S01DCXX8S20-Heating and Air Conditioning

Service
Workshop Manual
Altea 2004 ➤
Altea XL 2007 ➤
Altea XL Freetrack 2008 ➤
Toledo 2005 ➤
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Heating and air conditioning

permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Edition 12.2010
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
80 - Heating
87 - Air conditioning system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Seat S.A S01DCXX8S20

Altea 2004 ➤ , Altea XL 2007 ➤ , Altea XL Freetrack 2008 ➤ , Toledo 200 ...
Heating and air conditioning - Edition 12.2010
Contents
80 - Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Instrument panel vents and air conduits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Centre vent: Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Vent left and right side: Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Air duct system in vehicle interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 Air intake, air outlet and air flow in the heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Heater components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Heating system components: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Fresh air blower series resistor with overheating fuse N24 : Removing and installing . . . . 9
2.3 Removing and installing fresh air blowerr V2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4 Removing and installing fresh air and air recirculation flap servomotor V154 ( Servomotor for
air recirculation flap V113 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5 Check the operation of the fresh air and air recirculation flap servomotor V154 and the button
for the fresh air / air recirculation mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.6 Vents: removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3 Heating controls: operation, removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.1 Functions of the Heating control unitby J65 . SEAT
. . . .S.A. .does
. . not
. . guarantee
. . . . . .or. accept
. . . .any
. .liability
. . . .with
permitted unless authorised SEAT S.A. .......... 21
3.2 Heating control unit : removing and fitting
respect to the correctness . . . . .in .this
of information . .document.
. . . . . .Copyright
. . . . .by. SEAT
. . . .S.A.
.............. 29
3.3 Main board for the heating control: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.4 Control unit for heating and fresh air connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.5 Flexible axle (for air distribution): removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.6 Bowden cable for temperature adjustment: Removing and installing . . . . . . . . . . . . . . . . 34
4 Heating equipment: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.1 Heating equipment: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.2 Checking heat output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.3 Air inlet opening with fresh air / air recirculation flap: removing and fitting . . . . . . . . . . . . . . 41
5 Dismantling and assembling heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.1 Heating system components: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.2 Air distribution flap control mechanism Removing and installing . . . . . . . . . . . . . . . . . . . . 44
5.3 Control mechanism for the temperature flap: removing and fitting . . . . . . . . . . . . . . . . . . . . 45
5.4 Dismantling and assembling heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.5 Air flow duct: disassembling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
87 - Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

1 Safety precautions for work on vehicles with air conditioning and how to work with refrigerant
R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.1 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3 Refrigeration agent circuit: repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.1 Exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.2 Removing and fitting high-pressure sender G65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.3 Checking the pressure signal of the High pressure sender G65 . . . . . . . . . . . . . . . . . . . . . 58
3.4 O-rings for refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.5 Compressor on its holder: Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.6 Check the activation signal for the Compressor regulation valve, air conditioning N280 . . 64
4 Replacing the compressor pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.1 Replacing pulley (compressor, make „Denso“, version „1“) . . . . . . . . . . . . . . . . . . . . . . . . 68
4.2 Removing and refitting the compressor pulley („Denso“ brand compressor, version „1“) . . 69
4.3 Replacing pulley (compressor, make „Denso“, version „2“) . . . . . . . . . . . . . . . . . . . . . . . . 71
4.4 Removing and refitting the compressor pulley („Denso“ brand compressor, version „2“) . . 72
Contents i
4.5 Pulley: Replacing (compressor make „Zexel“) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

4.6 Removing and fitting the pulley (compressor brand „Zexel“) . . . . . . . . . . . . . . . . . . . . . . . . 76
4.7 Pulley: Replacing (compressor make „Sanden“) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5 Air conditioning with manual control: Climatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.1 Air conditioning and heating - Passenger compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.2 Air conditioning (Climatic): Disassembling and assembling . . . . . . . . . . . . . . . . . . . . . . . . 83
5.3 Air conditioning control unit J301 : removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.4 Connectors for the Air conditioning control unit J301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.5 Removing and fitting temperature flap control motor V68 . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.6 Removing and installing air recirculation flap control motor V113 . . . . . . . . . . . . . . . . . . . . 86
5.7 Removing and installing footwell vent temperature sender G192 . . . . . . . . . . . . . . . . . . . . 86
5.8 Removing and installing centre vent temperature sender G191 . . . . . . . . . . . . . . . . . . . . 86
6 Air conditioning with automatic control: Climatronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
6.1 Components located outside the passenger compartment . . . . . . . . . . . . . . . . . . . . . . . . 87
6.2 Air outlet vent: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6.3 Plenum chamber water drainage: testing and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6.4 Cover and grill for the air inlet: checking, removing and fitting . . . . . . . . . . . . . . . . . . . . . . 93
7 Air conditioning control and regulation components in the passenger compartment . . . . . . 94
7.1 Air conditioning: passenger compartment, removing and fitting . . . . . . . . . . . . . . . . . . . . . . 94
7.2 Removing and installing dash panel vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
7.3 Photosensor for solar radiation G107 and Photosensor 2 for solar radiation G134 removal
and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
7.4 Control unit for Climatronic J255 , function, removing and fitting . . . . . . . . . . . . . . . . . . . . 97
7.5 Flexible condensation drainage tube: removing, testing and fitting . . . . . . . . . . . . . . . . . . 100
7.6 Outlet temperature sender G150 : Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . 101
7.7 Right outlet temperature sender G151 : Removing and installing . . . . . . . . . . . . . . . . . . . . 101
8 Air conditioning system
permitted unless with
authorised automatic
by SEAT S.A. SEAT regulation „Climatronic“
S.A does not guarantee or accept any03.2009
liability with ► . . . . . . . . . . . . 103
8.1 Procedure for testing and adjusting components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
8.2 Mode of function of the Air-conditioning control unit and display, Climatronic E87 with the
Climatronic control unit J255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
8.3 Air-conditioning control unit and display, Climatronic E87 with Climatronic control unit J255
Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
8.4 Connectors for the Climatronic control unit J255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
8.5 Climatronic: Passenger compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
9 Air conditioning components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
9.1 Servomotor for air recirculation flap V113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
9.2 Preparing adapter cables for control motor actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
9.3 Central flap control motor V70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
9.4 Removing and installing right temperature flap control motor V159 . . . . . . . . . . . . . . . . . . 118
9.5 Removing and installing the evaporator outlet temperature sender G263 . . . . . . . . . . . . 119
9.6 Removing and fitting left footwell vent temperature sender G261 . . . . . . . . . . . . . . . . . . . . 119
9.7 Air temperature sender, right hand side foot well zone vent G262 : removing and fitting . . 120
9.8 Dust and pollen filter: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
9.9 Removing and installing fresh air blower control unit J126 and fresh air blower V2 . . . . . . 121
9.10 Removing and installing air flow flap control motor V71 with potentiometer for air flow flap
control motor G113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
9.11 Removing and fitting air recirculation flap control motor V113 - vehicles without air flow flap
control motor V71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
9.12 Heater element for supplementary air heater Z35 : Removing and installing, vehicles ►
11.2006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
9.13 Heater element for supplementary air heater Z35 : Checking. removing and installing,
vehicles 11.2006 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
10 Replace components that can only be removed and fitted with the air conditioning
removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
10.1 Air inlet opening with air retention, fresh air / air recirculation flap: removing and fitting . . 135
10.2 Removing and fitting fresh air intake duct temperature sensor G89 . . . . . . . . . . . . . . . . . . 136
ii Contents
10.3 Removing and fitting defroster flap control motor V107 . . . . . . . . . . . . . . . . . . . . . . . . . . 136
10.4 Removing and installing left temperature flap control motor V158 . . . . . . . . . . . . . . . . . . 137
11 Air conditioner heat exchanger (heating): Removing and installing . . . . . . . . . . . . . . . . . . 139
11.1 Preparation work before removing the heat exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . 139
11.2 Heating heat exchanger: Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
12 Basic connection schema for air distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
12.1 Air flow in the vehicle passenger compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
12.2 Air intake, air outlet and air flow in the air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
13 Refrigeration performance of the air conditioning: testing . . . . . . . . . . . . . . . . . . . . . . . . . . 152
13.1 Test prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
13.2 Check refrigerating output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
13.3 Locating faults in case of an increase in temperature after the evaporator . . . . . . . . . . . . 158
14 Check the heating performance of the air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
14.1 Test prerequisites ........................................................
160
14.2 Checking .respect
. . . .to. the
. . correctness
. . . . . . of. information
. . . . . . in. .this
. .document.
. . . . . Copyright
. . . . . by
. .SEAT
. . . S.A.
...................... 160
15 Refrigeration agent circuit: repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
15.1 Refrigeration agent circuit: repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
15.2 Refrigerant pipes at compressor: detaching and attaching . . . . . . . . . . . . . . . . . . . . . . . . 165
15.3 Compressor: Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
15.4 Refrigerant lines of the condenser: Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . 168
15.5 Removing and fitting the condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
15.6 Liquid tank: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
15.7 Refrigerant lines, expansion valve: Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . 172
15.8 Removing and fitting the expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
15.9 Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
16 Removing and fitting air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
16.1 Removal: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
16.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
17 Replace components that can only be removed and fitted with the air conditioning
removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
17.1 Air inlet opening with air retention, fresh air / air recirculation flap: removing and fitting . . 183
18 Air conditioning components: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
18.1 Air conditioning electrical components: removing and installing . . . . . . . . . . . . . . . . . . . . 185
18.2 Disassembling and assembling the air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . 189
18.3 Evaporator housing: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
18.4 Removing and fitting the evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
18.5 Air conditioning compressor installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
19 Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
19.1 Coolant agent R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
19.2 Refrigerant circuit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
19.3 Conversion table by relevance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Contents iii
iv Contents
80 – Heating
1 Instrument panel vents and air con‐
duits
Note
♦ Air intake ⇒ page 93 , air outlet and routing of air flow in

heater
♦ Location of components ⇒ page 1 .
♦ The passenger compartment is vented by way of two vent
grids (in the rear of the luggage compartment in the area of
the bumper) ⇒ page 92 .
♦ The configuration of the heating and of the air conditioning as
well as the operations for the removal of certain components,
is the same for vehicles with heating or air conditioning and,
for this reason is only described in the Repair Group 87 „Air
conditioning“.
♦ In repair group „80“, a description is only made of those com‐
ponents or work to be permitted
performedunless where
authorisedthere
by SEATis a SEAT
difference
S.A. S.A does not guarantee or accept any liability with
with the heater compared with the
respect aircorrectness
to the conditioner. Within com‐
of information this document. Copyright by SEAT S.A.
ponents and operations that are the same, this Repair Group
refers to the Repair Group 87 „air conditioning“.
1.1 Centre vent: Removing and installing

