MK1
Heating
Air conditioning
and
and
and
and
installing
installing
installing
installing
the
the
the
the
The ventilation of the passenger compartment occurs via the 2 ventilation frames (in the
luggage compartment on the right in the area of the bumper) Chapter.
1q
q
2-
Dash panel
with integrated air guide ducts for defroster vents and dash panel vents
removing and installing Body Work; Rep. Gr.70
Defroster vent side window
3-
q
4-
5q
6q
78q
9q
Removing and installing the centre and left dash panel vent
Removing the trim for the dash panel insert Body work; Rep. Gr.70.
t The fresh air is sucked in via a dust and pollen filter; remove and install Chapter
t
The illumination of the rotary switches is performed by way of a bulb at the start of
production. At a later stage it must be converted to LEDs, which can no longer be replaced.
1q
q
q
q
q
2q
Heater control
removing and installing Chapter
Remove and install Bowden cables Chapter
Adjust Bowden cables Chapter
Connection diagram for the Bowden cables Chapter
Replace light bulb Chapter
Switch for fresh air and re-circulating air flap - E159Inspect proper operation Chapter
Note
4-
Rear duct
5-
6-
7-
Footwell vent
8-
Heater unit
9-
Heat exchanger
q
q
10 -
11 -
Fresh air flap and re-circulating air flap control motor -V154-
12 q
13 q
10
11
12
Note
In order to avoid damage to the rotary knob, i.e use a thick cloth between the rotary knob and the jaws of
the pliers or use pliers with plastic or rubber jaws.
The illumination of the rotary switches is performed by way of a bulb at the start of production. At a later
t
stage it must be converted to LEDs, which can no longer be replaced.
t
13
Note
Removing and installing series resistor for fresh air blower -N24 -
resistor.
Release screws -B- and remove resistor carrier.
Remove series resistor from the resistor carrier
Removing and installing control motor of fresh air flap and re-circulating air flap - V154Removing
15
and off the ignition, position the lever -Fat the control motor in the centre
position -direction of arrow-.
Check the function of the fresh air flap and re-circulating air flap control motor -V154- and
the switch -E159Note
In order for the steam to quickly fade from the steamed-up windows, no re-circulating air
t operation is possible at air distribution to front windscreen. (Switch -E159- is
mechanically locked via the rotary switch).
Otherwise it could arise that the window panes steam up during the re-circulating air
t operation (the humidity of the air in the passenger compartment increases and then
condenses on the window panes).
Check the function of the switch -E159- and the fresh air flap and re-circulating air flap
control motor -V154
Switch on ignition.
17
Connect voltage tester -V.A.G1527Bbetween the contacts -1- and -3- of the
plug connection -A-.
19
1-
Surround
2-
Filter insert
3-
Plastic nut
4-
Removing
Install
Install
20
2 way valve for coolant shut-off valve -N147Vehicles with mapped cooling
Inspection
Replace valve.
Removing
21
Install
Installation is carried out in the reverse
order.
Determine the code for radio sets fitted with anti-theft coding.
Disconnect battery.
Reduce pressure in the coolant circuit by opening the cap on the coolant expansion
reservoir.
Disconnect both coolant hoses to heat
exchanger of the heater with hose
clamps (e. g. - V.A.G 3094-).
Note
22
remove the hexagon nuts with washer -Blocated behind them (tightening torque
15 Nm).
Remove hexagon nut with washer -C-.
Note
23
Install
Installation is performed in the reverse
order, pay attention to the following points:
Note
24
Install
Installation is performed in the reverse
order, pay attention to the following points:
Note
25
26
Air conditioner
Safety measures when working on vehicles with air conditioning and when using refrigerant R
134a
The assemblies and the line system of the air conditioning system are filled with refrigerant R
134a.
Safety measures must be observed for refrigerant R 134a (additional directives may apply in
individual countries):
Refrigerant must not be released into the environment, it must be drained off from the
refrigerant circuit using an exhaust system or service position. The drained off refrigerant is
processed on site or is returned to the manufacturer for ecological disposal (different or
additional directives may apply in certain countries).
If during repairs on the vehicle it is necessary to drain the refrigerant circuit, these tasks must
be carried out in a specialist service centre which has suitably trained personnel and is fitted
out for working on the refrigerant circuit!
Reasons:
Only the service centres have suitable service positions and properly trained personnel where
the refrigerant can be drained off professionally.
Note
All the safety measures when working on vehicles with air conditioning system, when using
the refrigerant as well as to the below-mentioned chapters can be found in the Workshop
Manual Air conditioning system with refrigerant R134a Air conditioning system with
refrigerant R134a; Rep. Gr.00 technical data.
t
t
t
t
t
t
t
t
t
Complaints
Check the pressure in the refrigerant circuit (with the service position of the air conditioning
systems)
Replacing components of the refrigerant circuit
Description and components of the air conditioning system, checks as well as repair work,
filling contents
Note
Detailed description of the function of the air conditioning system, checks as well as repair
work can be found in the Workshop Manual Air conditioning system with refrigerant R134a
Air conditioning system with refrigerant R134a; Rep. Gr.00 technical data.
The temperature in the passenger compartment is influenced by radiant heat through the window and by the
contact heat emitted by metallic parts. In order to provide agreeable temperatures for the passengers on very
hot days, some of the ambient heat must be evacuated.
