapter cable via a 5-A fuse
to the positive terminal of a 12-V battery.
– Connect the remaining wire of the adapter cable (e.g. using a
test lead from the auxiliary measuring set - V.A.G 1594/C- )
briefly to the negative terminal of the 12-V battery.
• Activate the control motor in such a way that shaft -D- is moved
to the position shown in the illustration with the minimum pos‐
sible travel.
– Observe direction of rotation of control motor shaft -D-. If shaft
turns into wrong direction, change polarity of wires.
– As soon as control motor shaft -D- is in appropriate position,
interrupt activation of control motor.

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3.5.4 Locally manufacturing an adapter cable

to activate control motors
Procedure
– Connect a wire with a cross section of 0.25 mm2 to each of
contacts “5” and “6” of connector -A- ( flat contact housing with
contact locking mechanism - 6Q0 972 706- ) ⇒ Electronic
parts catalogue .
– Connect a commercially available banana coupling -B- to oth‐
er end of each wire.

Note

The banana couplings -B- can be used to connect the wires (e.g.
using test leads from the auxiliary measuring set - V.A.G 1594/
C- ) to a 12-V power source (e.g. a 12-V battery).

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4 Technical data
⇒ “4.1 Refrigerant capacity”, page 13
⇒ “4.2 Refrigerant oil capacities”, page 13
⇒ “4.3 Oil distribution”, page 14

4.1 Refrigerant capacity

⇒ “4.1.1 Capacities for refrigerant R134a”, page 13
⇒ “4.1.2 Capacities for refrigerant R1234yf”, page 13

4.1.1 Capacities for refrigerant R134a

Air conditioner compressor manufacturer Total capacity
Sanden 0.525 kg ± 0.015 kg or 525 g ± 15 g
Denso or Sanden Vehicles with second evaporator
0.875 kg ± 0.015 kg or 875 g ± 15 g

4.1.2 Capacities for refrigerant R1234yf

Air conditioner compressor manufacturer Total capacity
Sanden 0.500 kg ± 0.015 kg or 500 g ± 15 g
Sanden Vehicles with second evaporator
0.825 kg ± 0.015 kg or 825 g ± 15 g

4.2 Refrigerant oil capacities

⇒ “4.2.1 Refrigerant oil capacities, refrigerant R134a”,
page 13
⇒ “4.2.2 Refrigerant oil capacities, refrigerant R1234yf”,
page 14

4.2.1 Refrigerant oil capacities, refrigerant

R134a

Note

♦ Refrigerant oils from containers which have been open for a

longer period of time are unusable.
♦ As refrigeration oil is extremely hygroscopic, open containers
must be immediately re-sealed after use to prevent the ingress
of moisture.

Air conditioner compressor, Denso

Part number for Denso air condi‐ Required refrigerant oil Total amount of oil in refrigerant cir‐
tioner compressor cuit *)
1K0 820 859 S -G 052 300 A2- 140 ml ± 10 ml **)
1) This volume of refrigerant oil is contained in a replacement air conditioner compressor and corresponds to the total capacity.
2) **) On vehicles with a second evaporator there are additional refrigerant oil volumes in the refrigerant circuit.

Volkswagen Technical Site: http://vwts.ru http://vwts.info

4. Technical data 13
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Part number for Denso air conditioner compressor Additional refrigerant oil volume in refrigerant circuit
1K0 820 859 S 110 ml ± 10 ml

Sanden air conditioner compressors

Part numbers for Sanden air condi‐ Required refrigerant oil Total amount of oil in refrigerant cir‐
tioner compressors cuit *)
1K0 820 808 F -G 052 154 A2- 110 ml ± 10 ml **)
7N0 820 803 D -G 052 154 A2- 110 ml ± 10 ml
7N0 820 803 E -G 052 154 A2- 110 ml ± 10 ml
3) This volume of refrigerant oil is contained in a replacement air conditioner compressor and corresponds to the total capacity.
4) **) On vehicles with a second evaporator there are additional refrigerant oil volumes in the refrigerant circuit.

Part number of Sanden air conditioner compressor Additional refrigerant oil volume in refrigerant circuit
1K0 820 808 F 110 ml ± 10 ml **)

4.2.2 Refrigerant oil capacities, refrigerant

R1234yf

Note

♦ Refrigerant oils from containers which have been open for a

longer period of time are unusable.
♦ As refrigeration oil is extremely hygroscopic, open containers
must be immediately re-sealed after use to prevent the ingress
of moisture.

Sanden air conditioner compressors

Part numbers for Sanden air condi‐ Required refrigerant oil Total amount of oil in refrigerant cir‐
tioner compressors cuit *)
1K0 820 808 F -G 052 535 M2- 110 ml ± 10 ml **)
7N0 816 803 B -G 052 535 M2- 110 ml ± 10 ml
7N0 816 803 D -G 052 535 M2- 110 ml ± 10 ml
5) This volume of refrigerant oil is contained in a replacement air conditioner compressor and corresponds to the total capacity.
6) **) On vehicles with a second evaporator there are additional refrigerant oil volumes in the refrigerant circuit.

Part number of Sanden air conditioner compressor Additional refrigerant oil volume in refrigerant circuit
1K0 820 808 F 110 ml ± 10 ml **)

4.3 Oil distribution

♦ During operation of the air conditioner, the refrigerant oil in the
air conditioner compressor prior to initial operation is distrib‐
uted throughout the refrigerant circuit.
♦ The distribution of the refrigerant oil depends on the operating
mode of the air conditioner when it was switched off, the am‐
bient temperatures etc. Consequently, it is not possible to

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make a general statement about how the refrigerant oil is dis‐

tributed within the refrigerant circuit. Observe notes on replac‐
ing refrigerant circuit components ⇒ Air conditioning system
with refrigerant R134a; Rep. gr. 00 ; Renewing components
(Air conditioning system with refrigerant R134a, Renewing re‐
frigerant circuit components) or ⇒ Air conditioning systems
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Refrigerant circuit; Renewing components .

4. Technical data 15
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80 – Heating
1 Heating

Note

♦ At the moment, the only heating system available for the Shar‐
an is a heating system integrated in the air conditioning sys‐
tem.
♦ For information on repairs, refer to
⇒ g r.87 “Air conditioning system”, page 17 .

16 Rep. gr.80 - Heating

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87 – Air conditioning system

1 Overview of fitting locations - air con‐
ditioning system
⇒ “1.1 Overview of fitting locations - components not located in
passenger compartment”, page 17
⇒ “1.2 Overview of fitting locations - components located in front
section of passenger compartment”, page 20
⇒ “1.3 Overview of fitting locations - components located in rear
section of passenger compartment”, page 24

1.1 Overview of fitting locations - compo‐

nents not located in passenger compart‐
ment
⇒ “1.1.1 Overview of fitting locations - components located out‐
side the passenger compartment, air conditioning system with
electric/manual controls”, page 17
⇒ “1.1.2 Overview of fitting locations - components not located in
passenger compartment, Climatronic”, page 18

1.1.1 Overview of fitting locations - compo‐

nents located outside the passenger
compartment, air conditioning system
with electric/manual controls

Note

♦ In some cases, it is no longer necessary on air conditioning

systems with refrigerant R1234yf to renew the desiccant bag
each time the refrigerant circuit is opened ⇒ Air conditioning
system with refrigerant R1234yf; Rep. gr. 87 ; Refrigerant cir‐
cuit; Renewing components .
♦ In some cases, it is no longer necessary on air conditioning
systems with R134a refrigerant to renew the desiccant bag
each time the refrigerant circuit is opened ⇒ Air conditioning
system with R134a refrigerant; Rep. gr. 00 ; Renewing com‐
ponents .

1. Overview of fitting locations - air conditioning system 17

 Sharan 2016 ➤
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1 - Fresh air blower - V2-

❑ Removing and installing
⇒ page 102
2 - Fresh air blower series re‐
sistor with overheating fuse -
N24-
❑ Removing and installing
⇒ page 109
3 - Evaporator temperature
sensor - G308-
❑ Removing and installing
⇒ page 107
4 - Operating and display unit
for front air conditioning sys‐
tem - E87- with air conditioning
system control unit - J301-
❑ Removing and installing
⇒ page 145
5 - Ambient temperature sen‐
sor - G17-
❑ Removing and installing
⇒ page 151
6 - Condenser with dryer bag
❑ Assembly overview
⇒ page 27
❑ Removing and installing
condenser ⇒ page 34
❑ Removing and installing
desiccant bag
⇒ page 36
7 - Air conditioner compressor
❑ Removing and installing
⇒ page 63
8 - High-pressure sender - G65-
❑ Removing and installing ⇒ page 28

1.1.2 Overview of fitting locations - compo‐

nents not located in passenger compart‐
ment, Climatronic

Note

♦ In some cases, it is no longer necessary on air conditioning

systems with refrigerant R1234yf to renew the desiccant bag
each time the refrigerant circuit is opened ⇒ Air conditioning
system with refrigerant R1234yf; Rep. gr. 87 ; Refrigerant cir‐
cuit; Renewing components .
♦ In some cases, it is no longer necessary on air conditioning
systems with R134a refrigerant to renew the desiccant bag
each time the refrigerant circuit is opened ⇒ Air conditioning
system with R134a refrigerant; Rep. gr. 00 ; Renewing com‐
ponents .

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1 - High-pressure sender -
G65-
❑ Removing and installing
⇒ page 28
2 - Air quality sensor - G238-
❑ Removing and installing
⇒ page 150
3 - Fresh air blower - V2- with
fresh air blower control unit -
J126-
❑ Fresh air blower - V2-
and fresh air blower
control unit - J126- com‐
prise one unit and can
only be renewed togeth‐
er.
❑ Removing and installing
⇒ page 102
4 - Right vent temperature
sender - G151-
❑ Removing and installing
⇒ page 151
5 - Evaporator temperature
sensor - G308-
❑ Removing and installing
⇒ page 107
6 - Right footwell vent temper‐
ature sender - G262-
❑ Removing and installing
⇒ page 153
7 - Operating and display unit
for front air conditioning sys‐
tem - E87- with Climatronic
control unit - J255-
❑ Removing and installing ⇒ page 145
8 - Left footwell vent temperature sender - G261-
❑ Removing and installing ⇒ page 152
9 - Heater and air conditioning unit with control motors
❑ Removing and installing ⇒ page 92
❑ Dismantling and assembling ⇒ page 89
❑ Overview of control motors on heater and air conditioning unit ⇒ page 73 .
10 - Left vent temperature sender - G150-
❑ Removing and installing ⇒ page 151
11 - Ambient temperature sensor - G17-
❑ Removing and installing ⇒ page 151
12 - Condenser with dryer bag
❑ Assembly overview ⇒ page 27
❑ Removing and installing condenser ⇒ page 34
❑ Removing and installing desiccant bag ⇒ page 36
13 - Air conditioner compressor

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 Sharan 2016 ➤
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1.2 Overview of fitting locations - compo‐

nents located in front section of passen‐
ger compartment
⇒ “1.2.1 Overview of fitting locations - components inside front
passenger compartment, air conditioning system with electric/
manual controls”, page 20
⇒ “1.2.2 Overview - components inside front passenger compart‐
ment, Climatronic”, page 22

1.2.1 Overview of fitting locations - components inside front passenger compart‐

ment, air conditioning system with electric/manual controls

1 - Dash panel
❑ Removing and installing
⇒ General body repairs,
interior; Rep. gr. 70 ;
Dash panel; Removing
and installing dash pan‐
el .
2 - Right side window vent
❑ Removing and installing
⇒ General body repairs,
interior; Rep. gr. 70 ;
Dash panel; Removing
and installing dash pan‐
el vents
3 - Right side vent
❑ Removing and installing
⇒ General body repairs,
interior; Rep. gr. 70 ;
Dash panel; Removing
and installing dash pan‐
el vents
4 - Centre vent
❑ Removing and installing
⇒ General body repairs,
interior; Rep. gr. 70 ;
Dash panel; Removing
and installing dash pan‐
el vents
5 - Trim for operating and dis‐
play unit for front air condition‐
ing system - E87-
6 - Operating and display unit
for front air conditioning sys‐
tem - E87- with air conditioning
system control unit - J301-
❑ Removing and installing
⇒ page 145
7 - Footwell vent air duct - right side, 2nd row of seats
❑ Removing and installing ⇒ page 128
8 - Dust and pollen filter
❑ Removing and installing ⇒ page 101
9 - Fresh air blower series resistor with overheating fuse - N24-
❑ Removing and installing ⇒ page 109

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10 - Heater and air conditioning unit

❑ Removing and installing ⇒ page 92
❑ Dismantling and assembling
11 - Air recirculation flap control motor - V113-
❑ Air recirculation flap control motor potentiometer - G143-
❑ Removing and installing ⇒ page 78
12 - Fresh air blower - V2-
❑ Removing and installing ⇒ page 102
13 - Evaporator temperature sensor - G308-
❑ Removing and installing ⇒ page 107
14 - Footwell vent air duct - left side, 2nd row of seats
❑ Removing and installing ⇒ page 128
15 - Condensate drain hose with valve
❑ Removing and installing ⇒ page 108
❑ Checking ⇒ page 108
16 - Expansion valve
❑ Removing and installing ⇒ page 30
17 - Seal
18 - Auxiliary air heater element - Z35-
❑ Removing and installing ⇒ page 91

Note

♦ Installed only in vehicles with

diesel engines without supple‐
mentary heater.
♦ Check using ⇒ Vehicle diagnos‐
tic tester: “Heating, ventilation,
air conditioning”; “Self-diagnosis
compatible systems”; “Auxiliary
heater”; “Electrical components”.

19 - Heat exchanger
❑ Removing and installing ⇒ page 103
20 - Temperature flap control motor - V68-
❑ With potentiometer for temperature flap control motor - G92-
❑ Removing and installing ⇒ page 74
21 - Air distribution flap control motor - V428-
❑ With potentiometer for air distribution flap control motor - G645-
❑ Removing and installing ⇒ page 86
22 - Left side vent
❑ Removing and installing ⇒ General body repairs, interior; Rep. gr. 70 ; Dash panel; Removing and
installing dash panel vents
23 - Left side window vent
❑ Removing and installing ⇒ General body repairs, interior; Rep. gr. 70 ; Dash panel; Removing and
installing dash panel vents
24 - Plenum chamber cover
❑ Intake duct is located under right plenum chamber cover.
❑ Removing and installing air intake duct ⇒ page 132 .

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1.2.2 Overview - components inside front passenger compartment, Climatronic

1 - Dash panel
❑ Removing and installing
⇒ General body repairs,
interior; Rep. gr. 68 .
2 - Right side window vent
❑ Removing and installing
⇒ General body repairs,
interior; Rep. gr. 70 ;
Dash panel; Removing
and installing dash pan‐
el vents
3 - Right side vent
❑ Removing and installing
⇒ General body repairs,
interior; Rep. gr. 70 ;
Dash panel; Removing
and installing dash pan‐
el vents
4 - Centre vent
❑ Removing and installing
⇒ General body repairs,
interior; Rep. gr. 70 ;
Dash panel; Removing
and installing dash pan‐
el vents
5 - Trim for operating and dis‐
play unit for front air condition‐
ing system - E87-
6 - Operating and display unit
for front air conditioning sys‐
tem - E87- with Climatronic
control unit - J255-
❑ Removing and installing
⇒ page 145
7 - Footwell vent air duct - right
side, 2nd row of seats
❑ Removing and installing ⇒ page 128
8 - Dust and pollen filter
❑ Removing and installing ⇒ page 101
9 - Heater and air conditioning unit
❑ Removing and installing ⇒ page 92
❑ Dismantling and assembling ⇒ page 89
10 - Fresh air/air recirculation, air flow flap control motor - V425-
❑ With potentiometer for fresh air/recirculated air and air flow flap control motor - G644-
❑ Removing and installing ⇒ page 83
11 - Right temperature flap control motor - V159-
❑ With potentiometer for right temperature flap control motor - G221-
❑ Removing and installing ⇒ page 82
12 - Fresh air blower - V2- with fresh air blower control unit - J126-
❑ Fresh air blower - V2- and fresh air blower control unit - J126- comprise one unit and can only be renewed
together.
❑ Removing and installing ⇒ page 102

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13 - Evaporator temperature sensor - G308-

❑ Removing and installing ⇒ page 107
14 - Footwell vent air duct - left side, 2nd row of seats
❑ Removing and installing ⇒ page 128
15 - Condensate drain hose with valve
❑ Removing and installing ⇒ page 108
❑ Checking ⇒ page 108
16 - Expansion valve
❑ Removing and installing ⇒ page 30
17 - Seal
18 - Auxiliary air heater element - Z35-
❑ Removing and installing ⇒ page 91

Note

♦ Installed only in vehicles with

diesel engines without supple‐
mentary heater.
♦ Check using ⇒ Vehicle diagnos‐
tic tester: “Heating, ventilation,
air conditioning”; “Self-diagnosis
compatible systems”; “Auxiliary
heater”; “Electrical components”.

19 - Heat exchanger
❑ Removing and installing ⇒ page 103
20 - Left temperature flap control motor - V158-
❑ With potentiometer for left temperature flap control motor - G220-
❑ Removing and installing ⇒ page 80
21 - Defroster flap control motor - V107-
❑ With potentiometer for defroster flap control motor - G135-
❑ Removing and installing ⇒ page 76
22 - Front air distribution flap control motor - V426-
❑ With potentiometer for front air distribution flap control motor - G642-
❑ Removing and installing ⇒ page 84
23 - Left side vent
❑ Removing and installing ⇒ General body repairs, interior; Rep. gr. 70 ; Dash panel; Removing and
installing dash panel vents
24 - Left side window vent
❑ Removing and installing ⇒ General body repairs, interior; Rep. gr. 70 ; Dash panel; Removing and
installing dash panel vents
25 - Plenum chamber cover
❑ Intake duct is located under right plenum chamber cover.
❑ Removing and installing air intake duct ⇒ page 132 .

1. Overview of fitting locations - air conditioning system 23

 Sharan 2016 ➤
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1.3 Overview of fitting locations - components located in rear section of pas‐

senger compartment

1 - Refrigerant line retainer,

middle on underbody
2 - Refrigerant line retainer,
middle on underbody
3 - Refrigerant line retainer,
rear on underbody
4 - Refrigerant lines to 2nd
heater and air conditioning unit
❑ Entry point to interior is
located on rear right of
underbody.
5 - 2nd heater and air condi‐
tioning unit
❑ Removing and installing
⇒ page 114
❑ Dismantling and assem‐
bling ⇒ page 118
6 - Refrigerant line retainer,
front on underbody
7 - Refrigerant line retainer,
front on underbody
8 - Heater and air conditioning
unit
❑ Removing and installing
⇒ page 92
❑ Dismantling and assem‐
bling ⇒ page 97
9 - Condenser with dryer bag
❑ Assembly overview
⇒ page 27
❑ Removing and installing
condenser ⇒ page 34
❑ Removing and installing desiccant bag ⇒ page 36
10 - Refrigerant line connection on condenser
11 - Bolts
❑ For refrigerant line on condenser
❑ 12 Nm
12 - Valve for deactivating heat exchanger 2 - N317-
❑ Removing and installing ⇒ page 139
13 - Bolts
❑ For refrigerant line connection to 2nd heater and air conditioning unit
❑ 12 Nm

24 Rep. gr.87 - Air conditioning system

 Sharan 2016 ➤
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2 Refrigerant circuit
⇒ “2.1 System overview - refrigerant circuit”, page 25
⇒ “2.2 Assembly overview - condenser”, page 27
⇒ “2.3 Removing and installing high-pressure sender G65 ”, page
28
⇒ “2.4 Removing and installing expansion valve”, page 30
⇒ “2.5 Removing and installing condenser”, page 34
⇒ “2.6 Removing and installing desiccant bag or cartridge”, page
36
⇒ “2.7 Removing and installing evacuating and charging valves
on low and high-pressure side”, page 40
⇒ “2.8 Removing and installing refrigerant line between condens‐
er and expansion valve”, page 43
⇒ “2.9 Removing and installing refrigerant line between condens‐
er and air conditioner compressor”, page 45
⇒ “2.10 Removing and installing refrigerant line between air con‐
ditioner compressor and expansion valve”, page 48
⇒ “2.11 Removing and installing refrigerant line to second heater
unit, high-pressure section”, page 50
⇒ “2.12 Removing and installing refrigerant line to second heater
unit, low-pressure section”, page 52
⇒ “2.13 Removing and installing refrigerant line from second
heater unit”, page 54

2.1 System overview - refrigerant circuit

Note

♦ In some cases, it is no longer necessary on air conditioning

systems with refrigerant R1234yf to renew the desiccant bag
each time the refrigerant circuit is opened ⇒ Air conditioning
system with refrigerant R1234yf; Rep. gr. 87 ; Refrigerant cir‐
cuit; Renewing components .
♦ In some cases, it is no longer necessary on air conditioning
systems with R134a refrigerant to renew the desiccant bag
each time the refrigerant circuit is opened ⇒ Air conditioning
system with R134a refrigerant; Rep. gr. 00 ; Renewing com‐
ponents .

