Heating & Air Conditioning PDF

Service
Workshop Manual
Amarok 2011 ➤
Heating, air conditioning
Edition 04.2013
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Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
80 - Heating
87 - Air conditioning system
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Technical information should always be available to the foremen and mechanics, because their
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Copyright © 2013 Volkswagen AG, Wolfsburg D3E802AA8CD

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Contents
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00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.1 Notes concerning odours in air conditioned vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.2 Notes for vehicles with a start-stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.3 Notes on repair work to vehicles with air conditioning and on handling refrigerant . . . . . . 2
1.4 Procedure for checking and adjusting components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Distribution of oil in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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2 Notes on safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2.1 Safety measures for when working on vehicles with a start-stop system . . . . . . . . . . . . . . 3
3 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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3.1 Check cooling performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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3.2 Opening refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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4.1 Capacities for refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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4.2 Refrigerant machine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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80 - Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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1 Heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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1.1 Fittings overview - heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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1.2 Assembly overview – heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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1.3 Removing and installing fresh air blower V2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.4 Removing and installing fresh air blower series resistor with overheating fuse N24 . . . . . . 9
1.5 Removing and installing dust and pollen filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.6 Dust and pollen filter with activated charcoal inlay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.7 Removing and installing heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.8 Removing and installing heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.9 Dismantling and assembling heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2 Control motors/actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1 Removing and installing air recirculation flap control motor V113 . . . . . . . . . . . . . . . . . . . . 18
3 Air duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1 Removing and installing fresh air vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2 Removing footwell vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3 Checking passenger compartment ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4 Operating and display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1 Removing and installing operating and display unit for heater . . . . . . . . . . . . . . . . . . . . . . 21
4.2 Cables on operating and display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
87 - Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1 Fittings overview - air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.1 Fittings overview - components not located in passenger compartment . . . . . . . . . . . . . . 23
1.2 Fittings overview - components located in front section of passenger compartment . . . . . . 25
2 Refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.1 Removing and installing high-pressure sender G65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.2 Removing and installing refrigerant lines on expansion valve . . . . . . . . . . . . . . . . . . . . . . 30
2.3 Removing and installing expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.4 Removing and installing condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.5 Removing and installing dryer element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.6 Removing and installing evacuating and charging valves on low and high-pressure side
........................................................................ 36
3 Air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.1 Removing and installing air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.2 Notes on installing air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Contents i
Amarok 2011 ➤
Heating, air conditioning - Edition 04.2013
3.3 Checking high-pressure safety valve on air conditioner compressor . . . . . . . . . . . . . . . . . . 45

4 Control motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.1 Fitting location overview - control motors on heater and air conditioning unit . . . . . . . . . . 47
4.2 Removing retaining plate for defroster flap control motor V107 and air distribution flap control
motor V428 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.3 Removing and installing defroster flap control motor V107 . . . . . . . . . . . . . . . . . . . . . . . . 48
4.4 Removing and installing air distribution flap control motor V428 . . . . . . . . . . . . . . . . . . . . 49
4.5 Removing and installing retaining plate with footwell flap control motor V261 and temperature
flap control motor V68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.6 Removing and installing footwell flap control motor V261 . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.7 Removing retaining plate with footwell flap control motor V261 and left temperature flap
control motor V158 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.8 Removing and installing left temperature flap control motor V158 . . . . . . . . . . . . . . . . . . 51
4.9 Removing and installing right temperature flap control motor V159 . . . . . . . . . . . . . . . . . . 51
5 Front heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.1 Assembly overview - heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.2 Removing and installing evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.3 Dismantling and assembling heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . 58
5.4 Removing and installing heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.5 Checking condensation drain hose with valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.6 Removing and installing evaporator temperature sensor G308 . . . . . . . . . . . . . . . . . . . . 62
6 Air duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.1 Removing and installing left vent temperature sender G150 . . . . . . . . . . . . . . . . . . . . . . 63
6.2 Removing and installing right vent temperature sender G151 . . . . . . . . . . . . . . . . . . . . . . 63
6.3 Removing and installing front vent temperature sender G152 . . . . . . . . . . . . . . . . . . . . . . 64
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6.5 Removing
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Removing and installing right footwell vent temperature
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sender G262 . . . . . . . . . . . . . . . . 65
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Operating and display unit for heater and air conditioning system with manually regulated air
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conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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7.2 Removing and installing operating and display unit, manually controlled air conditioning
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system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
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7.3 Functions of operating and display unit for Climatronic heater and air conditioning system
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7.4 Removing and installing Climatronic air conditioning operating and display unit E87 with
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Climatronic control unit J255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

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8 Other controlling and regulating components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

8.1 Removing and installing ambient temperature sensor -G17- . . . . . . . . . . . . . . . . . . . . . . . . 72
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8.2 Removing and installing sunlight penetration photosensor G107 . . . . . . . . . . . . . . . . . . . . 72

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8.3 Working principles of air quality sensor G238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

8.4 Removing and installing air quality sensor G238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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8.5 Removing and installing sender for front Bitron blower regulation G462 . . . . . . . . . . . . . . 75
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ii Contents
Amarok 2011 ➤
00 – Technical data
1 General notes
(VRL005527; Edition 04.2013)
⇒ “1.1 Notes concerning odours in air conditioned vehicles”, page
1
⇒ “1.2 Notes for vehicles with a start-stop system”, page 1
⇒ “1.3 Notes on repair work to vehicles with air conditioning and
on handling refrigerant”, page 2
⇒ “1.4 Procedure for checking and adjusting components”,
page 2
⇒ “1.5 Distribution of oil in refrigerant circuit”, page 2
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1.1 Notes concerning odours in air condi‐ lks es n
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The market offers various procedures for cleaning the evaporator
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sound A/C cleaner - VAS 6189A- or the Suction feed spray-gun -
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V.A.G 1538- and spray lance. If, in the course of time, other
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procedures are tested for suitability and subsequently approved
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by Volkswagen, relevant information will be provided in the work‐
shop manual for ⇒ air conditioning systems with refrigerant
R134a; Rep. gr. 00 ; Odours from heating and air conditioning
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1.2 Notes for vehicles with a start-stop sys‐
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Safety measures for vehicles with a start-stop system
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If a start-stop system is installed, the following abort conditions

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♦ The start-stop system has been switched off via the start-stop
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♦ The charge condition of the battery is insufficient to restart the
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engine (starting voltage prediction).
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♦ The defrost function is active.

♦ The windscreen heater function is active.
♦ The air conditioner system temperature set in the control panel
deviates by more than 8 °C from the actual temperature of the
interior.
♦ The engine speed is greater than 1200 rpm.
♦ The alternator - C- is defective, i.e. belt broken.
♦ Coolant temperature not within specifications of 25 °C - 100 °
C.
♦ Blower speed increase by more than 4 stages.
1. General notes 1
Amarok 2011 ➤
Additional information:
♦ Refer to ⇒ Self-study programme No. 426 ; Start/Stop System
2009 for full description.
1.3 Notes on repair work to vehicles with air

conditioning and on handling refrigerant
Note
♦ Notes on repairs to vehicles with air conditioning and on han‐

dling refrigerant can be found in ELSA under ⇒ Air condition‐
ing system with refrigerant R134a; Rep. gr. 00 ; General
information for air conditioning system, Safety precautions for
when working on vehicles with air conditioning and when han‐
dling refrigerant R134a .
♦ Notes on testers and tools for repairs to vehicles with air con‐
ditioning can be found in ELSA under ⇒ Air conditioning
system with refrigerant R134a; Rep. gr. 00 ; Testing equip‐
ment and tools .
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Do not kink or severely bend refrigerant lines. ss
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There is a film in the refrigerant lines which can be destroyed.
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Refrigerant lines must not be bent to a radius less than r =
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Additional information:
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♦ ⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
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1.4 Procedure for checking and adjusting
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components
Special tools and workshop equipment required
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♦ Vehicle diagnosis tester
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– Checking and adjusting components ⇒ Vehicle diagnostic

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1.5 Distribution of oil in refrigerant circuit

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The oil, which is located in the sump of the air conditioner com‐
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♦ Air conditioner compressor approx. 50 % Prote AG.
♦ Condenser approx. 10 %
♦ Suction hose approx. 10 %
♦ Evaporator approx. 20 %
♦ Receiver approx. 10 %
2 Rep. gr.00 - Technical data

Amarok 2011 ➤
2 Notes on safety
⇒ “2.1 Safety measures for when working on vehicles with a start-
stop system”, page 3
2.1 Safety measures for when working on

vehicles with a start-stop system
WARNING
Risk of injury due to automatic engine starting in vehicles with

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♦ When working on the vehicle, therefore, make sure that
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the start-stop system is deactivated (switch off the ignition;
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switch the ignition on again if necessary).
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2. Notes on safety 3
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⇒ “3.1 Check cooling performance”, pageau4th ra
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⇒ “3.2 Opening refrigerant circuit”, page 5
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3.1 Check cooling performance
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Checking
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– Close bonnet.
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– Measure ambient temperature.
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– Close doors, windows and sunroof.
– Open all dash panel vents.
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– Set air conditioning system temperature to coldest setting.
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– Set air distribution to chest vents.
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– Hold temperature probe -2- approx. 20 mm in area shown
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– Switch on air conditioning system via button AC .

Amarok 2011 ➤
– Start engine.
Note
Start time measurement (5 min).
– Raise 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
3.2 Opening refrigerant circuit

Repairs requiring the opening of the refrigerant circuit may only
can be carried out by specially trained personnel.
Repairs on air conditioning system that require evacuation of re‐
frigerant circuit are described under
⇒ g r.87 “Air conditioning system”, page 23 .
Special tools are required to evacuate the refrigerant circuit.
If these tools are not available, pass vehicle over to a workshop
that has the required tools and the respective specially trained
personnel to carry out the required repairs. olksw AG. V agen AG
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WARNING
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Danger from refrigerant escaping under pressure!

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Freezing of skin and other body parts.

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spec
• Evacuate the refrigerant and then open the refrigerant cir‐

es, in part or in w
cuit immediately.
t to the co
• If more than 10 minutes have elapsed since evacuation

and the coolant circuit has not been opened, evacuate the
rrectness of i
refrigerant again. Pressure builds up in the coolant circuit

as a result of secondary evaporation.
l purpos
nform
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Cop py
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Prote AG. 3. Repair notes
Amarok 2011 ➤
4 Technical data
⇒ “4.1 Capacities for refrigerant R134a”, page 6
⇒ “4.2 Refrigerant machine oil”, page 6
wage
4.1 Capacities for refrigerant R134a lks es n
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⇒ “4.1.1 Capacities for refrigerant R134a”, page 6 utho tee
or
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⇒ “4.2 Refrigerant machine oil”, page 6 ss
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4.1.1 Capacities for refrigerant R134a
an
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Air conditioner compressor Manufacturer Capacity
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7SEU17 Denso 525 ± 25 grams
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spec
6SEU14 Denso 525 ± 25 grams
es, in part or in w
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4.2 Refrigerant machine oil
rrectness of i
The special refrigerant oil (for use with refrigerant circuits R134a
l purpos
only) can no longer be obtained on the refrigerant/machine oil

market.
nf
ercia
or
Refrigerant oil can be obtained using following part number for
m
m
atio
m
7SEU17C Denso air conditioner compressor G 052 300 A2

o
n in
or c
6SEU14C Denso air conditioner compressor G 052 300 A2
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Type Total capacity1) Cop py
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140 cm3 ±10 cm3
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Prote AG.
1) This quantity of refrigerant oil is contained in a replacement compressor and

corresponds to the total capacity.
Important information:
Because refrigerant oil is very hygroscopic, opened containers
must be closed immediately after use to prevent moisture from
entering.