Vehicles with radio (Altea 2004 ►)
– Remove radio ⇒ Rep. gr. 91 .
– Remove the heating element or Climatic / Climatronic air con‐
ditioning units ⇒ Rep. gr. 68 . ⇒ page 29
Vehicles with radio / navigation system (Altea 2004 ►), radio or
radio / navigation (Altea 2009 PA►)
– Remove the decorative strip ⇒ Rep. gr. 91
– Remove the heating element or Climatic / Climatronic air con‐
ditioning units ⇒ Rep. gr. 68 . ⇒ page 97 or ⇒ page 106
1.2 Vent left and right side: Removing and

installing
– Applies for all vehicles: remove ⇒ Bodywork, interior fitting
work ; Rep. gr. 70 or ⇒ page 97
1.3 Air duct system in vehicle interior
1. Instrument panel vents and air conduits 1

1 - Dash panel
❑ with air ducts to defrost‐
er vents and dash panel
vents on the driver's and
front passenger's side
❑ Removing and fitting : ⇒
Bodywork, interior fitting
work; Rep. gr. 70
2 - Defroster vent
❑ For windscreen
❑ Crushing the intermedi‐
ate piece between the
heater and the air duct
on the instrument panel
when installing instru‐
ment panel will result in
irregular or inadequate
air flow to the wind‐
screen⇒ Bodywork, in‐
terior fitting work; Rep.
gr. 70
3 - Defroster vent
❑ Passenger's side win‐
dow
4 - Dash panel vent (right-side)
❑ Removing and fitting the
instrument panel air
vent ⇒ page 97 and ⇒
work; Rep. gr. 70
5 - Dash panel vent (centre
right) Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Removing and fitting the permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
instrument panel air respect to the correctness of information in this document. Copyright by SEAT S.A.
vent ⇒ page 97
6 - Dash panel vent (centre left)
❑ Removing and fitting the instrument panel air vent ⇒ page 97
7 - Dash panel vent (left-side)
❑ Removing and fitting the instrument panel air vent ⇒ page 97 and ⇒ Bodywork, interior fitting work;
Rep. gr. 70
8 - Defroster vent
❑ Side window (driver's side)
9 - Intermediate piece/defroster duct
❑ Removing and fitting : ⇒ Bodywork, interior fitting work; Rep. gr. 70
10 - Fresh-air intake
❑ The air is taken from the plenum chamber.
11 - Recirculated-air intake
❑ Air is drawn in beneath glove box from passenger's foot well
12 - Air duct / instrument panel vents
❑ To the vents, left and right side
13 - Footwell vent (front right)
❑ Removing and fitting ⇒ page 18
2 Rep. gr.80 - Heating

14 - Control unit of the heater / main board

15 - Air duct to the air vent in the right rear foot well
16 - Sealing plug
❑ Only fitted to vehicles without air duct to rear vent of the centre console.
17 - Air duct to the air vent in the left rear foot well
18 - Trim of the left footwell vent
19 - Heater
❑ Dismantling and assembling ⇒ page 43 .

1.4 Air intake, air outlet and air flow in the

heating
1.4.1 Air intake and air outlet openings
2 - Air intake of the interior (re‐
circulation)
3 - Air extraction to the air vent
in the front right foot well
4 - Air intake to the dash panel
vent, right-side
5 - Outlet
respectto thecorrectness
to the centre ofdash
information in this document. Copyright by SEAT S.A.
panel vents (left-side and right-
side)
6 - Air extraction to the dash
panel vent, left-side
in the front left foot well
8 - Outlet to the defroster vents
(the dash panel)
9 - Outlet to rear right footwell
vent
10 - Air extraction to the rear
left foot well vent
11 - Outlet to the central con‐
sole vents
❑ This is currently sealed
using a plug.
sole vents
using a plug.

1.4.2 Air duct in the air flow duct
1 - Air flow duct complete

2 - Recycled air / fresh air flap
❑ Opening for air intake
from plenum chamber
(fresh air)
3 - Air inlet opening in the en‐
gine compartment (fresh air)
4 - Fresh-air turbine -V2-
⇒ page 10
5 - Dust and pollen filter
❑ Heed replacement inter‐
vals ⇒ Maintenance ;
Booklet
6 - Noise insulation
❑ For those vehicles with
heating (without air con‐
ditioning), a sponge
based element is fitted
instead of an evaporator
(for sound insulation)
7 - Air flow duct, lower element
(with internal elements)
8 - Additional resistance for the
fresh air blower with overheat
fuse -N24-
❑ Removing and fitting
⇒ page 9
9 - Air outlet to the air distribu‐
tor body
10 - Air distribution housing
1.4.3 Routing of air flow in air distribution

housing
Note
♦ For the purpose of displaying the air duct in the air distributor
body, this section is shown along the lines „A“-„A“ and „B“-„B“.
♦ The different flaps for the air distribution move in the heating
by a flexible axle, various levers andby two
Protected cam
copyright. disks.
Copying for private or commercial purposes, in part or in whole, is not


2 - Left temperature flap (driv‐
er's side)
❑ Shown in centre posi‐
tion
❑ The two temperature
flaps, both left and right,
move together (individu‐
al adjustment is not pos‐
sible).
3 - Routing of air flow to air duct
to vent in rear centre console
and centre dash panel vents
5 - Right temperature flap (pas‐
senger's side)
tion
❑ The two temperature
flaps, both left and right,
move together (individu‐
al adjustment is not pos‐
sible).
6 - Temperature flap in the left
footwell (driver's side)
❑ Displayed in „closed“
position
7 - Air duct in the left footwell
(driver's side)
8 - Air distribution housing with
cross section made by the line
„A“-„A“
9 - heater element for additional air heater -Z35- with Additional air heater control unit -J604-
❑ Only for vehicles fitted with a Diesel engine, depending on the vehicle equipment there is additional
electric heating, see ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
❑ Vehicle with additional air heater control unit -J604- up to ► 11.2006
❑ Vehicles with Low heat output relay -J359- and high heat output relay -J360- from 11.2006 ►
10 - Heating heat exchanger
11 - Air intake in the air flow duct
12 - Right temperature flap (passenger's side)
❑ Shown in centre position
13 - Flap in the right footwell, (passenger's side)
❑permitted
Displayed in „closed“ position
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
14 - Defroster flap
❑ Displayed in „closed“ position
15 - Air distribution housing with cross section made by the line „B“-„B“
16 - Centre flap „centre“
❑ Displayed in „open“ position
17 - Flap in the air duct to the air duct routing to the vent in the rear centre console
❑ This flap is operated via an actuating arm on the centre flap

18 - Air duct to the air duct routing to the vent in the rear centre console
❑ This duct is currently sealed using a plug.
1.5 Contact corrosion

Contact corrosion can occur if unsuitable connecting elements
are used (bolts, nuts, washers), rivets, plugs, grommets, adhe‐
sives, etc.
For this reason, all the connecting elements fitted have been sub‐
jected to special surface treatment by the manufacturer. This can
be seen from the greenish colour of such elements. Use is also
made of rubber and plastic parts as well as adhesives which are
not electrically conductive.
These tested, aluminium-compatible components are also avail‐
able as replacement parts.
Always use genuine parts!
Always fit new parts in cases of doubt about reusability.
Accessories must have been released by SEAT!
Damage from contact corrosion is not covered under the warran‐
ty.

2 Heater components
2.1 Heating system components: removing and fitting
1 - Heating control / Heating

control unit -J65-
❑ There are different ver‐
sions according to the
different vehicle options
(with or without Thumb‐
wheel for regulation of
the heated driver's seat
-E94- and Thumbwheel
for regulation of the
heated passenger's
seat -E95- ) ⇒ Parts
catalogue
❑ Operation, removing
and fitting ⇒ page 20
2 - Control unit of the heater /
main board
⇒ page 20
3 - Bowden cable for tempera‐
ture control
⇒ page 34
4 - Flexible shaft
❑ To the transmission
gear / cam disk for the
air distribution flaps con‐
trol
⇒ page 34
5 - Heater
⇒ page 36
❑ Heating system compo‐

nents: removing and fit‐

ting ⇒ page 43
❑ Heating: dismantling and assembling ⇒ page 45
❑ Air flow duct: disassembling and assembling ⇒ page 47
❑ Heed replacement intervals ⇒ Maintenance ; Booklet
7 - Additional resistance for the fresh air blower with overheat fuse -N24-
9 - Air inlet opening with recirculated air / fresh air flap
10 - Servomotor for air recirculation flap -V113- ⇒ page 11
❑ Checking operation ⇒ page 15
❑ Removing and installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
11 - Transmission gear with cam disk for the air distribution flaps control in this document. Copyright by SEAT S.A.
respect to the correctness of information
❑ Do not remove, the correct readjustment is not possible
12 - Grommet
❑ Before fitting the heating, fit this in the transversal panel of the vehicle ⇒ page 36
❑ Installing ⇒ page 36
13 - Sponge material spacer
❑ Fitted between the grommet and the heating
14 - Transmission lever for the temperature flaps control
❑ There are different versions of additional air heaters: In vehicles with a diesel engine that have been built
from 2006 (smooth conversion), the heater element for additional air heater -Z35- is activated via the
additional air heating control unit -J604- . In vehicles with a diesel engine that have been built from 2006
(smooth conversion), a 3-stage heater element for supplementary air heater -Z35- is fitted; a high tem‐
perature relay -J360- and a low temperature relay -J359- are fitted; this element is activated by the
respective engine control unit via relays and ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations.
❑ Vehicles with a Diesel engine and the extra equipment for „independent heating“ also now carry a heating
element for additional heating -Z35- In the future (introduction pending) these vehicles will not carry the
heating element for additional heating -Z35- (the„independent heating“ will run the operation of the „ad‐
ditional heating“) ⇒ independent heating; Rep. gr. 01
❑ Check the operation of the control unit for the additional air heating -J604- , carry out self-diagnosis.
2.2 Fresh air blower series resistor with

overheating fuse -N24- : Removing and
installing
– Remove the glove compartment ⇒ Bodywork, interior fitting
work; Rep. gr. 68 .
– Remove the passenger side foot well cover ⇒ Bodywork, in‐
terior fitting work; Rep. gr. 68 .
2. Heater components 9
– Disconnect the connector -A- from the additional resistance

-B-.
– Release the block -C- and move the additional resistance
-B- towards the right -arrow-.
WARNING
The refrigerator body of the series resistance of the exterior air

fan with overheating fuse -N24- may get very hot.
– Extract the additional resistance -B- from the heating system.
2.3 Removing and installing fresh air blow‐

err -V2-
2.3.1 Removal:
work; Rep. gr. 68 .
– Remove the bolt -A-.
– Disconnect the connector -D-.
Caution
Do not touch the wheel of the fresh air blower -V2- ; the use of
force on the respect

wheel orcorrectness
movement of the counterweights can
to the of information in this document. Copyright by SEAT S.A.
cause imbalance which could lead to malfunction.
– Release the block -B- and rotate the fresh air blower housing
-C- in -the direction of the arrow-.
Note
♦ The join between the fresh air turbine housing -C- and the
heating system may be sealed by a sealing paste, in which
case it will be necessary to rotate the housing with more force.
♦ In the casing -C- the Fresh air blower -V2- is fitted and cannot
be replaced separately ⇒ Spare parts catalogue .
– Remove the fresh air turbine housing -C- from the heating
system.
2.3.2 Installing
Re-install all parts removed in reverse order, paying attention to
the following:
– After fitting, check the operation of the Fresh air blower -V2- .