2. Refrigerant circuit 25
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1 - Condenser
❑ Assembly overview
⇒ page 27
❑ Removing and installing
condenser ⇒ page 34
❑ Removing and installing
desiccant bag
⇒ page 36
2 - Refrigerant line
❑ Condenser/Air condi‐
tioner compressor
3 - Refrigerant line
❑ Condenser/expansion
valve
4 - Service connection, high-
pressure side
❑ Removing and installing
⇒ page 40
❑ Protective cap:
0.4 ± 0.1 Nm
❑ Valve: 2 ± 0.2 Nm
5 - High-pressure sender -
G65-
❑ Removing and installing
⇒ page 28
❑ 8± 1 Nm
6 - Service connection, low-
pressure side
❑ Removing and installing
⇒ page 40
❑ Protective cap:
0.4 ± 0.1 Nm
❑ Valve: 2 ± 0.2 Nm
7 - Refrigerant line
❑ Air conditioner compressor/expansion valve
8 - Bolt
❑ 12 Nm
9 - Refrigerant line
❑ To rear heater and air conditioning unit
❑ Vehicle-specific
10 - Refrigerant line
❑ Rear heater and air conditioning unit
❑ Vehicle-specific
11 - Expansion valve
❑ Removing and installing ⇒ page 30
12 - Bolts
❑ 5 Nm
13 - Bolts
❑ 10 Nm
14 - Air conditioner compressor
❑ Assembly overview ⇒ page 58

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❑ Removing and installing ⇒ page 63
❑ Removing from and installing on bracket ⇒ page 62

2.2 Assembly overview - condenser

Note

♦ In some cases, it is no longer necessary on air conditioning

systems with refrigerant R1234yf to renew the desiccant bag
each time the refrigerant circuit is opened ⇒ Air conditioning
system with refrigerant R1234yf; Rep. gr. 87 ; Refrigerant cir‐
cuit; Renewing components .
♦ In some cases, it is no longer necessary on air conditioning
systems with R134a refrigerant to renew the desiccant bag
each time the refrigerant circuit is opened ⇒ Air conditioning
system with R134a refrigerant; Rep. gr. 00 ; Renewing com‐
ponents .

1 - Condenser
❑ Removing and installing
condenser ⇒ page 34
❑ Removing and installing
desiccant bag
⇒ page 36
2 - Refrigerant lines
❑ Qty. 2
3 - Bolts
❑ Refrigerant line unions
❑ 12 Nm
4 - Bolt
❑ 5 Nm
5 - Desiccant bag
❑ Removing and installing
⇒ page 36
6 - Radiator
❑ Removing and installing
⇒ Rep. gr. 19 ; Cooling
system; Radiator/radia‐
tor fan; Removing and
installing radiator
7 - Seals
❑ Renew after removal
❑ Qty. 2

2. Refrigerant circuit 27
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2.3 Removing and installing high-pressure

sender - G65-
Special tools and workshop equipment required
♦ Tool insert, 17 mm - V.A.G 1331/6-

♦ Torque wrench - V.A.G 1410-

♦ Engine bung set - VAS 6122-

28 Rep. gr.87 - Air conditioning system

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Removing
– Disconnect connector from high-pressure sender - G65- -1-.

CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant. If handled incorrectly, union could break off and refriger‐
ant could escape.
There is a risk of injury to the skin and parts of the body due to
freezing.
– Wear protective gloves.
– Wear protective goggles.
– Counterhold refrigerant lines using a suitable tool.

– Counterhold refrigerant line -2- using a suitable tool. When

doing this, detach high pressure sender - G65- -1- using insert
tool, 17 mm - V.A.G 1331/6- .

CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due to
freezing.
– Wear protective gloves.
– Wear protective goggles.
– If, when detaching the pressure sender, refrigerant escapes
from the refrigerant line for longer than 1 second, tighten the
pressure sender and renew the non-return valve that is de‐
fective.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have passed since the refrigerant
was extracted, repeat the extraction process before opening
the refrigerant circuit. Pressure could build up in the refrig‐
erant circuit from continued evaporation.

– For any further work, immediately seal open lines and con‐
nections with clean plugs from engine bung set - VAS 6122- .
– Unscrew high-pressure sender - G65- -1-.
Installing
Install in reverse order of removal, observing the following:
– Renew seal for high pressure sender - G65- -1-.
Specified torques
♦ ⇒ “2.1 System overview - refrigerant circuit”, page 25

2. Refrigerant circuit 29
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2.4 Removing and installing expansion

valve
⇒ “2.4.1 Removing and installing front expansion valve”,
page 30
⇒ “2.4.2 Removing and installing rear expansion valve”,
page 32

2.4.1 Removing and installing front expansion

valve
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

♦ Engine bung set - VAS 6122-

♦ Drip tray for workshop hoist - VAS 6208-

Removing
Vehicles with TDI engine
– Remove charge air cooler connecting pipe ⇒ Rep. gr. 21 ;
Charge air system; Assembly overview - charge air system .

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Vehicles with independent/auxiliary heater

– Remove coolant pipes from locking valve for heating coolant
- N279- ⇒ Independent car heater, auxiliary heater; Rep. gr.
82 ; Coolant circuit with independent/auxiliary heater; Remov‐
ing and installing coolant pipes of independent/auxiliary heat‐
er; Removing and installing coolant pipe from locking valve for
heating coolant N279 .
– Removing coolant pipe between heat exchanger and inde‐
pendent/auxiliary heater ⇒ Independent heater, auxiliary
heater; Rep. gr. 82 ; Coolant circuit with independent/auxiliary
heater; Removing and installing coolant pipes of independent/
auxiliary heater; Removing and installing coolant pipe be‐
tween heat exchanger and independent/auxiliary heater .
Continued for all vehicles
– Drain coolant ⇒ Rep. gr. 19 ; Cooling system/coolant; Drain‐
ing and filling coolant .
– Release clasps -1-.
– Place drip tray for workshop hoist - VAS 6208- underneath.
– Pull off coolant hoses -2-.
– Unscrew nuts -3-.
– Detach panel -4-.
Vehicles with R134a refrigerant
– Drain refrigerant circuit ⇒ Air conditioning system with R134a
refrigerant; Rep. gr. 00 ; Working with air conditioner service
station .
Vehicles with R1234yf refrigerant
– Drain refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Draining refrigerant circuit .
Continued for all vehicles

CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due to
freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have passed since the refrigerant
was extracted, repeat the extraction process before opening
the refrigerant circuit. Pressure could build up in the refrig‐
erant circuit from continued evaporation.

– For any further work, immediately seal open lines and con‐
nections with clean plugs from engine bung set - VAS 6122- .
– Remove bolts -1- from refrigerant line -2-.
– Carefully pull refrigerant lines -2- out of expansion valve -4-.
– Unscrew bolts -8- from expansion valve -4-.

2. Refrigerant circuit 31
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– Carefully pull off expansion valve -4-.

Installing
Install in reverse order of removal, observing the following:
– Moisten new seals with refrigerant oil before installing.
♦ Always renew O-rings of high-pressure refrigerant
lines-6 and 7-.
♦ Always renew O-rings of low-pressure refrigerant
lines-3 and 5-.
– Fill up with coolant ⇒ Rep. gr. 19 ; Cooling system/coolant;
Draining and filling coolant .

NOTICE
Risk of damage to air conditioner compressor if refrigerant cir‐
cuit is empty.
– Never start the engine if the refrigerant circuit is empty.

Vehicles with R134a refrigerant

– Charge refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00 ; Working with air conditioner
service station .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00 ; Detecting leaks in refrigerant circuit .
Vehicles with R1234yf refrigerant
– Charge refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Charging refrigerant cir‐
cuit .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning systems with refrigerant
R1234yf - general information; Rep. gr. 87 ; Refrigerant circuit;
Detecting leaks .
Specified torques
♦ ⇒ “2.1 System overview - refrigerant circuit”, page 25

Component Specified torque

Nuts -3- 3.5 Nm

2.4.2 Removing and installing rear expansion

valve
Special tools and workshop equipment required

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♦ Torque wrench - V.A.G 1331-

♦ Engine bung set - VAS 6122-

Removing
– Remove rear underbody cladding ⇒ General body repair, ex‐
terior; Rep. gr. 50 .
Vehicles with R134a refrigerant
– Drain refrigerant circuit ⇒ Air conditioning system with R134a
refrigerant; Rep. gr. 00 ; Working with air conditioner service
station .
Vehicles with R1234yf refrigerant
– Drain refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Draining refrigerant circuit .
Continued for all vehicles

CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due to
freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have passed since the refrigerant
was extracted, repeat the extraction process before opening
the refrigerant circuit. Pressure could build up in the refrig‐
erant circuit from continued evaporation.

– For any further work, immediately seal open lines and con‐
nections with clean plugs from engine bung set - VAS 6122- .
– Remove bolts -6- from refrigerant line -7-.

2. Refrigerant circuit 33
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– Carefully pull refrigerant lines -7- out of expansion valve -3-.

– Unscrew bolts -5- from expansion valve -3-.
– Carefully pull off expansion valve -3-.
Installing
Install in reverse order of removal, observing the following:
– Moisten new seals with refrigerant oil before installing.
♦ Always renew seals of high-pressure refrigerant lines -1- and
-8-.
♦ Always renew seals of low-pressure refrigerant lines -2- and
-4-.

NOTICE
Risk of damage to air conditioner compressor if refrigerant cir‐
cuit is empty.
– Never start the engine if the refrigerant circuit is empty.

Vehicles with R134a refrigerant

– Charge refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00 ; Working with air conditioner
service station .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00 ; Detecting leaks in refrigerant circuit .
Vehicles with R1234yf refrigerant
– Charge refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Charging refrigerant cir‐
cuit .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning systems with refrigerant
R1234yf - general information; Rep. gr. 87 ; Refrigerant circuit;
Detecting leaks .
Specified torques
♦ ⇒ “6.1.1 Assembly overview - heater and air conditioning unit”,
page 111
Component Specified torque
Bolts -6- 10 Nm
Bolts -5- 5 Nm

2.5 Removing and installing condenser

Special tools and workshop equipment required

34 Rep. gr.87 - Air conditioning system

 Sharan 2016 ➤
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♦ Torque wrench - V.A.G 1331-

♦ Engine bung set - VAS 6122-

Removing
– Remove radiator ⇒ Rep. gr. 19 ; Radiator/radiator fan; Re‐
moving and installing radiator .
Vehicles with R134a refrigerant
– Drain refrigerant circuit ⇒ Air conditioning system with R134a
refrigerant; Rep. gr. 00 ; Working with air conditioner service
station .
Vehicles with R1234yf refrigerant
– Drain refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Draining refrigerant circuit .
Continued for all vehicles

CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due to
freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have passed since the refrigerant
was extracted, repeat the extraction process before opening
the refrigerant circuit. Pressure could build up in the refrig‐
erant circuit from continued evaporation.

– For any further work, immediately seal open lines and con‐
nections with clean plugs from engine bung set - VAS 6122- .

2. Refrigerant circuit 35
 Sharan 2016 ➤
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– Unscrew bolts -1-.

– Remove refrigerant lines -2-.
– Remove condenser.
Installing
– Install in reverse order of removal, observing the following:
– Renew seals ⇒ Electronic parts catalogue .
– If the condenser has been renewed, 10% of the total quantity
of refrigerant oil specified for the fitted air conditioning com‐
pressor must be filled into the refrigerant circuit
⇒ “4 Technical data”, page 13 .
– Moisten new seals with refrigerant oil before installing refrig‐
erant line.

NOTICE
Risk of damage to air conditioner compressor if refrigerant cir‐
cuit is empty.
– Never start the engine if the refrigerant circuit is empty.

Vehicles with R134a refrigerant

– Charge refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00 ; Working with air conditioner
service station .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00 ; Detecting leaks in refrigerant circuit .
Vehicles with R1234yf refrigerant
– Charge refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Charging refrigerant cir‐
cuit .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning systems with refrigerant
R1234yf - general information; Rep. gr. 87 ; Refrigerant circuit;
Detecting leaks .
Specified torques
♦ ⇒ “2.2 Assembly overview - condenser”, page 27

2.6 Removing and installing desiccant bag

or cartridge
Special tools and workshop equipment required
♦ Assembly tool - T10389-

36 Rep. gr.87 - Air conditioning system

 Sharan 2016 ➤
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♦ Torque wrench - V.A.G 1331-

Removing
– Remove radiator grille ⇒ General body repairs, exterior; Rep.
gr. 66 ; Radiator grille/front trim; Removing and installing ra‐
diator grille .
Initial assembly
– If fitted, separate plastic cap -2- from lock carrier -1- at marked
points -arrows-.

NOTICE
Risk of injury caused by plastic remains which project.
Skin and other parts of the body may be injured.
– Wear protective gloves.
– After separating plastic cap, remove residual remains im‐
mediately and smooth off.

Subsequent assembly

– Remove rubber cap (if fitted) from lock carrier.

1- Cap
2- Circlip
3- Cap
4- Desiccant bag
5- Strainer
Vehicles with R134a refrigerant
– Drain refrigerant circuit ⇒ Air conditioning system with R134a
refrigerant; Rep. gr. 00 ; Working with air conditioner service
station .
Vehicles with R1234yf refrigerant
– Drain refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Draining refrigerant circuit .
Continued for all vehicles
– Remove protective cap -1- (Torx 50).

2. Refrigerant circuit 37
 Sharan 2016 ➤
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– Drill an 8 mm hole through the centre of the removed protective

cap -2-.
– Insert a bolt (M6, approx. 35 mm long) through protective cap
from below and screw on a nut -1-.

Note

♦ For vehicles with a 2nd evaporator system, check the pressure

display using the air conditioning service station .
♦ If pressure is greater than 0 bar, evacuate system again.

CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due to
freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have passed since the refrigerant
was extracted, repeat the extraction process before opening
the refrigerant circuit. Pressure could build up in the refrig‐
erant circuit from continued evaporation.

– Remove circlip -arrow-, push sealing cap -1- downwards for

this.
– Screw the prepared protective cap onto the sealing cap.
– Pull sealing cap -1- out of condenser -2- using a pair of pliers.
– Pull desiccant bag out of condenser using a suitable tool.

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– Using assembly tool - T10389- , pull strainer out of condenser.

– Check removed strainer for damage -arrow-.

– Remove any strainer debris from receiver.
– Immediately seal open receiver with clean plugs from engine
bung set - VAS 6122- .

2. Refrigerant circuit 39
 Sharan 2016 ➤
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Installing
Install in reverse order of removal, observing the following:

Note

The protective cap, seals and desiccant bag must always be re‐
newed after opening the receiver ⇒ Electronic parts catalogue
(ETKA) .

– Insert strainer into receiver observing installation position

-arrow-.
– Guide dryer bag into condenser.
♦ Clean upper area of inner surface of receiver, and then mois‐
ten area with refrigerant oil.
♦ Renew sealing cap with seals.
♦ Moisten new seals with refrigerant oil before installing.

NOTICE
Risk of damage to air conditioner compressor if refrigerant cir‐
cuit is empty.
– Never start the engine if the refrigerant circuit is empty.

Vehicles with R134a refrigerant

– Charge refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00 ; Working with air conditioner
service station .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00 ; Detecting leaks in refrigerant circuit .
Vehicles with R1234yf refrigerant
– Charge refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Charging refrigerant cir‐
cuit .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning systems with refrigerant
R1234yf - general information; Rep. gr. 87 ; Refrigerant circuit;
Detecting leaks .
Specified torques
Component Specified torque
Cap 3 Nm

2.7 Removing and installing evacuating and

charging valves on low and high-pres‐
sure side
Special tools and workshop equipment required

40 Rep. gr.87 - Air conditioning system

 Sharan 2016 ➤
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♦ Adapter set for service connections - T10364-

♦ Torque wrench - V.A.G 1783-

♦ Engine bung set - VAS 6122-

Removing
Vehicles with R134a refrigerant
– Drain refrigerant circuit ⇒ Air conditioning system with R134a
refrigerant; Rep. gr. 00 ; Working with air conditioner service
station .
Vehicles with R1234yf refrigerant
– Drain refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Draining refrigerant circuit .

2. Refrigerant circuit 41
 Sharan 2016 ➤
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Continued for all vehicles

CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due to
freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have passed since the refrigerant
was extracted, repeat the extraction process before opening
the refrigerant circuit. Pressure could build up in the refrig‐
erant circuit from continued evaporation.

– For any further work, immediately seal open lines and con‐
nections with clean plugs from engine bung set - VAS 6122- .

Note

Disregard positions -1- and -3-.

– Unscrew valve core -2- with adapter set for service connec‐
tions - T10364- -4-.
Installing
Install in reverse order of removal, observing the following:

NOTICE
Risk of damage to air conditioner compressor if refrigerant cir‐
cuit is empty.
– Never start the engine if the refrigerant circuit is empty.

Vehicles with R134a refrigerant

– Charge refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00 ; Working with air conditioner
service station .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00 ; Detecting leaks in refrigerant circuit .
Vehicles with R1234yf refrigerant
– Charge refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Charging refrigerant cir‐
cuit .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning systems with refrigerant
R1234yf - general information; Rep. gr. 87 ; Refrigerant circuit;
Detecting leaks .
Specified torques
Component Specified torque
Valve 2 Nm

42 Rep. gr.87 - Air conditioning system

 Sharan 2016 ➤
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2.8 Removing and installing refrigerant line

between condenser and expansion
valve
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

♦ Engine bung set - VAS 6122-

Removing
– If necessary, remove parts of the air ducting ⇒ Rep. gr. 24 ;
Intake manifold; Assembly overview - intake manifold or ⇒
Rep. gr. 23 ; Intake manifold; Assembly overview - intake
manifold .
– If necessary, remove parts of charge air system/air duct ⇒
Rep. gr. 21 ; Charge air system; Assembly overview - charge
air system .
– Remove engine support ⇒ Rep. gr. 10 ; Assembly mountings;
Assembly overview - assembly mountings .
Vehicles with R134a refrigerant
– Drain refrigerant circuit ⇒ Air conditioning system with R134a
refrigerant; Rep. gr. 00 ; Working with air conditioner service
station .
Vehicles with R1234yf refrigerant
– Drain refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Draining refrigerant circuit .

2. Refrigerant circuit 43
 Sharan 2016 ➤
Heating, air conditioner - Edition 02.2019

Continued for all vehicles

CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due to
freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have passed since the refrigerant
was extracted, repeat the extraction process before opening
the refrigerant circuit. Pressure could build up in the refrig‐
erant circuit from continued evaporation.

– For any further work, immediately seal open lines and con‐
nections with clean plugs from engine bung set - VAS 6122- .

44 Rep. gr.87 - Air conditioning system

 Sharan 2016 ➤
Heating, air conditioner - Edition 02.2019

– Unscrew bolts -7- and -8-.

Rear heater and air conditioning unit
– Unscrew bolt -4-.
– Separate refrigerant line -2- from refrigerant line -1-.
All vehicles
– Unclip refrigerant line -1- from retainers -3-, -5- and -6-.
– Remove refrigerant line -1-.
Installing
Install in reverse order of removal, observing the following:

Note

Ensure proper seating of seals in the groove of the respective

refrigerant line.

NOTICE
Risk of damage to air conditioner compressor if refrigerant cir‐
cuit is empty.
– Never start the engine if the refrigerant circuit is empty.

Vehicles with R134a refrigerant

– Charge refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00 ; Working with air conditioner
service station .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00 ; Detecting leaks in refrigerant circuit .
Vehicles with R1234yf refrigerant
– Charge refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Charging refrigerant cir‐
cuit .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning systems with refrigerant
R1234yf - general information; Rep. gr. 87 ; Refrigerant circuit;
Detecting leaks .
Specified torques
♦ ⇒ “2.1 System overview - refrigerant circuit”, page 25
♦ ⇒ “2.2 Assembly overview - condenser”, page 27
♦ Assembly mountings; Assembly overview - assembly mount‐
ings ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview
- assembly mountings .

2.9 Removing and installing refrigerant line

between condenser and air conditioner
compressor
Special tools and workshop equipment required

2. Refrigerant circuit 45
 Sharan 2016 ➤
Heating, air conditioner - Edition 02.2019

♦ Torque wrench - V.A.G 1331-

♦ Engine bung set - VAS 6122-

Removing
– If necessary, remove parts of the air filter ⇒ Rep. gr. 24 ; Air
filter; Assembly overview - air filter housing or ⇒ Rep. gr. 23 ;
Air filter; Assembly overview - air filter housing .
– If necessary, remove parts of the air ducting ⇒ Rep. gr. 24 ;
Intake manifold; Assembly overview - intake manifold or ⇒
Rep. gr. 23 ; Intake manifold; Assembly overview - intake
manifold .
– If necessary, remove parts of charge air system/air duct ⇒
Rep. gr. 21 ; Charge air system; Assembly overview - charge
air system .
– If fitted, remove noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Noise insulation; Removing and installing
noise insulation .
Vehicles with R134a refrigerant
– Drain refrigerant circuit ⇒ Air conditioning system with R134a
refrigerant; Rep. gr. 00 ; Working with air conditioner service
station .
Vehicles with R1234yf refrigerant
– Drain refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Draining refrigerant circuit .