Amarok 2011 ➤
80 – Heating
1 Heater unit
⇒ “1.1 Fittings overview - heater unit”, page 7
⇒ “1.2 Assembly overview – heater unit”, page 8
⇒ “1.3 Removing and installing fresh air blower V2 ”, page
olks
w8age es n
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V
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⇒ “1.4 Removing and installing fresh air blower series
rised resistor with ran
tee
overheating fuse N24 ”, page 9 ut
ho
or
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ss
⇒ “1.5 Removing and installing dust and pollen filter”, page 9
ce
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an
⇒ “1.6 Dust and pollen filter with activated charcoal inlay”, d
itte
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page 10
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⇒ “1.7 Removing and installing heat exchanger”, page 11
ot
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⇒ “1.8 Removing and installing heater unit”, page 14
hole
spec
⇒ “1.9 Dismantling and assembling heater unit”, page 17
es, in part or in w
t to the co
1.1 Fittings overview - heater unit
rrectness of i
1 - Operating and display unit
l purpos
❑ Removing and installing

⇒ page 21 .
nform
ercia
♦ With fresh air blower switch

m
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com
tion in
♦ With fresh air and air recir‐
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culation flap switch -
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♦ With additional heat ex‐

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changer and rear control Cop py
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switch - E271- opyri
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♦ With front interior tempera‐
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cted agen
Prote
ture potentiometer - G276- .
AG.
2 - Air recirculation flap control

motor - V113-
⇒ page 18
3 - Fresh air blower - V2-
⇒ page 8 .
4 - Fresh air blower series re‐
sistor with overheating fuse -
N24-
⇒ page 9 .
5 - Dust and pollen filter
⇒ page 9 .
6 - Footwell vent
⇒ page 19 .
1. Heater unit 7
Amarok 2011 ➤
7 - Cables on operating and display unit

❑ Installing ⇒ page 22 .
8 - Heater unit
❑ Removing and installing ⇒ page 14 .
1.2 Assembly overview – heater unit
1 - Upper part of distribution

box
❑ Upper part is connected
to lower part by securing
bolts -3- and retaining
clips -2-.
❑ Dismantling and assem‐
bling heater unit
⇒ page 17
2 - Retaining clip
❑ Qty. 3.
3 - Securing bolts
4 - Blower housing
❑ Dismantling and assem‐ n AG. Volkswagen AG do
bling heater unit lkswage es n
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⇒ page 17 byV ua
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o
5 - Lower part of distribution auth or
ac
box ss
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an
d
bling heater unit

itte
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⇒ page 17
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1.3 Removing and installing fresh air blower

iva
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- V2-
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op
Before beginning repair work, perform the following steps: C py
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• Switch off all electrical consumers. cop Vo
by lksw
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Prote
• Switch off ignition.
AG.
• Remove ignition key.

Removing
The fresh air blower - V2- is accessible from the footwell on the
front passenger side.
8 Rep. gr.80 - Heating

Amarok 2011 ➤
– Separate connector from fresh air blower - V2- .

– Remove bolts -1- (1 Nm) for fresh air blower - V2- .
– Remove fresh air blower - V2- from heater unit.
Installing
Install in reverse order.
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1.4 Removing and installing fresh air blower
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series resistor with overheating fuse -
h re
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spec
N24-
t to the co
Before beginning repair work, perform the following steps:
• Switch off all electrical consumers.
rrectne
s
s o
cial p
f i
Removing
nform
mer
– Separate connector.
atio
om
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or
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WARNING
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Danger of burn injuries.

fo
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The fresh air blower series resistor with overheating fuse - N24- Cop py
can be hot.
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Before removing fresh air blower series resistor with overheat‐
by lksw
cted agen
Prote
ing fuse - N24- , let it cool off.
AG.
– Remove bolts -1- (1 Nm) and remove series resistor from

housing.
Installing
1.5 Removing and installing dust and pollen

filter
1. Heater unit 9
AG. Volkswagen AG d
agen oes
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Amarok 2011 ➤ rise
d b ara
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Removing
un
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Note
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Dust and pollen filter with activated charcoal filter insert is offered
ole,
spec
as optional extra.
t to the co
The dust and pollen filter is located in the front passenger footwell.
– Remove bolts -1-.
rrectne
– Remove cover.
ss
– Pull filter element out of housing.
o
cial p
f inform
mer
Note
atio
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Change intervals for dust and pollen filter ⇒ Maintenance ; Book‐
thi
te
let 19.1 .
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Installing
t.
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Cop py
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Installation is carried out in the reverse order. When installing,
p by
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note the following: Prote
cted AG.
agen
– Note installation position of filter -arrows-.
1.6 Dust and pollen filter with activated char‐

coal inlay
♦ The filter with activated charcoal inlay adopts the roll of the
dust and pollen filter. But it can also filter harmful gasses such
as ozone, benzene, nitrogen dioxide etc. out of the air flow
♦ The task of the activated charcoal is to absorb gaseous im‐
purities from the air flow until the fresh air flap is closed and
the system is operating in air recirculation mode. In vehicles
with Climatronic, the Climatronic control unit - J255- switches
from fresh air to air recirculation as soon as the air quality
sensor - G238- detects gaseous impurities in the air. The func‐
tion “automatic air recirculation” must be selected.
♦ The activated charcoal layer in the dust and pollen filter reacts
with noxious substances in the air in different ways:
- Certain noxious substances are stored permanently in the acti‐
vated charcoal layer.
- Others are converted into harmless compounds in a manner
similar to that of a catalytic converter.
- For the remaining substances, the activated charcoal functions
like a condenser. As noxious substances increase, initially they
are stored until a certain level of saturation is achieved. As the
portion of noxious substances in the air decreases, the activated
charcoal layer gradually releases the particles.

Amarok 2011 ➤
♦ Because the activated charcoal layer permanently stores part

of the noxious substances, renewing the dust and pollen filter
before the prescribed renewal period would be advantageous,
if:
- the vehicle is driven in areas with heavy air pollution.
- the vehicle is driven mainly with the “automatic recirculation
mode” switched off. AG. Volkswagen n AG do
wage
lks equipped with an air quality es
- the vehicle is Vonot
not sensor - G238-
gu
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and consequently
ris
ed has no “automatic air recirculation”
ara
nt function. ee
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♦ On au vehicles with air quality sensor, the air conditioning
r a system
c
ss
should always be operated with the “automatic recirculation
ce
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nl
mode” activated. However, if it is necessary or desired to
pt
du
an
switch the function off, the following should be observed:
itte
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-The activated charcoal layer in the dust and pollen filter will be‐
ility
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come saturated after a certain period of time.
wit
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-A saturated filter is not capable of absorbing any more noxious
hole
spec
substances, and these will flow unrestricted into the vehicle.
es, in part or in w
t to the co
♦ The main task of the dust and pollen filter and the air quality
sensor - G238- is to prevent peak levels of pollution from en‐
tering the passenger compartment of the vehicle. To this end,
rrectness of i
the following should be observed:
l purpos
-If the vehicle is being driven in an area with relatively clean air
(with low levels of noxious substances), switching from fresh air
to air recirculation mode is actuated at a different point in time
nf
ercia
than in an area with a high level of pollution (e.g. industrial area).

rm
m
atio
m
-The switch from fresh air to air recirculation occurs independently

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of the base level of pollution whenever the pollution level increa‐

or
thi
ses (e.g. when driving through a cloud of exhaust soot).

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♦ The filter with activated charcoal can be installed in all vehicles

o
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f
(also vehicles without an air quality sensor - G238- ). The same

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restrictions as those for operation of an air conditioning system
Co
Cop py
with deactivated “automatic recirculation mode” apply to these
t. rig
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vehicles. p by
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1.7 Removing and installing heat exchanger
Prote AG.

♦ Hose clamps up to 40 mm - 3093-
1. Heater unit 11
Amarok 2011 ➤
♦ Drip tray for workshop hoist - VAS 6208-

AG. Volkswagen AG d
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spec
t to the co
rrectne
ss o
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f
Removing
inform
mer
– Place drip tray - VAS 6208- beneath engine.
atio
om
– Clamp off coolant hoses -1- and -2- with hose clamps up to
n
c
i
or
n
40 mm Ø - 3093- .
thi
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WARNING
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t.
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op py
The cooling system remains pressurised while the engine is
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warm! py by
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Danger of scalding due to hot steam and coolant. Prote AG.
Reduce excess pressure by covering the cap of the coolant

expansion tank with cloths and opening it carefully.
– Disconnect coolant hoses -1- and -2- leading to heat exchang‐

er.
– Carefully blow remaining coolant out of heat exchanger via
connections using a compressed air pistol.
– Remove left and right dash panel trim and middle footwell trim
⇒ General body repairs, interior; Rep. gr. 70 ; Dash panel .
– Remove bolts -2- and remove trim -1-.

– Lay trim -1- to side.

Amarok 2011 ➤
Note
A retaining pin connects the lower heat exchanger cover to the

heater unit.
– Remove retaining pin -1- from catch -arrow A- and pull out in
direction of -arrow B-.
lkswage es n
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– Fold down cover -1-.
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spec
t to the co
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– Cover carpet in area under heat exchanger with waterproof foil
cial p
f in
and water absorbing paper.
form
mer
atio
– Pull retaining clips -1- off coolant lines.
om
n
c
– Slowly pull coolant lines out of heat exchanger and collect

or
n thi
e
coolant that leaks out in a container.

t
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ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove heat exchanger -1-.

Installing
1. Heater unit 13
Amarok 2011 ➤

note the following:
Seals -1- must be bonded left and right without gaps around the
edges. Bond seals -2- to upper and lower edge.
AG. Volkswagen AG d
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– Moisten seals -1- with coolant before installing.
ss c
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un
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an
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t to the co
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Note
nform
mer
atio
Always renew seals.
om
n
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i
or
n thi
e
– Ensure that clips are seated correctly after they have been
t
sd
va
installed -arrows-.
i
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pr
cum
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fo
en
ng
– Renew coolant after installing a new heat exchanger ⇒ Rep.

t.
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gr. 19 . Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
1.8 Removing and installing heater unit

♦ Hose clamps up to 40 mm - 3093-

Amarok 2011 ➤
♦ Drip tray for workshop hoist - VAS 6208-
AG. Volkswagen AG d
agen oes
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d by ara
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or eo
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aut ra
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nl
pt
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Removing
, is n
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hole
– Switch off all electrical consumers.
spec
es, in part or in w
– Switch off ignition.
t to the co
– Remove ignition key.
rrectness of i
– Place drip tray - VAS 6208- beneath engine.
l purpos
– Clamp off coolant hoses -1- and -2- with hose clamps up to
40 mm Ø - 3093- .
nform
ercia
WARNING
m
at
om
ion
c

in t
or
warm!
his
ate
do
priv
Danger of scalding due to hot steam and coolant.

cum
for
en
ng
t.
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op
C py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote
AG.
er.
– Remove dash panel ⇒ Rep. gr. 70 .
1. Heater unit 15
Amarok 2011 ➤
lkswage es n
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byV ua
d ran
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tho
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a ac
ss
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un
pt
an
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pe
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Remove bolts -2- (9 Nm).

m
– Remove subframe for dash panel -3- ⇒ Rep. gr. 70 .

com
tion in
– Disconnect connectors to heater -1- and remove heater unit.

r
te o
thi
s
iva
Installing
do
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cum
fo
Installation is carried out in reverse order.

en
ng
t.
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op
After installation, replenish coolant ⇒ Rep. gr. 19 .
C py
t. rig
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pyri by
Vo
co lksw
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cted agen
Note
Prote AG.
Ensure that seal is properly seated between heat exchanger and

bulkhead.