Note
♦ When fitting, pay attention to correct positioning of fresh-air

turbine in heater.
♦ Following the installation, check the correct positioning of the
fresh air blower casing in the heater and the operation of the
Fresh air blower -V2- .
♦ Take into account the different versions of the fresh air turbine
for vehicles fitted with heating and air conditioning ⇒ Parts
catalogue .
2.4 Removing and installing fresh air and air

recirculation flap servomotor -V154-
( Servomotor for air recirculation flap -
V113- )
Servomotor for the outer air/air recirculation flap -V154- in vehi‐
cles without air conditioning
Servomotor for the air recirculation flap -V113- in vehicles with
manual climate control
Note
♦ In the self-diagnosis and circuit diagrams for heating and man‐

ual climate control the servomotor has a different designation;
the removal andProtected
fitting byinstructions, however,
copyright. Copying for private or are the same.
commercial purposes, in part or in whole, is not
♦ Check the operationrespect
of the Servomotor
to the for theinfresh
correctness of information air / air
this document. Copyright by SEAT S.A.
recirculation flap -V154- and the Heating control unit -J65- .
(vehicles without air conditioning)
♦ Check operation of servomotor for the air recirculation flap -
V113- and the control unit for air conditioning -J301- (in vehi‐
cles with manual climate control)
♦ Check, once the new servomotor (in heating) is attached for
the activation from the heating control unit -J65- and the op‐
eration of the servomotor for the outer air/air recirculation flap
-V154- (correct position for air recirculation and fresh air
mode).
♦ Check, once the new servomotor (in manual climate control)
is attached for the activation from the air conditioning control
unit -J301- and the operation of the servomotor for the air re‐
circulation flap -V113- (correct position for air recirculation and
fresh air mode).
♦ The servomotor for fresh air/air recirculation flap -V154- ( ser‐
vomotor for air recirculation flap -V113- ) can only be removed
and fitted in the maximum position of „fresh air mode“. If the
servo motor is stopped in any other position and it may not be
moved into the position of „fresh air option“, it may only be
extracted and disassembled with difficulty.
♦ Different variations in the servomotor for vehicles with heating,
manual and automatic climate control (with end of run
switches or potentiometer). ⇒ Spare parts catalogue
2.4.1 Removal:
– Turn the ignition on and wait until the servo motor is in its final
position „fresh air option“.
– Switch ignition OFF.
– Remove the glove compartment: ⇒ Bodywork, interior instal‐

lation work; Rep. gr. 68 .
– Release the inserts -B- and -C- for the support -A- in the air
inlet opening and then remove the support -A-.
– Remove the servo motor -B- (in the direction of the arrow) from
the air inlet opening.
Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ The connection between the cogwheels of the servomotor and
the dynamic pressure flap is designed is such a way that the
servomotor may only be easily removed in the position „fresh
air option“ (the opening for the air recirculation inlet option by
the fresh air / air recirculation flap -A- is closed).
♦ If the servo motor is in any other position and cannot be
moved, it may not be extracted without first loosening the al‐
lotment points -C-, ensure to avoid any damage to the cog‐
wheel -D- during this operation.
2.4.2 Installing
Note
The servomotor is supplied as a spare in the position of „fresh air

option“. Only when the cogwheel -A- is at the limit -B-, it can then
only be inserted correctly into the cogwheel for the fresh air / air
retention flap. If the servo motor was removed in any other posi‐
tion or moved while being extracted, it may not be refitted. If the
cogwheel -A- of the servomotor is not at maximum -B- of „fresh
air option“, put it in this position for fitting.
Set the wheel of the servomotor in position „fresh air“

– Connect the detached servomotor to the vehicle cable har‐
ness (via the available connector)
– Connect ignition (the heating control unit -J65- / the air condi‐
tioning control unit -J301- activate the servomotor and move
it to the position „Maximum fresh air“).
– Wait until the cogwheel -A- of the servomotor reaches the limit
-B- „fresh air option“.
Installing
– Connect the servomotor to the vehicle cable harness via the
available connector.

– Insert a hand into the air inlet opening for the air recirculation
and move the fresh air / air recirculation flap -A- into the posi‐
tion „fresh air option“ (the opening for the air recirculation
option is closed).
– Fit the servo motor -B- in the opposition direction to the arrow
on the allotments -C- and onto the cogwheel -D-
– In order to move the cogwheel on the servomotor -A- onto the

cogwheel of the fresh air / air recirculation flap, the short tooth
-C- of the servomotor cogwheel must coincide with space be‐
tween the teeth -D- of the cogwheel on the fresh air/air recir‐
culation flap shaft-D-.
– Lay wiring harness so that it cannot come into contact with
moving components (e.g. servomotor lever).
– Fit the bracket -A-. Taking into account that the support guide
-D- is fitted correctly into the allotment in the air inlet opening
-E- and that the support correctly inserts into both slots -B- and
-C-.
– Check the servomotor. The bracket -A- must hold it in its po‐
sition. When they are not installed free of play, eliminate the
play at hand with a little foam that is applied to the inner side
of the fixing points -F- of the bracket -A-.
Note
♦ The position of the servomotor (and the flap) is not visible

when the glove compartment is mounted. For this purpose,
check operation before mounting the glove box. (in vehicles
without air conditioning) or (in vehicles with manual climate
control)
♦ If both cogwheels are not fitted in the correct position, the fresh
air / air recirculation flap will not reach the two final positions
or the servomotor will function in an irregular manner and may
jam.
– Switch on the ignition.

– Check function of the servomotor of the fresh air/air recircula‐
tion flap -V154- (of the servomotor of the air recirculation -
V113- ) and activation via the heating control unit -J65- (in
vehicles without air conditioning) or the air conditioning control
unit -J301- (in vehicles with manual climate control)
– Actuate the servomotor until the notched wheel -D- is located

at the limit „fresh air intake mode“ or am at the limit „re-circu‐
lated air mode“ and check the function of the fresh air in re-
circulated air / take flap -A-. This must be open (re-circulated
air mode) or closed (fresh air intake mode).
Re-install all components in reverse order of the removal opera‐
tions.
2.5 Check the operation of the fresh air and

air recirculation flap servomotor -V154-
and the button for the fresh air / air re‐
circulation mode .
Special tools and workshop equipment required
♦ Pressure tester -VAG 1527B-
Fresh air/air recirculation mode key fitted in the heating control

unit -J65-
Note
♦ With the air recirculation option there may be fogging of the

windows (due to an increase in the humidity of the air in the
passenger compartment and its deposit on the windows; the
air is not dried as it is in vehicles fitted with air conditioning).
♦ The function „air recirculation“ is turned off when the ignition
is turned off. When the ignition is turned on once more, the
Servomotor for the fresh air / air recirculation flap -V154- is
activated by the Heating control unit -J65- and the heating
system changes from air recirculation mode to fresh air mode
(if the air recirculation mode was already selected).
♦ To clear the windows that are fogged as quickly as possible,
it is only possible to use the air recirculation option for a limited
time; the rotating control for air distribution -B- is in the position
for the „ait to windscreen “ -D- The Heating control unit -J65-
changes to the fresh air option after placing the rotating control
for air distribution into this position (and the button LED is
turned off).
♦ Test the operation of the button for the air recirculation option
and activation of the Servomotor for fresh air / air recirculation
flap -V154- ⇒ page 23 .

2.5.1 Check the operation of the Servomotor

for the fresh air / air recirculation flap -
V154-
– Glove compartment, removing: ⇒ Bodywork, interior installa‐
tion work; Rep. gr. 68 .
– Set the control for the Fresh air blower -V2- -G- to level 3.
– Turn the rotating control for air distribution -B- to the position
„air distribution to the instrument panel air vents“
– The button -F- for the fresh air / air recirculation flap is not
activated (fresh air option, the LED indicator on the button is
not lit).
♦ The air is taken from the plenum chamber.
– Press the button -F- (air recirculation option, the LED indicator
on the button is lit).
♦ The air is taken in through the rear of the glove compartment
(air recirculation option).
„air distribution to the windscreen“ -D-.
♦ The indicator for the button -F- is turned off and the fresh air /
air recirculation flap moves to the position „fresh air option“.
Note
♦ If the operation is correct then the windows will fog up, test:
♦ Check dust and pollen filter for contamination ⇒ page 120 .
♦ Forcedpermitted
airingunless
of the passenger
authorised compartment
by SEAT S.A. ⇒guarantee
SEAT S.A does not page 92 . any liability with
or accept
♦ the passenger compartment for water leakage.
♦ The fresh air inlet in the plenum chamber and the water drain‐
age from the plenum chamber ⇒ page 92 .
♦ the joins between the various air inlets and the vehicle for
damage or leaks.
♦ If operation is not correct, check the electronics of the Heating
control unit -J65- and the activation of the Servomotor for the
fresh air / air recirculation -V154- .
2.5.2 Check the operation of the electronics of

the Heating control unit -J65- and the
Servomotor for the fresh air / air recircu‐
lation flap -V154-
work; Rep. gr. 68 .
„air distribution to the instrument panel air vents“
– The button -F- for the fresh air / air recirculation flap is not
activated (fresh air option, the LED indicator on the button is
not lit).
– Check the voltage on the connector -A- between pins -9- and
-10- for example with the voltage tester -VAG 1527B- -B- (to
the Servomotor for fresh air / air recirculation -V154- ).
– The „earth“ is on pin -9- and the „positive“ is on the pin -10-.
– The Servomotor for the fresh air / air recirculation flap -V154-
and the fresh air / air circulation flap are in the position „Fresh
air option“ (the opening for the air recirculation -C- is closed).
– Press the button -F- for the fresh air / air recirculation flap is
not activated (air recirculation option, the LED indicator on the
button is lit).
Note
When the button -F- is activated the Heating control unit -J65-
changes the voltage supply to the Servomotor for the fresh air /
air recirculation flap -V154- (the positive and by
Protected negative are inver‐
copyright. Copying for private or commercial purposes, in part or in whole, is not
ted). permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