46 Rep. gr.87 - Air conditioning system

 Sharan 2016 ➤
Heating, air conditioner - Edition 02.2019

Continued for all vehicles

CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due to
freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have passed since the refrigerant
was extracted, repeat the extraction process before opening
the refrigerant circuit. Pressure could build up in the refrig‐
erant circuit from continued evaporation.

– For any further work, immediately seal open lines and con‐
nections with clean plugs from engine bung set - VAS 6122- .
– Unscrew bolts -2- and -3-.
– Remove refrigerant line -1-.
Installing
Install in reverse order of removal, observing the following:

Note

Ensure proper seating of seals in the groove of the respective

refrigerant line.

NOTICE
Risk of damage to air conditioner compressor if refrigerant cir‐
cuit is empty.
– Never start the engine if the refrigerant circuit is empty.

Vehicles with R134a refrigerant

– Charge refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00 ; Working with air conditioner
service station .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00 ; Detecting leaks in refrigerant circuit .
Vehicles with R1234yf refrigerant
– Charge refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Charging refrigerant cir‐
cuit .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning systems with refrigerant
R1234yf - general information; Rep. gr. 87 ; Refrigerant circuit;
Detecting leaks .
Specified torques
♦ ⇒ “2.2 Assembly overview - condenser”, page 27
♦ ⇒ “3.1 Assembly overview - drive unit of air conditioner com‐
pressor”, page 58

2. Refrigerant circuit 47
 Sharan 2016 ➤
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2.10 Removing and installing refrigerant line

between air conditioner compressor and
expansion valve
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

♦ Engine bung set - VAS 6122-

Removing
– If necessary, remove parts of the air ducting ⇒ Rep. gr. 24 ;
Intake manifold; Assembly overview - intake manifold or ⇒
Rep. gr. 23 ; Intake manifold; Assembly overview - intake
manifold .
– If necessary, remove parts of charge air system/air duct ⇒
Rep. gr. 21 ; Charge air system; Assembly overview - charge
air system .
– Remove engine support ⇒ Rep. gr. 10 ; Assembly mountings;
Assembly overview - assembly mountings .
Vehicles with R134a refrigerant
– Drain refrigerant circuit ⇒ Air conditioning system with R134a
refrigerant; Rep. gr. 00 ; Working with air conditioner service
station .
Vehicles with R1234yf refrigerant
– Drain refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Draining refrigerant circuit .

48 Rep. gr.87 - Air conditioning system

 Sharan 2016 ➤
Heating, air conditioner - Edition 02.2019

Continued for all vehicles

CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due to
freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have passed since the refrigerant
was extracted, repeat the extraction process before opening
the refrigerant circuit. Pressure could build up in the refrig‐
erant circuit from continued evaporation.

– For any further work, immediately seal open lines and con‐
nections with clean plugs from engine bung set - VAS 6122- .

2. Refrigerant circuit 49
 Sharan 2016 ➤
Heating, air conditioner - Edition 02.2019

– Remove bolts -6- and -7-.

Rear heater and air conditioning unit
– Unscrew bolt -4-.
– Separate refrigerant line -2- from refrigerant line -1-.
All vehicles
– Unclip refrigerant line -1- from retainers -3- and -5-.
– Remove refrigerant line -1-.
Installing
Install in reverse order of removal, observing the following:

Note

Ensure proper seating of seals in the groove of the respective

refrigerant line.

NOTICE
Risk of damage to air conditioner compressor if refrigerant cir‐
cuit is empty.
– Never start the engine if the refrigerant circuit is empty.

Vehicles with R134a refrigerant

– Charge refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00 ; Working with air conditioner
service station .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00 ; Detecting leaks in refrigerant circuit .
Vehicles with R1234yf refrigerant
– Charge refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Charging refrigerant cir‐
cuit .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning systems with refrigerant
R1234yf - general information; Rep. gr. 87 ; Refrigerant circuit;
Detecting leaks .
Specified torques
♦ ⇒ “2.1 System overview - refrigerant circuit”, page 25
♦ ⇒ “3.1 Assembly overview - drive unit of air conditioner com‐
pressor”, page 58
♦ Assembly mountings; Assembly overview - assembly mount‐
ings ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview
- assembly mountings .

2.11 Removing and installing refrigerant line

to second heater unit, high-pressure
section
Special tools and workshop equipment required

50 Rep. gr.87 - Air conditioning system

 Sharan 2016 ➤
Heating, air conditioner - Edition 02.2019

♦ Torque wrench - V.A.G 1331-

♦ Engine bung set - VAS 6122-

Removing
– Depending on the type of engine, additional parts of the engine
may have to be removed to allow for removing the refrigerant
line.
– Remove right underbody cover ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Underbody cover; Assembly overview -
underbody covers .
Vehicles with R134a refrigerant
– Drain refrigerant circuit ⇒ Air conditioning system with R134a
refrigerant; Rep. gr. 00 ; Working with air conditioner service
station .
Vehicles with R1234yf refrigerant
– Drain refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Draining refrigerant circuit .
Continued for all vehicles

CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due to
freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have passed since the refrigerant
was extracted, repeat the extraction process before opening
the refrigerant circuit. Pressure could build up in the refrig‐
erant circuit from continued evaporation.

2. Refrigerant circuit 51
 Sharan 2016 ➤
Heating, air conditioner - Edition 02.2019

– For any further work, immediately seal open lines and con‐
nections with clean plugs from engine bung set - VAS 6122- .
– Unscrew bolt -4-.
– Loosen nut -7-.
– Unclip refrigerant line -2- from retainers -1-, and remove it.
Installing
Install in reverse order of removal, observing the following:

Note

Ensure proper seating of seals in the groove of the respective

refrigerant line.

NOTICE
Risk of damage to air conditioner compressor if refrigerant cir‐
cuit is empty.
– Never start the engine if the refrigerant circuit is empty.

Vehicles with R134a refrigerant

– Charge refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00 ; Working with air conditioner
service station .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00 ; Detecting leaks in refrigerant circuit .
Vehicles with R1234yf refrigerant
– Charge refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Charging refrigerant cir‐
cuit .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning systems with refrigerant
R1234yf - general information; Rep. gr. 87 ; Refrigerant circuit;
Detecting leaks .
Specified torques
♦ ⇒ “2.1 System overview - refrigerant circuit”, page 25 .
♦ Underbody cladding; Assembly overview - underbody clad‐
ding ⇒ General body repairs, exterior; Rep. gr. 66 ; Under‐
body cladding; Assembly overview - underbody cladding .
Component Specified torque
Nut -7- 17 Nm

2.12 Removing and installing refrigerant line

to second heater unit, low-pressure sec‐
tion
Special tools and workshop equipment required

52 Rep. gr.87 - Air conditioning system

 Sharan 2016 ➤
Heating, air conditioner - Edition 02.2019

♦ Torque wrench - V.A.G 1331-

♦ Engine bung set - VAS 6122-

Removing
– Depending on the type of engine, additional parts of the engine
may have to be removed to allow for removing the refrigerant
line.
– Remove right underbody cover ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Underbody cover; Assembly overview -
underbody covers .
Vehicles with R134a refrigerant
– Drain refrigerant circuit ⇒ Air conditioning system with R134a
refrigerant; Rep. gr. 00 ; Working with air conditioner service
station .
Vehicles with R1234yf refrigerant
– Drain refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Draining refrigerant circuit .
Continued for all vehicles

CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due to
freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have passed since the refrigerant
was extracted, repeat the extraction process before opening
the refrigerant circuit. Pressure could build up in the refrig‐
erant circuit from continued evaporation.

2. Refrigerant circuit 53
 Sharan 2016 ➤
Heating, air conditioner - Edition 02.2019

– For any further work, immediately seal open lines and con‐
nections with clean plugs from engine bung set - VAS 6122- .
– Unscrew bolt -5-.
– Loosen nut -6-.
– Unclip refrigerant line -3- from retainers -1-, and remove it.
Installing
Install in reverse order of removal, observing the following:

Note

Ensure proper seating of seals in the groove of the respective

refrigerant line.

NOTICE
Risk of damage to air conditioner compressor if refrigerant cir‐
cuit is empty.
– Never start the engine if the refrigerant circuit is empty.

Vehicles with R134a refrigerant

– Charge refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00 ; Working with air conditioner
service station .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00 ; Detecting leaks in refrigerant circuit .
Vehicles with R1234yf refrigerant
– Charge refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Charging refrigerant cir‐
cuit .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning systems with refrigerant
R1234yf - general information; Rep. gr. 87 ; Refrigerant circuit;
Detecting leaks .
Specified torques
♦ ⇒ “2.1 System overview - refrigerant circuit”, page 25 .
♦ Underbody cladding; Assembly overview - underbody clad‐
ding ⇒ General body repairs, exterior; Rep. gr. 66 ; Under‐
body cladding; Assembly overview - underbody cladding .
Component Specified torque
Nut -6- 35 Nm

2.13 Removing and installing refrigerant line

from second heater unit
Special tools and workshop equipment required

54 Rep. gr.87 - Air conditioning system

 Sharan 2016 ➤
Heating, air conditioner - Edition 02.2019

♦ Torque wrench - V.A.G 1331-

♦ Engine bung set - VAS 6122-

Removing
– Removing fuel tank ⇒ Rep. gr. 20 ; Fuel tank; Removing and
installing fuel tank .
Vehicles with R134a refrigerant
– Drain refrigerant circuit ⇒ Air conditioning system with R134a
refrigerant; Rep. gr. 00 ; Working with air conditioner service
station .
Vehicles with R1234yf refrigerant
– Drain refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Draining refrigerant circuit .
Continued for all vehicles

CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due to
freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have passed since the refrigerant
was extracted, repeat the extraction process before opening
the refrigerant circuit. Pressure could build up in the refrig‐
erant circuit from continued evaporation.

– For any further work, immediately seal open lines and con‐
nections with clean plugs from engine bung set - VAS 6122- .

2. Refrigerant circuit 55
 Sharan 2016 ➤
Heating, air conditioner - Edition 02.2019

– Loosen nuts -6- and -7-.

56 Rep. gr.87 - Air conditioning system

 Sharan 2016 ➤
Heating, air conditioner - Edition 02.2019

– Unscrew bolts -3-.

– Unscrew bolts -4-.
– Remove refrigerant line -1-.
Installing
Install in reverse order of removal, observing the following:

Note

Ensure proper seating of seals in the groove of the respective

refrigerant line.

NOTICE
Risk of damage to air conditioner compressor if refrigerant cir‐
cuit is empty.
– Never start the engine if the refrigerant circuit is empty.

Vehicles with R134a refrigerant

– Charge refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00 ; Working with air conditioner
service station .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00 ; Detecting leaks in refrigerant circuit .
Vehicles with R1234yf refrigerant
– Charge refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Charging refrigerant cir‐
cuit .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning systems with refrigerant
R1234yf - general information; Rep. gr. 87 ; Refrigerant circuit;
Detecting leaks .
Specified torques
♦ ⇒ “2.1 System overview - refrigerant circuit”, page 25 .
Component Specified torque
Nut for low-pressure line 35 Nm
Nut for high-pressure line 17 Nm
Bolts on expansion valve 10 Nm
Bolts for refrigerant line retainer 2.5 Nm

Volkswagen Technical Site: http://vwts.ru http://vwts.info

2. Refrigerant circuit 57
 Sharan 2016 ➤
Heating, air conditioner - Edition 02.2019

3 Air conditioner compressor

⇒ “3.1 Assembly overview - drive unit of air conditioner compres‐
sor”, page 58
⇒ “3.2 Assembly overview - pulley”, page 61
⇒ “3.3 Removing air conditioning compressor from and installing
on bracket”, page 62
⇒ “3.4 Removing and installing air conditioner compressor”, page
63
⇒ “3.5 Checking high-pressure safety valve on air conditioner
compressor”, page 69
⇒ “3.6 Removing and installing pulley”, page 70

3.1 Assembly overview - drive unit of air

conditioner compressor
⇒ “3.1.1 Assembly overview - drive unit of air conditioner com‐
pressor”, page 58
⇒ “3.1.2 Assembly overview - drive unit of air conditioner com‐
pressor with air conditioning system magnetic clutch N25 ”, page
60

3.1.1 Assembly overview - drive unit of air conditioner compressor

58 Rep. gr.87 - Air conditioning system

 Sharan 2016 ➤
Heating, air conditioner - Edition 02.2019

1 - Poly V-belt
2 - Bolts
❑ Qty. 2
❑ 22 Nm
3 - Connector for air condition‐
er compressor regulating valve
- N280-
❑ Check with ⇒ Vehicle di‐
agnostic tester in “Gui‐
ded Fault Finding” mode
and ⇒ Current flow dia‐
grams, Electrical fault
finding and Fitting loca‐
tions
4 - Air conditioner compressor
❑ Different versions. Re‐
fer to ⇒ Electronic parts
catalogue .
❑ Removing and installing
⇒ page 63
❑ Removing from and in‐
stalling on bracket
⇒ page 62
5 - Bolts
❑ Qty. 3
❑ 25 Nm

3. Air conditioner compressor 59

 Sharan 2016 ➤
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3.1.2 Assembly overview - drive unit of air conditioner compressor with air con‐
ditioning system magnetic clutch - N25-

1 - Air conditioner compressor

❑ Different versions. Re‐
fer to ⇒ Electronic parts
catalogue .
❑ Removing and installing
⇒ page 63
❑ Removing from and in‐
stalling on bracket
⇒ page 62
2 - Dowel sleeves
❑ Qty. 2
3 - Air conditioning system
magnetic clutch - N25-
4 - Seal
❑ Renew after removal
❑ Different versions. Re‐
fer to ⇒ Electronic parts
catalogue .
❑ Moisten with refrigerant
oil before installation
5 - Refrigerant line
❑ High-pressure side
6 - Bolts
❑ Qty. 2
❑ 22 Nm
7 - Refrigerant line
❑ Low-pressure side
8 - Seal
❑ Renew after removal
❑ Different versions. Re‐
fer to ⇒ Electronic parts
catalogue .
❑ Moisten with refrigerant oil before installation
9 - High-pressure safety valve
❑ Checking ⇒ page 69
10 - Bolts
❑ Qty. 3
❑ 25 Nm
11 - Air conditioner compressor regulating valve - N280-
❑ Renew after removal
❑ Check with ⇒ Vehicle diagnostic tester
12 - Oil drain plug
❑ Do not remove unless refrigerant circuit is empty
❑ Renew oil drain plug/seal after each removal
❑ Different versions ⇒ Electronic parts catalogue (ETKA)
❑ 15 Nm

60 Rep. gr.87 - Air conditioning system

 Sharan 2016 ➤
Heating, air conditioner - Edition 02.2019

3.2 Assembly overview - pulley

⇒ “3.2.1 Assembly overview - Denso pulley”, page 61

3.2.1 Assembly overview - Denso pulley

Note

♦ This type of poly V-belt pulley is installed on “7SEU17C” air

conditioner compressors.
♦ Various types of poly V-belt pulley are installed depending on
design of air conditioner compressor and type of engine ⇒
Parts catalogue .
♦ Removing and installing poly V-belt pulley ⇒ page 70 .

1 - Cap with circlip

❑ Remove carefully using
a small screwdriver or
long nose pliers (be es‐
pecially careful with the
poly V-belt pulley)
2 - Drive plate
3 - Retaining ring
❑ Always renew
❑ Install correctly (flat side
faces air conditioner
compressor)
4 - Spacer
5 - Poly V-belt pulley
❑ The poly V-belt pulley is
made of plastic and sen‐
sitive to impact. There‐
fore, exercise particular
caution when handling
it.
❑ Various versions ⇒
Parts catalogue
6 - Air conditioner compressor
❑ Various types are instal‐
led, depending on type
of engine and country
version ⇒ Parts cata‐
logue
❑ Clean air conditioner
compressor flange be‐
fore fitting poly V-belt
pulley
7 - Rubber element
❑ Qty. 6
❑ Flexible coupling between poly V-belt pulley and air conditioner compressor drive shaft, dampens vibra‐
tions and noise.
❑ Lightly moisten rubber elements with, for example, tyre assembly paste or soapy solution (used as a
lubricant) when installing.

3. Air conditioner compressor 61

 Sharan 2016 ➤
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3.3 Removing air conditioning compressor

from and installing on bracket
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

Removing
– If fitted, remove noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Noise insulation; Removing and installing
noise insulation .
If necessary, remove front right wheel housing liner ⇒ General
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; Remov‐
ing and installing front wheel housing liner .
Vehicles with air conditioning system magnetic clutch - N25-
– Disconnect electrical connector -1-.
Continued for all vehicles

Note

Instead of the poly V-belts being removed completely, they are

just removed from the air conditioner compressor pulley.

– Relieve tension from poly V-belt ⇒ Rep. gr. 13 ; Cylinder block

on pulley side; Removing and installing poly V-belt .
– Remove poly V-belt from air conditioner compressor pulley.

– Disconnect connector -6- on air conditioner compressor -1-.

– Unscrew bolts -5- and remove air conditioner compressor
-1-.

62 Rep. gr.87 - Air conditioning system

 Sharan 2016 ➤
Heating, air conditioner - Edition 02.2019

– Secure air conditioner compressor -1- to body with suitable

material (e.g. welding wire -2-).
Installing
The installation is carried out in reverse order of removal. Observe
the following:
– Thoroughly clean contact surfaces on air conditioner com‐
pressor and bracket.

– Insert dowel sleeves -1- into air conditioner compressor.

Note

Ensure that dowel sleeves are properly seated and that contact
surfaces are clean. Improperly fitted dowel sleeves or dirty or
damaged contact surfaces can cause deviations in alignment of
air conditioner compressor and engine. In the course of operation,
misalignment will result in damage to the air conditioner com‐
pressor.

NOTICE
Risk of damage to air conditioner compressor. Refrigerant oil
may accumulate in the compression chamber of a removed air
conditioner compressor.
– After installing a new air conditioner compressor or adding
new refrigerant oil, fully turn the air conditioner compressor
10 times by hand before the poly V-belt is fitted.

Specified torques
♦ ⇒ “3.1 Assembly overview - drive unit of air conditioner com‐
pressor”, page 58
Note the following when starting engine for first time after filling
the refrigerant circuit:
– Observe notes on commissioning the air conditioning system
after installing the air conditioner compressor ⇒ Air condition‐
ing system with refrigerant R134a or ⇒ Air conditioning sys‐
tems with refrigerant R1234yf - General information; Rep. gr.
87 ; Refrigerant circuit; Renewing components .

3.4 Removing and installing air conditioner

compressor
Special tools and workshop equipment required

3. Air conditioner compressor 63

 Sharan 2016 ➤
Heating, air conditioner - Edition 02.2019

♦ Torque wrench - V.A.G 1331-

♦ Engine bung set - VAS 6122-

♦ Vehicle diagnostic tester

Note

If a new air conditioner compressor is installed, a compressor run-

in must be carried out using ⇒ Vehicle diagnostic tester.

Removing

Note

Depending on engine, remove charge air hose.

– If fitted, remove noise insulation ⇒ General body repairs, ex‐

terior; Rep. gr. 66 ; Noise insulation; Removing and installing
noise insulation .
– If necessary, remove front right wheel housing liner ⇒ General
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; Re‐
moving and installing front wheel housing liner .

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Vehicles with air conditioning system magnetic clutch - N25-

– Disconnect electrical connector -1-.
Continued for all vehicles

Note

Instead of the poly V-belts being removed completely, they are

just removed from the air conditioner compressor pulley.

– Relieve tension from poly V-belt ⇒ Rep. gr. 13 ; Cylinder block

on pulley side; Removing and installing poly V-belt .
– Remove poly V-belt from air conditioner compressor pulley.
Vehicles with R134a refrigerant
– Drain refrigerant circuit ⇒ Air conditioning system with R134a
refrigerant; Rep. gr. 00 ; Working with air conditioner service
station .
Vehicles with R1234yf refrigerant
– Drain refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Draining refrigerant circuit .
Continued for all vehicles

CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due to
freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have passed since the refrigerant
was extracted, repeat the extraction process before opening
the refrigerant circuit. Pressure could build up in the refrig‐
erant circuit from continued evaporation.

– For any further work, immediately seal open lines and con‐
nections with clean plugs from engine bung set - VAS 6122- .
– Disconnect connector from air conditioner compressor regu‐
lating valve - N280- -3-.

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– Unscrew bolts -2- from air conditioner compressor -4-, and

disconnect refrigerant lines from air conditioner compressor
-4-.
– Unscrew hexagon bolts -5- and remove air conditioner com‐
pressor -4-.
Installing
Install in reverse order of removal, observing the following:
– If air conditioner compressor has been renewed, check poly-
V belt for damage and renew as needed ⇒ Rep. gr. 13 ;
Cylinder block, belt end; Removing and installing poly-V belt .
– Clean contact surfaces of air conditioner compressor and
holder.

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– Insert dowel sleeves -1- into air conditioner compressor -2-.