Amarok 2011 ➤
1.9 Dismantling and assembling heater unit

– Remove heater unit ⇒ page 14 .

box
❑ The upper part is con‐
nected to the lower part
by securing bolts -3- and
retaining clips -2-.
2 - Retaining clip
❑ Qty. 3
3 - Securing bolts
4 - Blower housing
5 - Lower part of distribution
box
AG. Volkswagen AG d
agen oes
olksw not
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au ra
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nl
pt
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itte
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ab
ility
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spec
es, in part or in w
t to the co
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nf
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orm
m
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om
n in
or c
thi
te
sd
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ng
t.
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Cop py
t. rig
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Vo
co lksw
by
cted agen
Prote AG.
1. Heater unit 17
Amarok 2011 ➤
2 Control motors/actuators ksw

agen
AG. Volkswagen AG d
oes
ol not
yV gu
⇒ “2.1 Removing and installing air recirculationseflap
d b control motor ara
nte
V113 ”, page 18 hori
eo
aut ra
s c
2.1 Removing and installing air recirculation s
ce
e
nl
pt
flap control motor - V113-
du
an
itte
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erm
ab
Removing
ility
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– Separate connector -1-.
, is n
h re
hole
– Unclip actuator -2-.
spec
es, in part or in w
– Remove bolt -arrows-.
t to the co
Installing
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
3 Air duct
⇒ “3.1 Removing and installing fresh air vent”, page 19
⇒ “3.2 Removing footwell vent”, page 19
⇒ “3.3 Checking passenger compartment ventilation”, page 20
3.1 Removing and installing fresh air vent

♦ Removal wedge - 3409-
Removing
– Use removal wedge - 3409- to pry vent out of dash panel
-arrow-.
Installing
Install in reverse order. agen
AG. Volkswagen AG d
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ab
pe
ility
ot
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3.2 Removing footwell vent

h re
hole
spec
Removing
es, in part or in w
t to the co
– Remove middle footwell trim ⇒ General body repairs, interior;

Rep. gr. 70 ; Removing and installing middle footwell trim .
rrectness of i
– Pull footwell vent off heater unit -in direction of arrow-.

l purpos
Installing
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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en
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t.
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Cop py
ht. rig
rig ht
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by lksw
cted agen
Prote AG.
3. Air duct 19
Amarok 2011 ➤
3.3 Checking passenger compartment ven‐

tilation
Note
♦ The stale air escapes via ventilation openings in the trim be‐
hind the rear seat bench.
♦ If the ventilation is to function properly, the exhaust openings
must not be covered.
♦ Ventilation frame is located in rear window frame.
♦ Remove loadbed in order to remove ⇒ Rep. gr. 55
– The sealing lips in the ventilation frame must be free to move

and close by themselves.
– Note installation position.
AG. Volkswagen AG d
agen oes
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y V gu
d b ara
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au ra
ss c
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nl
pt
du
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itte
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erm
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
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by Vol
gu
ara
Amarok 2011 ➤
d
orise Heating,
nte air
eo
conditioning - Edition 04.2013
th
au ra
ss c
ce
4 Operating and display unit
le
un
pt
an
d
itte
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⇒ “4.1 Removing and installing operating and display unit for erm
ab
heater”, page 21
ility
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⇒ “4.2 Cables on operating and display unit”, page 22
h re
ole,
spec
4.1 Removing and installing operating and
t to the co
display unit for heater
Removing
rrectne
– Remove lower centre dash panel trim panels ⇒ Rep. gr. 68 .
s
– Remove bolts -2- and remove controls -1- from dash panel.
s o
cial p
f i
– Separate connectors.
nform
mer
– Release cables on controls.
atio
om
n
c
Installing
i
or
n thi
te
sd
a

iv
o
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c
note the following:
um
r
fo
en
ng
t.
– Securing cables on operating and display unit ⇒ page 22 .
yi Co
Cop py
t. rig
Tightening torques
gh ht
pyri by
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by
Component Specified torque
cted agen
Prote AG.
Bolts -2- to control and display unit 1.5 Nm
4. Operating and display unit 21

Amarok 2011 ➤
4.2 Cables on operating and display unit
Note
♦ Cables are colour-coded.

♦ When rotary knobs are turned, all flaps must audibly contact stop.

⇒ page 21 .
2 - Temperature flap cable
❑ Cable is colour coded
red.
Note
Temperature flap cable (red) -2-

must be fitted first, then cable for
footwell flap (yellow) -3- and then
cable for defroster flap (green) -4-.
– Clip in, in direction of ar‐

row. n AG. Volkswagen AG do
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3 - Footwell flap cable d byV ua
ran
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❑ Cable is colour coded utho tee
or
yellow. ss
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row.
itte
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erm
ab
4 - Defroster flap cable
ility
ot p
wit
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❑ Cable is colour coded
h re
green.
ole,
spec
t to the co
row.
rrectness o
cial p
f inform
mer
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n
c
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or
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Prote AG.

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ra Amarok 2011 ➤
s c
s Heating, air conditioning - Edition 04.2013
ce
e
nl
pt
du
an
itte
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87 – Air conditioning system
erm
ab
ility
ot p
wit
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h re
1 Fittings overview - air conditioning
hole
spec
system
es, in part or in w
t to the co
⇒ “1.1 Fittings overview - components not located in passenger
compartment”, page 23
rrectness of i
⇒ “1.2 Fittings overview - components located in front section of
l purpos
passenger compartment”, page 25
1.1 Fittings overview - components not located in passenger compartment
nform
mercia
at
om
io
1 - Evacuating and charging
n
c
in t
r
valve, high-pressure side

o
his
ate
do
priv
c
⇒ page 36 .
um
for
en
ng
t.
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2 - Bolt
Co
Cop py
.
❑ Allocation ⇒ Electronic
ht rig
rig ht
by
parts catalogue (ETKA) copy Vo
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❑ 10 Nm ±1.8 Nm Prote AG.
3 - Seal
parts catalogue (ETKA)
❑ Renew after removing
4 - Expansion valve
⇒ page 31 .
5 - Refrigerant line
❑ Expansion valve refrig‐
erant line ⇒ Air condi‐
tioner compressor
6 - Heater and air conditioning
unit
⇒ page 59 .
bling ⇒ page 58 .
❑ Air conditioner com‐
pressor refrigerant line
⇒ Condenser
8 - Air conditioner compressor
❑ Allocation ⇒ Electronic parts catalogue (ETKA)
9 - Ambient temperature sensor - G17-
10 - Condenser with receiver
❑ Removing and installing condenser ⇒ page 32
1. Fittings overview - air conditioning system 23

Amarok 2011 ➤
11 - Receiver with dryer element
Note
♦ Under certain conditions, it is no

longer necessary to renew the
dryer cartridge each time the re‐
frigerant circuit is opened.
Please see ⇒ Air conditioning
system with refrigerant R134a;
Rep. gr. 00 ; Renewing compo‐
nents .
♦ Depending on engine type, re‐
ceiver with dryer cartridge may
be fitted on left or right of con‐
denser.
❑ Removing and installing dryer element ⇒ page 34 .
❑ Condenser refrigerant line ⇒ expansion valve.
❑ Allocation ⇒ Electronic parts catalogue (ETKA)
13 - High-pressure sender - G65-
AG. Volkswagen
14 - Evacuating and charging valve, low-pressure ksw
agenside AG do
es n
Vol ot g
❑ Refrigerant line with integrated evacuating
ed by and charging valve, low-pressure
ua
ran side
ris tee
❑ Removing and installing ⇒ page
ut
ho 39 . or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
24 Rep. gr.87 - Air conditioning system

Amarok 2011 ➤
1.2 Fittings overview - components located

in front section of passenger compart‐ en AG. Volkswagen AG
ment
ag does
ksw not
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ed nte
⇒ “1.2.1 Fittings overview - components located intho
rfront
is section e or
of passenger compartment, manually regulated auair conditioning ac
ss
system”, page 25
ce
le
un
pt
⇒ “1.2.2 Fitting location overview - components inside of front
an
d
itte
y li
passenger compartment, Climatronic”, page 27
rm
ab
pe
ility
⇒ “1.2.3 Fitting locations of control motors on Climatronic heater
ot
wit
, is n
and air conditioning unit”, page 29
h re
hole
spec
1.2.1 Fittings overview - components located in front section of passenger com‐
es, in part or in w
t to the co
partment, manually regulated air conditioning system
rrectness of i
1 - Dash panel
l purpos
⇒ General body repairs,

interior; Rep. gr. 70 ;
nform
ercia
Dash panel; Removing

and installing dash pan‐
m
a
el .
com
tion in
r
te o
2 - Centre fresh air vent
thi
s
iva
do
r
rp
c
⇒ page 19 .
um
fo
en
ng
t.
yi
3 - Air intake connecting pipe
Co
Cop py
t. rig
❑ Air intake connecting
gh ht
yri by
pipe for fresh air. cop Vo
by lksw
cted agen
❑ Located in front of ple‐
Prote AG.
num chamber.
4 - Outer fresh air vent
⇒ page 19 .
for heater and air conditioning
system
❑ With fresh air and air re‐
circulation flap switch -
E159- .
❑ With heated rear win‐
dow button - E230- .
❑ With fresh air blower
switch - E9- .
❑ For vehicles with seat
heating, also with heat‐
ed driver seat regulator
- E94- and heated front
passenger seat regula‐
tor - E95- .
❑ With air conditioning
system control unit - J301- .
6 - Heater and air conditioning unit
❑ Dismantling and assembling ⇒ page 58 .

AG. Volkswagen AG d
agen oes
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Amarok 2011 ➤ aut
h
ra
s c
Heating, air conditioning - Edition 04.2013 s
ce
le
un
pt
an
d
itte
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rm
ab
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ility
ot
wit
8 - Evaporator temperature sensor - G308-
, is n
h re
hole
spec
es, in part or in w
9 - Air recirculation flap control motor - V113-
t to the co
❑ Removing and installing ⇒ page 18
10 - Fresh air blower series resistor with overheating fuse - N24-
rrectness of i
l purpos

nform
ercia
12 - Evaporator
m
a
com
tio
n in
r
te o
thi
13 - Footwell vent air duct
s
iva
do
r
❑ With outlet for rear air duct.

rp
cum
fo
en
g

n
t.
yi Co
Cop py
14 - Right passenger compartment air duct ht. rig
rig ht
py by
❑ Connected to footwell air vent duct. co Vo
by lksw
cted agen
❑ Only for vehicles with double cab.
Prote AG.
15 - Left passenger compartment air duct

❑ Connected to footwell air vent duct.
❑ With no outlet for rear air duct.
17 - Heat exchanger cover
18 - Heat exchanger
19 - Air distribution box
❑ Dismantling and assembling heater and air conditioning unit ⇒ page 58 .
20 - Footwell vent temperature sender - G192-
21 - Control motors
❑ Fitting location of control motors ⇒ page 29 .
22 - Front vent temperature sender - G152-
23 - Air quality sensor - G238-
❑ Working principle of sensor ⇒ page 73 .