– Check the voltage on the connector -A- between pins -9- and
-10- for example with the voltage tester -VAG 1527B- -B- (to
the Servomotor for fresh air / air recirculation -V154- ).
– The „earth“ is on pin -10- and the „positive“ is on the pin -9-.
– The Servomotor for the fresh air / air recirculation flap -V154-
and the fresh air / air circulation flap are in the position „air
recirculation option“ (the opening for the air recirculation -C- is
open).
Note
♦ If no fault is detected during this test:

♦ Test the correct movement of the fresh air / air recirculation
flap.
♦ Replace the Servomotor for the fresh air / air recirculation flap
-V154- .
♦ If operation is not correct:
♦ Check the cable connection between the Heating control unit
-J65- and the Servomotor for the fresh air / air recirculation flap
-V154- for any open or short circuit ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
♦ Check the voltage supply and the earth connection to the
Heating control unit -J65- .
♦ Replace the Heating control unit -J65- ⇒ page 20 .
2.6 Vents: removing
2.6.1 Driver and passenger side vents: re‐

moving
– Remove the air vents of the instrument panel ⇒ page 97
2.6.2 Ai duct forS.A.theSEATfoot well: Removing andwith

permitted unless authorised by SEAT S.A does not guarantee or accept any liability
installing
Note
The removal of the ducts is the same for both sides.
– Remove the passenger and driver seats ⇒ Bodywork, interior

fitting work; Rep. gr. 72 .
– Removing central console ⇒ Bodywork, interior fitting work;
Rep. gr. 68 .
– Lift the carpet, release the duct from the underneath and ex‐
tract the heater -arrows-.
Install in reverse order.
Note
When fitting the duct ensure that the heating duct is fitted first
-arrow- and then insert into the underneath.
2.6.3 Right foot well vent: removing

work; Rep. gr. 68 .
– Unscrew the attachment bolt-2- and remove the vent for the
right hand side foot well -1-.
2.6.4 Remove the vent from the foot well area

on the left side
– Remove theProtected
driver by side footCopying
copyright. well cover ⇒or Bodywork,
for private interior
fitting work;permitted
Rep. gr. 68
unless .
authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

– Unscrew the attachment bolt-2- and remove the vent for the
left hand side foot well -1-.
3 Heating controls: operation, remov‐

ing and fitting
Note
♦ There are different versions of the Heating control unit -J65-

-A- (with or without Thumbwheel for regulation of the heated
driver's seat -E94- and Thumbwheel for regulation of the heat‐
ed passenger's seat -E95- -C-) ⇒ Spare parts catalogue .
♦ The heating control consists of the Heating control unit -J65-
-A- and a main board -B-.
♦ The Heating control unit -J65- -A- has no fault memory (there
is no self-diagnosis) and is not connected to the data bus sys‐
tem.
♦ On the main board -B- there is a gear system which, using the
main board of the heating system, with a rotation of the control,
moves the flexible axle twice ⇒ page 31 .
♦ Except for the two rotating controls -A-
Protected by and -B-
copyright. (they
Copying are in‐
for private or commercial purposes, in part or in whole, is not
serted and may be removed) therespect
components of the
to the correctness Heating
of information in this document. Copyright by SEAT S.A.
control unit -J65- or the LEDs for the buttons and the rotating
controls may not be replaced as individual parts.
♦ The illumination of the rotating controls and the buttons for the
heating control is powered from the terminals 58s and 58d.
⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations.
♦ The operation indicator for the air recirculation option -F- is
supplied from the terminals 58d.

3.1 Functions of the Heating control unit -

J65-
3.1.1 Activation of the Rear heated window -

Z1-
3. Heating controls: operation, removing and fitting 21

♦ Pressing the button -E-, when the ignition is on, activates the
Onboard network control -J519- (using an earth signal) (the
signal is applied during the use of the button). While the On‐
board network control -J519- is activating the heated rear
window (only while the engine is running) the indication LED
in the button -E- is lit (the Onboard network control unit -J519-
emits a positive signal). Pressing the button once more -E- and
turning the ignition off will deactivate the rear window heating
cations ⇒ Vehicle instruction manual
♦ If, on the Onboard network control unit -J519- , the voltage
measured on terminal „30“ falls below a value stored in the
Onboard network control unit -J519- , the activation of the
heated rear window will be cancelled completely Heated rear
window -Z1- (or the power will be regulated) thus discharging
the alternator ⇒ Vehicle diagnostic, testing and information
system VAS 5051.
♦ The heated rear window -Z1- will only be operated by the On‐
board supply control unit permitted
-J519-
Protectedwhen the Copying
by copyright. engine for is running.
private or commercial purposes, in part or in whole, is not
Operation is not carried out when the engine is not running
and this is also no confirmation by the Onboard supply control
unit -J519- , the LED display of the button -E- does not light-
up or goes out shortly after pressing the button ⇒ Vehicle
instructions manual ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations
♦ If the Heated rear window -Z1- must be deactivated by low
voltage from the Onboard network control unit -J519- for a
short interval, the indicator LED on the button for the rear
heated window -E- remains lit; if it is deactivated for a long
period of time, the Onboard network control unit -J519- deac‐
tivates the indicator LED.
♦ Testing of the rear window heating activation is described in
detail in the fault finding guide for the Onboard network control
unit -J519- and climate control⇒ Vehicle diagnostic, testing
and information system VAS 5051.
Note
♦ With outside temperatures above 0℃, the heated rear window

-Z1- is turned off by the Onboard supply control unit -J519-
after a deactivation time (approx. 10 Minutes) that has been
saved in the Onboard supply control unit -J519- elapses.
♦ For vehicles produced since the beginning of the production,
the heated rear window -Z1- will be turned off by the Onboard
supply control unit (00457) -J519- after approx. 20 minutes
with outside temperatures less than 0°C. In later models the
Onboard network control unit -J519- will be fitted (introduction
not specified) and the Heated rear windscreen -Z1- heating
remains active until the ignition is switched off (it may still be
activated and deactivated at any moment manually). When the
outside temperature climbs above 0°C when driving, the de‐
activation of the heated rear window is carried out by the
Onboard network control unit -J519- after the registered op‐
erating time (approx. 10 minutes) has elapsed.

3.1.2 Testing the operation of the button for

the air recirculation option and activation
of the Servomotor for fresh air / air re‐
circulation flap -V154-
♦ When the air recirculation function is selected, an indicator
lights on the button -F- (check the operation of the push button
for the Servomotor for the fresh air / air recirculation flap -
V154- ⇒ page 15 ) ⇒ Vehicle instructions manual ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations.
♦ The button -F- is used to select the function „air recirculation“
and the indication lamp on the button -F- lights. Pressing the
button -F- once more or turning the ignition off, deactivates the
function „air recirculation“ (when the ignition is turned on again
the servomotor returns to the position for the „Fresh air “) ⇒
Vehicle instructions manual .
♦ To clear fogged up windows as rapidly as possible, the func‐
tion „air recirculation option“ is deactivated a short time after
turning the air distribution rotating control -B- to the position
-D- „air distribution to windscreen“ and the indication lamp on
the button -F- is turned off.
– If the air distribution is changed for example to the foot well

area using the rotating control -B- the heating remains on the
fresh air option.
– If the rotating control -B- is turned past the position -D- „air
distribution to the windscreen“ (for example from the instru‐
ment panel vents to the upper or lower position) the air recir‐
culation option is not reactivated.
– If the rotating control -B- remainspermitted
in the position
unless -D-by„air
authorised SEATdistri‐
S.A. SEAT S.A does not guarantee or accept any liability with
bution to the windscreen“ the button -F- may be used to

reactivate the „air recirculation option“.
3.1.3 Activation of the seat heating (optional

equipment)
♦ The thumbwheel for adjusting the heated driver's seat -E94-
and the thumbwheel for adjusting the heated front passenger
seat -E95- (the thumbwheel activates a potentiometer) the
heating control unit -J65- -A- supplies power (in connector
-B- of the contact -11- to the heated seating control unit, driver
side -J726- and the contact -15- to the heated seating control
unit, passenger side -J727- ). The feed voltage depends on
the position of the knurled wheel and the on-board voltage.
This is less than 0.5 V at position „0“ to approx. 9 V at position
„5“ when the engine is running.

– The resistance of the potentiometer for the seat heater de‐

pends on the position of the knurled wheel. Between contact
-16- (voltage supply for terminal „75“) and contact -11- or
-15-, the resistance has the following values:
– for the position „0“ the value is more than 10 kOhm.
– at position „1“ (approx. 7.6 kOhm), at position „2“ (approx. 6.3
kOhm), at position „3“ (approx. 5.1 kOhm), at position „4“ (ap‐
prox. 3.8 kOhm) and at position „5“ (approx. 2.6 kOhm),
♦ To test and repair the operation of the seat heating ⇒ Body‐
work, interior fitting work ; Rep. gr. 74 ⇒ Current flow dia‐
grams, Electrical fault finding and Fitting locations.
3.1.4 Activation of the engine control unit (in

direct injection petrol engines „FSI“ and/
or an engine with refrigeration controlled
by this family of characteristics
♦ 105-pin tester box -V.A.G 1598/42-1-
♦permitted
Vehicle
unlessdiagnostic, testing
authorised by SEAT and
S.A. SEAT S.Ainformation system
does not guarantee or accept-VAS 5051
any liability with
A-respect
with tothe
the multimeter cablesin-VAS
correctness of information 5051/7-
this document. Copyright by SEAT S.A.
Note
♦ These functions depend on the version of the engine and en‐

gine control unit and are not available for all vehicles ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations and
⇒ Guided Fault Finding function of vehicle diagnostic, testing
and information system VAS 5051 (for the relevant engine
control unit).
♦ On vehicles with manually controlled air conditioner, the air
conditioning system control unit -J301- exchanges information
with the corresponding engine control unit by way of the data
bus system (reading measured value block of manual air con‐
ditioner) and ⇒ "Guided fault-finding" function of vehicle di‐
agnostic, testing and information system VAS 5051". (for the
manual air conditioner and the corresponding engine control
unit).