Note

♦ Improperly fitted dowel sleeves or dirty or damaged contact

surfaces can cause deviations in alignment of air conditioner
compressor and engine. Deviations in alignment will eventu‐
ally damage the air condition compressor.
♦ If the air conditioner compressor is renewed on account of
problems (e.g. internal damage), the refrigerant circuit must
be cleaned ⇒ Air conditioning systems with refrigerant
R1234yf - General information; Rep. gr. 87 ; Refrigerant cir‐
cuit; Renewing components or ⇒ Air conditioning system -
with R134a refrigerant .
♦ When it is removed, the air conditioner compressor contains
an indeterminate amount of refrigerant oil. For this reason it is
important to observe the notes on renewing the air conditioner
compressor ⇒ Air conditioning systems with R1234yf refrig‐
erant - General information; Rep. gr. 87 ; Refrigerant circuit;
Renewing components or ⇒ Air conditioning system - with
R134a refrigerant .

On air conditioning systems with R1234yf refrigerant

If the air conditioner compressor is replaced, the following table
gives an indication as to whether the refrigerant circuit needs to
be flushed before the new air conditioner compressor is installed.
The necessity for flushing depends on the supplier and the re‐
frigerant oil that it uses.
Supplier of replacement compressor
Denso Mahle/Del‐ Sanden
phi
Supplier of Denso Do not Flush Flush
air condi‐ flush
tioner com‐ Mahle/Del‐ Flush Do not flush Do not
pressor in‐ phi flush
stalled in
vehicle Sanden Flush Do not flush Do not
flush
– If necessary according to table, flush refrigerant circuit ⇒ Air
conditioning systems with R1234yf refrigerant - General infor‐
mation; Rep. gr. 87 ; Refrigerant circuit; Cleaning refrigerant
circuit .
Continued for all vehicles

NOTICE
Risk of damage to air conditioner compressor. Refrigerant oil
may accumulate in the compression chamber of a removed air
conditioner compressor.
– After installing a new air conditioner compressor or adding
new refrigerant oil, fully turn the air conditioner compressor
10 times by hand before the poly V-belt is fitted.

Note the following when starting engine for first time after filling
the refrigerant circuit:
– Observe notes on commissioning the air conditioning system
after installing the air conditioner compressor ⇒ Air condition‐
ing system with refrigerant R134a or ⇒ Air conditioning sys‐
tems with refrigerant R1234yf - General information; Rep. gr.
87 ; Refrigerant circuit; Renewing components .

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– Start engine with air conditioner compressor switched off (con‐

trol lamp in A/C button is off) and wait until idling speed is
stable.
– Open dash panel vents.
– Set temperature to “Lo” on heater and air conditioning controls
- EX21- or on temperature preselection.
– Switch on air conditioner compressor (control lamp in A/C
button lights up) and let it run for at least 5 minutes with engine
at idling speed.

Note

♦ The air conditioner compressor is driven by the poly V-belt

pulley (not fitted with a magnetic clutch).
♦ If an air conditioner compressor seizes, the overload protec‐
tion separates from the air conditioner compressor shaft. The
seizure can normally be detected by the bulges in the poly V-
belt pulley. Another indication of a seizure is abraded rubber
material around the poly V-belt pulley.
♦ The air conditioner compressor has an internal oil circuit to
ensure that the air conditioner compressor is not damaged
when the refrigerant circuit is empty. This means that approx.
40 to 50 cm3 of refrigerant oil remain in the air conditioner
compressor.
♦ Only start engine when refrigerant circuits are charged.
♦ Only start engine when refrigerant circuit has been correctly
installed. If, for example, the refrigerant lines are not connec‐
ted to the air conditioner compressor and the engine is run‐
ning, the compressor may heat up so much through internal
warming that it will be damaged beyond repair.
♦ The air conditioner compressor regulating valve - N280- is not
activated when the refrigerant circuit is empty and the air con‐
ditioner compressor idles with the engine.
♦ If it is necessary to start engine with an empty refrigerant cir‐
cuit:
♦ The refrigerant circuit must be fully assembled.
♦ At least ¼ of the quantity of refrigerant oil specified for this
refrigerant circuit must be in the air conditioner compressor.
♦ The engine speed must not exceed 2000 rpm.
♦ Run engine only as long as absolutely necessary, max.
10 min.

– Moisten new seals with refrigerant oil before installing refrig‐

erant line.

NOTICE
Risk of damage to air conditioner compressor if refrigerant cir‐
cuit is empty.
– Never start the engine if the refrigerant circuit is empty.

Vehicles with R134a refrigerant

– Charge refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00 ; Working with air conditioner
service station .

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– Perform leakage test on re-established line connections of re‐

frigerant circuit ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00 ; Detecting leaks in refrigerant circuit .
Vehicles with R1234yf refrigerant
– Charge refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Charging refrigerant cir‐
cuit .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning systems with refrigerant
R1234yf - general information; Rep. gr. 87 ; Refrigerant circuit;
Detecting leaks .
Specified torques
♦ ⇒ “3.1 Assembly overview - drive unit of air conditioner com‐
pressor”, page 58

3.5 Checking high-pressure safety valve on

air conditioner compressor
Check
♦ Function: protects refrigerant circuit against excessive pres‐
sures.

CAUTION
Risk of freezing injury caused by refrigerant. The high-pressure
safety valve releases refrigerant when the engine is running and
the pressure in the refrigerant circuit is too high.
There is a risk of injury on hands and other parts of the body
due to freezing.
– Wear protective gloves.
– Wear protective goggles.
– Switch off engine.

High-pressure safety valve on Denso air conditioner compressor

♦ The high-pressure safety valve -arrow- has been activated
when refrigerant oil is found in the immediate vicinity.
♦ In this case, entrust a suitable workshop to perform the work
⇒ page 5 .

Note

On air conditioner compressors from other manufacturers the

high-pressure safety valve is located in a similar position.

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3.6 Removing and installing pulley

⇒ “3.6.1 Removing and installing pulley, Denso”, page 70

3.6.1 Removing and installing pulley, Denso

Removing
– Carefully remove cap with retaining ring -A- using, for exam‐
ple, a small screwdriver or long-nose pliers. When doing this,
be particularly careful not to damage the poly V-belt pulley.
– Counterhold drive plate -C- and poly V-belt pulley -D- using
commercially available strap wrench in -direction of arrow E-,
and loosen drive shaft -B- (35 ± 5 Nm) in
-direction of arrow F-.
– Remove drive plate -C-.

– Remove circlip -A-.

– Pull off poly V-belt pulley -B-.
Installing
– Renew circlip -A-.
– Clean air conditioner compressor flange before fitting poly V-
belt pulley

– When installing retaining ring -A-, ensure that it is not expan‐

ded more than necessary.
– Install poly V-belt pulley -B-.
– Install circlip -A- correctly, chamfer -C- faces away from air
conditioner compressor (flat side towards air conditioner com‐
pressor).
– Insert rubber elements -D- into poly V-belt pulley -B-, as shown
in figure.

Note

♦ When installing drive plate, lightly moisten rubber elements

-D- e.g. with tyre mounting paste or soap solution (as a lubri‐
cant).
♦ To prevent any damage to the air conditioner compressor
mounting, use protective jaw covers -2- between the vice and
air conditioner compressor.

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– Insert drive plate -C- between rubber elements so far that plate
contacts drive shaft of air conditioner compressor -B-.

– Counterhold drive plate -1- in direction of -arrow A- using com‐

mercially-available strap wrench, and tighten drive shaft by
turning torque wrench in direction of -arrow B- (35 ± 5 Nm).
– Fit cap with retaining ring.

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4 Control motors
⇒ “4.1 Overview of fitting locations - front control motors”,
page 72
⇒ “4.2 Removing and installing temperature flap control motor
V68 ”, page 74
⇒ “4.3 Removing and installing defroster flap control motor V107
”, page 76
⇒ “4.4 Removing and installing air recirculation flap control motor
V113 ”, page 78
⇒ “4.5 Removing and installing rear temperature flap control mo‐
tor V137 ”, page 79
⇒ “4.6 Removing and installing left temperature flap control motor
V158 ”, page 80
⇒ “4.7 Removing and installing right temperature flap control mo‐
tor V159 ”, page 82
⇒ “4.8 Removing and installing fresh air/air recirculation, air flow
flap control motor V425 ”, page 83
⇒ “4.9 Removing and installing front air distribution flap control
motor V426 ”, page 84
⇒ “4.10 Removing and installing rear air distribution flap control
motor V427 with potentiometer for rear air distribution flap control
motor G643 ”, page 85
⇒ “4.11 Removing and installing air distribution flap control motor
V428 ”, page 86

4.1 Overview of fitting locations - front con‐

trol motors
⇒ “4.1.1 Overview of fitting locations - front control motors, air
conditioning system with electric and manual controls”,
page 72
⇒ “4.1.2 Overview of fitting locations - front control motors, Cli‐
matronic”, page 73

4.1.1 Overview of fitting locations - front con‐

trol motors, air conditioning system with
electric and manual controls
The following information applies to left-hand drive vehicles. A
right-hand drive vehicle is similar.

Note

♦ View -A- shows the arrangement of the control motors on the left side of the heater and air conditioning unit.
♦ View -B- shows the arrangement of the control motors on the right side of the heater and air conditioning
unit.

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1 - Temperature flap control

motor - V68-
❑ With potentiometer for
temperature flap control
motor - G92-
❑ Removing and installing
⇒ page 74
2 - Air distribution flap control
motor - V428-
❑ With potentiometer for
air distribution flap con‐
trol motor - G645-
❑ Removing and installing
⇒ page 86
3 - Air recirculation flap control
motor - V113-
❑ With potentiometer for
air recirculation flap
control motor - G143-
❑ Removing and installing
⇒ page 78

4.1.2 Overview of fitting locations - front con‐

trol motors, Climatronic
The following information applies to left-hand drive vehicles. A
right-hand drive vehicle is similar.

Note

♦ View -A- shows the arrangement of the control motors on the

left side of the heater and air conditioning unit.
♦ View -B- shows the arrangement of the control motors on the
right side of the heater and air conditioning unit.
♦ View -C- shows the arrangement of the control motors on the
air intake of the heater and air conditioning unit.

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1 - Fresh air/air recirculation,

air flow flap control motor -
V425-
❑ With potentiometer for
fresh air/recirculated air
and air flow flap control
motor - G644-
❑ Removing and installing
⇒ page 83
2 - Left temperature flap con‐
trol motor - V158-
❑ With potentiometer for
left temperature flap
control motor - G220-
❑ Removing and installing
⇒ page 80
3 - Defroster flap control motor
- V107-
❑ With potentiometer for
defroster flap control
motor - G135-
❑ Removing and installing
⇒ page 76
4 - Front air distribution flap
control motor - V426-
❑ With potentiometer for
front air distribution flap
control motor - G642-
❑ Removing and installing
⇒ page 84
5 - Right temperature flap con‐
trol motor - V159-
❑ With potentiometer for
right temperature flap
control motor - G221-
❑ Removing and installing ⇒ page 82

4.2 Removing and installing temperature

flap control motor - V68-
The following information applies to left-hand drive vehicles. A
right-hand drive vehicle is similar.
Special tools and workshop equipment required
♦ Vehicle diagnostic tester

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Note

♦ As of week 45/2013, control motors have been changed grad‐

ually. Comply with the notes
⇒ “3.5 Notes on control motors”, page 7 , and refer to the ⇒
Electronic parts catalogue .
♦ The colour-marked links which were factory-fitted and provi‐
ded as replacement parts earlier have been discontinued
gradually as of week 45/2013. In addition, the links are not any
longer pre-installed on the control motors provided as replace‐
ment parts.
♦ There are various available versions of control motors and the
corresponding links. In some cases there are very slight dif‐
ferences which may not be obvious at first glance. However,
if the wrong version of a control motor or link is installed, prob‐
lems may occur not before the basic setting is performed.

Removing
– Remove footwell vent on driver side ⇒ page 133 .
– Remove left side trim panel from centre console ⇒ General
body repairs, interior; Rep. gr. 68 ; Centre console; Assembly
overview - centre console .
– Unscrew lower bolts -4- from bracket for heater and air con‐
ditioning unit.

– Pull bracket -1- towards brake pedal and secure with a cable
tie.
– Mark connector of temperature flap control motor - V68- -C-
and disconnect.
– Remove bolts -3- from temperature flap control motor - V68-
-C-.

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– Remove bolts -arrows- and remove heat exchanger cover

-1-.

– Release control motor lever from connecting rod.

– Remove temperature flap control motor - V68- -C-.
Installing
– Observe notes ⇒ page 7 .

Note

♦ Risk of malfunction of heater or air conditioning system caused

by improperly installed control motors or links.
♦ Mark the correct allocation of the connectors to the control
motors.
♦ Always install the appropriate links to the control motors.

– Install temperature flap control motor - V68- in reverse order

of removal.
Specified torques
♦ Left side trim panel of centre console ⇒ General body repairs,
interior; Rep. gr. 68 ; Centre console; Assembly overview -
centre console .
Component Specified torque
Bolts for control motor 1.5 Nm
Bolts for bracket 9 Nm

4.3 Removing and installing defroster flap

control motor - V107-
The following information applies to left-hand drive vehicles. A
right-hand drive vehicle is similar.
Special tools and workshop equipment required
♦ Vehicle diagnostic tester

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Note

♦ As of week 45/2013, control motors have been changed grad‐

ually. Comply with the notes
⇒ “3.5 Notes on control motors”, page 7 , and refer to the ⇒
Electronic parts catalogue .
♦ The colour-marked links which were factory-fitted and provi‐
ded as replacement parts earlier have been discontinued
gradually as of week 45/2013. In addition, the links are not any
longer pre-installed on the control motors provided as replace‐
ment parts.
♦ There are various available versions of control motors and the
corresponding links. In some cases there are very slight dif‐
ferences which may not be obvious at first glance. However,
if the wrong version of a control motor or link is installed, prob‐
lems may occur not before the basic setting is performed.

Removing
– Remove dash panel ⇒ General body repairs, interior; Rep. gr.
70 ; Dash panel; Removing and installing dash panel .
– Remove footwell vent on driver side ⇒ page 133 .
– Unscrew bolts -1-, -2- and -4- from bracket for heater and air
conditioning unit.
– Remove bracket for heater and air conditioner -3-.
– Mark connector of defroster flap control motor - V107- -A- and
disconnect.

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– Remove bolts -1- from defroster flap control motor - V107-

-A-.
– Detach control motor lever from connecting rod and remove
control motor.
Installing
– Observe notes ⇒ page 7 .

Note

♦ Risk of malfunction of heater or air conditioning system caused

by improperly installed control motors or links.
♦ Mark the correct allocation of the connectors to the control
motors.
♦ Always install the appropriate links to the control motors.

– Install defroster flap control motor - V107- in reverse order of

removal.
Specified torques
♦ Dash panel ⇒ General body repairs, interior; Rep. gr. 70 ;
Dash panel; Removing and installing dash panel .
Component Specified torque
Bolts for control motor 1.5 Nm
Bolts for bracket 9 Nm

4.4 Removing and installing air recirculation

flap control motor - V113-
The following information applies to left-hand drive vehicles. A
right-hand drive vehicle is similar.
Special tools and workshop equipment required
♦ Vehicle diagnostic tester

Note

♦ As of week 45/2013, control motors have been changed grad‐

ually. Comply with the notes
⇒ “3.5 Notes on control motors”, page 7 , and refer to the ⇒
Electronic parts catalogue .
♦ The colour-marked links which were factory-fitted and provi‐
ded as replacement parts earlier have been discontinued
gradually as of week 45/2013. In addition, the links are not any
longer pre-installed on the control motors provided as replace‐
ment parts.
♦ There are various available versions of control motors and the
corresponding links. In some cases there are very slight dif‐
ferences which may not be obvious at first glance. However,
if the wrong version of a control motor or link is installed, prob‐
lems may occur not before the basic setting is performed.

Removing
– Remove glove compartment ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments/covers; Removing and installing
glove compartment .

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– Remove voltage converter with bracket ⇒ Electrical system;

Rep. gr. 27 ; Start/Stop system; Removing and installing volt‐
age stabiliser .
– Disconnect connector -1- from air recirculation flap control
motor - V113- .
– Unclip cable from retainer -3-.
– Release retaining tabs -A- and -B- from carrier -2-.
– Pull air recirculation flap control motor - V113- with carrier
-2- out of retainer -C- and remove it.
Installing
– Observe notes ⇒ page 7 .

Note

♦ Risk of malfunction of heater or air conditioning system caused

by improperly installed control motors or links.
♦ Mark the correct allocation of the connectors to the control
motors.
♦ Always install the appropriate links to the control motors.

– Install air recirculation flap control motor - V113- in reverse

order of removal.
Specified torques
♦ Glove compartment ⇒ General body repairs, interior; Rep. gr.
68 ; Compartments/covers; Removing and installing glove
compartment .
♦ Voltage converter ⇒ Electrical system; Rep. gr. 27 ; Start/Stop
system; Removing and installing voltage stabiliser .
Component Specified torque
Bolt 1.5 Nm

4.5 Removing and installing rear tempera‐

ture flap control motor - V137-
Special tools and workshop equipment required
♦ Vehicle diagnostic tester
Removing
– Remove right luggage compartment side trim ⇒ General body
repairs, interior; Rep. gr. 70 ; Luggage compartment trims;
Overview of fitting locations - luggage compartment trims .
– Disconnect connector -3- from rear temperature flap control
motor - V137- -1-.
– Disconnect connecting rod -2- from rear temperature flap con‐
trol motor - V137- -1-.
– Unscrew bolts -arrow A-.

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– Pull rear temperature flap control motor - V137- -1- out of guide
-arrow B-.
Installing
Install in reverse order of removal, observing the following:
Specified torques
♦ Right luggage compartment side trim ⇒ General body repairs,
interior; Rep. gr. 70 ; Luggage compartment trims; Overview
of fitting locations - luggage compartment trims .
Component Specified torque
Bolts 1.5 Nm

4.6 Removing and installing left tempera‐

ture flap control motor - V158-
The following information applies to left-hand drive vehicles. A
right-hand drive vehicle is similar.
Special tools and workshop equipment required
♦ Vehicle diagnostic tester

Note

♦ As of week 45/2013, control motors have been changed grad‐

ually. Comply with the notes
⇒ “3.5 Notes on control motors”, page 7 , and refer to the ⇒
Electronic parts catalogue .
♦ The colour-marked links which were factory-fitted and provi‐
ded as replacement parts earlier have been discontinued
gradually as of week 45/2013. In addition, the links are not any
longer pre-installed on the control motors provided as replace‐
ment parts.
♦ There are various available versions of control motors and the
corresponding links. In some cases there are very slight dif‐
ferences which may not be obvious at first glance. However,
if the wrong version of a control motor or link is installed, prob‐
lems may occur not before the basic setting is performed.

Removing
Removing
– If installed, remove knee airbag ⇒ General body repairs, in‐
terior; Rep. gr. 69 ; Knee airbag; Removing and installing knee
airbag with igniter .
– Remove data bus diagnostic interface - J533- ⇒ Electrical
system; Rep. gr. 97 ; Assembly overview -diagnostic interface
for data bus .
– Remove footwell vent on driver side ⇒ page 133 .
– Remove left side trim panel from centre console ⇒ General
body repairs, interior; Rep. gr. 68 ; Centre console; Assembly
overview - centre console .

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– Remove lower bolts -4- (9 Nm) from bracket for heater and air
conditioning unit.

– Pull bracket -1- towards brake pedal and secure with a cable
tie.
– Mark connector of left temperature flap control motor - V158-
-C- and disconnect.
– Remove bolts -3- from left temperature flap control motor -
V158- -C-.

– Remove bolts -arrows- and remove heat exchanger cover

-1-.

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– Release control motor lever from connecting rod.

– Remove left temperature flap control motor - V158- -C-.
Installing
– Observe notes ⇒ page 7 .

Note

♦ Risk of malfunction of heater or air conditioning system caused

by improperly installed control motors or links.
♦ Mark the correct allocation of the connectors to the control
motors.
♦ Always install the appropriate links to the control motors.

– Install left temperature flap control motor - V158- in reverse

order of removal.
Specified torques
♦ Left side trim panel of centre console ⇒ General body repairs,
interior; Rep. gr. 68 ; Centre console; Assembly overview -
centre console .
Component Specified torque
Bolts for control motor 1.5 Nm
Bolt for bracket 9 Nm

4.7 Removing and installing right tempera‐

ture flap control motor - V159-
The following information applies to left-hand drive vehicles. A
right-hand drive vehicle is similar.
Special tools and workshop equipment required
♦ Vehicle diagnostic tester

Note

♦ As of week 45/2013, control motors have been changed grad‐

ually. Comply with the notes
⇒ “3.5 Notes on control motors”, page 7 , and refer to the ⇒
Electronic parts catalogue .
♦ The colour-marked links which were factory-fitted and provi‐
ded as replacement parts earlier have been discontinued
gradually as of week 45/2013. In addition, the links are not any
longer pre-installed on the control motors provided as replace‐
ment parts.
♦ There are various available versions of control motors and the
corresponding links. In some cases there are very slight dif‐
ferences which may not be obvious at first glance. However,
if the wrong version of a control motor or link is installed, prob‐
lems may occur not before the basic setting is performed.

Removing
– Remove glove compartment ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments/covers; Removing and installing
glove compartment .