As it is a well known fact that heat spreads towards colder temperatures, an aggregate that generates lower
temperatures has been fitted to the vehicle, i.e. the evaporator. Liquid refrigerant is continuously evaporated
in this aggregate. The heat required for this operation is drawn from the air flowing through the evaporator.
The refrigerant gas together with the absorbed heat is pumped out of the evaporator by the compressor. The
compressor's compression work increases the heat content and the temperature of the refrigerant. It is now
considerably higher than the ambient air temperature.
The high-temperature refrigerant and its heat content flow to the condenser. There, because of the
temperature difference between the refrigerant and the ambient air, the refrigerant releases heat into the
ambient air via the condenser and liquifies.
The refrigerant is also a heat conveyor. As it will be re-used, it is again pumped to the evaporator.
Structure of the refrigerant circuit
Note
All air conditioning components marked * as well as all refrigerant hoses and refrigerant lines must be
repaired or replaced in service centres, as the refrigerant must first be drained off at a service position.
HP = High-pressure side
LP = Low-pressure side
28
1234567-
High-pressure side
8Cap
9Connection with valve*
10 Air conditioner pressure switch -F129- or high pressure sensor -G6511 Expansion valve*
12 Evaporator*
13 Cap
14 Exhaust, filler and measurement valve*
q
Low-pressure side
15 Pre-cubic contents*
29
Compressor
The compressor is driven by the ribbed V-belt of
the vehicle engine.
A magnetic coupling -N25- fitted to the
compressor generates the shaft grip between the
belt pulley and compressor shaft when the air
conditioning system is on.
The compressor sucks refrigerant gas from the
evaporator, compresses it and transfers it to the
condenser.
Note
The compressor contains refrigerant oil, which
can be mixed with the -R 134a- refrigerant at all
temperatures.
Condenser
The condenser dissipates heat from the
compressed refrigerant gas into the ambient air.
During this process the refrigerant gas condenses
and liquifies.
Fluid reservoir
The fluid reservoir gathers the liquid drops and
conveys them to the expansion valve in a constant
flow. Humidity, that has penetrated into the
refrigerant circuit during assembly, is bound by a
dessicator integrated in the fluid reservoir.
30
Expansion valve
The expansion valve atomizes incoming
refrigerant and controls the flow in accordance
with the different pressures in such a way that,
depending on the heat transport, the vapour only
becomes gaseous at the outlet of the evaporator.
Evaporator
The liquid refrigerant evaporates in the
evaporator. The heat required for this operation is
drawn from the air flowing through the
evaporator fins. This cools down the evaporator.
The refrigerant evaporates and is sucked in with
the absorbed heat as gas by the compressor.
Tubes and hoses of the refrigerant circuit
The mixture of refrigerant oil and refrigerant -R
134a- corrodes certain metals (e.g. copper) and
alloys and dissolves certain hose materials.
Therefore only original spare parts may be used.
O-ring seals
These rings seal off the connection points
between the individual components of the
refrigerant circuit.
Only use O-rings that are resistant to
refrigerant -R 134a- and related refrigerant oils.
Original spare parts offer this guarantee.
O-ring seals:
t Only use once, replace.
t Pay attention to correct diameter -a- and -b-.
t Moisten with refrigerant oil before inserting.
t Only use valves and connections that are resistant to refrigerant -R 134a- and related refrigerant oils.
Different connections (outside diameter) for high-pressure and low-pressure side guarantee that the
t
connections are not interchanged.
31
t After disconnecting the quick-coupling adapter tighten the caps to prevent any dirt from penetrating.
Connection to high-pressure valve
12345-
12345-
32
Coil for magnetic coupling -N25An overheating fuse is built into the solenoid
coil. The overheating fuse will cut out the
t solenoid coil as soon as (e.g. because of
compressor resistance) the magnetic coupling
starts overheating (approx. 180C)
The solenoid coil also includes a protective
t diode (reduces voltage peaks that may occur
when disconnecting the magnetic coupling).
34
Outside temperature switch -F38Switches off the magnetic coupling via the
radiator fan control unit at a temperature of 2C
and switches on again at a temperature of 5C
(evaporator icing protection).
Contents
Refrigerant circuit
750+50 g refrigerant R 134a
Note
When filling, always fill the refrigerant circuit up to the top tolerance limit (there will still be some
refrigerant in the filling hoses).
Refrigerant oil
For compressor firm Sanden or Zexel: 135+ 15 cm3 PAG oil (Order No. -G 052 154A2-).
Oil distribution
The oil, which before the first activation of the air conditioning system was located in the compressor's oil
pan, is distributed as follows in the refrigerant circuit:
Compressor approx. 50 %
Condensor approx. 10%
Suction hose approx. 10%
Pressure hose Evaporator approx. 20 %
Fluid reservoir approx. 10%
Summary of components for air conditioning and heating - engine compartment (manual
control)
Note
The parts marked with an * must only be repaired in specialist service centres which have
suitably trained personnel and are fitted out for working on the refrigerant circuit!
t Comply with the safety measures when working on vehicles with air conditioning system
and when using refrigerant R 134a and observe the instructions for working on the
refrigerant circuit Air conditioning system with refrigerant R134a; Rep. Gr.00 technical
35
data.