♦ There is a potentiometer fitted on the Heating control unit -

J65- . This potentiometer is activated by the dial controller for
temperature selection -A- and through this the engine control
unit is informed of the position of the temperature dial position.
– Where vehicles have refrigeration controlled by a character‐
istic field, the engine control unit in certain engines influences
the activation of the refrigeration thermostat of the engine
regulated by a map of characteristics -F265- . When the tem‐
perature selector switch -A- is at the limit for „Warm“ or is
positioned just before this, the temperature of the refrigerant
is reduced (limited to approx. 95 °C), to prevent the air outlet
temperature to the vents of the heater from being too high ⇒
Vehicle diagnostic, testing and information system VAS 5051
in the function "Guided fault finding". (for the relevant engine
control unit).
– In vehicles with certain direct injection petrol engines „FSI“, the
relevant engine control unit influences the fuel mixture prepa‐
ration. When the temperature selector switch -A- is at the limit
for „Warm“ or is positioned just before this, the mode stratified
loading for the preparation of the mixture is initiated to achieve
an improved heating of the refrigerant (and therefore, an in‐
creased heating performance). The engine runs in normal
mode ⇒ Vehicle diagnostic, testing and information system
VAS 5051 in the function "Guided fault finding". (for the rele‐
vant engine control unit).
– For vehicles that have been fitted with this function, a voltage
of approx. 5 V (of the respective engine control unit) is applied
to the electric connector -B- (between contacts „1“ and „10“)
when the ignition is turned on. ⇒ Current flow diagrams, Elec‐
trical fault finding and Fitting locations and ⇒ Vehicle diag‐
nostic, testing and information system unlessVAS 5051 in the
permitted authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
function "Guided fault finding". (forrespect
the relevant engine
to the correctness controlin this document. Copyright by SEAT S.A.
of information
unit).
– A voltage of approx. 0.5 V (at the limit „cold“) and approx. 4.5
V (at the limit „warm“) is released via the contact „2“ on the
electric connector -B- to the Heating control unit -J65- -A-, de‐
pending on the position of the rotary switch for selecting the
temperature -A-. The relevant engine control unit detects the
position of the temperature controller -A- through this voltage.
The engine control unit evaluates this voltage and regulates
coolant temperature and mixture formation in line with the
stored characteristic curves. ⇒ Vehicle diagnostic, testing and
information system VAS 5051 in "Guided fault finding" func‐
tion. (for the relevant engine control unit).

3.1.5 Activation of the additional heating ( in

vehicles without air conditioning)
Only Vehicles with diesel engine
Note
♦ Vehicles with Diesel engines currently have electric powered

additional air heating. This system applies heating to the air
when this leaves the heating radiator if so requested by the
heating control panel ( heating control unit -J65- ). The acti‐
vation of the electric additional heating is performed by the
additional air heating control unit -J604- or the engine control
unit (in 3 phase version through the low temperature relay -
J359- and the high temperature relay -J360- ) ⇒ Vehicle
diagnostic, testing and information system VAS 5051 in the
function "Guided fault finding" (fault finding assisted by the
relevant engine control unit) and ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations
♦ There are different versions of additional air heaters: In vehi‐
cles with a diesel engine that have been built from 2006
(smooth conversion), the heater element for additional air
heater -Z35- is activated via the additional air heating control
unit -J604- . Vehicles with diesel engine manufactured as of
November 2006 (gradual conversion) are fitted with a 3-stage
supplementary heater element -Z35- which is actuated by the
corresponding engine control unit via a relay ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations and ⇒
"Guided fault-finding" function of vehicle diagnostic, testing
and information system VAS 5051 (Fault finding assisted for
the relevant engine control unit).
♦ The inspection of the control for the electric supplementary
heater in vehicles with additional air heating control unit -J604-
is described in the guided fault finding of the air conditioner.
⇒ Measurement, information and diagnosis of vehicles sys‐
tem VAS 5051 in "Guided fault finding" function.
♦ The measured values block of the additional air heating control
unit -J604- indicates whether the additional heating activates
or, if not, why it does not when a request is made and ⇒ Ve‐
hicle diagnostic, testing and information system VAS 5051 in
the function "Guided fault finding".
♦ The inspection of the control for the electric supplementary
heater in vehicles with 3 stage heater element for additional
air heater -Z35- is described in the guided fault finding of the
respective engine control unit. ⇒ Measurement, information
and diagnosis of vehicles system VAS 5051 in "Guided fault
finding" function.
♦ For vehicles with a petrol engine, no additional heating is fitted.
Check the activation of the heating control panel ( heating control

unit -J65- )
♦ 105-pin tester box -V.A.G 1598/42-1-
♦ Vehicle diagnostic, testing and information system -VAS 5051
A- with the multimeter cables -VAS 5051/7-

♦ There is a switch fitted on the Heating control unit -J65- . This

switch can be moved (closed) to the limit „warm“ using the
rotary switch for selecting the temperature -A- in the scope of
the adjustment of approx. 3 hours.

– If the heating switch is closed, the electronics of the Heating

control unit -J65- , with the ignition on, connects through pin
„7“ earth to the Additional air heating control unit -J604- . The
Additional air heating control unit -J604- detects that more
heating power is required and activates the additional electric
heating, if the remaining conditions for activation are fulfilled
in the Additional air heating control unit -J604- .
♦ Connection conditions for electric additional heating (activa‐
tion of the heating element for additional heating -Z35- ) of the
additional air heating control unit -J604-
♦ Connection conditions for independent heating as additional
heating (in the additional heating control unit -J364- ) in vehi‐
cles with the extra equipment ⇒ independent heating; Rep.
gr.
♦ Connection conditions for electric additional heating (activa‐
tion of the heating element for additional heating -Z35- ) of the
relevant engine control unit ⇒ Vehicle diagnostic, testing and
information system VAS 5051 in the function "Guided fault
finding". (Fault finding assisted for the relevant engine control
unit).
Note
In order for the relevant engine control unit to activate the heating
element for additional heating -Z35- with three phases via the low
temperature relay -J359- and the high temperature relay -J360- ,
the same conditions must be met in the engine control unit
Protected by as in Copying for private or commercial purposes, in part or in whole, is not
copyright.
the air conditioning control unit -J301- in vehicles permitted
with manual
climate control. respect to the correctness of information in this document. Copyright by SEAT S.A.
Connection criteria for activation of electric additional heating

– The engine control unit activates the low temperature relay -
J359- , the high temperature relay -J360- and the heating
element for additional heating -Z35- if the following prior con‐
ditions are met:
♦ The engine control unit receives an earth signal from the heat‐
ing control unit -J65- .
♦ The engine has been running for at least 8 seconds and the
engine speed is over 500 rpm.
♦ The engine temperature is below 75 °C
♦ Calculated ambient temperature is lower than 8° C
♦ The onboard voltage is over 12.2 V and the onboard network
control unit -J519- does not send any signal to block the con‐
nection.
♦ No fault is stored in the engine control unit and the alternator
-C- stress is below 30 ...77% (depending on the engine speed)
Note
In vehicles with 3 stage heater element for additional air heater -

Z35- , the engine control unit activates both relays for the addi‐
tional heating in such as way that the loading of the generator -
C- does not exceed 95 %. ⇒ Measurement, information and
diagnosis of vehicles system VAS 5051 in "Guided fault finding"
function. (for the relevant engine control unit) and ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations. The follow‐
ing phase only connects when the alternator -C- stress is below
30 ...77% (depending on engine speed)

Disconnection criteria for additional heating
Note
Vehicles without air conditioning cancel the activation if the en‐

gine control unit fails to meet the connection criteria, or detects
one of the disconnection criteria.
♦ If one of the connection conditions is lost

♦ Calculated ambient temperature greater than 11° C
♦ The alternator -C- stress is over 95%.
♦ The engine control unit does not receive an earth signal from
the heating control unit -J65- .
3.2 Heating control unit : removing and fit‐

ting
Heating controller panel ( heating control unit -J65- ) in vehicles
without air conditioning
Air conditioning control unit -J301- in vehicles with manual climate
control
Note
♦ There are different versions of the Heating control unit -J65-

-A- (with or without Thumbwheel for regulation of the heated
driver's seat -E94- and Thumbwheel for regulation of the heat‐
ed passenger's seat -E95- -C-) ⇒ Spare parts catalogue .
♦ The Heating control unit -J65- -A- has no fault memory (there
is no self-diagnosis) and is not connected to the data bus sys‐
tem.
3.2.1 Removal:
– Remove the radio or radio and navigation system: ⇒ Radio,
telephone, navigation; Rep. gr. 91
– Remove the moulding from the heating controls -A- by remov‐
ing the securing screws.
– Unscrew the bolts -B- and -C-.
– Release the Heating control unit -J65- -D- from the centre
console.

– Release the connector safety catch -A- by pulling in the direc‐

tion of the -arrow-.
– Squeeze the connector holder -B- until the connector -arrow-
and then remove the connector -C-.
– Release the connector block -D- and remove the connector
-D-.
3.2.2 Installing
Installation is carried out in the reverse sequence; note the fol‐
lowing:
– Both shafts of the heating control unit -J65- -C- can only be
inserted in one position in the mount of the main board -D-.
For this purpose, turn the rotary switch -A- and -B-, until the
position of its shaft corresponds with the shaft mount on the
main board.
– Securing element of the adjusting lever -D- and -F- are moun‐
ted on the main board of the operating element of heater -A-
(for the production so that the position cannot be altered during
transportation). When connecting, these securing elements
are released via the pinion -C- for the air distribution) and -E-
(for the temperature setting) of the heating control unit -J65-
-B-. If the pivots -C- and -E-unless
permitted areauthorised
not correctly inserted,
by SEAT S.A. SEAT S.Athe does not guarantee or accept any liability with
corresponding rotating controlrespect can only be of
to the correctness moved with
information some
in this document. Copyright by SEAT S.A.
difficulty or makes noise.