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– Remove cooling vent hose for glove compartment

⇒ page 110 .
– Disconnect connector -2- from right temperature flap control
motor - V159- -1-.
– Remove bolts -arrows- (1.5 Nm).
– Take right temperature flap control motor - V159- -1- off heater
and air conditioning unit; detach strut while doing this.
Installing
– Observe notes ⇒ page 7 .

Note

♦ Risk of malfunction of heater or air conditioning system caused

by improperly installed control motors or links.
♦ Mark the correct allocation of the connectors to the control
motors.
♦ Always install the appropriate links to the control motors.

– Install right temperature flap control motor - V159- in reverse

order of removal.
Specified torques
♦ Glove compartment ⇒ General body repairs, interior; Rep. gr.
68 ; Compartments/covers; Removing and installing glove
compartment .
Component Specified torque
Bolt 1.5 Nm

4.8 Removing and installing fresh air/air re‐

circulation, air flow flap control motor -
V425-
The following information applies to left-hand drive vehicles. A
right-hand drive vehicle is similar.
Special tools and workshop equipment required
♦ Vehicle diagnostic tester

Note

♦ As of week 45/2013, control motors have been changed grad‐

ually. Comply with the notes
⇒ “3.5 Notes on control motors”, page 7 , and refer to the ⇒
Electronic parts catalogue .
♦ The colour-marked links which were factory-fitted and provi‐
ded as replacement parts earlier have been discontinued
gradually as of week 45/2013. In addition, the links are not any
longer pre-installed on the control motors provided as replace‐
ment parts.
♦ There are various available versions of control motors and the
corresponding links. In some cases there are very slight dif‐
ferences which may not be obvious at first glance. However,
if the wrong version of a control motor or link is installed, prob‐
lems may occur not before the basic setting is performed.

4. Control motors 83
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Removing
– Remove glove compartment ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments/covers; Removing and installing
glove compartment .
– Remove voltage converter with bracket ⇒ Electrical system;
Rep. gr. 27 ; Start/Stop system; Removing and installing volt‐
age stabiliser .
– Separate electrical connector -2-.
– Unscrew bolts -arrows-.
– Pull fresh air/air recirculation, air flow flap control motor - V425-
out of guide -A- and take off of heater and air conditioning unit.
Installing
– Observe notes ⇒ page 7 .

Note

♦ Risk of malfunction of heater or air conditioning system caused

by improperly installed control motors or links.
♦ Mark the correct allocation of the connectors to the control
motors.
♦ Always install the appropriate links to the control motors.

– Install fresh air/air recirculation, air flow flap control motor -

V425- in reverse order of removal.
Specified torques
♦ Glove compartment ⇒ General body repairs, interior; Rep. gr.
68 ; Compartments/covers; Removing and installing glove
compartment .
♦ Voltage converter ⇒ Electrical system; Rep. gr. 27 ; Start/Stop
system; Removing and installing voltage stabiliser .
Component Specified torque
Bolt 1.5 Nm

4.9 Removing and installing front air distri‐

bution flap control motor - V426-
The following information applies to left-hand drive vehicles. A
right-hand drive vehicle is similar.
Special tools and workshop equipment required
♦ Vehicle diagnostic tester

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Note

♦ As of week 45/2013, control motors have been changed grad‐

ually. Comply with the notes
⇒ “3.5 Notes on control motors”, page 7 , and refer to the ⇒
Electronic parts catalogue .
♦ The colour-marked links which were factory-fitted and provi‐
ded as replacement parts earlier have been discontinued
gradually as of week 45/2013. In addition, the links are not any
longer pre-installed on the control motors provided as replace‐
ment parts.
♦ There are various available versions of control motors and the
corresponding links. In some cases there are very slight dif‐
ferences which may not be obvious at first glance. However,
if the wrong version of a control motor or link is installed, prob‐
lems may occur not before the basic setting is performed.

Removing
– Remove centre vent ⇒ General body repairs, interior; Rep.
gr. 70 ; Dash panel; Removing and installing dash panel vent .
– Remove dash panel insert ⇒ Electrical system; Rep. gr. 90 ;
Dash panel insert; Assembly overview - dash panel insert .
– Disconnect connector from front air distribution flap control
motor - V426- -B-.
– Remove bolts -2- (1.5 Nm).
– Remove front air distribution flap control motor - V426- -B-
from heater and air conditioning unit.
Installing
– Observe notes ⇒ page 7 .

Note

♦ Risk of malfunction of heater or air conditioning system caused

by improperly installed control motors or links.
♦ Mark the correct allocation of the connectors to the control
motors.
♦ Always install the appropriate links to the control motors.

– Install front air distribution flap control motor - V426- in reverse

order of removal.
Specified torques
♦ Dash panel insert ⇒ Electrical system; Rep. gr. 90 ; Dash
panel insert; Assembly overview - dash panel insert .
Component Specified torque
Bolt 1.5 Nm

4.10 Removing and installing rear air distri‐

bution flap control motor - V427- with
potentiometer for rear air distribution
flap control motor - G643-
Special tools and workshop equipment required

4. Control motors 85
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♦ Vehicle diagnostic tester

Removing
– Remove right luggage compartment side trim ⇒ General body
repairs, interior; Rep. gr. 70 ; Luggage compartment trims;
Overview of fitting locations - luggage compartment trims .
– Disconnect connector -2- from rear air distribution flap control
motor - V427- -1-.
– Unscrew bolts -arrows A-.
– Pull rear air distribution flap control motor - V427- -1- out of
guide -arrow B-.
Installing
Install in reverse order of removal, observing the following:
Specified torques
♦ Right luggage compartment side trim ⇒ General body repairs,
interior; Rep. gr. 70 ; Luggage compartment trims; Overview
of fitting locations - luggage compartment trims .
Component Specified torque
Bolts 1.5 Nm

4.11 Removing and installing air distribution

flap control motor - V428-
The following information applies to left-hand drive vehicles. A
right-hand drive vehicle is similar.
Special tools and workshop equipment required
♦ Vehicle diagnostic tester
Removing
– Remove centre vent ⇒ General body repairs, interior; Rep.
gr. 70 ; Dash panel; Removing and installing dash panel vent .
– Remove dash panel insert ⇒ Electrical system; Rep. gr. 90 ;
Dash panel insert; Assembly overview - dash panel insert .
– Disconnect electrical connector from air distribution flap con‐
trol motor - V428- -1-.
– Unscrew bolts -arrows-.
– Remove air distribution flap control motor - V428- -1-
Installing
Install in reverse order of removal, observing the following:
Specified torques
♦ Dash panel insert ⇒ Electrical system; Rep. gr. 90 ; Dash
panel insert; Removing and installing dash panel insert KX2
Component Specified torque
Bolts 1.5 Nm

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5 Front heater and air conditioning unit

⇒ “5.1 Assembly overview - heater and air conditioning unit”, page
87
⇒ “5.2 Removing and installing auxiliary air heater element Z35 ”,
page 91
⇒ “5.3 Removing and installing heater and air conditioning unit”,
page 92
⇒ “5.5 Assembly overview - evaporator housing”, page 99 .
⇒ “5.6 Removing and installing evaporator”, page 100 .
⇒ “5.7 Removing and installing dust and pollen filter”, page 101
⇒ “5.8 Removing and installing fresh air blower V2 ”, page 102
⇒ “5.9 Removing and installing heat exchanger”, page 103
⇒ “5.10 Removing and installing evaporator temperature sensor
G308 ”, page 107
⇒ “5.11 Removing and installing condensation drain”, page 108
⇒ “5.12 Checking condensation drain”, page 108
⇒ “5.13 Removing and installing fresh air blower series resistor
with overheating fuse N24 ”, page 109
⇒ “5.14 Removing and installing glove box cooling”, page 110

5.1 Assembly overview - heater and air con‐

ditioning unit
⇒ “5.1.1 Assembly overview - heater and air conditioning unit,
manually controlled air conditioning system”, page 87
⇒ “5.1.2 Assembly overview - heater and air conditioning unit,
Climatronic”, page 89

5.1.1 Assembly overview - heater and air con‐

ditioning unit, manually controlled air
conditioning system

Note

♦ In some cases, it is no longer necessary on air conditioning

systems with refrigerant R1234yf to renew the desiccant bag
each time the refrigerant circuit is opened ⇒ Air conditioning
system with refrigerant R1234yf; Rep. gr. 87 ; Refrigerant cir‐
cuit; Renewing components .
♦ In some cases, it is no longer necessary on air conditioning
systems with R134a refrigerant to renew the desiccant bag
each time the refrigerant circuit is opened ⇒ Air conditioning
system with R134a refrigerant; Rep. gr. 00 ; Renewing com‐
ponents .

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1 - Temperature flap control

motor - V68-
❑ With potentiometer for
temperature flap control
motor - G92-
❑ Removing and installing
⇒ page 74
2 - Air distribution flap control
motor - V428-
❑ With potentiometer for
air distribution flap con‐
trol motor - G645-
❑ Removing and installing
⇒ page 86
3 - Distribution box
4 - Hose for glove box cooling
❑ Removing and installing
⇒ page 110
5 - Valve for glove compart‐
ment cooling
❑ Removing and installing
⇒ page 110
6 - Air recirculation flap control
motor - V113-
❑ With potentiometer for
air recirculation flap
control motor - G143-
❑ Removing and installing
⇒ page 78
7 - Seal
8 - Air intake housing
9 - Air recirculation flap
10 - Condensate drain hose with valve
❑ Removing and installing ⇒ page 108
❑ Checking ⇒ page 108
11 - Bracket
12 - Evaporator housing - upper part
❑ Dismantling and assembling evaporator housing ⇒ page 99
13 - Wiring harness for heater and air conditioning unit
14 - Evaporator housing - lower part
❑ Dismantling and assembling evaporator housing ⇒ page 99
15 - Fresh air blower - V2-
❑ Removing and installing ⇒ page 102
16 - Footwell trim panel, front passenger side
17 - Fresh air blower series resistor with overheating fuse - N24-
❑ Removing and installing ⇒ page 109
18 - Cover
❑ For dust and pollen filter
19 - Dust and pollen filter
❑ Removing and installing ⇒ page 101

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20 - Evaporator temperature sensor - G308-

❑ Removing and installing ⇒ page 107
21 - Heat exchanger
❑ Removing and installing ⇒ page 103
22 - Auxiliary air heater element - Z35-
❑ Removing and installing ⇒ page 91

Note

♦ Installed only in vehicles with

diesel engines without supple‐
mentary heater.
♦ Check using ⇒ Vehicle diagnos‐
tic tester: “Heating, ventilation,
air conditioning”; “Self-diagnosis
compatible systems”; “Auxiliary
heater”; “Electrical components”.

23 - Evaporator
❑ Removing and installing ⇒ page 100
24 - Expansion valve
❑ Removing and installing ⇒ page 30
25 - Seal

5.1.2 Assembly overview - heater and air con‐

ditioning unit, Climatronic

Note

♦ In some cases, it is no longer necessary on air conditioning

systems with refrigerant R1234yf to renew the desiccant bag
each time the refrigerant circuit is opened ⇒ Air conditioning
system with refrigerant R1234yf; Rep. gr. 87 ; Refrigerant cir‐
cuit; Renewing components .
♦ In some cases, it is no longer necessary on air conditioning
systems with R134a refrigerant to renew the desiccant bag
each time the refrigerant circuit is opened ⇒ Air conditioning
system with R134a refrigerant; Rep. gr. 00 ; Renewing com‐
ponents .

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1 - Defroster flap control motor

- V107-
❑ With potentiometer for
defroster flap control
motor - G135-
❑ Removing and installing
⇒ page 76
2 - Front air distribution flap
control motor - V426-
❑ With potentiometer for
front air distribution flap
control motor - G642-
❑ Removing and installing
⇒ page 84
3 - Left footwell vent tempera‐
ture sender - G261-
❑ Removing and installing
⇒ page 152
4 - Distribution box
5 - Right footwell vent temper‐
ature sender - G262-
❑ Removing and installing
⇒ page 153
6 - Right temperature flap con‐
trol motor - V159-
❑ With potentiometer for
right temperature flap
control motor - G221-
❑ Removing and installing
⇒ page 82
7 - Hose for glove box cooling
❑ Removing and installing
⇒ page 110
8 - Valve for glove compartment cooling
❑ Removing and installing ⇒ page 110
9 - Fresh air/air recirculation, air flow flap control motor - V425-
❑ With potentiometer for fresh air/recirculated air and air flow flap control motor - G644-
❑ Removing and installing ⇒ page 83
10 - Seal
11 - Air intake housing
12 - Fresh air/air recirculation, air flow flap
13 - Condensate drain hose with valve
❑ Removing and installing ⇒ page 108
14 - Bracket
15 - Evaporator housing - upper part
❑ Dismantling and assembling ⇒ page 99
16 - Wiring harness for heater and air conditioning unit
17 - Evaporator housing - lower part
❑ Dismantling and assembling ⇒ page 99
18 - Fresh air blower - V2-
❑ With fresh air blower control unit - J126-

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❑ Removing and installing ⇒ page 102

Note

Fresh air blower - V2- and fresh air

blower control unit - J126- comprise
one unit and can only be renewed
together ⇒ ETKA .

19 - Footwell trim panel, front passenger side

20 - Dust and pollen filter cover
21 - Dust and pollen filter
❑ Removing and installing ⇒ page 101
22 - Evaporator temperature sensor - G308-
❑ Removing and installing ⇒ page 107
23 - Heat exchanger
❑ Removing and installing ⇒ page 103
24 - Auxiliary air heater element - Z35-
❑ Removing and installing ⇒ page 91
25 - Evaporator
❑ Removing and installing ⇒ page 100
26 - Expansion valve
❑ Removing and installing ⇒ page 30
27 - Seal
28 - Left temperature flap control motor - V158-
❑ With potentiometer for left temperature flap control motor - G220-
❑ Removing and installing ⇒ page 80

5.2 Removing and installing auxiliary air

heater element - Z35-

Note

Check using ⇒ Vehicle diagnostic tester: “Heating, ventilation, air

conditioning”; “Self-diagnosis compatible systems”; “Auxiliary
heater”; “Electrical components”.

Removing
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and reconnecting battery .
– Remove driver side knee airbag ⇒ General body repairs, in‐
terior; Rep. gr. 69 ; Knee airbags; Assembly overview - knee
airbag .
– Remove footwell vent on driver side ⇒ page 133 .
– Mark installation position of positioner -1- to heater and air
conditioning unit -2-.

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– Pull positioner -1- out of heater and air conditioning unit -2-.

– Remove heat exchanger cover -1-, undo bolts -arrows- for this.

CAUTION
Risk of burns on metal surfaces of auxiliary air heater element.
The heater elements may become very hot.
Risk of burns to the skin.
– Wear protective gloves.
– Never touch the metal surfaces of the heater element.

– Disconnect connector -2- for auxiliary air heater element - Z35-

-1-.
– Pull auxiliary air heater element - Z35- out of heater and air
conditioning unit.
Installing
Install in reverse order of removal. Observe the following:

Note

Ensure that the earth wire is in proper position and bolted on cor‐
rectly.

Specified torques
♦ ⇒ “5.1 Assembly overview - heater and air conditioning unit”,
page 87
♦ Knee airbag ⇒ General body repairs, interior; Rep. gr. 69 ;
Knee airbags; Assembly overview - knee airbag .

5.3 Removing and installing heater and air

conditioning unit
Special tools and workshop equipment required

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♦ Hose clamps up to 25 mm - 3094-

♦ Torque wrench - V.A.G 1331-

♦ Engine bung set - VAS 6122-

♦ Drip tray for workshop hoist - VAS 6208-

♦ Compressed air gun

Removing
– Remove plenum chamber bulkhead ⇒ General body repairs,
exterior; Rep. gr. 50 ; Bulkhead; Assembly overview - bulk‐
head .

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– Place drip tray for workshop hoist - VAS 6208- beneath en‐
gine.
– Mark coolant hoses -2- and -3- so that they can be reconnec‐
ted to proper sides again later. The heat exchanger is de‐
signed for a certain direction of coolant flow only.
– Clamp off coolant hoses with hose clamps up to 25 mm - 3094-
-1- and -4-.

CAUTION
On a warm engine, the cooling system is under high pressure.
Danger of scalding by steam and hot coolant.
Skin and other parts of the body may be scalded.
– Wear protective gloves.
– Wear protective goggles.
– Reduce excess pressure by covering cap of coolant expan‐
sion tank with cloths and opening it carefully.

– Lift up retaining clips.

– Remove coolant hoses.
– Push a piece of hose onto upper union.
– Insert compressed air gun into end of hose.
– Place drip tray beneath lower connection, and carefully blow
coolant out of heat exchanger using compressed air gun.
– For any further work, immediately seal open lines and con‐
nections with clean plugs from engine bung set - VAS 6122- .
Vehicles with R134a refrigerant
– Drain refrigerant circuit ⇒ Air conditioning system with R134a
refrigerant; Rep. gr. 00 ; Working with air conditioner service
station .
Vehicles with R1234yf refrigerant
– Drain refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Draining refrigerant circuit .
Continued for all vehicles

CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due to
freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have passed since the refrigerant
was extracted, repeat the extraction process before opening
the refrigerant circuit. Pressure could build up in the refrig‐
erant circuit from continued evaporation.

– Unscrew bolts -1- for refrigerant lines -2- from expansion valve
-3-.

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– Carefully pull refrigerant lines -2- out of expansion valve -3-.

– Seal refrigerant lines and expansion valve using suitable
means.
– Cover carpet in area of footwell suitably.
– Remove central tube for dash panel ⇒ General body repairs,
interior; Rep. gr. 70 ; Central tube for dash panel; Removing
and installing central tube for dash panel .
– Remove condensate drain hose ⇒ page 108 .
– Remove footwell air ducts for 2nd row of seats ⇒ page 128 .
– Disconnect all connectors from heater and air conditioning
unit.

– Unscrew nuts for bracket -3- from module carrier -5-.

– Unscrew bolts from brackets -4- and -6-, and remove them
from module carrier -5-.

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Note

The following work steps must be performed by a second me‐

chanic.

– Remove heater and air conditioning unit to the side.

– Drain remains of coolant using drip tray for workshop hoist -
VAS 6208- .

96 Rep. gr.87 - Air conditioning system

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Installing
Install in reverse order of removal, observing the following:
– Ensure seal -A- seats correctly.
– Moisten new seals with refrigerant oil before installing refrig‐
erant line.

NOTICE
Risk of damage to air conditioner compressor if refrigerant cir‐
cuit is empty.
– Never start the engine if the refrigerant circuit is empty.

Vehicles with R134a refrigerant

– Charge refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00 ; Working with air conditioner
service station .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00 ; Detecting leaks in refrigerant circuit .
Vehicles with R1234yf refrigerant
– Charge refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Charging refrigerant cir‐
cuit .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning systems with refrigerant
R1234yf - general information; Rep. gr. 87 ; Refrigerant circuit;
Detecting leaks .
Continued for all vehicles
– Fill up with coolant ⇒ Rep. gr. 19 ; Cooling system/coolant;
Draining and filling coolant .
– Check operation of heater and air conditioning system.
Specified torques
♦ ⇒ “2.1 System overview - refrigerant circuit”, page 25
♦ ⇒ “5.1 Assembly overview - heater and air conditioning unit”,
page 87
♦ Central tube for dash panel; Assembly overview - central tube
for dash panel ⇒ General body repairs, interior; Rep. gr. 70 ;
Central tube for dash panel; Assembly overview - central tube
for dash panel
Component Specified torque
Nuts on module carrier -3- 9 Nm
Bolts on module carrier -4- and 9 Nm
-6-

5.4 Dismantling and assembling heater and

air conditioning unit
The following information applies to left-hand drive vehicles. A
right-hand drive vehicle is similar.

5. Front heater and air conditioning unit 97

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1 - Defroster flap control motor

- V107-
❑ With potentiometer for
defroster flap control
motor - G135-
❑ Removing and installing
⇒ page 76
2 - Front air distribution flap
control motor - V426-
❑ With potentiometer for
front air distribution flap
control motor - G642-
❑ Removing and installing
⇒ page 84
3 - Left footwell vent tempera‐
ture sender - G261-
❑ Removing and installing
⇒ page 152
4 - Distribution box
5 - Right footwell vent temper‐
ature sender - G262-
❑ Removing and installing
⇒ page 153
6 - Right temperature flap con‐
trol motor - V159-
❑ With potentiometer for
right temperature flap
control motor - G221-
❑ Removing and installing
⇒ page 82
7 - Hose for glove box cooling
❑ Removing and installing
⇒ page 110
8 - Valve for glove compartment cooling
❑ Removing and installing ⇒ page 110
9 - Fresh air/air recirculation, air flow flap control motor - V425-
❑ With potentiometer for fresh air/recirculated air and air flow flap control motor - G644-
❑ Removing and installing ⇒ page 83
10 - Seal
11 - Air intake housing
12 - Fresh air/air recirculation, air flow flap
13 - Condensate drain hose with valve
❑ Removing and installing ⇒ page 108
14 - Bracket
15 - Evaporator housing - upper part
❑ Dismantling and assembling ⇒ page 99
16 - Wiring harness for heater and air conditioning unit
17 - Evaporator housing - lower part
❑ Dismantling and assembling ⇒ page 99
18 - Fresh air blower - V2-
❑ With fresh air blower control unit - J126-

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❑ Removing and installing ⇒ page 102

Note

Fresh air blower - V2- and fresh air

blower control unit - J126- comprise
one unit and can only be renewed
together ⇒ ETKA .