1q
2q
q
Air conditioner pressure switch -F129- or high pressure sensor -G65for vehicles as of model year 99 with 1.6 ltr./74kW engine, the -G65- is installed instead of
the -F129 on all vehicles is installed -G65- as of model year 00
-F129- (4-pin plug connection) function, remove and install, check Chapter
-G65- (3-pin plug connection) function Chapter, remove and install, check Chapter
3-
Expansion valve*
36
4-
5q
switches off the magnetic coupling -N25- if the ambient temperature is too low (off at 2C is valid for vehicles up to model year 99, off at 0C - is valid for vehicles as of model year
00, on at 5C)
6-
7-
q -F14- switches off the magnetic coupling -N25- if the coolant temperature is too high (off at
119C, on at 112C)
q
1.6 Itr./74 kW up to model year 1998 and all other vehicles as of model year 1999
8-
q
q
9-
Tightening torque: 10 Nm
check Chapter
10 -
Tightening torque: 15 Nm
Note
Remove compressor:
Turn the compressor with the clutch disk of the magnetic coupling to speed up the
evacuation of the oil.
11 -
Compressor*
Mark the direction of rotation before removing the V-ribbed belt, the reversal of the direction
of rotation can lead to the damage of the belt.
The stroke of piston of the compressor is variable, it adjusts itself depending upon the
determined refrigerating capacity.
If a new compressor was installed or new refrigerant oil was filled into the compressor (e. g.
after blowing through the refrigerant circuit and emptying the compressor via the oil drain
t
plug), the compressor must be turned by hand approx. 10 turns after installing (in order to
avoid damage to the compressor before operation).
12 q
13 q
14 q
q
15 q
q
38
Note
If the vehicle has been fitted with air conditioner with automatic regulation (Climatronic), the
pressure switch for the air conditioning system -F129 - is checked by the self-diagnosis
Chapter
Operation
The low/high pressure switch (switch
between the contacts 1 and 2) switches
t the compressor off when there is
underpressure or overpressure in the
refrigerant circuit.
Switching pressures (in bar overpressure):
AC not operating
Fresh air blower switch -E9- on position
1
39
Switch on ignition.
Note
AC operating
Switch on ignition.
Note
High pressure sensor for air conditioning system -G65Removing and installing
40
41
Remove and install the heat-protection insulation for the expansion valve
42
Inspection
43
Version -I.-:
The condensation water drain valve -A- should
not stick and must close, its drain opening must
be located at the bottom.
l
Version -II.-:
Note: The water drain openings must not be
blocked by contaminations and must be located
at the bottom.
Removing and installing
Open the flap -D- of the heat-protection
matting (at the pre-type punched points) and
remove the condensation water drain valve.
Note
t
t
Remove condensation water drain valve -Atowards the bottom out of the floor plate, when
installing pay attention to the proper position in
the bulkhead -B-.
The condensation water drain valve must not
rest against the flap of the heat-protection
matting in the installed position -D-.
The condensation water drain valve must not
stick with wax or underbody sealant (version
-I-.) or it must not be blocked (version -II-).
If problems exist due to humidity in the
passenger compartment, check the
condensation water drain -C- for correct fitting
position in the condensation water drain valve
-A-.
Only use valve version -II- when replacing
valve -A-.
44
After removal, attach the compressor e. g. with wire to the compressor holder and do not
suspend on the refrigerant lines.
t Do not drain refrigerant circuit, do not remove refrigerant lines from the compressor.
t
Mark the direction of rotation before removing the V-ribbed belt, the reversal of the
direction of rotation can lead to the damage of the belt.
Remove V-ribbed belt Engine, Mechanics; Rep. Gr.13
Remove bottom cover and separation between engine compartment and right wheel house
Body Work; Rep. Gr.66
Remove vane pump for power-assisted steering from bracket Chassis; Rep. Gr.48
Note
Only required for engines with the vane pump arranged at the bottom (e. g. 1.6 / 74 kW,
1.8 / 92 kW).
45
Installation is performed in the reverse order, pay attention to the following points:
Note
46
of the support.
Installation is performed in the reverse order, pay
attention to the following points:
Note
Replace O-ring seals -F- and -B- (10.8 mm;
1.8 mm).
Keep the fluid reservoir closed as long as
possible and remove the caps just before
installing (a dessicator bag is located in the
t
fluid reservoir which saturates with humidity
over a short time and therefore becomes
unusable if the reservoir is opened).
t
Remove the compressor from the bracket for repairing the magnetic coupling (do not open
the refrigerant circuit).
Counterholder -MP 9-601 Flywheel type belt pulley fitting tool -MP 9-400-
48
1t
Nut
self-locking, replace
Tightening torque: 15 Nm
2t
Clutch disc
remove Fig.
3t
t
t
Spacers
to set the gap between the clutch disk and belt pulley
Clearance: 0.4 up to 0.8 mm
Testing and adjusting gap Fig.
4-
Circlip
t
t
t
replace
Fit on correct side (the smooth side points to the compressor).
pay attention to correct fit in slot
5-
Belt pulley
remove Fig.
installing Fig.
6-
Circlip
t
t
t
replace
Fit on correct side (the smooth side points to the compressor).
pay attention to correct fit in slot
7t
Solenoid coil
installing Fig.
Note
An overheating fuse is built into the solenoid coil. The overheating fuse will cut out the
t solenoid coil as soon as (e.g. because of compressor resistance) the magnetic coupling
starts overheating (approx. 180C)
t The solenoid coil also includes a protective diode (reduces voltage peaks that may occur
49
9-
Support
10 -
Support
11 -
Screw
12 -
Compressor
13 -
Slide bush
with thread
t
t
self-locking, replace
-MP 9-601- use with 6 mm pin
diameter
50
51
Repair air conditioning system and heating - passenger compartment (manual control)
Note
The parts marked with an * must only be repaired in specialist service centres which have
suitably trained personnel and are fitted out for working on the refrigerant circuit!