3.3 Main board for the heating control: re‐

moving and fitting
3.3.1 Removal:
– Fit the rotating control for temperature selection -A- in the po‐
sition „cold limit“.
work; Rep. gr. 68 .
– Remove the vent from the foot well area on the passenger
side.
– Replace the Heating control unit -J65- ⇒ page 29 .
– Release the flexible axle insert -H-

– Release the insert -D- for the Bowden cable sheath -E- and
remove the Bowden cable sheath from the allotment.
– Release the ball on the Bowden cable -F- from the operation
lever -G-.
– Remove the main board from the centre console.

3.3.2 Installing
Note
♦ There are transmission gears fitted on the main board for the
heating controls and in the heating system. Rotating the air
distribution control makes the flexible axle rotate twice.
♦ Due to the fact that when the instrument panel is fitted the flap
positions cannot be seen, take into account the air distribution
flap positions when connecting the flexible axle to the main
board.
– Connect the Bowden cable for the temperature flap to the main
board -A-.
– Assemble the main board -A- and the control unit -B-
⇒ page 29 . respect to the correctness of information in this document. Copyright by SEAT S.A.
– Fit the rotating control -D- into position so that the flexible axle
-C- can be inserted into the allotment on the main board -A-.
– Insert the flexible shaft -C- onto the main board -A-.
– Fit the rotating control -D- into the position „foot well air
distribution“ (as shown in the diagram).
– Check the position of the flap in the area of the right hand side
foot well -E-, the air duct -F- must be completely open.
– If the air duct -F- is closed:
– Release the flexible axle -C- from the main board -A-.
– Turn the rotating control -D- to the position „air distribution to
the windscreen“.
– Insert the flexible shaft -C- onto the main board -A-.
– Fit the rotating control -D- into the position „foot well air
distribution“ (as shown in the diagram).
– Check the position of the flap in the area of the right hand side
foot well -E-, the air duct -F- must be completely open.
The assembly is carried out in reverse order.

3.4 Control unit for heating and fresh air

connectors
♦ Check box -V.A.G 1598/42-
♦ Adapter cable -V.A.G 1598/47-

♦ template -V.A.G 1598/47-2-
3.4.1 Pin allocation for the multi-connectors

on the rear of the control unit for heating
and fresh air

16-pin connector is vacant.

Electrical connector, 5-pin, T5
1 - 3rd blower speed
2 - 2nd blower speed
3 - 1st blower speed
4 - 4th blower speed
5 - Terminal X
Electrical connector, 20-pin, T20 c

3 - fresh air and air recirculation flap servomotor -V154-
6 - fresh air and air recirculation flap servomotor -V154-
8 - Rear windscreen
11 - Heated driver seat regulator -E94- (optional equipment)
15 - Heated passenger seat regulator -E95- (optional equipment)
16 - Heater/heat output switch -E16-
18 - Terminal 30
19 - Terminal 15
20 - Terminal 31

3.5 Flexible axle (for air distribution): remov‐

ing and fitting
3.5.1 Removal:
– Remove the control unit adapter carefully.
– Squeeze the retaining tab -arrow- on the flexible axle and re‐
move it.
Note
When fitting the flexible shaft, the adaptor and the rotating con‐
trols of the hot air and outside air control unit must be fitted in a
defined position relative to each other; otherwise will result in
problems.
3.5.2 Checking
Air distribution flap control mechanism flexible shaft:
– Turn the exterior air turbine to the maximum. In the „de-icing“
position air comes from the de-icing vent and not from the vent
in the foot well then the shaft is fitted correctly. Otherwise, re‐
move the flexible shaft from the adapter. Fit the Heating control
unit -J65- into the adaptor and rotate by a 1/2 turn (180°) the
air distribution control. Reinsert the flexible shaft again. Re‐
peat the verification.
3.5.3 Installing
Note
There are transmission gears fitted on the main board for the
heating controls and in the heating system. Rotating the air dis‐
tribution control makes the flexible axle rotate twice.
The assembly is carried out in reverse order.
3.6 Bowden cable for temperature adjust‐

ment: Removing and installing
– Fit the rotating control for temperature selection -A- in the po‐
sition „cold limit“.
– Remove the instrument panel and the crossbeam for the in‐
strument panel (centre tube) ⇒ Bodywork, interior fitting work;
Rep. gr. 70 .
Note
So as not to damage instrument panel outside lining, the control

panel is only to be placed on a clean workbench covered, for ex‐
ample, with clean cardboard.

– Release the insert -D- for the Bowden cable sheath -E- and
remove the Bowden cable sheath from the allotment on the
heating controls carrier plate.
– Release the ball on the Bowden cable -F- from the operation
lever -G-.
– Release the counter support -A- for the Bowden cable sheath
-E- and remove the Bowden cable sheath from the heating
guide -C-.
– Release the ball on the Bowden cable -F- from the tempera‐
ture flap operation lever.
3.6.1 Installing permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

lowing:
– Only fit a Bowden cable that has not been bent and that moves
correctly inside the Bowden cable sheath.
– Do not bend the Bowden cable.

4 Heating equipment: removing and fit‐

ting
4.1 Heating equipment: removing and fitting

♦ Cooling (leak) tester SAT 1274
♦ U-30042 Installation tool
♦ Commercially available compressed-air gun
4.1.1 Removal:
– Disconnecting battery ⇒ Electrical system; Rep. gr. 27
Note
♦ On removal, note down bolt lengths and assignment for re-

installation.
♦ All cable ties and other wiring harness fasteners released or
cut open on removing heater are to be re-attached in same
position on installation.
– Release the pressure in coolant circuit by opening cap on the

coolant expansion tank ⇒ Engine, mechanics; Rep. gr. 19 .
– Depending on the motor, remove the elements necessary to
gain access to the connections of the heat exchanger.

– Mark the position of the refrigerant hoses -A- and -B- (the po‐
sition is the same for vehicles with heating or air conditioning.
This illustration shows the position in a vehicle with air condi‐
tioner).
– Disconnect the air release tube (from the upper junction -A- to
the coolant expansion tank).
– Pinch off both coolant tubes to heating system heat exchanger

(e.g. using the clamp -U-30042- ) and detach tubes.
Note
♦ Connect coolant hoses by the correct sides:

♦ Coolant hose -A- , supplied from cylinder head.
♦ Coolant hose -B-, return to water pump.
♦ Bleed the coolant circuit of air ⇒ Engine, mechanics; Rep. gr.
19 .
– Connect a piece of hose -A- to the upper junction.

– Keep a suitable recipient -B- under the lower connection -C-.
– Use a compressed air pistol to carefully blow the liquid coolant
from the heat exchanger (into the recipient -B-).
– Remove the passenger and driver seats ⇒ Bodywork, interior
– Remove the glove compartment, the lower trim on the driver's
side, the centre console and the instrument panel⇒ Bodywork,
interior fitting work; Rep. gr. 70 .
Note
So as not to damage instrument panelpermitted
outside lining,
unless thebycontrol
authorised SEAT S.A. SEAT S.A does not guarantee or accept any liability with
panel is only to be placed on a clean workbench
respect tocovered, forofex‐
the correctness information in this document. Copyright by SEAT S.A.
– Remove the accelerator pedal module ⇒ Fuel supply system;

Rep. gr. 20 .
– Fold the mat on the driver side and passenger side back so
that it is possible to remove the vents for the foot well ⇒ Body‐
work, interior fitting work; Rep. gr. 70 .
– Remove the two vents from the foot well for the rear area.
– Remove the Fresh air blower -V2- ⇒ page 10 .
– Remove the Heating control unit -J65- (do not remove the
main board for the heating controls) ⇒ page 29 .
Rep. gr. 70 .
4. Heating equipment: removing and fitting 37

– Remove the Data bus diagnostic interface -J533- (in the area
of the steering column secured to the bracket -A-) ⇒ Electric
System; Rep. gr. 90 .
– Remove the bolts -B- (tightening torque 9 Nm) and release the
support -A- for the heating (the support is attached to the cable
harness of the vehicle).
– Remove the two bolts -A- in the cable harness support -B-
– Unplug connector -C-.
– Loosen the attachment of vehicle wiring harness (with cable
ties) to the heater.
– For those vehicles with an additional electric heating (only for
diesel powered vehicles), release the cable connections to the
voltage supply of the Additional heating element -Z35-
⇒ page 130 .
– Unplug all connectors between vehicle wiring harness and
electrical components at heater.
Note
The „Heating system“ wiring harness is removed with heater.
– Pull out the heating system a little bit from the right hand side
(until the bolt -B- in the right hand side support -A- may be
unscrewed).
Note
♦ Pull gently on the heating system so that the support -A- does
not break.
♦ To unscrew thecorrectness
respect to the bolt -B-ofinsert a hand
information between
in this document. the heating
Copyright and
by SEAT S.A.
the floor mat in the right hand side wheel housing (this is pos‐
sible if the fresh air turbine has first been removed).
– Remove the bolts -B- and release the support -A- for the heat‐
ing (the support remains attached to the cable harness of the
vehicle).
– Release the bracket for the coolant hoses to the heat ex‐
changer -A- from the openings of the grommet -B-.
Note
♦ On removing the heater, pay attention to both coolant pipes to

heat exchanger to ensure that they do not catch on the open‐
ing to the plenum chamber or on the sound proofing mat and
are bent or damaged.
♦ Pay attention to wiring harness. Pulling too firmly could dam‐
age individual wires.

– Remove the heating -A- in the direction of the passenger side

(the layout and the shape of the housing is the same for vehi‐
cles with heating or air conditioning).
4.1.2 Installing
lowing:
– To fit the heating, the help of a second mechanic is required.
Note
♦ Check all sealspermitted
at heater
unless for damage
authorised prior
by SEAT to installation
S.A. SEAT and or accept any liability with
S.A does not guarantee
replace damaged seals.
♦ Check attachment of coolant pipes to heat exchanger.
– Fit the seal -A- (as viewed from the interior to the outside) to
the transversal panel -B-. Note the correct fitting position of the
seal -A- on the transversal panel.
– Seek the help of another person to fit the heating.