Amarok 2011 ➤
1.2.2 Fitting location overview - components inside of front passenger compart‐

ment, Climatronic
Note
♦ The vehicle has two-zone automatic

swa
gen AGair conditioning.
. Volkswagen AG
does
k not
Vol
♦ The air flow and the temperature can be set individually foruathe
ran driver, the front passenger and the rear
by g
ed
passengers withinthaorispecific
s
temperature range. tee
or
au ac
♦ Pressing the ss
AUTO button will cancel all individual settings which deviate from automatic operation.
ce
e
nl
pt
du
♦ In ECON operation, only the air conditioner compressor is switched to almost zero delivery. The heating
an
itte
and ventilation operations continue to be controlled electronically.
y li
erm
ab
ility
♦ Modifications made to automatic operation before the engine is switched off will be saved.
ot p
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♦ Deviations from automatic operation ⇒ appropriate operating instructions .
h re
hole
spec
♦ If the the system is malfunctioning, first read the event memory using ⇒ Vehicle diagnostic tester guided
es, in part or in w
t to the co
fault finding .
rrectness of i
1 - Dash panel
l purpos

⇒ General body repairs,
interior; Rep. gr. 70 ;
nf
ercia
o
Dash panel; Removing
rm
m
and installing dash pan‐
atio
m
el .
o
n in
or c
thi
2 - Centre fresh air vent
te
sd
iva

r
rp
cu
o
⇒ page 19 .
f
en
ng
t.
yi Co
op
3 - Air intake connecting pipe C py
t. rig
gh ht
❑ Air intake connecting pyri by
Vo
co
pipe for fresh air.
by lksw
cted agen
Prote AG.
❑ Located in front of ple‐
num chamber.
4 - Outer fresh air vent
⇒ page 19 .
5 - Climatronic operating and
display unit - E87- with Clima‐
tronic control unit - J255-
⇒ page 71 .
❑ The appearance of the
operating and display
unit for Climatronic air
conditioning system -
E87- may differ depend‐
ing on equipment instal‐
led
6 - Right vent temperature
sender - G151-
⇒ page 63 .
❑ Dismantling and assembling ⇒ page 58 .

Amarok 2011 ➤

10 - Right footwell vent temperature sender - G262-
❑ Right footwell vent temperature sender - G262- is installed in right footwell vent ducting.
12 - Sender for front Bitron blower regulation - G462-
14 - Evaporator
❑ With outlet for rear air duct.
16 - Right passenger compartment air duct
❑ Connected to footwell air vent duct.
AG. Volkswagen AG d
agen oes
olksw cab.
❑ Only for vehicles withydouble not
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17 - Left passenger compartment
tho
ris air duct e or
u
❑ Connected to ss a
footwell air vent duct. ac
ce
le

un
pt
an
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itte
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rm
ab
pe
❑ With no outlet for rear air duct.

ility
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wit
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h re
hole
19 - Heat exchanger cover

spec
es, in part or in w
t to the co
20 - Heat exchanger
rrectness of i
21 - Air distribution box

❑ Dismantling and assembling heater and air conditioning unit ⇒ page 58 .
l purpos
22 - Right temperature flap control motor - V159-

nform
ercia

m
23 - Left footwell vent temperature sender - G261-

a
com
tion in
❑ Left footwell vent temperature sender - G261- is installed in left footwell vent.
r
te o
thi

s
iva
do
r
rp
24 - Control motors
um
fo
en
ng
t.
❑ Fitting location of control motors ⇒ page 29 .
yi Co
Cop py
t. rig
25 - Left vent temperature sender - G150-
gh ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.
❑ Working principle of sensor ⇒ page 73 .

Amarok 2011 ➤
1.2.3 Fitting locations of control motors on Climatronic heater and air conditioning
unit
Note
Checking control motors using ⇒ Vehicle diagnostic tester guided fault finding .
1 - Defroster flap control motor

- V107-
❑ With potentiometer for
front cold air flap control
motor - G315- .
⇒ page 48 .
2 - Air distribution flap control
motor - V428-
front air distribution con‐
trol motor - G470- po‐
tentiometer for side vent
control motor - G469-
⇒ page 49 .
3 - Retaining plate with defrost‐
er flap control motor n AG. Volkswagen AG do
lk swa-geV107- es n
and air distributionbyV
o flap control ot g
ua
motor - V428-
o
ir se
d ran
tee
th
❑ s aRemoving
u and installing or
ac
s ⇒ page 48 .
ce
le
un
pt
4 - Retaining plate with right

an
d
itte
y li
temperature flap control motor

erm
ab
- V159-
ility
ot p
wit
❑ On right side of air dis‐

is n
h re
tribution housing.
ole,
spec
5 - Right temperature flap con‐

t to the co
trol motor - V159-

tribution housing.
rrectne

right temperature flap
s
control motor - G221-

s o
cial p

inform
⇒ page 51
mer
atio
m
6 - Footwell flap control motor - V261-

o
n
c
i
or
❑ With potentiometer for footwell vent control motor - G468- .

thi
te
sd
a

iv
o
pr
cum
r
fo
7 - Retaining plate with footwell flap control motor - V261- and left temperature flap control motor - V158-
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
8 - Left temperature flap control motor - V158-
p by
co Vo
by lksw
cted
❑ With potentiometer for left temperature flap control motor - G220- .
agen
Prote AG.

Amarok 2011 ➤
2 Refrigerant circuit
⇒ “2.1 Removing and installing high-pressure sender G65 ”, page AG. Volkswagen AG d
30 agen oes
olksw not
V gu
by ara
⇒ “2.2 Removing and installing refrigerant lines on expansion ris ed
nte
valve”, page 30 aut
ho eo
ra
ss c
⇒ “2.3 Removing and installing expansion valve”, page 31
ce
e
nl
pt
du
an
⇒ “2.4 Removing and installing condenser”, page 32
itte
y li
erm
ab
⇒ “2.5 Removing and installing dryer element”, page 34
ility
ot p
wit
, is n
⇒ “2.6 Removing and installing evacuating and charging valves
h re
on low and high-pressure side”, page 36
hole
spec
2.1 Removing and installing high-pressure es, in part or in w
t to the co
sender - G65-
Removing
rrectness of i
l purpos
Note
nf
ercia
o
♦ The high-pressure sender can be removed without evacuating
rm
m
atio
the refrigerant from the refrigerant circuit.
om
n in
c
♦ Counterhold threaded connection with suitable tool when loos‐

or
thi
e
ening and tightening.

t
sd
iva
o
r
rp
cu
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m
f
– Disconnect connector from high-pressure sender.
en
ng
t.
yi Co
op
– Unscrew high-pressure sender -1- from refrigerant line con‐
C py
t. rig
gh
nection.
ht
pyri by
Vo
o
by c lksw
cted
Installing
agen
Prote AG.
– Install high-pressure sender - G65- in reverse order of remov‐

al, noting the following:
♦ Renew O-ring -2-, ⇒ Parts catalogue .
Tightening torques
High pressure sender -1- on refrig‐ 8 ± 1 Nm
erant line connection
2.2 Removing and installing refrigerant lines

on expansion valve
♦ Air conditioner service station - VAS 6007A-

Amarok 2011 ➤
Note
♦ The refrigerant must be extracted beforehand, e.g. with air

conditioner service station - VAS 6007A- .
♦ The previously used air conditioner service stations can still
be used ⇒ Volkswagen Workshop Equipment catalogue.
♦ To prevent the intrusion of moisture, all components of the re‐
frigerant circuit which have been opened must be sealed with
suitable plugs.
WARNING
Danger from escaping pressurised refrigerant!

• Extract refrigerant and then immediately open refrigerant
circuit.
• If the refrigerant was extracted more than 10 minutes be‐
fore the opening of refrigerant circuit, the refrigerant must
be extracted again. The pressure in the circuit will increase
due to subsequent evaporation.
Removing
– Remove bolts -1- for refrigerant lines.
– Remove refrigerant lines from expansion valve.
Installing
note the following:
– Renew O-rings -2- ⇒ Partsagcatalogue
en AG. V . agen AG do
olksw
w es n
olks ot g
byV ua
ed ran
ris tee
tho or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
2.3 Removing and installing expansion

ot
wit
, is n
valve
h re
hole
spec

es, in part or in w
t to the co

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
31
cted agen
Prote AG.
2. Refrigerant circuit
Amarok 2011 ➤
Note

suitable plugs.
WARNING
Danger from escaping pressurised refrigerant!

• Extract refrigerant and then immediately open refrigerant
circuit.
• If the refrigerant was extracted more than 10 minutes be‐
fore the opening of refrigerant circuit, the refrigerant must
be extracted again. The pressure in the circuit will increase
due to subsequent evaporation.
Removing
– Removing refrigerant lines on expansion
wage
n AG. Vovalve
lkswag⇒
enpage
AG do 30 .
e ks s no
Vol t gu
– Unscrew bolts -1- from eexpansion
db
y valve -2-. ara
ris nte
1- Bolts utho eo
ra
a c
ss
2- Expansion valve
ce
e
nl
pt
du
an
3- O-ring
itte
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erm
ab
4- O-ring
ility
ot p
wit
, is n
Installing
h re
hole
spec

es, in part or in w
note the following:

t to the co
– Renew O-rings -3- and -4- ⇒ Parts catalogue .

Tightening torques
rrectness of i

l purpos
Bolts -1- on expansion valve 5 Nm

nf
ercia
orm
2.4 Removing and installing condenser

m
atio
om
n in
or c

thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
Note

suitable plugs.
Removing
– Remove front bumper ⇒ Rep. gr. 63 .
– Remove lock carrier ⇒ General body repairs, exterior; Rep.
gr. 50 ; Removing and installing lock carrier .
AG. Volkswagen AG d
agen oes
olksw not
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aut ra
ss c
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nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Refrigerant circuit 33
Amarok 2011 ➤
1 - Bolts for refrigerant line

❑ 12 Nm
2 - Mounting
❑ For condenser.
3 - Condenser with dryer ele‐
ment
dryer element
⇒ page 34 .
❑ Removing condenser:
WARNING
Danger from refrigerant
escaping under pres‐
sure!
Freezing of skin and oth‐
er body parts.
Evacuate
• the refrigerant
and then open the refrig‐ agen
AG. Volkswagen AG d
oes
erant circuit immediately. olksw not
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d by ara
e
If• more than 10 minutes horis nte
eo
have elapsed since evac‐ aut ra
s c
uation and the coolant s
ce
e
circuit has not been

nl
pt
du
an
opened, evacuate the re‐
itte
y li
frigerant again. Pressure
erm
ab
builds up in the coolant
ility
ot p
circuit as a result of sec‐
wit
, is n
h re
ondary evaporation.
hole
spec
es, in part or in w
– Loosen bolts -1- on re‐
t to the co
frigerant lines.
– Push fasteners -A- to‐
rrectness of i
gether in direction of arrow.
l purpos
– Remove condenser -3- from retainers -2-. nf

ercia
orm
Installing
m
atio
om

n in
or c
note the following:

thi
te
sd
iva
– Renew O-rings ⇒ Parts catalogue .

r
rp
cu
o
m
f
en
ng
2.5 Removing and installing dryer element

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
Note Prote
cted AG.
agen
Under certain conditions, it is not necessary to renew the dryer

cartridge every time that the refrigerant circuit is opened. Refer to
ELSA under ⇒ Air conditioning system with refrigerant R134a;
Rep. gr. 00 ; Renewing components .