Comply with the safety measures when working on vehicles with air conditioning system
and when using refrigerant R 134a and observe the instructions for working on the
t
refrigerant circuit Air conditioning system with refrigerant R134a; Rep. Gr.00 technical
data.
t The fresh air is sucked in via a dust and pollen filter; remove and install Chapter.
t
The ventilation of the passenger compartment occurs via 2 ventilation frames (in the
luggage compartment on the right in the area of the bumper) Chapter.
52
1t
2t
3t
4t
5t
Dash panel
Removing and installing Body Work; Rep. Gr.70
Outer dash panel vent
clipped into place
Right dash panel vent
removing and installing Chapter
Centre, right dash panel vent
removing and installing Chapter
Air guide duct to the dash panel vents
screwed to the heating, locked on the top
6-
Fresh air flap and re-circulating air flap control motor -V154-
7-
Series resistor for fresh air blower with overheating fuse -N24-
8-
9-
10 t
t
t
Heater control
11 t
Switch for fresh air and re-circulating air flap -E159Inspect proper operation Chapter
Note
t
t
13 14 15 -
16 -
17 t
Footwell vent
removing and installing Chapter
18 t
t
Heat exchanger*
removing and installing Chapter
for vehicles with mapped cooling on the basis of higher temperatures in an all-metal
version
19 t
20 t
21 -
Drain the refrigerant circuit with the aid of the A/C service station.
Removing dust and pollen filter Chapter.
Disconnect battery earth strap Electrical System; Rep. Gr.27.
Reduce pressure in the coolant circuit by opening the cap on the coolant expansion
reservoir.
55
56
remove the hexagon nuts with washer -Blocated behind them (tightening torque
15 Nm).
57
Install
Installation is performed in the reverse
order, pay attention to the following points:
Note
58
Removing and installing the heat exchanger of the air conditioning unit
(Must only be performed in service centres!)
59
60
1t
Evaporator housing
disassembling and assembling Chapter
2t
Tensioning strap
pay attention to the correct routing Fig.
3-
4t
fixed with the tensioning strap -Pos. 2- and both screw clips -Pos. 5- on the evaporator
housing
56t
t
t
Cover
Screw clip
Heater control
Remove and install Bowden cables Chapter
Adjust Bowden cables Chapter
Connection diagram for the Bowden cables Chapter
61
7-
do not disassemble
8-
Heat exchanger
t
t
9t
10 -
Screw
11 t
Retaining clip
release with a screwdriver
12 t
Gasket
install on the evaporator housing Fig.
62
63
1t
t
Check the gasket at the suction channel, replace if damaged (it seals the suction channel to
the passenger compartment)
2-
Fresh air flap and re-circulating air flap control motor -V154-
345t
6t
Screw
Fresh/re-circulating air flap
Evaporator housing - bottom part
Assembling the evaporator housing Fig.
Fresh air blower -V2removing and installing Chapter
64
7-
8t
Evaporator
Install seal on the refrigerant lines of the evaporator Fig.
9t
Seal
Install seal on the refrigerant lines of the evaporator Fig.
10 t
t
Seal
replace
t seals the connecting area of the refrigerant lines to the engine compartment
11 t
O-ring seal
removing and installing Chapter
12 t
O-ring seal
removing and installing Chapter
13 -
Threaded plate
14 -
Expansion valve
t
t
15 t
Screw
Tightening torque: 8 Nm
65
connection flange.
67
Note
Some of the components and functions of the climatronic are not checked by the self-diagnosis (for example
the temperature sensor blower V42). If in spite of a problem no fault has been recognized after interrogating
the fault memory, the further test must be carried out with reference to the problem.
Operation
The climatronic control unit receives information from the electrical and electronic
components (information transmitters), which are processed by the control unit in compliance
with the nominal values. The output signals of the control unit control the electrical
components (actuators).
The Climatronic control unit -J255- is located behind the control and display unit for air
conditioner, Climatronic -E87-. Both components form a unit that must not be disassembled.
In order to rapidly determine the cause of the fault in the event of the failure of a component
or a line interruption, the control unit is fitted with a fault memory that can be read with the
vehicle system tester -V.A.G1552-, or Vehicle diagnosis, testing and information system VAS
5051.
If malfunctions occur in the monitored sensors or components, they are stored in the fault
memory with indication of the fault type.
If a fault of a component is stored, which has a lasting effect on the operation of the
Climatronic, the display of the control and display unit for air conditioner, Climatronic -E87flashes after switching on the ignition for approx. 15 seconds. The climatronic control unit can
maintain the operation, which has been canceled, in the emergency running mode for all
occuring faults.
Initiate the self-diagnosis at the start of fault finding and retrieve the stored information using
the vehicle system tester -V.A.G1552-, or Vehicle diagnosis, testing and information system
VAS 5051.
The displayed fault information refers to a fault table including indications on the possible
causes as well as targeted repairs.
The vehicle system tester -V.A.G1551-, or Vehicle diagnosis, testing and information system
VAS 5051 is used for the self-diagnosis. The following description only relates to the vehicle
system tester -V.A.G1552-.
