Climatronic Components In Passenger Compartment, Servicing
Climatronic Components In Passenger Compartment, Servicing
CAUTION!
- Before working on the electrical system, obtain radio security code and disconnect battery Ground (GND) strap.
- When reconnecting battery, always check operation of vehicle equipment such as radio, clock, and power windows.
NOTE: System components identified with an * must only be serviced or replaced after discharging refrigerant system. Use kent Moore A CR4 or equivalent.
1 - Clip
- Lift out with screwdriver
2 - Dust and pollen filter
3 - Air intake housing
4 - Sunlight photo sensor -G107-
- Function: Controls temperature flap and fresh air blower speed depending on light intensity
- In event of failure: Climatronic control module -J255- assumes fixed value
5 - Defroster air outlet
- Removing and installing:
6 - Side window air outlet
7 - Instrument panel interior temperature sensor -G56- with interior temperature sensor fan -V42-
- Climatronic control module - J255-, A/C control head - E87- and instrument panel interior temperature sensor -G56- with interior temperature sensor blower -V42- are integrated into a single unit and cannot be serviced separately.
- Function: Temperature sensor controls temperature flap and fresh air blower speed dependant on temperature measurement of interior air.
- In event of G56- malfunction, operation continues using assumed value of 24 °C (75 °F)
- Replacing and adjusting: Code Climatronic control module, function 07 and then set Basic setting, Function 04 using VAG 1551 Scan Tool (ST); Climatronic, On Board Diagnostic (OBD).
8 - A/C control head -E87-
- Climatronic control module - J255-, A/C control head - E87- and instrument panel interior temperature sensor -G56- with interior temperature sensor blower -V42- are integrated into a single unit and cannot be serviced separately.
- Replacing and adjusting; Code Climatronic control module, Function 07 and then initiate Basic setting, Function 04 using VAG 1551 Scan Tool (ST); Climatronic, On Board Diagnostic (OBD).
9 - Air outlets
10 - Instrument panel cross member
11 - Defroster duct
- Replacing:
- Remove instrument panel
- Loosen cross member -10-.
12 - Evaporator water drain guide
13 - Fresh air intake duct temperature sensor -G89-
- Function: Temperature sensor controls temperature flap and fresh air blower speed dependant on temperature measurement of intake air.
- In event of malfunction, outside air temperature sensor -G17- value is used instead.
- Replacing:
- Remove passenger side shelf (glove box)
- Reach behind heater/evaporator unit from below.
- Turn sensor 90° and pull out.
- Lubricate seal -15- with oil when installing.
NOTE:
If unable to access and remove sensor as described above, proceed as follows:
- Remove instrument panel
- Loosen cross member -10-.
14 - Evaporator vent temperature sensor -G263-
- Vehicles from 10.00 only
- Replacing
- Remove passenger side shelf (glove box)
- Reach behind heater/evaporator unit from below.
- Turn sensor 90° and pull out.
- Lubricate seal -15- with oil when installing.
15 - Seal
- Lubricate with oil when installing.
16 - Airflow flap motor -V71-
- Also operates fresh and recirculating air flap
- Replacing and adjusting;
- Initiate Basic setting, Function 04 with VAG 1551 Scan Tool (ST); Climatronic On Board Diagnostic (OBD).
17 - Fresh air blower -V2-
18 - Control module for fresh air blower -J126-
- Function: Controls fresh air blower speed with variable voltage signal.
19 - Air outlet for glove box
20 - Temperature regulator flap motor -V68-
- Replacing and adjusting:
- Initiate Basic setting, Function 04 with VAG 1551 Scan Tool (ST); Climatronic On Board Diagnostic (OBD).
21 - Central air flap motor -V70-
- Replacing and adjusting;
- Initiate Basic setting, Function 04 with VAG 1551 Scan Tool (ST); Climatronic On Board Diagnostic (OBD).
NOTE: A modified flap (with cut-out at top) was introduced 11.98. This design allows air flow to footwell to be blocked.
22 - Climatronic control unit -J255-
- Climatronic control module J255-, A/C control head - E87- and instrument panel interior temperature sensor -G56- with interior temperature sensor blower -V42- are integrated into a single unit and cannot be serviced separately.
- Replacing and adjusting:
- Initiate Basic setting, Function 04 with VAG 1551 Scan Tool (ST); Climatronic On Board Diagnostic (OBD).
23 - Center trim
24 - Sender for outlet temperature, center -G191-
- Function; Controls center air distribution and fresh air blower speed, dependent on air outlet temperature measurement.
25 - Center air outlet duct
26 - Heater/evaporator unit*
Contains:
- Heater core
- Evaporator
27 - Sender for outlet temperature, floor outlet -G192-
- Function: Controls air distribution to defrost/footwell and fresh air blower speed dependant on outlet temperature measurement.
- In event of malfunction, operation continues using assumed value of 80 °C (176 °F)
- Removing and installing See Fig. 1
28 Footwell/defroster-flap motor -V85-
- Replacing and adjusting:
- Initiate Basic setting, Function 04 with VAG 1551 Scan Tool (ST); Climatronic On Board Diagnostic (OBD)
29 - Heater core*
- Always use new coolant after replacement
- Removing:
30 - Left rear duct
31 - Lower duct
32 - Upper duct
33 - Footwell air outlet
- Replacing;
- Remove instrument panel
- Remove instrument panel cross member -10-
- Remove upper duct.
- Carefully lift heater/evaporator unit.
- Remove footwell air outlet.
34 - Instrument panel cross member and left side support securing bolt
35 - Relay
First Speed Coolant Fan Control (FC) relay -J279-
- Vehicles up to 10.00 : Control number 214
- Vehicles from 10.00 : Control number 373
Second Speed Coolant Fan Control (FC) Relay -J280-
- Vehicles up to 10.00 : Control number 213
- Vehicles from 10.00 : Control number 370
Component locations
36 - A/C clutch relay -J44-
- Control number 267
Component locations
37 - Instrument panel
- Removing and installing:
Fig. 1 Sender for outlet temperature, floor outlet -G192-, removing and installing
Removing
- Remove driver side shelf
- Disconnect electrical connector from sender -G192-.
- Rotate sender -2-, 90° -arrow- and remove from housing -1-.
Installing
Lubricate rubber seal on footwell sender - G192- with oil when installing.
Fig. 2 Air outlet for glovebox, removing and installing
Removing
- Remove passenger side shelf (glove box)
- Remove securing screw -5-.
- Pull air outlet -4- out from guides on heater/evaporator unit -2-.
- Pull off hose -1-.
Installing
- Replace seal -3- if damaged.
When installing, ensure that locking lugs engage in guides on heater/evaporator unit -arrows-.
Fig. 3 Sender for outlet temperature, center -G191, removing
CAUTION!
- Before working on the electrical system, obtain radio security code and disconnect battery Ground (GND) strap.
- When reconnecting battery, always check operation of vehicle equipment such as radio, clock, and power windows.
- Remove radio
- Remove Climatronic control module -J255-
- Remove center trim
- Disconnect electrical connector -2- from sender -G191-.
- Rotate sender -1-, 90° -arrow A- and remove from housing -3-.
Fig. 4 Sunlight photo sensor -G107-, removing
- Carefully lift sender -1- at side with small screwdriver.