Amarok 2011 ➤
AG. Volkswagen AG d
agen
Removing olksw
oes
not
byV gu
ara
d
– First evacuate refrigerant circuit using e.g. air conditioner
orise serv‐ nte
eo
ice station - VAS 6007A- . Then - and only then -auopenth ra
refrigerant circuit. ss c
ce
e
nl
pt
– Comply with notes ⇒ page 23 .
du
an
itte
y li
erm
– Remove front bumper ⇒ Rep. gr. 63 .
ab
ility
ot p
– Remove lock carrier ⇒ General body repairs, exterior; Rep.
wit
, is n
gr. 50 ; Removing and installing lock carrier .
h re
hole
spec
es, in part or in w
WARNING
t to the co
rrectness of i
l purpos

cuit immediately.
nf
ercia
o
rm
m
atio
m

o
n in
c

or
thi
te
sd
iva
o
r
rp
cu
o
m
– Remove cap -1-.
f
en
ng
t.
yi Co
op
– Pull strainer with dryer element out of condenser using long C py
ht. rig
nose pliers. rig ht
py by
co Vo
by lksw
Installing cted agen
Prote AG.

note the following:
– Renew dryer element.
– Renew O-rings ⇒ Parts catalogue .
Amarok 2011 ➤
Heating, air conditioning -olEdition
ksw
04.2013
AG. V agen AG
agen does
lksw not
2.6 Removing and installing evacuating and
o
yV gu
db ara
ise nte
charging valves on low and high-pres‐
r
tho eo
au ra
sure side
ss c
ce
e
nl
pt
du
an
⇒ “2.6.1 Removing and installing evacuating and charging valves,
itte
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high-pressure side”, page 36
erm
ab
ility
ot p
⇒ “2.6.2 Removing and installing evacuating and charging valves,
wit
, is n
low-pressure side”, page 39
h re
hole
spec
2.6.1 Removing and installing evacuating and
es, in part or in w
t to the co
charging valves, high-pressure side
Special tools and work‐
rrectness of i
shop equipment re‐
quired
l purpos
♦ Extract refrigerant,
e.g. with air condition‐
nf
ercia
er service station -
orm
VAS 6007A- (or suc‐
m
atio
m
cessor model).
o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Torque wrench -
V.A.G 1783- (2…10
Nm)
♦ Ratchet adapter 1/4"

- VAS 6234-

Amarok 2011 ➤
♦ Adapter set for evac‐

uating and charging
valve
Removing:
WARNING
Danger from escaping

pressurised refriger‐ agen
AG. Volkswagen AG d
oes
ant! yV
olksw not
g b ua
ed ran
Freezing of skin ho
risand tee
other body parts.
s aut or
ac
s
• Extract refriger‐ ce
le
un
pt
ant and then im‐ an
d
itte
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mediately open
rm
ab
refrigerant circuit.
pe
ility
ot
wit
• If the refrigerant
, is n
h re
was extracted
hole
spec
more than 10 mi‐

es, in part or in w
nutes before the

t to the co
opening of refrig‐
erant circuit, the
refrigerant must
rrectness of i
be extracted
again. The pres‐
l purpos
sure in the circuit

will increase due
nform
ercia
to subsequent
evaporation.
m
a
com
tion in
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te o
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♦ The refrigerant must
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conditioner service
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Prote
station - VAS 6007A-
AG.
(or successor model).

♦ Releasing refrigerant
into the environment
is a punishable of‐
fence.
♦ Comply with notes
⇒ page 23 .
1 - Connection with inter‐

nal thread
2 - O-ring
Amarok 2011 ➤
3 - Evacuating and
charging valve
4 - O-ring
5 - Cap
Installing
Installation is carried out
in the reverse order.
When installing, note the
following:
– Renew O-rings ⇒
Parts catalogue .
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Cop py
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pyri by
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Prote AG.

Amarok 2011 ➤
2.6.2 Removing and installing evacuating and

charging valves, low-pressure side
Special tools and work‐
shop equipment re‐
quired
♦ Extract refrigerant,
e.g. with air condition‐
er service station -
VAS 6007A- (or suc‐
cessor model).
♦ Torque wrench -
V.A.G 1783- (2…10
Nm)
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♦ Ratchet adapter 1/4" d by Vo ot g
ua
- VAS 6234- o
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rrectness of i
♦ Adapter set for evac‐

uating and charging
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valve
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Amarok 2011 ➤
Removing:
WARNING
Danger from escaping

pressurised refriger‐
ant!
Freezing of skin and
other body parts.
• Extract refriger‐ agen
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ant and then im‐
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mediately open ed b ara
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refrigerant circuit. horis
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• If the refrigerant ss c
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was extracted
un
pt
more than 10 mi‐
an
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rm
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pe
ility
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erant circuit, the
wit
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refrigerant must
h re
hole
be extracted
spec
again. The pres‐
es, in part or in w
t to the co
sure in the circuit
will increase due
to subsequent
evaporation.
rrectness of i
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Note
m
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t
♦ The refrigerant must
ion in
be extracted before‐
r
te o
thi
hand, e.g. with air
s
iva
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conditioner service
r
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station - VAS 6007A-
fo
en
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(or successor model).

n
t.
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Cop py
♦ Releasing refrigerant
ht. rig
rig ht
by
into the environment copy Vo
by lksw
is a punishable of‐ cted agen
Prote AG.
fence.
♦ Comply with notes
⇒ page 23 .
1 - Connection with ex‐

ternal thread and groove
for O-ring
2 - O-ring
3 - Evacuating and
charging valve
4 - O-ring
5 - Cap
Installing
Installation is carried out
in the reverse order.
When installing, note the
following:

Amarok 2011 ➤
– Renew O-rings ⇒
Parts catalogue .
lkswage es n
o ot g
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nl
pt
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Prote AG.
Amarok 2011 ➤
3 Air conditioner compressor

⇒ “3.1 Removing and installing air conditioner compressor”, page
42
⇒ “3.2 Notes on installing air conditioner compressor”,
page 44
⇒ “3.3 Checking high-pressure safety valve on air conditioner
compressor”, page 45
AG. Volkswagen AG d
agen
3.1 Removing and installing air conditioner
by
Vol
ksw
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compressor d ara
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ris
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spec
t to the co
rrectness o
cial p
f inform
♦ Torque wrench - V.A.G 1331-
mer
atio
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n
c
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or
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te
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by
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Prote AG.
Removing
Note
♦ The refrigerant must be extracted beforehand, e.g. with air conditioner service station - VAS 6007A- .
♦ Comply with notes ⇒ page 23 .

Amarok 2011 ➤
lkswage es n
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t to the co
rrectness o
cial p
f inform
mer
atio
om
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c
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or
n thi
te
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o
pr
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t.
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Cop py
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Vo
co lksw
by
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Prote AG.

WARNING

– Remove refrigerant line bolts and pull refrigerant lines out of

air conditioner compressor.
– Remove bolts -4- and remove air conditioner compressor from
bracket -1-.
3. Air conditioner compressor 43

Amarok 2011 ➤
Installing
Note
Make sure dowel sleeves -2- and elastic drive coupling fit properlyAG. Volkswagen AG d
between air conditioner compressor and power steering agen
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Tightening torques ss
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Bolts -4- for air conditioner compres‐ 25 Nm
erm
ab
sor
ility
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wit
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3.2 Notes on installing air conditioner com‐
h re
ole,
spec
pressor
t to the co
The following must be observed:
– Only start engine after refrigerant circuit has been assembled.
rrectne
– After installing a new air conditioner compressor or filling with
fresh refrigerant oil, turn air conditioner compressor pulley 10
ss
revolutions by hand before starting engine. This will prevent
o
cial p
f
damage to the air conditioner compressor.
inform
mer
– Only start engine when refrigerant circuits are charged.
atio
om
n
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e
Note
t
sd
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♦ The air conditioner compressor is permanently driven by the
en
ng
t.
poly V-belt pulley/elastic drive coupling. It is not fitted with a
yi Co
op
magnetic clutch.
C py
t. rig
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♦ If an air conditioner compressor locks up, the overload pro‐
op Vo
by c lksw
tection for the compressor shaft is triggered. A seized air
cted agen
Prote AG.
conditioner compressor cannot always be identified by visible
deformations in the poly V-belt pulley and overload protection.
Another indication is abraded rubber material around the poly
V-belt pulley or overload protection.
♦ 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 about
40 to 50 cm3 refrigerant oil remain in the air conditioner com‐
pressor.
♦ The engine may be started only when the refrigerant circuit is
properly assembled. If, for example, the refrigerant lines are
not connected to the air conditioner compressor and the en‐
gine is running, the compressor may heat up so much through
internal warming that it will be destroyed.
♦ The air conditioner compressor regulating valve - N280- is not
activated when the refrigerant circuit is empty. The air condi‐
tioner 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 2500 rpm.
♦ Run engine only as long as absolutely necessary.

Amarok 2011 ➤
Note the following when starting engine for first time after filling
refrigerant circuit:
– Switch on ignition.
– Select “ECON” function on Climatronic operating and display
unit - E87- .
– Start engine.
As soon as the idling speed stabilizes.
– Open dash panel vents.
– Set temperature to “Lo” on Climatronic operating and display
unit - E87- .
– Now switch to “Auto” mode and let the air conditioner run for
at least 5 minutes with the engine at idling speed.
3.3 Checking high-pressure safety valve on

air conditioner compressor lksw
agen
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WARNING ut
ho or
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ab
ility
ot p
cuit immediately.
wit
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spec
es, in part or in w
t to the co
rrectness of i
♦ Function: protects refrigerant circuit against excessive pres‐
l purpos
sures.
♦ The high-pressure safety valve indicates whether the valve
nf
ercia
has been opened. An attached adhesive plate -arrow- is push‐
orm
ed out.
m
atio
om
n in
or c
thi
te
sd
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t.
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Cop py
t. rig
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Vo
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by
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Prote AG.
3. Air conditioner compressor 45

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
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c
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or
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te
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pr
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en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
4 Control motors
⇒ “4.1 Fitting location overview - control motors on heater and air
conditioning unit”, page 47
⇒ “4.2 Removing retaining plate for defroster flap control motor
V107 and air distribution flap control motor V428 ”, page 48
⇒ “4.3 Removing and installing defroster flap control motor V107
”, page 48
⇒ “4.4 Removing and installing air distribution flap control motor
V428 ”, page 49
⇒ “4.5 Removing and installing retaining plate
wage
n AG.with
Volksfootwell
wagen AG flap
doe
control motor V261 and temperature yV
olkflap control motor V68 ”, s not gu
s
page 49 ise
d b ara
n r tee
ho
⇒ “4.6 Removing and installing
sa
ut footwell flap control motor V261 ”, or
ac
page 50 s
ce
e
nl
pt
du
⇒ “4.7 Removing retaining plate with footwell flap control motor
an
itte
y li
V261 and left temperature flap control motor V158 ”, page 50
erm
ab
ility
ot p
⇒ “4.8 Removing and installing left temperature flap control motor
wit
, is n
V158 ”, page 51
h re
hole
⇒ “4.9 Removing and installing right temperature flap control mo‐
spec
es, in part or in w
tor V159 ”, page 51
t to the co
4.1 Fitting location overview - control motors on heater and air conditioning unit
rrectness of i
Note
l purpos
♦ Checking control motors using ⇒ Vehicle diagnostic tester guided fault finding
nf
ercia
♦ After installing a new control motor, perform function “Basic settings” ⇒ page 2 . orm
m
atio
om
♦ Check motor/connecting element for fault “adaption limit exceeded”. No play may exist between control
n in
or c
motor shaft and connecting element.