Memory:
Data output:
01 Interrogate control unit version:
02 Interrogate fault memory:
03 Actuator diagnosis:
04 Basic setting:
05 Erase fault memory:
Permanent memory
Vehicle system test
yes
yes
yes
yes
yes
68
06 End output:
07 Coding control unit:
08 Read measured value block:
yes
yes
yes
l
l
l
Connect vehicle system tester V.A.G 1552 and select climatronic control unit
Special tools and workshop equipment required
t
Readout on display:
Note
Vehicle system test
HELP
Select function XX
Switch on ignition.
Readout on display:
Enter 08 for the address word heating/air conditioning
1J1907044 CLIMATRONIC
SXX
Coding 01000
WSC
t
t
t
Press key.
1J1907044 CLIMATRONIC
Coding 01000
Readout on display:
Note
HELP
WSC XXXXX
If the key is pressed, the programme of the vehicle system tester -V.A.G 1552- returns to
the initial position.
Select function XX
confirm entry with the Q key.
The number of stored faults or No fault recognised! appears in the
display.
If no fault is stored:
X faults detected!
Press key.
Fault table
Note
All the possible faults which can be detected by the Climatronic control unit -J255- and can
be displayed by -V.A.G 1552- are listed below according to the fault code.
t If faults only occur occasionally, these faults are displayed as sporadic faults (SP).
t
After repair always erase the fault memory again using vehicle system tester -V.A.G 1552 and interrogate again.
If in spite of a problem with the climatronic no fault is detected, the function final control
diagnosis 03 Chapter or the function read measured value block 08 Chapter must
be performed. If the display flashes, although no fault was detected, the function coding
t
control unit 07 and the function basic setting 04 must be initiated Chapter in
sequence. If applicable problem-related fault finding without self-diagnosis must be
performed.
Readout on Possible cause of fault
-V.A.G 155200000
no fault
detected
Rectifying fault
00281
Vehicle speed
sender -G681)
This display only appears if a final control diagnosis was carried out before
interrogating the fault memory. This fault is erased in the fault memory of the
control unit after switching off the ignition. -G68- is defective, if the fault
reappears when driving.
00532
Supply
voltage
Signal too
high
AC generator defective
locations
Signal too
low
1)
A fault is detected by the speedometer sender -G22- and not by the vehicle speed sender
-G68 -. The fault is only recognized if during the 5 driving cycles (start, drive more than 15
km/h, switch off) within 4 minutes after engine start, a speed signal cannot be measured.
Display
Possible cause of fault
-V.A.G 155
2-
Rectifying fault
00538
Reference
voltage
00576
1)
Terminal
15
Signal too Voltage regulator on AC generator defective
high
AC generator defective
1)
Readout on
-V.A.G 1552-
Rectifying fault
00603
Footwell/defroster
flap control motor
74
-V85-1)
Short-circuit or open circuit on
wiring or plug connections to the
footwell/defroster flap control
motor -V85-
-V85- defective
-N147- defective
007052)
Radiator fan relay
stage 1
Short circuit to
positive
-J293-
-J293- defective
007062)
Radiator fan relay
stage 2
1)
This fault is recognized in the basic setting 04, final control diagnosis 03 and in normal
operation. Both end stops must be reached.
2)
1)
This fault is detected in the basic setting 04, final control diagnosis 03 and in normal
operation. Both end stops must be reached.
2)
Rectifying fault
00779
Outside
temperature sensor
-G17 -
Open circuit/short
circuit to positive
-G17- defective
00787
Temperature sensor
- Fresh air intake
76
-G89- defective
Display
-V.A.G 1552-
Rectifying fault
00792
Air conditioner
pressure switch
-F129-1)
-F129- defective
cannot be
tested at
present
This display only appears if a final control diagnosis was carried out before
interrogating the fault memory and the pressure switch could not be checked
(e.g. if the measured ambient temperature is below 12C). This fault is
erased in the fault memory of the control unit after switching off the ignition.
00797
Sunlight
penetration
77
photosensor
-G107Open
circuit/short
circuit to
positive
earth
connections to the sunlight
according to current flow diagram.
penetration photosensor -G107-G107- defective
1)
This fault cannot be detected at an ambient temperature below 12C or in the event that
-G17- and -G89- fails. The switch is a 3-position-switch. The 0.2 MPa (2 bar)/3.2 MPa (32 bar)
switch part is checked, the 1.6 MPa (16 bar) switch part is not checked.
Display
-V.A.G 1552-
Rectifying fault
00818
Evaporator
vent
temperature
sender
Open
circuit/short
circuit to
positive
00819
High-pressure
78
Open
Short-circuit to earth or open circuit
circuit/shorton wiring or plug connections to the
circuit to earth high pressure sensor -G65-
-G65- defective
Display
-V.A.G 1552-
Rectifying fault
01044
Control unit
wrongly coded
01087
Basic setting
not performed
Basic setting was not or
incorrectly performed
79
01206
Immobilization
time signal 1)
Dash panel insert defective
1)
The permanent immobilization time signal is received from the dash panel insert. The
climatronic control unit -J255- utilises the time measurement after the engine has been
switched off in order to replace the measured values of the ambient temperature sensor
-G17- and the fresh air intake duct temperature sensor -G89- with the temperatures used
during the last operation after the vehicle has stopped (ignition off) and a restart has occured.
The measured values are otherwise inaccurate through the radiant heat while the engine is in
idle. The immobilization time signal occurs only after the start.
Display
-V.A.G 1552-
Rectifying fault
01271
Temperature flap
control motor
-V68-1)
80
-V68- defective
01272
Central flap
control motor
-V70-1)
Short-circuit or open circuit on
wiring or plug connections to the
central flap control motor -V70-
-V70- defective
1)
This fault is recognized in the basic setting 04, final control diagnosis 03 and in normal
operation. Both end stops must be reached.