– Guide the bracket for the coolant hoses to the heat exchanger
-A- when fitting the heating (from the engine compartment)
through the openings of the grommet -B-.
Note
♦ On fitting the heater, pay attention to both coolant pipes to heat

exchanger to ensure that they do not catch on the opening to
the plenum chamber or on the sound proofing mat and are
bent or damaged.
– Re-install components removed with the exception of the driv‐

er sides lower trim in reverse order.
Note
♦ When installing the instrument panel, make sure the inter‐

mediate de-icer element is properly positioned on heater and
that de-icer nozzle does not squash intermediate piece.
♦ After installingProtected
instrument panel,
by copyright. check
Copying exitordirection
for private and dis‐
tribution of airpermitted
flowrespect
from de-icer vent to windscreen.
to the correctness of information in this document. Copyright by SEAT S.A.
– Connect the flexible tubes for the liquid coolant correctly to the
heat exchanger. Note the markings:
A - Cylinder head feed
B - Return tube to the water pump
– Bleed the coolant circuit of air ⇒ Engine, mechanics; Rep. gr.
19 .
– Check coolant circuit for leaks, paying particular attention to
connection between coolant pipes and heat exchanger
⇒ page 139 , ⇒ Engine, mechanics; Rep. gr. 19 .
– Check the correct positioning of the grommet -B- in the trans‐

verse panel.
– Seal the brackets for the coolant hoses to the heat exchanger
-A- in the openings of the grommet -B-, for example using sil‐
icon sealing paste (so that it is water tight).
– Refit the lower lining on the driver side as well as any other
components that were removed.
– Check the operation of the heating.
– Check the direction of the air diffusion, depending on the con‐
trol position (one rotation of the heating control rotates the
flexible axle twice by the transmission gear) ⇒ page 31 .

4.2 Checking heat output
Note
When the refrigerant circuit is not purged after filling, air may ac‐
cumulate in the heat exchanger of the heater that will lead to a
reduction of the heating performance. Noises are also possible or
the customer complains about different air temperatures originat‐
ing from the vents on the driver and passenger sides.
Solution for deficient heating capacity or noise coming from the

coolant circuit:
Carry out a long test run at high engine speeds (at least ten mi‐
nutes with a minimum engine speed of 2500 rpm). Use low gears
so that the vehicle does not have to be driven quickly.
If a client complains of low heating power at certain engine
speeds, check the fitting of the heating heat exchanger in the
cooling liquid circuit. If the liquid coolant tubes from the engine
have been mixed up (feed and return), the liquid will flow in the
wrong direction through the heat exchanger ⇒ Engine, mechan‐
ics; Rep. gr. 19 .
4.2.1 Requirements for achieving maximum

heating potentialProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• The liquid coolant circuit must be purged according
respect to the toinformation
correctness of the in‐ in this document. Copyright by SEAT S.A.
structions ⇒ Engine, mechanics; Rep. gr. 19 .
• All air ducts, covers and seals in good condition and properly
fitted.
• The air flow through the dust and pollen filter is not obstructed
by dirt.
• Engine warm.
• The Bowden cable and the levers for the operation of the tem‐
perature flaps are in good condition.
• The liquid coolant thermostat must be in good condition.
• The sponge material seal in the heat exchanger in the heating
must be in good condition ⇒ page 139 .
• For diesel engine vehicles the operation of the additional heat‐
ing and the activation of the Heating control unit -J65- must
function correctly ⇒ page 20 .
• In vehicles with direct petrol injection „FSI“ the activation of the
engine control unit by the heating control unit -J65- is correct
4.3 Air inlet opening with fresh air / air recir‐

culation flap: removing and fitting
4.3.1 Removal:
– Remove the entire instrument panel and the crossbeam for the
instrument panel ⇒ Bodywork, interior fitting work; Rep. gr.
70 .
– Removing the heating ⇒ page 36 .

– Unscrew bolts -A-.

– Remove the cover -B-.

– Release the air inlet opening -D- of the heating.
4.3.2 Installing
the following:
– When fitting the air inlet opening, ensure the correct position‐
ing of the attachment points -E- and -F-.

5 Dismantling and assembling heater

5.1 Heating system components: removing and fitting
1 - Control mechanism for the

temperature flap
❑ Different versions (for
example, with or without
connection to the Addi‐
tional heating control
unit -J604- ) ⇒ Parts
catalogue
❑ Mark the position before
removing the connec‐
tors (identical connec‐
tors for different compo‐
nents)
❑ Fit the cable harness in‐
to the fastening points
on the housing (using
cable ties, or in the allot‐
ments) so that it does
not come into contact
with any moving parts
⇒ page 45
2 - Spring retainer
3 - Cover
4 - Servomotor for the fresh
air / air recirculation flap -V154-
❑ Check: ⇒ Vehicle diag‐
nostic, testing and infor‐
mation system
Protected VAS 5051
by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Removing andoffitting
respect to the correctness information in this document. Copyright by SEAT S.A.
⇒ page 11
❑ Replacing: initiate the
basic settings with the
self diagnosis -VAS
5051-
5 - Air inlet housing
❑ With outside air and recycled air flap
6 - Heater
10 - Cover
❑ For dust and pollen filter.
11 - Heat exchanger
5. Dismantling and assembling heater 43

12 - Heat exchanger covering

14 - Air distribution flap control mechanism
5.2 Air distribution flap control mechanism

Removing and installing
5.2.1 Removal:
– Remove the vent from the foot well area on the left side.
– Unclip the flexible shaft from the adaptor in the control unit
⇒ page 34 .
– Unscrew the bolts -1- and extract the air distribution flap con‐
trol mechanism.
5.2.2 Installing
– The arrows on the cogwheels must be lined up.
– Fit the air distribution flap control mechanism and tighten the
bolts -1-.
Note
After installing, check operation of air distribution flap.

5.3 Control mechanism for the temperature

flap: removing and fitting
5.3.1 Removal:
– Unhook the mechanism cable from the temperature flap -2-
⇒ page 34 .
– Release the block -1- and push the air distribution flap control
mechanism in the direction of the -arrow- as far as it will go.
– Extract the control mechanism for the temperature flap.
5.3.2 Installing
Note
After installation, check operation of temperature flap. Ensure that

the rotating control for the hot air and exterior air control mecha‐
nism may be moved easily from „cold“ to „hot“.
5.4 Dismantling and assembling heater

– Remove heater components ⇒ page 43 .

1 - Air distribution housing of

the heating
❑ Do not dismantle further
❑ In vehicles without heat‐
er element for additional
air heating -Z35- the
opening for the heater
element for additional
air heating -Z35- is
blocked by the cover of
the heat exchanger.
❑ Lightly grease the sup‐
port points and the tem‐
perature flap guides (for
example using G 052
745)
2 - Bolt.
3 - Air duct to the air vent in the
left foot well
❑ Version „Heating“
⇒ page 139
5 - Seal ring
❑ Replace
❑ Lightly cover with liquid
coolant and fit correctly
into place ⇒ page 139
6 - Clip
❑ Replace
❑ Ensure that it is properly
positioned.

⇒ page 139
7 - Bolt.
❑ Tightening torque: 2.5 Nm
8 - Coolant tubes
❑ Remove and fit at the heat exchanger ⇒ page 139
❑ Fitted between the grommet and the heating
10 - Grommet
❑ Before fitting the heating, fit this in the transversal panel of the vehicle ⇒ page 36
11 - Air flow duct
❑ Heed replacement intervals ⇒ Maintenance ; Booklet 1
13 - Cover for the dust and pollen filter
❑ Removing and fitting ⇒ page Protected
120 by copyright. Copying for private or commercial purposes, in part or in whole, is not
14 - Air duct to the air vent in the right foot
respectwell
❑ Version „Heating“
15 - Sealing plug
5.5 Air flow duct: disassembling and assem‐

bling
– Remove heater components ⇒ page 43 .
– Remove the heating air duct ⇒ page 45 .

1 - Air flow duct, lower element

2 - Noise insulation
❑ For those vehicles with
heating (without air con‐
3 - Clip
4 - Air flow duct, upper element
5 - Bolt.

87 – Air conditioning system

1 Safety precautions for work on vehi‐
cles with air conditioning and how to
work with refrigerant R134a
The assemblies and the piping of the air conditioning system are
filled with the following refrigerant:
Tetrafluoroethane (CF3-CH2F or CH2F-CF3)
This refrigerant is currently commercially known as R134a, H-
FKW 134a, SUVA 134a and KLEA 134a (there may be other
commercial names for this product in other countries).
1.1 Safety precautions
1.1.1 Safety precautions

The following safety measures are to be followed for this refrig‐
erant (additional regulations may apply in other countries).
If work is required on the refrigerant circuit then this circuit must
first be emptied ⇒ page 50 . Any contact with the refrigerant
liquid or vapours of this liquid must be avoided. Should any of the
refrigerant be spilled despite precautions then the mix of air and
refrigerant must not be breathed in.
In this situation, turn on any suction system and protect hands
with gloves and the eyes with protective glasses.
Reasons:
The intensive action of the refrigerant on unprotected parts of the
body may lead to freezing of those parts.
WARNING
It is recommended that you always have an eye-bath ready for

use in case it is needed.
If the refrigerant comes into contact with the eyes, immediately
begin thorough rinsing of the eyes for 15 minutes.
Then, apply eye drops and seek medical assistance even if the
eyes do not cause any pain.
The medical assistance must be given all of the details of the
refrigerant causing the problem.
If, despite taking the safety precautions, any part of the body
comes into contact with the refrigerant, also rinse thoroughly and
immediately with cold water for about 15 minutes minimum.
Even though the refrigerant is not flammable, in any enclosed
space where work is carried out with the refrigerant, smoking and
electric welding equipment as well as hard or soft soldering work
are forbidden.
Reasons:
If the refrigerant comes into contact with flame or hot elements,
the gas in the refrigerant is chemically separated. When this re‐
leased poisonous gas is breathed in, it produces an irritated
cough and dizziness.
1. Safety precautions for work on vehicles with air conditioning and how to work with refrigerant R134a 49
1.1.2 Draining the refrigerant circuit

The refrigerant should not be disposed of in the environment. It
must be extracted from the refrigerant circuit using an extraction
unit or a service device. The refrigerant removed is then either to
be re-processed on site or returned to the manufacturer for proper
disposal (different or additional regulations may apply in other
countries). For this reason, the vehicle must be brought to a sup‐
port workshop dealing with air conditioning systems (these work‐
shops posses the tools and equipment required).
Reasons:
The refrigerant R134a contributes enormously to the global
warming effect if released into the atmosphere.
Note
♦ The greenhouse effect of the refrigerating agent R134a is sig‐

nificantly lower than that of the refrigerating agent R12.
♦ Refrigerant R134a does not affect the earth's ozone layer
(R134a is an hydrofluorocarbon with no chlorine atoms). De‐
pletion of the ozone layer in the upper atmosphere is only
brought about by the splitting of carbon chlorine bonds (as is
the case, for example, with refrigerant R12).
After emptying the air conditioner, separate the connector for the
Compressor regulation valve, air conditioning -N280- or of the
High pressure sender -G65- .
Reasons:
The Air compressor regulation valve, air conditioning -N280- is no
longer activated and the compressor works slowly. The compres‐
sor is made in such a way that when it runs slowly, the lubrication
of all compressor elements is guaranteed by an internal oil circuit
(while there is sufficient cooling oil in the compressor).
1.1.3 Working on the refrigerant circuit