19 - Footwell trim panel, front passenger side

20 - Dust and pollen filter cover
21 - Dust and pollen filter
❑ Removing and installing ⇒ page 101
22 - Evaporator temperature sensor - G308-
❑ Removing and installing ⇒ page 107
23 - Heat exchanger
❑ Removing and installing ⇒ page 103
24 - Auxiliary air heater element - Z35-
❑ Removing and installing ⇒ page 91
25 - Evaporator
❑ Removing and installing ⇒ page 100
26 - Expansion valve
❑ Removing and installing ⇒ page 30
27 - Seal
28 - Left temperature flap control motor - V158-
❑ With potentiometer for left temperature flap control motor - G220-
❑ Removing and installing ⇒ page 80

5.5 Assembly overview - evaporator hous‐

ing

Note

♦ In some cases, it is no longer necessary on air conditioning

systems with refrigerant R1234yf to renew the desiccant bag
each time the refrigerant circuit is opened ⇒ Air conditioning
system with refrigerant R1234yf; Rep. gr. 87 ; Refrigerant cir‐
cuit; Renewing components .
♦ In some cases, it is no longer necessary on air conditioning
systems with R134a refrigerant to renew the desiccant bag
each time the refrigerant circuit is opened ⇒ Air conditioning
system with R134a refrigerant; Rep. gr. 00 ; Renewing com‐
ponents .

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1 - Evaporator housing - lower

part
2 - Evaporator
❑ Check insulation. It
must be complete.
❑ Removing and installing
⇒ page 100
3 - Clip
4 - Evaporator housing - upper
part
5 - Bolt
6 - Sealing and insulation
❑ Heat insulation for ex‐
pansion valve
7 - Bracket

5.6 Removing and installing evaporator

The following information applies to left-hand drive vehicles. A
right-hand drive vehicle is similar.

Note

♦ The refrigerant must be extracted beforehand, with the air

conditioning service station .
♦ Releasing refrigerant into the environment is a punishable of‐
fence.
♦ Observe notes ⇒ page 5 .
♦ In vehicles with start-stop system, note abort conditions
⇒ page 3 .

Removing
– Remove heater and air conditioning unit ⇒ page 92 .
– Dismantling and assembling heater and air conditioner unit
⇒ page 97 .

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– Dismantling evaporator housing ⇒ page 99 .

– Pull evaporator -A- out of lower part of evaporator housing.
Installing

Note

♦ Before inserting evaporator, check condensate drain and

clean if necessary.
♦ Before inserting evaporator, clean evaporator housing and, if
necessary, evaporator.

– When inserting evaporator -A-, ensure seal -F- is not dam‐

aged.

– Before inserting evaporator, examine seal -F- (it must be bon‐

ded all around).
– Set retainer -C- and combined seal and insulation -B- on con‐
nection pipes of evaporator -D and E-.
– Insert evaporator -A- in lower part of evaporator housing as
shown in figure.

Note

♦ After assembling parts of evaporator housing, check for proper

seating of combined seal and insulation -B- at opening for both
refrigerant lines -D and E-.
♦ Check seating of retainer -C- on both refrigerant lines
-D and E- for proper seating.
♦ If heat insulation -B- is missing or improperly installed, it may
lead to reduced performance of the air conditioning system
(due to changes in the set mapped values of the expansion
valve through heat radiation).

5.7 Removing and installing dust and pollen

filter
The following information applies to left-hand drive vehicles. A
right-hand drive vehicle is similar.
Special tools and workshop equipment required
♦ Commercially available vacuum cleaner
Removing
– Remove plastic bolts -2- and remove footwell trim panel -1- on
front passenger side.

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– Release pollen filter cover -1- in -direction of arrow-.

– Pull filter element out of housing.
Installing
– Install dust and pollen filter in reverse order of removal. Ensure
filter is seated correctly.
– Install footwell trim on front passenger side.

5.8 Removing and installing fresh air blower

- V2-
The following information applies to left-hand drive vehicles. A
right-hand drive vehicle is similar.
Removing
– Remove plastic bolts -2- and remove footwell trim panel -1- on
front passenger side.
– Remove glove compartment ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments/covers; Removing and installing
glove compartment .
– Remove footwell vent on front passenger side ⇒ page 134 .
– Disconnect connector -2- from fresh air blower - V2- -1-.

CAUTION
Risk of burns when touching hot cooling surface of control unit.
Risk of burns to the hands.
– Wear protective gloves.

– Release catch -arrow A- and turn fresh air blower - V2- -1- in
-direction of arrow-.

Vehicles with manual regulation of air conditioning system

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Vehicles with Climatronic

– Remove fresh air blower - V2- -1- from heater unit.
Installing

NOTICE
Improper handling may damage the fresh air blower.
Imbalance leading to customer complaints may occur during
operation.
– Avoid applying excessive pressure to the fan wheel.
– Never change position of the balancing weights on fan
wheel.

– Install fresh air blower - V2- in reverse order. Ensure cables

are routed correctly.
Specified torques
♦ ⇒ “5.1 Assembly overview - heater and air conditioning unit”,
page 87
♦ Remove glove compartment ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments/covers; Removing and installing
glove compartment .

5.9 Removing and installing heat exchanger

Special tools and workshop equipment required
♦ Drip tray for workshop hoist - VAS 6208-

♦ Hose clamps up to 25 mm - 3094-

♦ Commercially available compressed air pistol

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♦ Engine bung set - VAS 6122-

Removing
– If necessary, remove engine cover panel ⇒ Rep. gr. 10 ; En‐
gine cover panel; Removing and installing engine cover panel .
Vehicles with TDI engine
– If necessary, remove charge air cooler connecting pipe ⇒
Rep. gr. 21 ; Charge air system; Assembly overview - charge
air system .
Continued for all vehicles
Continued for all vehicles
– Place drip tray for workshop hoist - VAS 6208- beneath en‐
gine.
– Mark coolant hoses -2- and -3- so that they can be reconnec‐
ted to proper sides again later. The heat exchanger is de‐
signed for a certain direction of coolant flow only.
– Clamp off coolant hoses with hose clamps up to 25 mm - 3094-
-1- and -4-.

CAUTION
On a warm engine, the cooling system is under high pressure.
Danger of scalding by steam and hot coolant.
Skin and other parts of the body may be scalded.
– Wear protective gloves.
– Wear protective goggles.
– Reduce excess pressure by covering cap of coolant expan‐
sion tank with cloths and opening it carefully.

– Lift up retaining clips.

– Remove coolant hoses.
– Push a piece of hose onto upper union.
– Insert compressed air gun into end of hose.
– Place drip tray beneath lower connection, and carefully blow
coolant out of heat exchanger using compressed air gun.
– Seal open lines and connections with clean plugs from engine
bung set - VAS 6122- .

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– Slightly loosen bolt -1- on connecting flange between heat ex‐

changer connections (do not unscrew it completely).
– Remove driver side knee airbag ⇒ General body repairs, in‐
terior; Rep. gr. 69 ; Knee airbags; Assembly overview - knee
airbag .
– Remove footwell vent on driver side ⇒ page 133 .
– Pull interior carpet away from centre tunnel in left-hand area.
– Mark installation position of positioner -1- to heater and air
conditioning unit -2-.

– Pull positioner -1- out of heater and air conditioning unit -2-.

– Remove heat exchanger cover -1-, undo bolts -arrows- for this.
– Cover carpet in area under heat exchanger with waterproof foil
and water absorbing paper.

CAUTION
On a warm engine, the cooling system is under high pressure.
Danger of scalding by steam and hot coolant.
Skin and other parts of the body may be scalded.
– Wear protective gloves.
– Wear protective goggles.
– Reduce excess pressure by covering cap of coolant expan‐
sion tank with cloths and opening it carefully.

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– Loosen bolts -arrows- from clamps -1- of coolant lines.

– Slowly pull coolant lines out of heat exchanger and collect
coolant that leaks out in a container.
– Loosen threaded connections of dash panel far enough that
heat exchanger can be pulled out by pulling the dash panel
back ⇒ General body repairs, interior; Rep. gr. 70 .
– Pull heat exchanger from heater and air conditioning unit.
Installing
Install in reverse order of removal. Observe the following:
– Check heater slot for dirt with heat exchanger removed.
– If necessary, remove dirt or residue of leaked coolant.
• Always renew seals.
– Carefully slide heat exchanger into heater and air conditioning
unit to stop.

Note

When sliding in the heat exchanger, make sure not to damage

the connections and coolant pipes.

– Push coolant pipes into heat exchanger as far as stop.

NOTICE
Risk of heat exchanger malfunction due to defective seals and
leaks.
– Never pinch seals.
– Never cant coolant pipes.
– Slide on coolant pipes completely.

– Check clip and screw-type clip for proper seating on connec‐

tions of heat exchanger and check coolant pipes. The coolant
pipes must not contact air distribution housing or any other
components.
Vehicles with petrol engine (1.8 and 2.0 l, 4 V, EA 888 gen 3,
turbocharger, chain drive)
– Check cooling system for irregularities listed in section “Flush‐
ing cooling system”, flush cooling system if necessary ⇒ Rep.
gr. 19 ; Cooling system/coolant; Flushing cooling system .
Vehicles with diesel engine (1.6 and 2.0 l, 4 V, turbocharger, EA
288)
Procedure for installing new heat exchanger:
– Flush cooling system ⇒ Rep. gr. 19 ; Cooling system/coolant;
Flushing cooling system .
Procedure if old heat exchanger is to remain installed:
– Check cooling system for irregularities listed in section “Flush‐
ing cooling system”, flush cooling system if necessary ⇒ Rep.
gr. 19 ; Cooling system/coolant; Flushing cooling system .
Continued for all vehicles
– Fill up with coolant ⇒ Rep. gr. 19 ; Cooling system/coolant;
Draining and filling coolant .
– Read event memory and clear any entries displayed using
⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode.

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– Check operation of heater and air conditioning system.

Specified torques
Component Specified torque
Bolts for clamps on heat ex‐ 2 Nm
changer
♦ ⇒ “5.1 Assembly overview - heater and air conditioning unit”,
page 87
♦ Turbocharger; Assembly overview - turbocharger ⇒ Rep. gr.
21 ; Turbocharger; Assembly overview - turbocharger .
♦ Centre console; Assembly overview – centre console ⇒ Gen‐
eral body repairs, interior; Rep. gr. 68 ; Centre console;
Assembly overview – centre console
♦ Knee airbags; Assembly overview - knee airbag ⇒ General
body repairs, interior; Rep. gr. 69 ; Knee airbags; Assembly
overview - knee airbag .
♦ Assembly overview - charge air system ⇒ Rep. gr. 21 ; Charge
air system; Assembly overview - charge air system

5.10 Removing and installing evaporator

temperature sensor - G308-
The following information applies to left-hand drive vehicles. A
right-hand drive vehicle is similar.
Special tools and workshop equipment required
♦ Removal wedge - 3409-

Removing
– Remove right centre console trim in footwell ⇒ General body
repairs, interior; Rep. gr. 68 ; Centre console; Assembly over‐
view - centre console .
– Disconnect connector -2- from evaporator temperature sensor
- G308- -1-.

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– Turn evaporator temperature sensor - G308- -1- 90° in

-direction of arrow- and remove it.
Installing
– Install evaporator temperature sensor - G308- in reverse order
of removal.
Specified torques
♦ Right centre console trim in footwell ⇒ General body repairs,
interior; Rep. gr. 68 ; Centre console; Assembly overview -
centre console .

5.11 Removing and installing condensation

drain
The following information applies to left-hand drive vehicles. A
right-hand drive vehicle is similar.
Removing
– Remove right centre console trim in footwell ⇒ General body
repairs, interior; Rep. gr. 68 ; Centre console; Assembly over‐
view - centre console .
– Release carpet in right footwell and pull it out until condensate
drain hose -1- is visible.
– Pull condensate drain hose -1- off heater and air conditioning
unit and body.
Installing
– Install condensate drain hose -1- in reverse order of removal,
noting the following:
♦ It must be possible to push condensate drain hose onto heater
and air conditioning unit connection without tension.
♦ Condensate drain hose must be seated securely on heater
and air conditioning unit.
♦ Condensate drain hose must not be kinked or pinched.
Specified torques
♦ Right centre console trim in footwell ⇒ General body repairs,
interior; Rep. gr. 68 ; Centre console; Assembly overview -
centre console .

5.12 Checking condensation drain

Check
– Detach underbody cladding in area of valve.

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– Check valve -2-:

♦ Must not be blocked with wax, undercoating or dirt.
♦ It must open and close properly.
– Attach underbody cladding.

5.13 Removing and installing fresh air blower

series resistor with overheating fuse -
N24-
Removing
– Remove plastic bolts -2- and remove footwell trim panel -1- on
front passenger side.

– Pull connector -1- off fresh air blower series resistor with over‐
heating fuse - N24- .

NOTICE
Risk of burns when touching the hot cooling surface on the fresh
air blower series resistor.
Risk of burns to the hands.
– Wear protective gloves.

– Press locking device in -direction of arrow- and pull fresh air

blower series resistor with overheating fuse - N24- out of heat‐
er and air conditioning unit -2-.
Installing
– Install fresh air blower series resistor with overheating fuse -
N24- in reverse order of removal.
– Install footwell trim on front passenger side.

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5.14 Removing and installing glove box cool‐

ing
Removing
– Remove glove compartment ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments/covers; Removing and installing
glove compartment .
– Pull glove compartment cooling hose -1- off valve -3-.
– Pull glove compartment cooling hose -1- off union -2- on heat‐
er and air conditioning unit.
Installing
– Install glove compartment cooling hose in reverse order of re‐
moval, noting the following:
♦ Hose fits only in one position. Recess must align with lug.
♦ Hose must not be kinked or pinched.
Specified torques
♦ Glove compartment ⇒ General body repairs, interior; Rep. gr.
68 ; Compartments/covers; Removing and installing glove
compartment .

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6 Rear heater and air conditioning unit

⇒ “6.1 Assembly overview - heater and air conditioning unit”, page
111
⇒ “6.2 Removing and installing heater and air conditioning unit”,
page 114
⇒ “6.3 Dismantling and assembling heater and air conditioning
unit”, page 118
⇒ “6.4 Removing and installing rear fresh air blower V80 ”,
page 120
⇒ “6.5 Removing and installing rear fresh air blower control unit
J391 ”, page 120
⇒ “6.6 Removing and installing heat exchanger”, page 122

6.1 Assembly overview - heater and air con‐

ditioning unit
⇒ “6.1.1 Assembly overview - heater and air conditioning unit”,
page 111
⇒ “6.1.2 Assembly overview - heater and air conditioning unit,
vehicles as of week 45/2017”, page 113

6.1.1 Assembly overview - heater and air conditioning unit

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1 - 2nd heat exchanger

❑ Removing and installing
⇒ page 122
2 - Rear vent temperature
sender - G174-
❑ Removing and installing
⇒ page 153
3 - Evaporator housing - upper
part
4 - Rear air distribution flap
control motor - V427-
❑ With potentiometer for
rear air distribution flap
control motor - G643- .
❑ Removing and installing
⇒ page 85
5 - Rear fresh air blower - V80-
❑ Removing and installing
⇒ page 120
6 - Rear temperature flap mo‐
tor - V137-
❑ With potentiometer for
rear temperature flap
control motor - G479-
❑ Removing and installing
⇒ page 79
7 - Rear fresh air blower control
unit - J391-
❑ Removing and installing
⇒ page 120
8 - Evaporator
9 - Evaporator housing - lower
part
10 - Expansion valve
❑ Removing and installing ⇒ page 32
11 - Valve for deactivating heat exchanger 2 - N317-
❑ Removing and installing ⇒ page 139

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6.1.2 Assembly overview - heater and air conditioning unit, vehicles as of week
45/2017

1 - Heat exchanger
❑ Removing and installing
⇒ page 122
2 - Rear vent temperature
sender - G174-
❑ Removing and installing
⇒ page 153
3 - Evaporator housing
❑ Upper part
4 - Rear fresh air blower control
unit - J391-
❑ Removing and installing
⇒ page 121
5 - Bolts
❑ Qty. 2
❑ 1.5 Nm
6 - Rear air distribution flap
control motor - V427-
❑ With potentiometer for
rear air distribution flap
control motor - G643- .
❑ Removing and installing
⇒ page 85
7 - Bolts
❑ Qty. 2
❑ Specified torque
⇒ page 86
8 - Rear fresh air blower - V80-
❑ Removing and installing
⇒ page 120
9 - Rear temperature flap mo‐
tor - V137-
❑ With potentiometer for rear temperature flap control motor - G479-
❑ Removing and installing ⇒ page 79
10 - Bolts
❑ Qty. 2
❑ Specified torque ⇒ page 80
11 - Coupling rod
❑ For temperature flap
12 - Evaporator
13 - Seal
14 - Bracket
15 - Expansion valve
❑ Removing and installing ⇒ page 32
16 - Bolts
❑ Qty. 2
Volkswagen Technical Site: http://vwts.ru http://vwts.info

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❑ Specified torque ⇒ page 34
17 - Guide pins
❑ Qty. 2
18 - Bolts
❑ Qty. 7
❑ 1.5 Nm
19 - Evaporator housing
❑ Lower part
20 - Valve for deactivating heat exchanger 2 - N317-
❑ Removing and installing ⇒ page 139
21 - Clamps
❑ Qty. 2
22 - Coolant hose
23 - Seal

6.2 Removing and installing heater and air

conditioning unit
Special tools and workshop equipment required
♦ Hose clamps up to 25 mm - 3094-

♦ Torque wrench - V.A.G 1331-

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♦ Engine bung set - VAS 6122-

♦ Drip tray for workshop hoist - VAS 6208-

♦ Compressed air gun

Removing
– Remove rear underbody cladding ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody cladding; Assembly over‐
view - underbody cladding .
– Remove right luggage compartment side trim ⇒ General body
repairs, interior; Rep. gr. 70 ; Luggage compartment trims;
Overview of fitting locations - luggage compartment trims .
– Drain coolant circuit ⇒ Power unit; Rep. gr. 19 .
Vehicles with R134a refrigerant
– Drain refrigerant circuit ⇒ Air conditioning system with R134a
refrigerant; Rep. gr. 00 ; Working with air conditioner service
station .
Vehicles with R1234yf refrigerant
– Drain refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Draining refrigerant circuit .

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Continued for all vehicles

CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due to
freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have passed since the refrigerant
was extracted, repeat the extraction process before opening
the refrigerant circuit. Pressure could build up in the refrig‐
erant circuit from continued evaporation.

– For any further work, immediately seal open lines and con‐
nections with clean plugs from engine bung set - VAS 6122- .
– Disconnect refrigerant lines from rear heater and air condi‐
tioner unit.

CAUTION
On a warm engine, the cooling system is under high pressure.
Danger of scalding by steam and hot coolant.
Skin and other parts of the body may be scalded.
– Wear protective gloves.
– Wear protective goggles.
– Reduce excess pressure by covering cap of coolant expan‐
sion tank with cloths and opening it carefully.

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– Remove air ducts -4-.

– Mark coolant hoses to second heat exchanger, and clamp
them off.
– Disconnect connectors -3- from rear heater and air condition‐
ing unit -1-.
– Loosen clamps -5-, and remove coolant hoses.
– Unscrew bolts -2- from rear heater and air conditioning unit
-1-.
– Unscrew nuts -6- from rear heater and air conditioning unit
-1-.
– Pull rear heater and air conditioning unit -1- towards front.
– Disconnect connectors -7- from rear heater and air condition‐
ing unit -1-.
– Remove rear heater and air conditioning unit.
Installing
Install in reverse order of removal, observing the following:
– Moisten new seals with refrigerant oil before installing refrig‐
erant line.

NOTICE
Risk of damage to air conditioner compressor if refrigerant cir‐
cuit is empty.
– Never start the engine if the refrigerant circuit is empty.

Vehicles with R134a refrigerant

– Charge refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00 ; Working with air conditioner
service station .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00 ; Detecting leaks in refrigerant circuit .
Vehicles with R1234yf refrigerant
– Charge refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Charging refrigerant cir‐
cuit .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning systems with refrigerant
R1234yf - general information; Rep. gr. 87 ; Refrigerant circuit;
Detecting leaks .
Continued for all vehicles
– Fill up with coolant ⇒ Rep. gr. 19 ; Cooling system/coolant;
Draining and filling coolant .
– Check operation of heater and air conditioning system.
Specified torques
♦ Underbody cladding; Assembly overview - underbody clad‐
ding ⇒ General body repairs, exterior; Rep. gr. 66 ; Under‐
body cladding; Assembly overview - underbody cladding .
♦ Luggage compartment trim; Overview of fitting locations - lug‐
gage compartment trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Luggage compartment trim; Overview of fitting loca‐
tions - luggage compartment trim .