Display
-V.A.G 1552-
Rectifying fault
01273
Fresh air blower
-V2-
-V2-
01274
Air flow flap
control motor
-V71-1)
Short-circuit or open circuit on wiring or
Check -V71- with 08 read
plug connections to the air flow flap
measured value block
control motor -V71 Chapter.
-V71- is blocked
-V71- defective
1)
This fault is recognized in the basic setting 04, final control diagnosis 03 and in normal
operation. Both end stops must be reached.
Display
-V.A.G 1552-
Rectifying fault
012961)
Middle vent
temperature
sender -G191-
82
Short circuit to
earth
-G191- defective
01297
Footwell vent
temperature
sender -G192Open circuit/short Short-circuit to positive or open circuit on
circuit to positive wiring or plug connections to the footwell
vent temperature sender -G192-
Short circuit to
earth
-G192- defective
1)
Display
Possible cause of fault
-V.A.G 1552
-
Rectifying fault
65535
Control unit
defective
83
Wiring or plug
connections to the
climatronic control unit
-J255- defective
Climatronic control unit
defective
Actuator diagnosis
Note
The final control diagnosis must be carried out when the engine is not running, the ignition is
switched on and the climatronic is switched off (push-button for blower slower Chapter.
t
t During the final control diagnosis a control of the climatronic is not performed.
t This final control diagnosis may be repeated a number of times if necessary.
Connect the vehicle system tester -V.A.G 1552- and select the address word 08 for the
climatronic control unit. (Connect the vehicle system tester and select the climatronic
control unit Chapter.)
Readout on display:
Enter 03 for the function final control diagnosis and
Note
Readout on display:
Enter 000 for the display group number and confirm entry with the Q
key.
Note
Basic setting
Enter display
group number XXX
When extending all the control motors until they reach the final setting,
the climatronic control unit -J255- stores the values of the potentiometer
and takes over the basic settings of the control motors.
Readout on display:
Note
System in basic setting
0
XXX
XXX
XXX
XXX
Basic setting
Q
Enter display group number 000
Readout on display:
Display 0 indicates that the basic setting is completed. Faults
detected by the system are stored in the fault memory.
Press key.
Basic setting 0
->
0
0
0
0
Readout on display:
Enter function 02 interrogate fault memory and
Press key.
X faults
detected!
After the display of the last fault, the faults must be eliminated
according to the fault table Chapter.
Press key.
Readout on display:
86
HELP
Precondition:
l
Fault memory was interrogated.
Erasing fault memory
Readout on display:
Vehicle system test
Enter function 05 erase fault memory and confirm entry with HELP
Select function XX
the Q key.
Vehicle system test
HELP
Readout on display:
Fault
memory
erased!
->
Press key.
Readout on display:
HELP
Ending output
Readout on display:
Enter function 06 end output and confirm entry with the
Q key.
Readout on display:
-V.A.G 1552-.
t Each spare part climatronic control unit J255 -J255- must be coded after installing.
t
If the code displayed does not match the vehicle or the equipment, the climatronic control
unit must be coded.
The display of the Control and display unit for air conditioner, Climatronic -E87 - flashes for
15 seconds if the Climatronic control unit -J255- was not coded.
Connect the vehicle system tester -V.A.G 1552- and select the address word 08 for the
climatronic control unit. (Connect the vehicle system tester and select the climatronic
control unit Chapter.)
Readout on display:
Select function 07 Code control unit and confirm
Readout on display:
Enter code number in accordance with the table
Vehicles
87
Q
(0
01000
11000
11010
Press key.
1J1907044
SXX ->
Coding 01000
XXXXX
WSC
Readout on display:
Note
During the function read measured value block the control of the climatronic is operative.
Connect the vehicle system tester -V.A.G 1552- and select the address word 08 for the
climatronic control unit Chapter.
Readout on display:
Readout on display:
Readout on display:
Readout on display:
Note
Press key.
Readout on display:
Note
Vehicle system test
Select function XX
HELP
V.A.G1552
higher
Press key
lower
Press key
skip
Denomination
The AC compressor, the air conditioner magnetic coupling -N25- (code No.
1 to 17 gives the reason for the deactivation)
code:0
-N25- is not deactivated.
Code: 1
-N25- is deactivated by the air conditioner pressure switch -F129- because
of excessive pressure in the refrigerant circuit
code: 2
-N25- is deactivated, because the fresh air blower -V2- or the fresh air
blower control unit -J126- is defective.
Code: 3
-N25- is deactivated by the air conditioner pressure switch -F129- because
of a too low pressure in the refrigerant circuit.
Code: 4
Is not displayed.
Code: 5
-N25- is deactivated for 4 seconds (no defect).
Code 5 is displayed for only 5 seconds. If still indicating, check speed
signal.
Code: 6
-N25- is deactivated, ECON mode (no defect).
Code: 7
-N25- is deactivated, because the output of the fresh air blower was
switched off (no defect) by the button fan.