thi
te
sd
iva
o
r
rp
cu
1 - Defroster flap control motor

o
m
f
en
ng
- V107-
t.
yi Co
op
C py
ht. rig
front cold air flap control
rig ht
py by
o Vo
motor - G315- . by c lksw
cted agen
Prote AG.
⇒ “4.3 Removing and in‐
stalling defroster flap
control motor V107 ”,
page 48 .
2 - Air distribution flap control
motor - V428-
front air distribution con‐
trol motor - G470- .
⇒ “4.4 Removing and in‐
stalling air distribution
flap control motor V428
”, page 49 .
trol motor - V159-
tribution housing.
4. Control motors 47
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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Amarok 2011 ➤ aut
h
ra
s c
Heating, air conditioning - Edition 04.2013 s
ce
e
nl
pt
du
an
right temperature flap control motor - G221-
itte
y li
erm
ab
ility
ot p
⇒ “4.9 Removing and installing right temperature flap control motor V159 ”, page 51 .
wit
, is n
h re
4 - Footwell flap control motor - V261-
hole
spec
❑ With potentiometer for footwell vent control motor - G468- .
es, in part or in w
t to the co
❑ Removing and installing ⇒ “4.6 Removing and installing footwell flap control motor V261 ”, page 50 .
5 - Left temperature flap control motor - V158-
rrectness of i
❑ With potentiometer for left temperature flap control motor - G220- .
l purpos
⇒ “4.8 Removing and installing left temperature flap control motor V158 ”, page 51 .
nform
mercia
at
4.2 Removing retaining plate for defroster
om
ion
flap control motor - V107- and air distri‐ c
in t
or
his
ate
bution flap control motor - V428-
do
priv
cum
for
Removing
en
ng t.
yi Co
op py
. C rig
ht ht
rig by
py
– Removing lower retaining plate for footwell flap control motor
co Vo
by lksw
cted
- V261- and temperature flap control motor - V68-
agen
Prote AG.
⇒ page 49 .
Note
To remove the retaining plate, the bolts -1- are not loosened or
removed. They are used for guiding the retaining plate.
– Pull out retaining plate with control motors downwards.
Installing
4.3 Removing and installing defroster flap

control motor - V107-
Removing
– Remove retaining plate -2- ⇒ page 48 .
– Remove bolts -4- (Qty. 3) from defroster flap control motor -
V107- -A-.
– Remove control motor from retaining plate -2-.
Installing
Install in reverse order. Note the following when doing this:
– Initiate basic setting using ⇒ Vehicle diagnostic tester
⇒ page 2 .

Amarok 2011 ➤
4.4 Removing and installing air distribution

flap control motor - V428-
Removing
– Remove retaining plate -2- ⇒ page 48 .
– Remove bolts -4- (Qty. 3) from air distribution flap control mo‐
tor - V428- -B-.
Installing AG. Volkswagen AG d
agen oes
olksw not
Install in reverse order.d by Note
V the following when doing this:
gu
ara
rise nte
– Initiate basic utho setting using ⇒ Vehicle diagnostic tester eo
ra
a
⇒ page 2 .ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
4.5 Removing and installing retaining plate
h re
hole
spec
with footwell flap control motor - V261-
es, in part or in w
and temperature flap control motor -
t to the co
V68-
rrectness of i
Removing
l purpos

nform
mercia
at
om
Note
on
c
in t
or
his
te
a
do
riv

p
cum
for
en
ng
t.
yi Co
– Separate connectors. Cop py
t. rig
gh ht
yri
– Pull out retaining plate with control motors downwards. p by
co Vo
by lksw
cted agen
Installing Prote AG.
– During installation, ensure that control motor drive -A- is push‐

ed into mounting -B-.
⇒ page 2 .
Amarok 2011 ➤
4.6 Removing and installing footwell flap

control motor - V261-
Removing
– Remove lower retaining plate -2- for footwell flap control motor
- V261- and temperature flap control motor - V68-n AG. Volkswagen AG do
⇒ page 49 . lkswage es n
o o V t gu
by ara
– Remove bolts -4- (Qty. 3) from footwell
ise
d
flap control motor - nte
or
V261- -B-. auth eo
ra
ss c
ce
le
un
pt
an
d
Installing
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
⇒ page 2 .
spec
t to the co
rrectne
4.7 Removing retaining plate with footwell
flap control motor - V261- and left tem‐
ss o
cial p
perature flap control motor - V158-
f inform
mer
Removing
atio
om
n
– Initiate Service position of control motors using ⇒ Ve‐
c
i
or
n thi
hicle diagnostic tester ⇒ page 2 .
te
sd
iva
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– When “SF” appears on display of Climatronic operating unit,

p
cum
r
fo
switch ignition off.

en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
Note
p by
co Vo
by lksw
cted agen
Prote AG.
♦ After removal, the control motors can be reinstalled only when
set in the service position “SF”.
♦ Replacement parts are supplied set in the service position!

Note
– Pull out retaining plate with control motors downwards.
Installing

Amarok 2011 ➤
– During installation, ensure that control motor drive -A- is push‐

⇒ page 2 .
4.8 Removing and installing left tempera‐

ture flap control motor - V158-
Removing
– Remove lower retaining plate -2- for footwell flap control motor
- V261- and left temperature flap control motor - V158-
⇒ page 50
– Remove bolts -4- (Qty. 3) from left temperature flap control
motor - V158- -A-.
– Remove control motor from retaining plate -2-. agen
AG. Volkswagen AG d
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Installing d by V gu
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Installation is carried out in the reverse order. When
utho
installing, eo
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note the following: ss a c
ce
le
un
pt
an
d
itte
⇒ page 2 .
y li
erm
ab
ility
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is n
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ole,
spec
4.9 Removing and installing right tempera‐
t to the co
ture flap control motor - V159-
Removing
rrectne
– Initiate Service position of control motors using ⇒ Ve‐
hicle diagnostic tester. ss o
cial p
– When “SF” appears on display of Climatronic operating unit,

f in
switch ignition off.

form
mer
atio
om
n
c
Note
i
or
n thi
te
sd
iva
♦ Once the control motors have been removed, they can be re‐
o
pr
cum
r
fo
installed only in the service position “SF”.

en
ng
t.
yi Co
♦ Replacement parts are supplied set in the service position! Cop py
t. rig
gh ht
pyri by
Vo
o
– Remove glove compartment ⇒ General body repairs, interior;
c by lksw
cted agen
Rep. gr. 68 ; Removing and installing glove compartment
Prote AG.
– Remove centre dash panel trim panels ⇒ General body re‐

pairs, interior; Rep. gr. 68 ; Removing and installing centre
dash panel trim panels
AG. Volkswagen AG d
agen oes
olksw not
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Amarok 2011 ➤ rise
d b ara
nte
Heating, air conditioning - Edition 04.2013 autho eo
ra
ss c
ce
e
– Unscrew bolts -arrows- from retaining plate of right tempera‐
nl
pt
du
ture flap control motor - V159- .
an
itte
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erm
ab
– Pull out retaining plate with control motor downwards.
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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orm
m
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om
n in
or c
thi
te
sd
iva
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cu
– Remove bolts -3- (Qty. 3) from temperature flap control motor
o
m
f
-4-.
en
ng
t.
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op py
– Remove control motor from retaining plate -1-. t. C rig
gh ht
pyri by
Installing
co Vo
by lksw
cted agen
Prote AG.
note the following:
– Screw right temperature flap control motor - V159- to retaining
plate.
– Fit connector.
– Switch on ignition.
– Set rotary knob for interior temperature, right to “24°”.
– During installation, ensure that control motor driver -A- is push‐

If necessary, move the driver to the correct position by gently
turning the rotary knob for interior temperature control, right.
The remaining steps for installation are carried out in reverse or‐
der.

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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orm
m
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om
n in
or c
thi
te
sd
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o
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5. Front heater and air conditioning unit 53

Amarok 2011 ➤
5 Front heater and air conditioning unit agen

AG. Volkswagen AG d
oes
olksw not
⇒ “5.1 Assembly overview - heater and air conditioning unit”,edpage
by
V gu
ara
54 horis nte
eo
aut ra
⇒ “5.2 Removing and installing evaporator”, page 57 ss c
ce
e
nl
⇒ “5.3 Dismantling and assembling heater and air conditioning
pt
du
an
itte
unit”, page 58
y li
erm
ab
⇒ “5.4 Removing and installing heater and air conditioning unit”,
ility
ot p
page 59
wit
, is n
h re
hole
⇒ “5.5 Checking condensation drain hose with valve”, page 62
spec
es, in part or in w
⇒ “5.6 Removing and installing evaporator temperature sensor
t to the co
G308 ”, page 62
5.1 Assembly overview - heater and air con‐
rrectness of i
ditioning unit
l purpos
⇒ “5.1.1 Assembly overview - heater and air conditioning unit,

manually controlled air conditioning system”, page 54
nform
ercia
⇒ “5.1.2 Assembly overview - heater and air conditioning unit,

m
at
Climatronic”, page 55
om
ion
c
in t
or
5.1.1 Assembly overview - heater and air conditioning unit, manually controlled
his
ate
do
riv
air conditioning system

p
cum
for
en
ng
t.
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1 - Heating and air conditioning
Co
Cop py
controls ht. rig
rig ht
py by
❑ With fresh air and air re‐
co Vo
by lksw
cted
circulation flap switch -
agen
Prote AG.
E159- .
❑ With heated rear win‐
dow button - E230- .
❑ With fresh air blower
switch - E9-
❑ For vehicles with seat
heating, also with heat‐
ed driver seat regulator
- E94- and heated front
passenger seat regula‐
tor - E95- .
❑ With air conditioning
system control unit -
J301- .
⇒ page 68
motor - V113-
⇒ page 18
⇒ page 8 .
4 - Fresh air blower series re‐
sistor with overheating fuse -
N24-
⇒ page 9 .

Amarok 2011 ➤

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5.1.2 Assembly overview - heater and air conditioning unit, Climatronic
rrectness of i
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1 - Climatronic operating and

display unit - E87- with Clima‐
nform
ercia
tronic control unit - J255-

m
at
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ion
⇒ page 71 .
c
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2 - Control motors
❑ Installation position of
control motors
⇒ page 29 .
3 - Heater and air conditioning
unit
⇒ page 59 .
4 - Left vent temperature send‐
er - G150-
⇒ page 63 .
5 - Right vent temperature
sender - G151-
⇒ page 63 .
trol motor - V159-
⇒ page 51 .
7 - Evaporator temperature
sensor - G308-

Amarok 2011 ➤

10 - Sender for front Bitron blower regulation - G462-
11 - Right footwell vent
❑ Removing and installing ⇒ page 9 . lkswage es n
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13 - Right footwell vent temperature sender - G262- o
ir se
ran
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s
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14 - Left footwell vent temperature sender - G261- d
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❑ Left footwell vent temperature sender - G261- is installed in left footwell vent.
pe
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15 - Left footwell vent
spec
es, in part or in w
t to the co
rrectness of i
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Amarok 2011 ➤
5.2 Removing and installing evaporator

Removing
– Remove heater and air conditioner unit ⇒ page 59 .

box
2 - Retaining clip
❑ Qty. 3
3 - Securing bolts
4 - Blower housing agen
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Evaporator seal Prote AG.
Observe seal -arrows- along perimeter of evaporator.

Amarok 2011 ➤
5.3 Dismantling and assembling heater and air conditioning unit

Dismantling and assembling.
– Remove heater and air conditioner unit ⇒ page 59 .

box
2 - Retaining clip
❑ Qty. 3.
3 - Securing bolts
4 - Blower housing
5 - Evaporator
❑ Observe seal
⇒ page 57 .
box
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5.4 Removing and installing heater and air conditioning unit
pt
du
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Note
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♦ The refrigerant must be extracted beforehand, e.g. with air conditioner service station - VAS 6007A- .
spec
es, in part or in w
♦ Comply with notes ⇒ page 23 .
t to the co
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Special tools and workshop
equipment required
l purpos
♦ Hose clamps up to 40 mm -
3093-
nform
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♦ Drip tray for workshop hoist
m
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- VAS 6208-
ion
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♦ Torque wrench - V.A.G
his
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do
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tion - VAS 6007A-
Co
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Removing
– Remove noise insulation from engine .