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Component Specified torque

Bolts for refrigerant lines on 10 Nm
rear heater and air conditioner
unit
Bolt -2- 8 Nm
Nut -6- 5 Nm

6.3 Dismantling and assembling heater and

air conditioning unit
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331/-

♦ Hose clamps up to 25 mm - 3094-

♦ Drip tray for workshop hoist - VAS 6208-

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♦ Engine bung set - VAS 6122-

♦ Air conditioner service station

♦ Commercially available compressed air pistol
Removing
– Remove rear heater and air conditioning unit ⇒ page 114 .

1 - 2nd heat exchanger

❑ Removing and installing
⇒ page 122
2 - Rear vent temperature
sender - G174-
❑ Removing and installing
⇒ page 153
3 - Evaporator housing - upper
part
4 - Rear air distribution flap
control motor - V427-
❑ With potentiometer for
rear air distribution flap
control motor - G643- .
❑ Removing and installing
⇒ page 85
5 - Rear fresh air blower - V80-
❑ Removing and installing
⇒ page 120
6 - Rear temperature flap mo‐
tor - V137-
❑ With potentiometer for
rear temperature flap
control motor - G479-
❑ Removing and installing
⇒ page 79
7 - Rear fresh air blower control
unit - J391-
❑ Removing and installing
⇒ page 120
8 - Evaporator
9 - Evaporator housing - lower
part
10 - Expansion valve
❑ Removing and installing ⇒ page 32

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11 - Valve for deactivating heat exchanger 2 - N317-

❑ Removing and installing ⇒ page 139

– Dismantle rear heater and air conditioning unit.

Installing
– Assemble rear heater and air conditioning unit in reverse order
of removal, noting the following:
– Fill up with coolant ⇒ Rep. gr. 19 ; Cooling system/coolant;
Draining and filling coolant .
♦ Always renew seals and moisten them with refrigerant oil.
Specified torques
♦ ⇒ “6.2 Removing and installing heater and air conditioning
unit”, page 114

6.4 Removing and installing rear fresh air

blower - V80-
Removing
– Remove right luggage compartment side trim ⇒ General body
repairs, interior; Rep. gr. 70 ; Luggage compartment trims;
Overview of fitting locations - luggage compartment trims .
– Remove rear temperature flap control motor - V137-
⇒ page 79 .
– Disconnect connector -1- from rear fresh air blower - V80-
-2-.
– Pull locking device -arrow- out forwards slightly.
– Turn rear fresh air blower - V80- -2- in -direction of arrow- and
pull it out of housing.
Installing
– Install rear fresh air blower - V80- in reverse order of removal.
Specified torques
– Right luggage compartment side trim ⇒ General body repairs,
interior; Rep. gr. 70 ; Luggage compartment trims; Overview
of fitting locations - luggage compartment trims .

6.5 Removing and installing rear fresh air

blower control unit - J391-
⇒ “6.5.1 Removing and installing rear fresh air blower control unit
J391 ”, page 120
⇒ “6.5.2 Removing and installing rear fresh air blower control unit
J391 , vehicles as of week 45/2017”, page 121

6.5.1 Removing and installing rear fresh air

blower control unit - J391-
Special tools and workshop equipment required

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♦ Torque wrench - VAS 6494-

Removing
– Remove right-side luggage compartment trim ⇒ General body
repairs, interior; Rep. gr. 70 ; Luggage compartment trims;
Removing and installing side luggage compartment trims .
– Disconnect electrical connectors -2-.
– Unscrew bolts -arrows-.
– Remove fresh air blower control unit - J391- -1-.
Installing
Install in reverse order of removal, observing the following:
Specified torques
Component Specified torque
Bolts -arrows- 1.5 Nm

6.5.2 Removing and installing rear fresh air

blower control unit - J391- , vehicles as
of week 45/2017
Special tools and workshop equipment required
♦ Torque wrench - VAS 6494-

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Removing
– Remove right-side luggage compartment trim ⇒ General body
repairs, interior; Rep. gr. 70 ; Luggage compartment trims;
Removing and installing side luggage compartment trims .
– Disconnect electrical connectors -1-.
– Unscrew bolts -2-.
– Remove fresh air blower control unit - J391- -3-.
Installing
Install in reverse order of removal, observing the following:
Specified torques
♦ ⇒ “6.1.2 Assembly overview - heater and air conditioning unit,
vehicles as of week 45/2017”, page 113

6.6 Removing and installing heat exchanger

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331/-

♦ Hose clamps up to 25 mm - 3094-

♦ Drip tray for workshop hoist - VAS 6208-

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♦ Engine bung set - VAS 6122-

♦ Air conditioner service station

♦ Commercially available compressed air pistol
Removing
– Remove rear underbody cladding ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody cladding; Assembly over‐
view - underbody cladding .
– Remove right luggage compartment side trim ⇒ General body
repairs, interior; Rep. gr. 70 ; Luggage compartment trims;
Overview of fitting locations - luggage compartment trims .
– Drain coolant circuit ⇒ Power unit; Rep. gr. 19 .
– Extract refrigerant with air conditioning service station .

CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due to
freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have passed since the refrigerant
was extracted, repeat the extraction process before opening
the refrigerant circuit. Pressure could build up in the refrig‐
erant circuit from continued evaporation.

– Disconnect refrigerant lines from rear heater and air condi‐

tioner unit.

CAUTION
On a warm engine, the cooling system is under high pressure.
Danger of scalding by steam and hot coolant.
Skin and other parts of the body may be scalded.
– Wear protective gloves.
– Wear protective goggles.
– Reduce excess pressure by covering cap of coolant expan‐
sion tank with cloths and opening it carefully.

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– Remove air ducts -4-.

– Mark coolant hoses to second heat exchanger, and clamp
them off.
– Disconnect connectors -3- from rear heater and air condition‐
ing unit -1-.
– Loosen clamps -5-, and remove coolant hoses.
– Unscrew bolts -2- from rear heater and air conditioning unit
-1-.
– Unscrew nuts -6- from rear heater and air conditioning unit
-1-.
– Pull rear heater and air conditioning unit -1- towards front.
– Disconnect connectors -7- from rear heater and air condition‐
ing unit -1-.
– Pull out rear heater and air conditioning unit to ease access to
second heat exchanger.
– Press in tabs on housing and pull out second heat exchanger.
Installing
– Install 2nd heat exchanger in reverse order of removal. Note
the following:
– Fill up with coolant ⇒ Rep. gr. 19 ; Cooling system/coolant;
Draining and filling coolant .
♦ Always renew seals and moisten them with refrigerant oil.
Specified torques
♦ Underbody cladding ⇒ General body repairs, exterior; Rep.
gr. 66 ; Underbody cladding; Assembly overview - underbody
cladding .
– Right luggage compartment side trim ⇒ General body repairs,
interior; Rep. gr. 70 ; Luggage compartment trims; Overview
of fitting locations - luggage compartment trims .
Component Specified torque
Bolts for refrigerant lines on 10 Nm
rear heater and air conditioner
unit
Bolt -2- 8 Nm
Nut -6- 5 Nm

124 Rep. gr.87 - Air conditioning system

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7 Air duct
⇒ “7.1 Assembly overview - air duct and air distribution in pas‐
senger compartment”, page 125
⇒ “7.2 Removing and installing air ducts”, page 126
⇒ “7.3 Removing and installing forced ventilation for passenger
compartment”, page 131
⇒ “7.4 Checking forced ventilation for passenger compartment”,
page 132
⇒ “7.5 Removing and installing fresh air intake”, page 132
⇒ “7.6 Removing and installing driver side footwell vents”,
page 133
⇒ “7.7 Removing and installing front passenger side footwell
vents”, page 134
⇒ “7.8 Removing and installing long rear vent”, page 135
⇒ “7.9 Removing and installing short rear vent”, page 135
⇒ “7.10 Removing and installing footwell vents for 3rd row of
seats”, page 136

7.1 Assembly overview - air duct and air distribution in passenger compartment

1 - Side vent air duct - driver

side
❑ Removing and installing
⇒ page 126
2 - Windscreen air distribution
❑ To remove, dash panel
must be removed.
3 - Side vent air duct - front
passenger side
❑ Removing and installing
⇒ page 126
4 - Centre vent air duct
❑ Removing and installing
⇒ page 126
5 - Footwell vent air duct - right
side, 2nd row of seats
❑ Removing and installing
⇒ page 128
6 - Rear right vent air duct
❑ Removing and installing
⇒ page 127
7 - Air distribution to rear left
passenger compartment vent
air duct
8 - Rear heater and air condi‐
tioning unit connection to
headliner air duct
❑ Removing and installing
⇒ page 131

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9 - 2nd heater and air conditioning unit - rear

10 - Footwell vent air duct - 3rd row of seats
❑ Removing and installing ⇒ page 130
11 - Rear left vent air duct
❑ Removing and installing ⇒ page 127
12 - Footwell vent air duct - left side, 2nd row of seats
❑ Removing and installing ⇒ page 128

7.2 Removing and installing air ducts

⇒ “7.2.1 Removing and installing side vent air ducts”, page 126
⇒ “7.2.2 Removing and installing centre vent air duct”,
page 126
⇒ “7.2.3 Removing and installing rear air ducts”, page 127
⇒ “7.2.4 Removing and installing footwell vent air ducts for 2nd
row of seats”, page 128
⇒ “7.2.5 Removing and installing footwell vent air ducts for 3rd
row of seats”, page 130
⇒ “7.2.6 Removing and installing air ducting from rear heater and
air conditioning unit to moulded headliner”, page 131

7.2.1 Removing and installing side vent air

ducts
Removing
– Remove dash panel ⇒ General body repairs, interior; Rep. gr.
70 ; Dash panel; Removing and installing dash panel .
– Place dash panel down on a padded surface.
– Unscrew bolts -1-.
– Remove air ducts -2-.
Installing
– Install air duct in reverse order of removal.
– The remaining installation steps are carried out in the reverse
order of removal.
Specified torques
♦ Dash panel ⇒ General body repairs, interior; Rep. gr. 70 ;
Dash panel; Removing and installing dash panel
Component Specified torque
Bolts 1.5 Nm

7.2.2 Removing and installing centre vent air

duct
Removing
– Remove dash panel centre storage compartment ⇒ General
body repairs, interior; Rep. gr. 68 ; Compartments/covers;
Overview of fitting locations - compartments/covers .
– Pull air duct -1- off centre vent -2- and heater and air condi‐
tioning unit.

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– Take air duct -1- upwards out of opening.

Installing
– Install air duct in reverse order of removal, ensuring correct
seating on centre vent and heater and air conditioning unit.
– The remaining installation steps are carried out in the reverse
order of removal.
Specified torques
♦ Dash panel centre storage compartment ⇒ General body re‐
pairs, interior; Rep. gr. 68 ; Compartments/covers; Overview
of fitting locations - compartments/covers .

7.2.3 Removing and installing rear air ducts

Note

The air ducts are bonded to the moulded headliner.

Removing
– Remove moulded headliner ⇒ General body repairs, interior;
Rep. gr. 70 ; Roof trims; Removing and installing moulded
headliner .
– Place moulded headliner down on a clean and padded sur‐
face.
– Mark installation position of air ducts -1-, -2- and -3- on moul‐
ded headliner.
– Carefully detach air ducts -1-, -2- and -3- from moulded head‐
liner using suitable workshop equipment, and remove them.

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Installing
– Secure air ducts to moulded headliner using commercially
available hot melt glue gun.
– The remaining installation steps are carried out in the reverse
order of removal.
Specified torques
♦ Moulded headliner ⇒ General body repairs, interior; Rep. gr.
70 ; Roof trims; Removing and installing moulded headliner .

7.2.4 Removing and installing footwell vent air ducts for 2nd row of seats
Removing
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and reconnecting battery .
– Remove front passenger and driver seats ⇒ General body
repairs, interior; Rep. gr. 72 ; Front seats; Removing and in‐
stalling front seat .
– Remove centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console; Assembly overview - centre console .
– Release carpet in footwell.

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– Fold carpet back, to rear, until the air ducts are completely
visible.
– Detach air ducts -1- and -2- from floor, and pull them off heater
and air conditioning unit.

Installing
– Fit air ducts (angled slightly) on heater and air conditioning
unit.
– Clip air ducts onto floor.
– Check air ducts are seated correctly on heater and air condi‐
tioning unit.
– The remaining installation steps are carried out in the reverse
order of removal.
Specified torques
♦ Front passenger and driver seats ⇒ General body repairs,
interior; Rep. gr. 72 ; Front seats; Removing and installing
front seat .
♦ Centre console ⇒ General body repairs, interior; Rep. gr. 68 ;
Centre console; Assembly overview - centre console

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7.2.5 Removing and installing footwell vent air ducts for 3rd row of seats
Removing
– Remove left and right luggage compartment side trims ⇒
General body repairs, interior; Rep. gr. 70 ; Luggage com‐
partment trims; Overview of fitting locations - luggage com‐
partment trims .
– Remove footwell vents for 3rd row of seats ⇒ page 136 .
– Pull carpet away slightly and fold back.
– Pull connecting piece -1- off 2nd heater and air conditioning
unit -2- and air duct -5-.
– Unscrew bolt -4- on left and right.
– Unclip air duct -5- from floor -3- (2 clips).
– Remove air duct -5-.

Installing
– Install air duct and connecting piece, ensure air ducts are clip‐
ped correctly.

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– Check that connecting piece is seated correctly on 2nd heater

and air conditioning unit and air duct.
– The remaining installation steps are carried out in the reverse
order of removal.
Specified torques
Component Specified torque
Bolt 3 Nm
♦ Left and right luggage compartment side trims ⇒ General body
repairs, interior; Rep. gr. 70 ; Luggage compartment trims;
Overview of fitting locations - luggage compartment trims .

7.2.6 Removing and installing air ducting from

rear heater and air conditioning unit to
moulded headliner
Removing
– Remove right luggage compartment side trim ⇒ General body
repairs, interior; Rep. gr. 70 ; Luggage compartment trims;
Overview of fitting locations - luggage compartment trims .
– Pull air duct -1- off 2nd heater and air conditioning unit -2- and
moulded headliner.
Installing
– Install air duct, ensuring correct seating on 2nd heater and air
conditioning unit and moulded headliner.
– The remaining installation steps are carried out in the reverse
order of removal.
Specified torques
♦ Right luggage compartment side trim ⇒ General body repairs,
interior; Rep. gr. 70 ; Luggage compartment trims; Overview
of fitting locations - luggage compartment trims .

7.3 Removing and installing forced ventila‐

tion for passenger compartment
Special tools and workshop equipment required
♦ Removal wedge - 3409-

Removing
– Remove rear bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Rear bumper; Removing and installing bumper
cover .

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– Unclip ventilation outlet -1- from side panel -2- using removal
wedge - 3409- .
Installing
Install in reverse order of removal.
– Clip ventilation outlet audibly into side panel.
Specified torques
♦ Rear bumper; Assembly overview - rear bumper ⇒ General
body repairs, exterior; Rep. gr. 63 ; Rear bumper; Assembly
overview - bumper cover .

7.4 Checking forced ventilation for passen‐

ger compartment
Check

Note

♦ The stale air escapes via ventilation outlets in the luggage

compartment trim.
♦ The ventilation openings must not be covered if the ventilation
is to function properly.
♦ The ventilation frames are located in the rear side panels be‐
hind the bumper.

The ventilation can be checked through the luggage compart‐

ment.
Additional units may have to be removed.
– Sealing lips in ventilation frames -1- on both sides of vehicle
must be free to move and close autonomously.

7.5 Removing and installing fresh air intake

The following information applies to left-hand drive vehicles. A
right-hand drive vehicle is similar.
Removing
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Plenum chamber cover; Removing and
installing plenum chamber cover .
Vehicles with Climatronic
– Remove air quality sensor - G238- ⇒ page 150 .
Continued for all vehicles
– Loosen nuts -2-.

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– Remove fresh air intake -1- from plenum chamber.

Installing
– Install fresh air intake in reverse order.
Vehicles with Climatronic
– Install air quality sensor - G238- ⇒ page 150 .
Continued for all vehicles
– Install right plenum chamber cover ⇒ General body repairs,
exterior; Rep. gr. 50 ; Bulkhead; Removing and installing ple‐
num chamber cover .
Specified torques
♦ Install plenum chamber cover ⇒ General body repairs, exte‐
rior; Rep. gr. 50 ; Plenum chamber bulkhead; Removing and
installing plenum chamber cover
Component Specified torque
Nut 3.5 Nm

7.6 Removing and installing driver side foot‐

well vents
Special tools and workshop equipment required
♦ Removal wedge - 3409-

Removing
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and reconnecting battery .
– Remove driver side knee airbag ⇒ General body repairs, in‐
terior; Rep. gr. 69 ; Knee airbags; Assembly overview - knee
airbag .
– Remove footwell trim panel on driver side ⇒ General body
repair, interior; Rep. gr. 70 .
– Remove bolt -1- (1.5 Nm).

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– Pull footwell vent -2- off heater and air conditioning unit in
-direction of arrow-.
Installing
– Install footwell vents in reverse order of removal, ensuring
correct seating on heater and air conditioning unit.
– Install knee airbag ⇒ General body repair, interior; Rep. gr.
69 .
– Install footwell trim panel on driver side ⇒ General body repair,
interior; Rep. gr. 70 .
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and reconnecting battery .

7.7 Removing and installing front passenger

side footwell vents
Special tools and workshop equipment required
♦ Removal wedge - 3409-

Removing
– Remove plastic bolts -2- and remove footwell trim panel -1- on
front passenger side.

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– Remove glove compartment ⇒ General body repairs, interior;

Rep. gr. 68 ; Compartments/covers; Removing and installing
glove compartment .
– Remove bolt -2- (1.5 Nm).
– Pull footwell vent -1- off heater and air conditioning unit in
-direction of arrow-.
Installing
– Install footwell vents in reverse order of removal, ensuring
correct seating on heater and air conditioning unit.
– Remove glove compartment ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments/covers; Removing and installing
glove compartment .
– Install footwell trim panel on front passenger side ⇒ General
body repair, interior; Rep. gr. 70 .

7.8 Removing and installing long rear vent

Special tools and workshop equipment required
♦ Removal wedge - 3409-

Removing
– Remove bolt -2- (20 Nm).
– Pull rear vent -1- out of headliner.
Installing
– Install rear vent in reverse order of removal.

7.9 Removing and installing short rear vent

Special tools and workshop equipment required

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♦ Removal wedge - 3409-

Removing
– Unclip rear vent -1- from headliner using removal wedge -
3409- .
Installing
– Clip rear vent into headliner.

7.10 Removing and installing footwell vents

for 3rd row of seats
Special tools and workshop equipment required
♦ Removal wedge - 3409-

Removing
– Slide 2nd row of seats as far forwards as possible.

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– Unclip rear footwell vent -2- from air duct -1- using removal
wedge - 3409- .
Installing
– Clip footwell vent into air duct.

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8 Coolant circuit
⇒ “8.1 Checking 2nd heat exchanger switch-off valve N317 ”,
page 138
⇒ “8.2 Removing and installing 2nd heat exchanger switch-off
valve N317 ”, page 139

8.1 Checking 2nd heat exchanger switch-off

valve - N317-
Special tools and workshop equipment required
♦ Vehicle diagnostic tester
♦ Hand multimeter - V.A.G 1526 E-

Check
– Using ⇒ Vehicle diagnostic tester, select the data bus diag‐
nostic interface - J533- via Guided fault finding.
– Select the function “Switch transport mode on/off” and set ve‐
hicle to transport mode.
– Switch off ignition (terminal 15).
– The Climatronic control unit - J255- switches off immediately
and the 2nd heat exchanger switch-off valve - N317- opens.

Note

A second mechanic is needed to listen for the opening of the 2nd

heat exchanger switch-off valve - N317- .

– Switch on ignition (terminal 15).

– The Climatronic control unit - J255- switches on and the 2nd
heat exchanger switch-off valve - N317- closes.
– Check actuation of 2nd heat exchanger switch-off valve -
N317- using hand multimeter - V.A.G 1526 E- according to
⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations; if necessary, repair the wiring connection using wiring
harness repair set - VAS 1978 B- .
– If noticeable noises such as clicking or chattering can be heard
from 2nd heat exchanger switch-off valve - N317- during op‐
eration, or there is no sound at all (if valve is stuck in closed
position), then 2nd heat exchanger switch-off valve - N317-
must be renewed.
– After renewing valve, repeat test.
– Deactivate transport mode.

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8.2 Removing and installing 2nd heat ex‐

changer switch-off valve - N317-
Special tools and workshop equipment required
♦ Hose clamps up to 25 mm - 3094-

♦ Drip tray for workshop hoist - VAS 6208-

♦ Air conditioner service station

Removing
– Remove rear heater and air conditioning unit ⇒ page 114 .
– Release clamp -2-, and pull coolant hose off rear heater and
air conditioning unit.
Installing
– Install 2nd heat exchanger switch-off valve - N317- in reverse
order of removal.
– Replenish coolant and bleed cooling system ⇒ Power unit;
Rep. gr. 19 .
Specified torques
♦ Rear heater and air conditioning unit
⇒ “6.2 Removing and installing heater and air conditioning
unit”, page 114 .
The 2nd heat exchanger switch-off valve - N317- is not capable
of diagnosis.