Code: 8
89
Display group
number
Display
field
001
Vehicle speed
(Value 0 up to 255 km/h)
Immobilization time
(code 0 up to 240 - time for ignition off in minutes)
(code 250 - battery was disconnected)
(code 255 - incorrect transmittance)
002
Denomination
90
003
Display Displa
group y field
number
004
Central flap control motor -V70flap stop: air to the dash panel vents
(code 0 up to 149 -V70- defective)
(code 150 up to 250 -V70- is in order, on condition that the
function 04
basic setting was performed)
(code 251 up to 255 -V70- defective)
Central flap control motor -V70flap stop: air to the footwell/defrost vents
(code 0 up to 4 -V70- defective)
(code 5 up to 100 -V70- is in order, on condition that the
function 04
basic setting was performed)
(code 101 up to 255 -V70- defective)
Denomination
005
006
Footwell/defroster flap control motor -V85flap stop: air to the front windscreen
(code 0 up to 4 - V85- defective)
(code 5 up to 100 - V85- is in order, on condition that the function 04
basic setting was performed)
(code 101 up to 255 - V85- defective)
Control motor of air flow flap -V71(code of the measured value: 0 up to 255)
(allowed deviation from the nominal value 2)
Air flow flap control motor -V71flap stop: fresh air to the passenger compartment
(code 0 up to 149 -V71- defective)
(code 150 up to 250 -V71- is in order, on condition that the function 04
basic setting was performed)
(code 251 up to 255 -V71- defective)
Air flow flap control motor -V71flap stop: re-circulating air to the passenger compartment
(code 0 up to 4 -V71- defective)
(code 5 up to 100 -V71- is in order, on condition that the function 04
basic setting was performed)
(code 101 up to 255 -V71- defective)
009
010
4)
3)4)
008
1)
Denomination
1)
Terminal 15
(measured value: voltage in V)
Is not displayed.
Is not displayed.
Is not displayed.
Is not displayed.
Heating
(off/on)
Windscreen wipers
93
(off/on)
0114)
Is not displayed.
Is not displayed.
1)
2)
3)
4)
Interrogate the fault memory after ending the function Reading measured value block
Chapter.
94
By pressing the AUTO button all deviating settings from automatic operation are
cancelled.
In ECON operation only the compressor is disconnected, the heating and ventilation
operation continues to be controlled electronically.
If automatic operation is cancelled before switching off the ignition; the selected functions
t will remain stored. Only the function re-circulating air operation is erased 20 minutes after
switching off the ignition.
t
If after switching on the ignition all symbols in the display field of the Control and display
t unit for air conditioner, Climatronic -E87- flash, there is a system failure. In this case the
fault memory must first be interrogated Chapter.
The components, i.e the Climatronic control unit -J255-, the Control and display unit for air
t conditioner, Climatronic -E87- and the dash panel temperature sensor -G56- with the
temperature sensor blower -V42- cannot be disassembled.
Function of the Control and display unit for air conditioner, Climatronic -E87-
95
Disconnect the earth strap from the battery before commencing work on the electrical
system Electrical System; Rep. Gr.27.
Note
Pay attention to the sequence when connecting the battery Electrical System; Rep.
Gr.27.
The parts marked with an * must only be repaired in specialist service centres which have
suitably trained personnel and are fitted out for working on the refrigerant circuit!
97
1t
2t
3-
t remove: carefully lever out, remove plug of sunlight penetration photosensor -G1074-
Function: depending on the intensity of the sunlight controls the temperature flap and the
fresh air blower
Emergency operation in the event of failure: Climatronic control unit -J255- adopts fixed
value
5-
remove: carefully lever out, remove plug from warning light switch
6 - Dash panel temperature sensor -G56- with Temperature sensor blower -V42the components, i.e the Climatronic control unit -J255-, the Control and display unit for air
t conditioner, Climatronic -E87- and the dash panel temperature sensor -G56- with the
temperature sensor blower -V42- cannot be disassembled
t
Function: the temperature sensor controls the temperature flap and the fresh air blower
according to the temperature
Emergency operation in the event -G56- fails: System keeps running at an assumed value
of + 24C
after replacing: function 07 code control unit Chapter and subsequently perform
function 04 basic setting Chapter
7-
the components, i.e the Climatronic control unit -J255-, the Control and display unit for air
t conditioner, Climatronic -E87- and the dash panel temperature sensor -G56- with the
temperature sensor blower -V42- cannot be disassembled
t
after replacing: function 07 code control unit Chapter and subsequently perform
function 04 basic setting Chapter
8-
is fitted in the air guide duct for the dash panel vent
9t
10 t
11 t
Function: the temperature sensor controls the temperature flap and the fresh air blower
according to the temperature
99
Emergency operation in the event of failure: The Ambient temperature sensor -G17performs the task
replace:
12 t
operated simultaneously with the fresh air and re-circulating air flap
t
t
replace Chapter
adjust: Perform function 04 basic setting Chapter
13 t
removing Fig.
14 t
Function: smoothly controls the output of the fresh air blower in accordance with the
voltage values
replace Fig.
15 -
with evaporator
16 t
t
t
replace Chapter
adjust: Perform function 04 basic setting Chapter
17 t
t
t
18 t
19 -
the components, i.e the Climatronic control unit -J255-, the Control and display unit for air
t conditioner, Climatronic -E87- and the dash panel temperature sensor -G56- with the
temperature sensor blower -V42- cannot be disassembled
t
t
t
20 t
Footwell vent
only passenger side
21 22 23 t
Rear duct
Connecting piece to rear duct
Footwell vent
removing and installing Chapter
24 -
Function: controls the defrost/footwell air distribution and the output of the fresh air blower
in accordance with the vent temperature
Emergency operation in the event of failure: System keeps running at an assumed value of
+80C coolant temperature
25 t
t
t
replace Chapter
adjust: Perform function 04 basic setting Chapter
26 t
Heat exchanger*
t
27 t
28 -
29 -
Vehicles as of 03.01
102
Install
When fitting moisten the rubber seal with
oil on the footwell vent temperature sender
-G192-.