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Amarok 2011 ➤ wage
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– Place drip tray - VAS 6208- aubeneath
t
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– Clamp off coolant hoses using hose clamps up to 40 mm -
ce
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WARNING
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Danger of scalding due to hot steam and coolant.
rrectness of i
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AG.

– Disconnect refrigerant lines on expansion valve ⇒ page 30 .


Amarok 2011 ➤
AG. Volkswagen AG d
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ion
c
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or
– Remove subframe for dash panel -3- ⇒ Rep. gr. 70 .

his
ate
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– Disconnect connectors to heater and air conditioning unit -1-

p
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and remove unit.

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Installing C py
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Installation is carried out in reverse order.
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After installation, replenish coolant ⇒ Rep. gr. 19 .
AG.
Note
Ensure that seal is properly seated between heat exchanger and

bulkhead.

Amarok 2011 ➤
5.5 Checking condensation drain hose with

valve
AG. Volkswagen AG d
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– Removing footwell trim on front risepassenger side ⇒ Rep. gr.
d b ara
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♦ It must be possible to push the condensation drain hose -1- s
ce
le
onto the heater and air conditioner unit connection without

un
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d
tension.
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♦ The condensation drain hose must not be pinched by the in‐
ility
ot p
sulation mat.
wit
is n
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– Rework insulation mat if necessary.
spec
♦ The condensation drain hose must fit securely on the conden‐
t to the co
sation drain hose connector on the heater and air conditioner
unit.
rrectne
– The valve on the condensation drain hose -2- is located on the
bulkhead on the right in the engine compartment.
ss o
cial p
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Note
inform
mer
atio
The function of the valve must not be impaired by conservation
om
wax or underseal. It must open and close properly.
n
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5.6 Removing and installing evaporator
um
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Note
Evaporator temperature sensor - G308- can be reached from front

passenger footwell.
– Separate connector on evaporator temperature sensor -

G308- -1-.
– Turn evaporator temperature sensor - G308- -1- 90° and re‐
move it from housing.
Installing

Amarok 2011 ➤
6 Air duct
⇒ “6.1 Removing and installing left vent temperature sender G150
”, page 63
⇒ “6.2 Removing and installing right vent temperature sender n AG. Volkswagen AG do
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G152 ”, page 64 utho eo
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⇒ “6.4 Removing and installing footwell vent temperature sender
ce
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pt
G192 ”, page 64
du
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⇒ “6.5 Removing and installing left footwell vent temperature
erm
ab
ility
sender G261 ”, page 64
ot p
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⇒ “6.6 Removing and installing right footwell vent temperature
h re
hole
sender G262 ”, page 65
spec
es, in part or in w
6.1 Removing and installing left vent tem‐
t to the co
perature sender - G150-
rrectness of i
Removing
l purpos
– Remove retaining plate for control motors V107 and V428

⇒ page 48 .
nf
ercia
– Pull connector off vent temperature sender -1-.
orm
m
atio
– Turn left vent temperature sender - G150- -1- 90° and remove
om
it from housing.
n in
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t
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– Install in reverse order.
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cted agen
Prote AG.
6.2 Removing and installing right vent tem‐

Removing
– Remove passenger side airbag unit ⇒ General body repairs,
interior; Rep. gr. 69 ; Removing and installing passenger side
airbag unit .
– Pull connector off vent temperature sender -1-.
– Turn right vent temperature sender - G151- -1- 90° and re‐
Installing
6. Air duct 63
Amarok 2011 ➤
6.3 Removing and installing front vent tem‐

Removing
– Remove passenger side airbag unit ⇒ General body repairs,
interior; Rep. gr. 69 ; Removing and installing passenger side
airbag unit or remove dash panel storage compartment ⇒ AG. Volkswagen AG d
General body repairs, interior; Rep. gr. 68 ; Removing and agen oes
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– Turn front vent temperature sender - G152- -1- 90° and re‐
ce
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6.4 Removing and installing footwell vent
l purpos
temperature sender - G192-
nf
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o
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rm
m
atio
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– Remove heating and air conditioning controls and installation

o
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c
frame ⇒ page 68 .
or
thi
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– Pull connector off sender -1- for footwell vent temperature

iv
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sender - G192- .
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– Turn footwell vent temperature sender -1- 90° and remove
Co
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from footwell vent. t. C rig
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cted agen
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6.5 Removing and installing left footwell

vent temperature sender - G261-
Removing
– Removing operating and display unit for Climatronic air con‐
ditioning system - E87- with Climatronic control unit - J255-
⇒ page 68 .

AG. Volkswagen AG d
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Heating, air conditioning
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ho eo
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– Pull connector off senders -1- for left footwell vent temperature
s c
ce
e
sender - G261- .
nl
pt
du
an
itte
– Turn footwell vent temperature sender -1- 90° and remove
y li
erm
ab
from footwell vent.
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Installing
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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6.6 Removing and installing right footwell
nform
ercia
vent temperature sender - G262-

m
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om
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ion
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Note
p
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Right footwell vent temperature sender - G262- can be reached

t.
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from front passenger footwell.
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rig ht
py by
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– Pull connector off right footwell vent temperature sender - Prote
cted AG.
agen
G262- -1-.
– Turn right footwell vent temperature sender - G262- -1- 90°
and remove from footwell vent.
Installing
6. Air duct 65
Amarok 2011 ➤
7 Operating and display unit

⇒ “7.1 Operating and display unit for heater and air conditioning
system with manually regulated air conditioning system”,
page 66
⇒ “7.2 Removing and installing operating and display unit, man‐
ually controlled air conditioning system”, page 68
⇒ “7.3 Functions of operating and display unit for Climatronic
heater and air conditioning system”, page 68
⇒ “7.4 Removing and installing Climatronic air conditioning oper‐
ating and display unit E87 with Climatronic control unit J255 ”,
page 71
7.1 Operating and display unit for heater

and air conditioning system with man‐
ually regulated air conditioning system
⇒ “7.1.1 Functions of operating and display unit for heater and air
conditioning system”, page 66
G. Volkswage
7.1.1 Functions of operating and display
olks
wage unit for heater
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1 - Rotary knob for interior tem‐
ce
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perature
pt
du
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2 - AC button
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ility
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❑ Press AC button to
wit
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switch cooling on and
h re
off.
hole
spec
❑ Warning lamp in button
es, in part or in w
t to the co
lights up yellow when air
conditioner compressor
is switched on.
rrectness of i
Note
l purpos
If AC button is switched off, air con‐

nform
ercia
ditioner compressor will be switched

to almost zero delivery. The heating
m
at
and ventilation operations continue

om
ion
to be controlled automatically.
c
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3 - Button for recirculation

p
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mode
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4 - Rotary regulator for air dis‐ Cop py
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5 - Fresh air blower switch -
by lksw
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E9-
AG.

Amarok 2011 ➤
Pin assignment on rear of operating and display unit for heater

and air conditioning system
20-pin connector, connector housing -A-, T20 in current flow di‐
agram
1 - Air distribution flap control motor - V428- closed
2 - Air distribution flap control motor - V428- open
4 - Potentiometer for front air distribution control motor - G470-
5 - Air conditioning system pressure switch - F129-
7 - CAN, low
8 - CAN, high
9 - Footwell flap control motor - V261- , closed
10 - Footwell flap control motor - V261- , open
11 - Potentiometer for footwell vent control motor - G468- n AG. Volkswagen AG do
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14 - Circulation pump - V55- byV
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16 - Air conditioner compressor regulating valve - N280-
tho tee
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18 - Signal, earth ss
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19 - Terminal 30
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20 - Terminal 31
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16-pin connector, connector housing -B-, T16k in current flow di‐
h re
ole,
agram
spec
1 - Temperature flap control motor - V68- , warm
t to the co
2 - Evaporator output temperature sender - G263-
3 - Potentiometer for defroster flap control motor - G135-
rrectne
ss o
5 - Temperature flap control motor potentiometer - G92-
cial p
f inform
7 - + 5 volt
mer
atio
m
8 - Earth signal for potentiometer

o
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9 - Air recirculation flap control motor - V113- open
thi
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10 - Air recirculation flap control motor - V113- closed

pr
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11 - Temperature flap control motor - V68- , cold

t.
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12 - Defroster flap control motor - V107- , open
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13 - Defroster flap control motor - V107- , closed
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Prote AG.
5-pin connector, connector housing -C-, T5n in current flow dia‐

gram
1 - Blower 3rd speed
2 - Blower 2nd speed
3 - Blower 1st speed
4 - Blower 4th speed
5 - X terminal

Amarok 2011 ➤
7.2 Removing and installing operating and

display unit, manually controlled air con‐
ditioning system
Removing
– Remove bolts -2- and remove controls -1- from dash panel.
Installing
Tightening torques
Bolts -2- for control and display unit 1.5 Nm
7.3 Functions of operating and display unit

for Climatronic heater and air condition‐
ing system . Volkswage AG n AG d
agen oes
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⇒ “7.3.1 Functions of operating and ydisplay not
Vol gu
air conditioning system E87 withiseClimatronic
db control unit J255 ”, ara
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page 68 thor eo
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7.3.1 Functions of operating and display unit
ce
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pt
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for Climatronic air conditioning system -

an
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E87- with Climatronic control unit - J255-

erm
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Note
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♦ A warning lamp in the instrument panel controls will indicate

that the selected function is active. In addition, the radio or
radio navigation system display will indicate the selected func‐
tion for a short time when a button is pressed or a regulator is
rrectness of i
operated.
l purpos
♦ If a new operating and display unit for Climatronic air condi‐

tioning system - E87- with Climatronic control unit - J255- is
nf
ercia
installed, basic setting and adaptation “Compressor first run”

orm
must be carried out in Guided fault finding or in Guided func‐

m
atio
m
tions using ⇒ Vehicle diagnostic tester.

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Amarok 2011 ➤
1 - Rotary knob for interior tem‐

perature, left n AG. Volkswagen A G do
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2 - AUTO button Volks ot g
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❑ Pressingththeise
or AUTO but‐ tee
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ton causes
au the Clima‐ ac
ss
tronic to maintain the
ce
le
selected interior tem‐

un
pt
an
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perature completely au‐

itte
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ab
pe
ility
setting, the vent air tem‐
ot
wit
perature, the blower
, is n
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speed and the air distri‐
hole
bution are controlled au‐
spec
es, in part or in w
tomatically.
t to the co
3 - Defrost function button for
windscreen
rrectness of i
4 - Upwards air distribution but‐
ton
l purpos
5 - Centre air distribution but‐
nform
ton
mercia
6 - Downwards air distribution
a
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button
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7 - Button for air recirculation
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rig ht
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circulation mode and by c lksw
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prevent polluted air from
Prote AG.
entering the interior.

❑ Pressing the air recircu‐
lation mode button
again will activate the
automatic recirculation
mode.
Note
Function of air quality sensor -

G238- ⇒ page 73 .
8 - Button for heated rear window

9 - AC pushbutton
❑ Press the AC button to switch cooling on and off.
❑ If the lamp in the button is on, the air conditioner compressor is switched on.
10 - Rotary knob for interior temperature, right
11 - Synchronisation button
❑ If the lamp in the button is not on, the left and right temperatures may be adjusted independently.
❑ If the Synchronisation button is pressed (warning lamp lights up), the passenger side will assume the
temperature setting for the driver side.
12 - Residual button
❑ When the residual heat function is switched on, residual engine heat is pumped to the heat exchanger
by a coolant pump.
13 - Blower regulator
❑ Press briefly to change the blower speed.