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9 Operating and display unit

⇒ “9.1 Overview of operating and display unit”, page 140
⇒ “9.2 Removing and installing operating and display unit”, page
145

9.1 Overview of operating and display unit

⇒ “9.1.1 Overview of control and display unit, air conditioning
system with electric/manual controls”, page 140
⇒ “9.1.2 Overview of operating and display unit, Climatronic”,
page 142
⇒ “9.1.3 Overview of operating and display unit, rear”,
page 145

9.1.1 Overview of control and display unit, air

conditioning system with electric/man‐
ual controls

Note

♦ A warning lamp in the instrument panel controls will indicate

that the selected function is active.
♦ If the indicator lamp does not light up after the A/C button is
pressed, a fault may be stored in the control unit. Read the
event memory using the ⇒ Vehicle diagnostic tester. If the en‐
try “Compressor first run not performed” is stored in the event
memory, a “Compressor first run” adaptation must be carried
out in Guided Fault Finding or Guided Functions.

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1 - AC button
❑ If the A/C button is de‐
activated, the air condi‐
tioner compressor will
be set to almost zero de‐
livery.
2 - Heated rear window button
❑ Depending on ambient
temperature, rear win‐
dow heating will remain
on from 4 to 20 minutes.
3 - Button for heated wind‐
screen or instant heating -
E537-
❑ Depending on equip‐
ment
4 - Air recirculation button

Note

♦ Air recirculation mode changes

to fresh air mode when ignition is
switched off.
♦ In vehicles for Japanese market,
“air recirculation mode” remains
unchanged when ignition is
switched off.

5 - Rotary knob for setting air

distribution
6 - Heated front passenger
seat regulator - E95- (optional)
❑ The seat heater has 3
heat settings. Current
setting is shown by LED.
❑ If no LED is lit, seat heating is switched off.
7 - Display for blower speed
8 - Rotary knob for setting blower speed
❑ Anticlockwise: reduces blower speed
❑ Clockwise: increases speed
9 - Rotary knob for setting temperature
❑ Anticlockwise: lowers temperature
❑ Clockwise: increases temperature
10 - Heated driver seat regulator - E94- (optional)
❑ The seat heater has 3 heat settings. Current setting is shown by LED.
❑ If no LED is lit, seat heating is switched off.

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9.1.2 Overview of operating and display unit,

Climatronic

Note

♦ A warning lamp in the instrument panel controls will indicate

that the selected function is active. In addition, the display of
the radio or of the radio navigation system will indicate the
selected function for a short time when a button is pressed or
a regulator is operated.
♦ You can switch between °C and °F in the radio or radio navi‐
gation system display via the main menu in the dash panel
insert. Press rocker switch in windscreen wiper lever (or in
multifunction steering wheel) to call up main menu. Then, se‐
lect Settings, Units and Temperature.
♦ If new heater and air conditioning controls - EX21- with Cli‐
matronic control unit - J255- is installed, the basic setting and
an adaptation (“Compressor first run”) must be carried out in
the “Guided fault finding” or in the “Guided functions”.
♦ On vehicles with start/stop system, note abort conditions.
♦ If the indicator lamp does not light up after the AC button is
pressed, a fault may be stored in the control unit. Read the
event memory using the ⇒ Vehicle diagnostic tester. If the
event entry “Compressor first run not performed” is stored, an
adaption (“Compressor first run”) must be carried out in the
"Guided Fault Finding".
♦ Pressing the AUTO button will cancel all settings which deviate
from automatic mode.
♦ Deviations from automatic mode ⇒ respective operating in‐
structions.
♦ OFF button activated, Climatronic out of operation. There is no
heating and ventilation.
♦ OFF button deactivated, Climatronic in operation.
♦ A/C button activated, air conditioner compressor switched on.
The heating and ventilation operations continue to be control‐
led electronically.
♦ A/C button deactivated, air conditioner compressor will be
switched to almost zero delivery. The heating and ventilation
operations continue to be controlled electronically.

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1 - Left temperature indicator

❑ Indicates temperature
setting on driver side.
2 - Button for left seat heating
- E653-
❑ Optional
❑ The seat heater has 3
heat settings. Current
setting is shown by LED.
❑ If no LED is lit, seat heat‐
ing is switched off.
3 - Windscreen air distribution
button
❑ LED lights up when set‐
tings are active.
4 - Centre air distribution but‐
ton
❑ Air distributed to upper
body via middle vents.
❑ LED lights up when set‐
tings are active.
5 - Lower air distribution button
❑ Air distributed to foot‐
well.
❑ LED lights up when set‐
tings are active.
6 - Air recirculation button
❑ LED lights up when set‐
tings are active.
❑ Manual and automatic
air recirculation mode.
❑ Pressing the air recircu‐
lation button will prevent
polluted air from entering the interior.
Air recirculation is switched on automatically under the following conditions:

• if the windscreen washer system is operated,

• if the air quality sensor - G238- is active;
• if the reverse gear is engaged (this function is active only for the first 2 minutes after starting engine);
• when the blower speed on heater and air conditioning controls - EX21- is off;
• if the heater and air conditioning controls - EX21- are “OFF”.
7 - Button for right seat heating - E654-
❑ Optional
❑ The seat heater has 3 heat settings. Current setting is shown by LED.
❑ If no LED is lit, seat heating is switched off.
8 - Right temperature indicator
❑ Indicates temperature setting on front passenger side.
9 - Max A/C or REST button
❑ Max A/C
❑ LED lights up when settings are active.
❑ Air conditioning system is operated with maximum cooling output.
❑ REST

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❑ Push REST to use the residual heat. If the engine is hot and the ignition is switched off, the residual heat
of the engine is used to heat the vehicle interior. If this function is activated, the indicator lamp in the
REST button lights up. This function is switched off automatically after 30 minutes or if the charge level
of the vehicle battery is low.
10 - A/C button
❑ LED lights up when settings are active.
❑ If the A/C button is deactivated, the air conditioner compressor will be set to almost zero delivery. If the
AUTO button is activated, heating and ventilation mode will continue to be controlled electronically.

11 - Rotary knob for setting right temperature

❑ Set temperature is indicated in display.
12 - Sync button
❑ LED lights up when settings are active.
❑ Synchronisation of climate zones to driver value.
13 - Reduce blower speed
❑ Display only, no function.
14 - AUTO function button
❑ LED lights up when settings are active.
❑ In automatic mode, the Climatronic maintains the selected interior temperature automatically. With this
setting, the vent air temperature, the blower speed and the air distribution are controlled automatically.
15 - SETUP or REAR button
❑ When SETUP button is pressed, the menu for setting e.g. recirculation mode, auxiliary heater mode etc.
is displayed.
❑ Press the REAR button to control the air conditioning system settings for the rear seats from the front. If
this function is activated, the indicator lamp in the REAR button lights up. The settings for the rear seats
are shown on the displays. Press the button again or do not press any button for 10 seconds to switch
off the function.
16 - Rotary knob for blower adjustment
❑ Turning the rotary knob enables individual adjustment of the blower speed.
❑ If the fan speed is changed individually, the AUTO function is deactivated automatically.
17 - Increase blower speed
❑ Display only, no function.
18 - Immediate heating button for switching auxiliary/supplementary heater ON/OFF or OFF button for switching
air conditioning system ON/OFF
❑ Depending on equipment
❑ OFF button activated, Climatronic out of operation. There is no heating and ventilation.
19 - Max. defrost function button
❑ Air drawn in from the outside is channelled to the windscreen and air recirculation mode, if activated, is
automatically switched off.
❑ To demist the windscreen as quickly as possible, the air is dried at temperatures above approx. +1.5°C
(35°F). The air conditioner compressor is switched on and the blower is set to a high speed.
20 - Heated rear window button
❑ LED lights up when settings are active.
❑ Works only while engine is running and switches off automatically after 10 minutes at the latest.
21 - Rotary knob for setting left temperature
❑ Set temperature is indicated in display.

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9.1.3 Overview of operating and display unit, rear

1 - Centre air distribution but‐

ton
❑ LED lights up when set‐
tings are active.
2 - AUTO function button
❑ In automatic mode, the
Climatronic maintains
the selected interior
temperature automati‐
cally. With this setting,
the vent air tempera‐
ture, the blower speed
and the air distribution
are controlled automati‐
cally.
3 - Lower air distribution button
❑ LED lights up when set‐
tings are active.
4 - Display for set blower speed
❑ Selected blower speed
is illuminated.
5 - Rotary knob for setting
blower speed
6 - Display for set temperature
❑ Selected temperature is
illuminated.
7 - Rotary knob for setting tem‐
perature

9.2 Removing and installing operating and

display unit
⇒ “9.2.1 Removing and installing operating and display unit,
front”, page 145
⇒ “9.2.2 Removing and installing rear operating and display unit”,
page 146

9.2.1 Removing and installing operating and

display unit, front
Special tools and workshop equipment required

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♦ Removal wedge - 3409-

Note

♦ If a new Climatronic control unit - J255- or air conditioning

system control unit - J301- is installed, the function "Renew
control unit", the basic setting and an adaption (“Compressor
first run”) must be carried out in the "Guided Fault Finding" or
in the "Guided Functions".
♦ The picture shows a vehicle with Climatronic. The removal and
installation for vehicles with manual electronic air conditioning
is identical.

Removing
– Remove trim for operating and display unit ⇒ General body
repairs, interior; Rep. gr. 68 ; Compartments/covers; Over‐
view of fitting locations - compartments/covers .
– Unscrew bolts -1- from operating and display unit -2-.
– Disconnect connectors, and remove operating and display unit
-2- from dash panel.
Installing
– Install operating and display unit in reverse order of removal.
– After installing a new operating and display unit, check control
unit code using ⇒ Vehicle diagnostic tester; in “Guided fault
finding” mode.
Specified torques
Component Specified torque
Bolts 1.5 Nm
♦ Trim for operating and display unit ⇒ General body repairs,
interior; Rep. gr. 68 ; Compartments/covers; Overview of fit‐
ting locations - compartments/covers .

9.2.2 Removing and installing rear operating

and display unit
Special tools and workshop equipment required

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♦ Removal wedge - 3409-

Note

If a new operating and display unit for rear air conditioning system
- E265- is installed, the function “Renew control unit” as well as
the “Basic setting” must be performed in the Guided Fault Finding
or in the Guided Functions.

Removing
– Remove trim for rear centre console ⇒ General body repairs,
interior; Rep. gr. 68 ; Centre console; Removing and installing
trim for rear centre console .
– Separate electrical connector -3-.
– Press locking lugs -arrows-downwards slightly.
– Pull lower part of operating and display unit for rear air condi‐
tioning system - E265- -1- out forwards. Then unclip upper part
out of centre console trim -2-.
Installing
– Install operating and display unit for rear air conditioning sys‐
tem - E265- in reverse order of removal. Ensure locking devi‐
ces are seated correctly.
Specified torques
♦ Trim for rear centre console ⇒ General body repairs, interior;
Rep. gr. 68 ; Centre console; Removing and installing trim for
rear centre console .

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10 Other controlling and regulating com‐

ponents
⇒ “10.1 Removing and installing sunlight penetration photosensor
G107 ”, page 148
⇒ “10.2 Principle of operation of air quality sensor G238 ”,
page 149
⇒ “10.3 Removing and installing air quality sensor G238 ”,
page 150
⇒ “10.4 Removing and installing ambient temperature sensor G17
”, page 151
⇒ “10.5 Removing and installing left vent temperature sender
G150 ”, page 151
⇒ “10.6 Removing and installing right vent temperature sender
G151 ”, page 152
⇒ “10.7 Removing and installing left footwell vent temperature
sender G261 ”, page 152
⇒ “10.8 Removing and installing right footwell vent temperature
sender G262 ”, page 153
⇒ “10.9 Removing and installing rear vent temperature sender
G174 ”, page 153

10.1 Removing and installing sunlight pene‐

tration photosensor - G107-
Special tools and workshop equipment required
♦ Removal wedge - 3409-

Removing
– Unclip sunlight penetration photosensor - G107- from dash
panel -1- using removal wedge - 3409- at positions shown
-arrows-.
– Disconnect connector from sunlight penetration photosensor
- G107- -2-.
Installing
– Install sunlight penetration photosensor - G107- in reverse or‐
der of removal.

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10.2 Principle of operation of air quality sen‐

sor - G238-
The air quality sensor - G238- detects pollutants in the air and
sends the respective signals to the Climatronic control unit . The
Climatronic control unit actuates the air conditioning system de‐
pending on the degree, type and concentration of pollutant.
The air quality sensor - G238- requires approx. 30 seconds to
become operational once the ignition has been switched on. The
air quality sensor sends no signals within this period.
Automatic air recirculation
The Climatronic control unit switches to the automatic air recir‐
culation mode according to the ambient temperature:
♦ At an ambient temperature higher than approx. +2 °C, the Cli‐
matronic control unit switches to air recirculation mode even
when there is a minimal increase in noxious substances.
♦ At ambient temperatures between approx. +2 °C and ap‐
prox. -5 °C, the Climatronic control unit switches to air recir‐
culation mode only when noxious substances in the ambient
air increase significantly. It simultaneously switches on the air
conditioner compressor.
♦ At ambient temperatures lower than approx. -5 ℃ as well, the
Climatronic control unit switches to air recirculation mode only
when noxious substances in the ambient air increase signifi‐
cantly. When the concentration reduces the Climatronic con‐
trol unit switches the air conditioning system back to the fresh
air mode. The operation of the air conditioner compressor is
not possible.
When the air conditioner compressor is switched off ( AC button
off), the Climatronic control unit - J255- limits the operation of the
air recirculation mode to approx. 15 s to prevent the windows from
fogging. To clear condensation from windows as quickly as pos‐
sible, the Climatronic control unit does not permit air recirculation
when the “defrost function” is activated.
The “automatic recirculation mode” can be switched off at any
time.
Adaptation of air quality sensor - G238- to environmental condi‐
tions
So that the air conditioning system does not operate continually
in air recirculation mode in areas with consistently high levels of
noxious substances in the ambient air, the "intelligent" air quality
sensor - G238- adapts its sensitivity to the prevailing environ‐
mental pollution. Therefore, when the concentration of noxious
substances remains relatively high over a longer period, the air
quality sensor - G238- adapts its sensitivity to the changed envi‐
ronmental conditions through a learning function. As a result, the
recirculated air request in a uniformly polluted environment gen‐
erally lasts less than 12 minutes. The air conditioning system may
run in the air recirculation mode over longer periods when a series
of peaks in the pollutant level occurs.
Dust and pollen filter
The fresh air and recirculated air flap requires a certain amount
of time to switch positions. To prevent a sudden increase in nox‐
ious substances from entering the passenger compartment while
the flaps are closing (e.g. when driving through a cloud of diesel
smoke), a dust and pollen filter with an activated charcoal layer
is installed. In order to avoid a too frequent switching of the fresh
air and recirculated air flap the Climatronic control unit does not
react immediately to a slight rise in concentration of noxious sub‐
stances. The filtering action of the activated charcoal layer in the
dust and pollen filter is adequate for this. In addition, a request

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from the air quality sensor - G238- lasts at least 25 seconds. This
also applies when the concentration of noxious substances in the
air has reduced to a level where the air recirculation mode is no
longer required. A dust and pollen filter saturated with pollutants
must be renewed.

Note

The air quality sensor - G238- is a highly sensitive electronic

component which could be destroyed by direct contact with sol‐
vents, fuels and certain chemical compounds. Never install sen‐
sors that have come into contact with such substances.

10.3 Removing and installing air quality sen‐

sor - G238-
The following information applies to left-hand drive vehicles. A
right-hand drive vehicle is similar.

Note

♦ The air quality sensor - G238- is installed on the front right (in
direction of travel) of the air intake grille in the plenum cham‐
ber.
♦ The air quality sensor - G238- is a highly sensitive electronic
component which could be destroyed by direct contact with
solvents, fuels and certain chemical compounds.
♦ Do not install a sensor that has been kept e.g. in a tool box.
♦ Do not place a removed sensor in an area where it can come
into contact with solvents, fuels and certain chemical com‐
pounds.
♦ The air quality sensor - G238- is installed only in vehicles with
Climatronic.

Removing
– Remove right plenum chamber cover ⇒ General body repairs,
exterior; Rep. gr. 50 ; Plenum chamber bulkhead; Removing
and installing plenum chamber cover .
– Disconnect connector -2- from air quality sensor - G238- -1-.
– Turn air quality sensor - G238- 90° in -direction of arrow- and
pull it out of retainer.
Installing
– Install air quality sensor - G238- in reverse order of removal.
Specified torques
♦ Right plenum chamber cover ⇒ General body repairs, exteri‐
or; Rep. gr. 50 ; Plenum chamber bulkhead; Removing and
installing plenum chamber cover

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10.4 Removing and installing ambient tem‐

perature sensor - G17-
Removing

Note

Removal and assembly are carried out through the air inlet in the
bumper.

– Disconnect connector from ambient temperature sensor -

G17- -1-.
– Unhook retaining lug -arrow A- from bracket using a suitable
tool.
– Pull ambient temperature sensor - G17- -1- out of retainer
downwards in -direction of arrow-.
Installing
– Install in reverse order of removal.

10.5 Removing and installing left vent tem‐

perature sender - G150-
The following information applies to left-hand drive vehicles. A
right-hand drive vehicle is similar.
Special tools and workshop equipment required
♦ Vehicle diagnostic tester

Note

Removal of the right side is described. Removal of the left side is

similar.

Removing
– Remove dash panel end cover ⇒ General body repairs, inte‐
rior; Rep. gr. 70 ; Dash panel; Removing and installing dash
panel end cover .
– Separate electrical connector -3-.
– Turn vent temperature sender -2- 90° in -direction of arrow-
and pull it out of air duct -1-.
Installing
– Install vent temperature sender in reverse order of removal.
Specified torques
♦ Dash panel end cover ⇒ General body repairs, interior; Rep.
gr. 70 ; Dash panel: Removing and installing dash panel end
cover .

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10.6 Removing and installing right vent tem‐

perature sender - G151-
The following information applies to left-hand drive vehicles. A
right-hand drive vehicle is similar.
Special tools and workshop equipment required
♦ Vehicle diagnostic tester

Note

Removal of the right side is described. Removal of the left side is

similar.

Removing
– Remove dash panel end cover ⇒ General body repairs, inte‐
rior; Rep. gr. 70 ; Dash panel; Removing and installing dash
panel end cover .
– Separate electrical connector -3-.
– Turn vent temperature sender -2- 90° in -direction of arrow-
and pull it out of air duct -1-.
Installing
– Install vent temperature sender in reverse order of removal.
Specified torques
♦ Dash panel end cover ⇒ General body repairs, interior; Rep.
gr. 70 ; Dash panel: Removing and installing dash panel end
cover .

10.7 Removing and installing left footwell

vent temperature sender - G261-
The following information applies to left-hand drive vehicles. A
right-hand drive vehicle is similar.
Special tools and workshop equipment required
♦ Vehicle diagnostic tester
Removing
– Remove footwell vent on driver side ⇒ page 133 .
– Disconnect connector -2- from left footwell vent temperature
sender - G261- -1-.
– Turn left footwell vent temperature sender - G261- -1- 90° in
-direction of arrow- and remove it.
Installing
– Install left footwell vent temperature sender - G261- in reverse
order of removal.
Specified torques
♦ Footwell vent on driver side
⇒ “7.6 Removing and installing driver side footwell vents”,
page 133 .

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10.8 Removing and installing right footwell

vent temperature sender - G262-
The following information applies to left-hand drive vehicles. A
right-hand drive vehicle is similar.
Special tools and workshop equipment required
♦ Vehicle diagnostic tester
Removing
– Remove glove compartment ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments/covers; Removing and installing
glove compartment .
– Remove footwell vent on front passenger side ⇒ page 134 .
– Disconnect connector -2- from right footwell vent temperature
sender - G262- -1-.
– Turn right footwell vent temperature sender - G262- -1- 90° in
-direction of arrow- and pull it out of heater and air conditioning
unit.
Installing
– Install right footwell vent temperature sender - G262- in re‐
verse order of removal.
Specified torques
♦ Glove compartment ⇒ General body repairs, interior; Rep. gr.
68 ; Compartments/covers; Removing and installing glove
compartment .

10.9 Removing and installing rear vent tem‐

perature sender - G174-
Special tools and workshop equipment required
♦ Vehicle diagnostic tester

Note

♦ The rear vent temperature sender - G174- is located on right

of 2nd heater and air conditioning unit.
♦ The 2nd heater and air conditioning unit need not be removed.

Removing
– Remove right luggage compartment side trim ⇒ General body
repairs, interior; Rep. gr. 70 ; Luggage compartment trims;
Assembly overview - luggage compartment side trims .
– Disconnect connector -3- from rear vent temperature sender -
G174- -1-.

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– Turn rear vent temperature sender - G174- 90° in

-direction of arrow-.
– Pull rear vent temperature sender - G174- -1- out of 2nd heater
and air conditioning unit -2-.
Installing
– Install rear vent temperature sender - G174- in reverse order
of removal.
Specified torques
♦ Right luggage compartment side trim ⇒ General body repairs,
interior; Rep. gr. 70 ; Luggage compartment trims; Assembly
overview - luggage compartment side trims .

154 Rep. gr.87 - Air conditioning system