Removing and installing Control and display unit for air conditioner, Climatronic -E87- with
103
The climatronic control unit and the control and display unit for air conditioner cannot be
disassembled.
Removing
Install
Disconnect the earth strap from the battery before commencing work on the electrical
system Electrical System; Rep. Gr.27.
Note
When installing the control motors, pay attention to the correct routing of the wiring looms.
t They must be fitted in such a way that they do not come in contact with moving parts (for
example the levers of the control motors).
t Pay attention to the sequence when connecting the battery Electrical System; Rep. Gr.27.
t After installing a new control motor perform the function 04 basic setting Chapter.
104
Removing and installing the control motor of air flow flap -V71Note
The fresh air and re-circulating air flap is also controlled by the control motor of air flow flap.
Removing
Install
A new control motor is supplied in position
"re-circulating air operation". To facilitate
installation of the control motor, carry out
the following work steps before installing:
105
Switch on ignition.
Operate push-button for fresh air/recirculation.
Removing and installing the control motor of temperature flap -V68First carry out the following tasks:
Remove the glove compartment, the trim for the dash panel and the bottom part of dash
panel on the left Body Work; Rep. Gr.70
Remove centre console Body Work; Rep. Gr.68
Remove the dash panel middle part Body Work; Rep. Gr.70
Remove right footwell vent Chapter.
Removing
106
Install
Removing and installing the control motor of central flap -V70First carry out the following tasks:
Remove the glove compartment, the trim for the dash panel and the bottom part of dash
panel on the left Body Work; Rep. Gr.70
Remove centre console Body Work; Rep. Gr.68
Remove the dash panel middle part Body Work; Rep. Gr.70
Remove right footwell vent Chapter.
Removing
Install
Removing and installing the footwell flap and defroster flap control motor -V85Removing
107
Remove bottom part of dash panel on the left Body Work; Rep. Gr.70
Install
108
Disconnect plug.
Turn sender -1- by 90 -arrow- and take
out.
Install
Installation is carried out in the reverse
order.
Inspection
Measure the resistence between the
contacts of the sender using a
multimeter.
Nominal value at 25C: 9.7... 10,3 k
If the specified value is not reached:
Removing
The evaporator vent temperature sender is located at the back of the evaporator housing.
Disconnect plug.
Install
Installation is carried out in the reverse order.
Inspection
Check the resistence between the contacts of the sender using a multimeter.
Inspect wiring according to the current flow diagram and repair if necessary Current flow
diagrams and Fitting locations.
If wiring is o.k.:
110
1t
2t
3t
t
Seal
replace
Installing the seal on the evaporator housing Fig.
4t
5t
t
6-
Seal
Install seal on the refrigerant lines of the evaporator Fig.
Evaporator
Install seal on the refrigerant lines of the evaporator
Installing the seal on the evaporator Fig.
Evaporator housing - bottom part
111
7-
8-
screwed
9-
t
t
screwed and fixed with tensioning strap -2must be positioned firmly at the evaporator housing
10 -
t when installing, make sure that there is clearance between the moving parts Fig.
11 t
Heat exchanger
12 -
Vehicles as of 03.01
112
113
The parts marked with an * must only be repaired in specialist service centres which have
suitably trained personnel and are fitted out for working on the refrigerant circuit!
Comply with the safety measures when working on vehicles with air conditioning system
and when using refrigerant R 134a and observe the instructions for working on the
t
refrigerant circuit Air conditioning system with refrigerant R134a; Rep. Gr.00 technical
data.
114
1t
t the fluid reservoir must be replaced after each opening of the refrigerant circuit
2t
3t
4-
t for vehicles as of model year 99 with 1.6 Itr./74 kW engine, the -G65- is installed instead of
115
the -F129 t
t -F129- (4-pin plug connection), function, remove and install, check Chapter
t -G65- (3-pin plug connection) function Chapter, remove and install, check Chapter
5-
Expansion valve*
6-
7-
8-
t
t
9t
t the magnetic coupling -N25- of the compressor is also switched via this control unit
10 t
Function: the temperature sensor controls the temperature flap and the fresh air blower
according to the temperature
Emergency operation in the event of failure: Fresh air intake duct temperature sensor -G89performs the task. If both sensors are defective, the system keeps running at an assumed
t
value of +10C; re-circulating air operation is not possible; readout in the display of the
Control and display unit for air conditioner, Climatronic -E87-: -
t
t
11 t
t
check Chapter
12 t
Tightening torque: 15 Nm
Note
Remove compressor:
Turn the compressor with the clutch disk of the magnetic coupling to speed up the
evacuation of the oil.
13 -
Compressor*
Mark the direction of rotation before removing the V-ribbed belt, the reversal of the direction
of rotation can lead to the damage of the belt.
The stroke of piston of the compressor is variable, it adjusts itself depending upon the
determined refrigerating capacity.
If a new compressor was installed or new refrigerant oil was filled into the compressor (e. g.
after blowing through the refrigerant circuit and emptying the compressor via the oil drain
t
plug), the compressor must be turned by hand approx. 10 turns after installing (in order to
avoid damage to the compressor before operation).
14 t
15 t
117
118