Amarok 2011 ➤
14 - Air conditioner OFF button

❑ For switching Climatronic on or off
Pin assignment on rear of operating and display unit for Clima‐

tronic air conditioning system - E87- with Climatronic control unit
- J255-
20-pin connector, T20a in current flow diagram -A-
1 - Sunlight penetration photosensor - G107- , signal
2 - Air conditioning system pressure switch - F129-
3 - Sunlight penetration photosensor - G107- , signal
5 - CAN, high
6 - CAN, low
9 - + 5 V for sunlight penetration photosensor - G107-
13 - Vent temperature sender - G150-
14 - Right vent temperature sender - G151-
17 - Earth signal for sunlight penetration photosensor - G107- ,
vent temperature sender - G150- , right vent temperature sender
- G151- ; evaporator temperature sensor - G308- ; left footwell
vent temperature sender - G261- and right footwell vent temper‐
ature sender - G262-
18 - Air conditioner compressor regulating valve - N280-
19 - Terminal 31
20 - Terminal 30
16-pin connector, T16l in current

swa
geflow diagram
n AG. V -B- does
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ed
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2 - Potentiometer
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th motor - G220- or a
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3 - Potentiometer for right temperature flap control motor - G221-
ce
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pt
an
d
4 - Potentiometer for defroster flap control motor - G135-

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ab
pe
5 - Potentiometer for left footwell flap control motor - G139-

ility
ot
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6 - Potentiometer for front air distribution control motor - G470-

h re
hole
spec
7 - Potentiometer for fresh air/recirculated air, air flow flap control

es, in part or in w
motor - G644-
t to the co

9 - Right footwell vent temperature sender - G262-
rrectness of i

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12 - Fresh air blower control unit - J126- , signal

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14 - Signal earth, potentiometer

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15 - Auxiliary coolant heater relay - J493-

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Amarok 2011 ➤
16-pin connector, T16m in current flow diagram -C-

1 - Left temperature flap control motor - V158- , cold
2 - Left temperature flap control motor - V158- , warm
3 - Defroster flap control motor - V107- , closed
4 - Defroster flap control motor - V107- , open
5 - Left footwell flap control motor - V108- , open
6 - Left footwell flap control motor - V108- , closed
7 - Air distribution flap control motor - V428- , closed
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8 - Air distribution flap controlbmotor
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10 - Air recirculation flap
ss control motor - V113- , closed
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11 - Right temperature flap control motor - V159- , cold
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12 - Right temperature flap control motor - V159- , warm
ility
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15 - Fresh air blower control unit - J126-
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7.4 Removing and installing Climatronic air
es, in part or in w
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conditioning operating and display unit -
E87- with Climatronic control unit - J255-
rrectness of i
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Note
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Climatronic control unit - J255- and operating and display unit for
Climatronic air conditioning system - E87- cannot be dismantled. orm
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Removing
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– Remove bolts -arrows- and remove operating and display unit

f
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for Climatronic air conditioning system - E87- -1- from dash
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Installing
Tightening torques
Bolts -arrows- for control and display 1.5 Nm
unit

Amarok 2011 ➤
8 Other controlling and regulating com‐

ponents
⇒ “8.1 Removing and installing ambient temperature sensor -
G17-”, page 72
⇒ “8.2 Removing and installing sunlight penetration photosensor
G107 ”, page 72
⇒ “8.3 Working principles of air quality sensor G238 ”,
page 73
⇒ “8.4 Removing and installing air quality sensor G238 ”,
page 74
⇒ “8.5 Removing and installing sender for front Bitron blower reg‐
ulation G462 ”, page 75
8.1 Removing and installing ambient tem‐

perature sensor -G17-
Location
The ambient temperature sensor - G17- is located behind the
bumper.
Removing
– Remove bumper cover ⇒ General body repairs, exterior; Rep.
gr. 63 ; Removing and installing bumper cover .
– Remove retaining clip from ambient temperature sensor -
G17- and remove sensor. wage
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Installing byV ua
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– Install in reverse order. auth or
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8.2 Removing and installing sunlight pene‐

pt
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tration photosensor - G107-
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Checking
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Check using ⇒ Vehicle diagnostic tester guided fault find- h re

hole
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ing .
es, in part or in w
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Functions:
♦ Controls the temperature flap and the fresh air blower based
rrectness of i
on the intensity of the light

l purpos
Emergency operation in the event of a failure:

♦ The Climatronic control unit - J255- takes on a fixed value.
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Amarok 2011 ➤
AG. Volkswagen AG d
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– Unclip sensor -1- from dash panel. thori
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Installing ss c
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8.3 Working principles of air quality sensor -
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G238-
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♦ The air quality sensor - G238- detects noxious substances in

the ambient air (primarily petrol and/or diesel fumes).
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♦ The Climatronic control unit - J255- evaluates the signal from
r
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the air quality sensor - G238- . The air conditioning system is
s
iva
actuated depending on the degree and manner of ambient air
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At an ambient temperature higher than approx. + 3 ℃, air recir‐
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culation mode is activated even when there is a minimal increase
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At an ambient temperature of less than approximately +3 ℃, air Prote AG.
recirculation is not actuated until there is a strong increase in
noxious substances in the outside air, and only for approximately
15 seconds. The air conditioner compressor is not actuated.
When the concentration decreases, the air conditioning system
is switched back to fresh air mode.
♦ The “automatic recirculation mode” can be switched off at any
time.
♦ So that the air conditioning system does not operate continu‐
ally in air recirculation mode in areas with consistently high
levels of pollutants, the "intelligent" sensor adapts its sensitiv‐
ity to the prevailing environmental pollution. It adapts its sen‐
sitivity to the environmental pollution.
♦ If the level of pollutants in the outside air remains high over a
longer period the intelligent sensor starts to adapt to the
change in environmental conditions. Therefore the require‐
ment for recirculated air in an uniformly polluted outside air
environment usually less than 12 minutes. If a series of pollu‐
tion peaks occur, the air conditioning system may operate over
a longer period of time in air recirculation mode.
♦ A certain amount of time is required for repositioning of the air
conditioning system flaps. To prevent noxious 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 instal‐
led. A saturated filter cannot perform this task and should be
renewed ⇒ page 9 .
♦ To prevent frequent operation of the recirculation/fresh air flap,
the flap is not actuated immediately if there is a nominal in‐
crease in harmful substances in the outside air. The sensor
does not send a request to the Climatronic control unit - J255- .
The effect of the activated charcoal filter in the dust and pollen
filter is adequate for this.
8. Other controlling and regulating components 73

Amarok 2011 ➤
♦ To prevent frequent operation of the air recirculation/fresh air

flap, the request from the “automatic recirculation mode” sen‐
sor continues for at least 25 seconds (minimum waiting peri‐
od). This also applies when the concentration of noxious
substances in the air has reduced to a level where the air re‐
circulation mode is no longer required.
♦ If the air conditioner compressor is switched off (e.g. in ECON
mode), the maximum period of “automatic air recirculation” is
limited to approx. 15 seconds by the Climatronic control unit -
J255- , so that condensation does not develop on the windows.
Volkswa AG. gen AG
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♦ To clear condensation Vol
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the Climatronic d by
control unit - J255- does not permit aair
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se
culation when
thori the “defrost function” is activated. tee
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♦ The air squality
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sensor - G238- requires approx. 30 seconds to
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become operational once the ignition has been switched on

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(warm-up period). During this time, the sensor can send no
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request for “automatic recirculation mode” to the Climatronic
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control unit - J255- .
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♦ The air quality sensor - G238- is a highly sensitive electronic
h re
component which direct contact with solvents, fuels and cer‐
hole
spec
tain chemical compositions could damage beyond repair. For
es, in part or in w
this reason, do not install sensors that may have come into
t to the co
contact with these substances.
8.4 Removing and installing air quality sen‐

rrectness of i
sor - G238-
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Removing
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Note
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♦ Air quality sensor - G238- is installed in plenum chamber.

his
ate
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♦ The air quality sensor - G238- is a highly sensitive electronic

p
cum
or
component which direct contact with solvents, fuels and cer‐

f
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t.
tain chemical compositions could damage beyond repair.
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♦ Do not install a sensor that has been kept, for example, in a
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♦ Do not place a removed sensor in an area where it can come
into contact with solvents, fuels and certain chemical com‐
pounds (fluids or vapours).
– Remove plenum chamber cover.

– Unclip air quality sensor - G238- -1-.
Installing

Amarok 2011 ➤
8.5 Removing and installing sender for front

Bitron blower regulation - G462-
Removing
– Separate connectors from sender for front Bitron blower reg‐
ulation - G462- . gen AG
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Danger of burn injuries. ss
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The sender for front Bitron blower regulation - G462- can be
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Before removing sender for front Bitron blower regulation -
wit
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G462- , let it cool down.
h re
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spec
es, in part or in w
– Remove bolts -arrows- and remove sender from housing.
t to the co
Installing
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Tightening torques
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Bolts -arrows- for sender for front Bi‐ 1 Nm

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tron blower regulation
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8. Other controlling and regulating components 75

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Service

Service Department. Technical Information

matter of course, be observed.

Copyright © 2013 Volkswagen AG, Wolfsburg D3E802AA8CD

3.2 Opening refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4.1 Capacities for refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4.2 Refrigerant machine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.3 Removing and installing fresh air blower V2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

87 - Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.3 Checking high-pressure safety valve on air conditioner compressor . . . . . . . . . . . . . . . . . . 45

Climatronic control unit J255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

8 Other controlling and regulating components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

8.2 Removing and installing sunlight penetration photosensor G107 . . . . . . . . . . . . . . . . . . . . 72

8.3 Working principles of air quality sensor G238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

tested and authorised cleaning the evaporator with the Ultra‐

procedures are tested for suitability and subsequently approved

1.2 Notes for vehicles with a start-stop sys‐

If a start-stop system is installed, the following abort conditions

will deactivate the start-stop function: cum

♦ The defrost function is active.

1.3 Notes on repair work to vehicles with air

♦ Notes on repairs to vehicles with air conditioning and on han‐

There is a film in the refrigerant lines which can be destroyed.

– Checking and adjusting components ⇒ Vehicle diagnostic

tester, Guided functions

1.5 Distribution of oil in refrigerant circuit

2 Rep. gr.00 - Technical data

2.1 Safety measures for when working on

Risk of injury due to automatic engine starting in vehicles with

– Measure ambient temperature.

-3- of vents -1-.

– Switch on air conditioning system via button AC .

4 Rep. gr.00 - Technical data

Start time measurement (5 min).

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

3.2 Opening refrigerant circuit

Danger from refrigerant escaping under pressure!

Freezing of skin and other body parts.

• Evacuate the refrigerant and then open the refrigerant cir‐

• If more than 10 minutes have elapsed since evacuation

refrigerant again. Pressure builds up in the coolant circuit

only) can no longer be obtained on the refrigerant/machine oil

7SEU17C Denso air conditioner compressor G 052 300 A2

6SEU14C Denso air conditioner compressor G 052 300 A2

1) This quantity of refrigerant oil is contained in a replacement compressor and

6 Rep. gr.00 - Technical data

❑ Removing and installing

♦ With fresh air blower switch

♦ With additional heat ex‐

2 - Air recirculation flap control

7 - Cables on operating and display unit

1.2 Assembly overview – heater unit

1 - Upper part of distribution

❑ Dismantling and assem‐

bling heater unit

1.3 Removing and installing fresh air blower

• Remove ignition key.

8 Rep. gr.80 - Heating

– Separate connector from fresh air blower - V2- .

series resistor with overheating fuse -

Danger of burn injuries.

– Remove bolts -1- (1 Nm) and remove series resistor from

1.5 Removing and installing dust and pollen