Work on the refrigerant circuit should only be carried out in well
ventilatedpermitted
areas.unless
At the same
authorised time,S.A.ensure
by SEAT SEAT S.Aabsolutely thator within
does not guarantee accept any liability with
a radius of 5 meters
respect tothere are no
the correctness mechanic
of information pits,
in this wellsCopyright
document. or cellar
by SEAT S.A.
entrances. Turn on all ventilation equipment.
Reasons:
The refrigeration agent that leaks into the air is colourless, odour‐
less and is also more dense than air and thus displaces the
oxygen. If, despite taking the necessary precautions, there is a
leak of refrigerant, there is a danger of asphyxia without any
warning, especially in insufficiently ventilated areas or in mechan‐
ics pits.
Note
The mixture of gas and air which forms when refrigerant gas es‐
capes must not be inhaled. Suitable workshop extractors must be
used.
Never carry out any welding work of any kind on or near the air
conditioning system if it still contains refrigerant. The same ap‐
plies to all vehicles if there is a risk of heating elements of the air
conditioning system.
50 Rep. gr.87 - Air conditioning system

Reasons:
Due to heating, there will be an extreme pressure build up in the
air conditioning installation which could lead to an explosion of
the system.
Remedy
Drain the refrigerant circuit ⇒ page 50 .
Note
No damaged or non-airtight part of the air conditioning may be

repaired using welding and they must be replaced by new parts.
When servicing air conditioning, all open components and pipe

connections are to be immediately re-sealed.
Reasons:
Moisture will penetrate the air conditioner component if they are
left open for a long period. If this is the case, air conditioners can‐
not be re-filled without having to replace parts of the system.
1.1.4 Paint work for vehicles with air condi‐

tioning
When carrying out paint work temperatures of 80℃ must not be
exceeded either in the drying oven or in the preheating area.
Reasons:
Due to heating, there will be an extreme pressure build up in the
air conditioning installation which could lead to an explosion of
the system.
Further information: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ The circuit diagrams concerned may be found in the folder

cations
♦ A plate fitted in the engine compartment indicates the type of
refrigerating agent and amount in the system.
♦ There are more notes about work on vehicles with air condi‐
tioning and the handling of the refrigerant agents in the ELSA
system.
– On the ELSA website, enter the technical information: ⇒ Air
conditioning - with refrigerant R134a SEAT .
1. Safety precautions for work on vehicles with air conditioning and how to work with refrigerant R134a 51
2 General repair instructions
WARNING
Before carrying out any repairs to cables, remove the corre‐

sponding fuse or fuses.
Note
Before any welding work on the vehicle, disconnect the battery ⇒

Electrical system; Rep. gr. 27 .
It is only permissible if so required by theofpertinent
information insafety meas‐
respect to the correctness this document. Copyright by SEAT S.A.
ures ⇒ page 50 or if parts of the air conditioning refrigerant circuit
have to be replaced to drain and open the air conditioner refrig‐
erant circuit ⇒ page 50 .
The venting device for the air conditioner -SAT 4006C- includes
an adaptor for rapid connection to the service connections on the
high or low pressure sides of the system.
The manufacturer continuously develops charging stations de‐
pending on the latest technology; for this reason the designation
and instructions may alter slightly ⇒ Equipment instruction man‐
ual .
For all other work on the vehicle the refrigerant agent circuit for
the air conditioning remains closed.
If the circuit must be opened for the purpose of repair work, use
the conical plugs from the kit -T20017A- to avoid penetration of
dust and humidity into the system.
Service work which can be performed on the heater and air con‐
ditioner without opening the refrigerant circuit is described in this
Workshop Manual ⇒ page 87 .
Note
The connections for the senders / switches mentioned in this

workshop manual are provided with a valve which closes auto‐
matically when the switches are unscrewed. For this reason,
these switches may be replaced in any Seat workshop when the
air conditioning system is filled.
Work on the air conditioning system requiring the drainage of the

refrigerant circuit of must be carried out in specific SEAT work‐
shops is described ⇒ page 162 (to drain the refrigeration circuit
the vehicle must be brought to a support workshop specialised in
air conditioning systems).
2.1 Contact corrosion

Contact corrosion can occur if unsuitable connecting elements
are used (bolts, nuts, washers), rivets, plugs, grommets, adhe‐
sives, etc.
For this reason, all the connecting elements fitted have been sub‐
jected to special surface treatment by the manufacturer. This can
be seen from the greenish colour of such elements. Use is also

made of rubber and plastic parts as well as adhesives which are

not electrically conductive.
These tested, aluminium-compatible components are also avail‐
able as replacement parts.
Always use genuine parts!
Always fit new parts in cases of doubt about reusability.
Accessories must have been released by SEAT!
Damage from contact corrosion is not covered under the warran‐
ty.
2. General repair instructions 53

3 Refrigeration agent circuit: repairs
Note
♦ Repair work on refrigerant circuit ⇒ page 162 .

♦ All parts marked with a 1) or work, may be repaired, changed
or carried out in any workshop (work on these does not affect
the refrigerant agent circuit).
♦ All those parts from the refrigerant circuit that are not marked
with a 1) as well as the flexible and rigid refrigerant tubes can
only be repaired in a support workshop specialised in air con‐
ditioning systems (the refrigerant agent must be drained for
work on these parts).
3.1 Exploded view of components

HD = High-pressure end (high density)
LP = Low-pressure side
1 - Compressor control valve,

air conditioning -N280-
❑ Check activation and
operation ⇒ page 64 1)
2 - Compressor
❑ Detaching compressor
from holder/re-attaching
⇒ page 62 1)
❑ When fitting the refriger‐
ation agent tubes with
the corresponding sup‐
port, ensure that there is
sufficient space be‐
tween the belt, the sup‐
port and the pulley
❑ Depending on the en‐
gine, the design of the
compressor may vary ⇒
Spare parts catalogue
3 - Pulley
❑ Replacement 1)
⇒ page 68
Poly-V belt 1) ⇒ Engine,
mechanics; Rep. gr. 13
❑ Poly-V selection ⇒
Spare parts catalogue Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note
♦ Between the pulley and the shaft

for operation of the compressor,
there is a protection element fit‐
ted to prevent overcharging, to
protect the belt in case the com‐
pressor is blocked or is impeded.

♦ The overcharge protection re‐

duces the transmission of force
to the compressor if its move‐
ment becomes difficult.
♦ Rubber elements are installed
between the pulley and the com‐
pressor drive shaft. These rub‐
ber elements reduce the vibra‐
tions that occur during the
compressor operation (damper
function in the case of torque
fluctuations).
4 - Oil drain plug

5 - Pressure relief valve
6 - Junction with valve
❑ Different fitting locations depending on the engine. Pos. „a“ shows the fitting location in vehicles with a
2.0 l diesel engine.
7 - High-pressure sender -G65- 1)
❑ Test the signal ⇒ page 58
8 - Condenser Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ For those vehicles designed for degraded roads there may be an additional protection in the lower area
against stone impacts

9 - Liquid tank
❑ The liquid tank is fitted directly on the condenser
10 - Service connection
❑ High-pressure side
❑ Different versions (with primary seal valve or Schrader valve) depending on the coolant hose, distin‐
guishing features ⇒ Air conditioning - with refrigerant R134a
❑ For service station (measurement of pressure and draining of the air conditioning circuit⇒ Air conditioning
with refrigerant R134a
❑ For workshops specializing in climate control, for measurement, drainage and filling⇒ Air conditioning
❑ Depending on the version of the engine fitted, it may be necessary to remove certain components (for
example the active carbon filter) to connect the service connection
WARNING
Only remove the service
connections when the
refrigeration circuit is
empty; they do not have
valves.
3. Refrigeration agent circuit: repairs 55

11 - Sealing cap
❑ With gasket
❑ Screw in
12 - Expansion valve
13 - Evaporator
❑ Low-pressure section
❑ Different versions (with primary seal valve or Schrader valve) depending on the coolant hose, distin‐
guishing features ⇒ Air conditioning - with refrigerant R134a
❑ For service station (measurement of pressure and draining of the air conditioning circuit⇒ Air conditioning
❑ For workshops specializing in climate control, for measurement, drainage and filling⇒ Air conditioning
WARNING
valves.
15 - Sealing cap
❑ With gasket
❑ Screw in

3.2 Removing and fitting high-pressure

sender -G65-
Note
♦ In vehicles with automatic climate control, the control and in‐

dicator panel, Climate control unit -J255- , processes the
signal from the high pressure sender -G65- and activates the
compressor via the compressor regulator valve, air condition‐
ing -N280- .
♦ In vehicles with manual climate control, it is the Air conditioning
control unit -J301- which processes the signal from the high
pressure sender -G65- and activates the compressor via the
compressor regulator valve, air conditioning -N280- .
♦ The cooling power cannot be tested once the High pressure
sender -G65- is removed, the Climatronic control unit -J255- /
Air conditioning control unit -J301- will not activate the com‐
pressor.
♦ The refrigerant circuit remains closed, valve connection.
♦ Check the operation of the High pressure sender -G65- and
the output signal ⇒ page 59 .
♦ Different fitting locations depending on the engine, for vehicles
with 2.0 litre Diesel engine, the High pressure sender -G65-
for example is not fitted on the coolant hose from the expan‐
sion valve to the condenser; it is fitted instead to the tube from
the compressor to the condenser.
♦ For those vehicles with a 1.6 litre petrol engine, the High pres‐
sure sender -G65- may be removed without first removing
other components (access from above).
– Remove the sound insulated (if fitted) ⇒ Bodywork, exterior

installation work; Rep. gr. 50 .
– Remove the connector -A- from the high pressure sender
-B-.
– Remove the high pressure sender -B- (tightening torque: 8
Nm).
– Replace the O-ring -C- ⇒ page 61 , allocation ⇒ Spare parts
catalogue .

3.3 Checking the pressure signal of the High

pressure sender -G65- .
Note
♦ In vehicles with automatic climate control, the control and in‐

dicator panel, Climate control unit -J255- , processes the
signal from the high pressure sender -G65- and activates the
compressor via the compressor regulator valve, air condition‐
ing -N280- .
♦ In vehicles with manual climate control, it is the Air conditioning
control unit -J301- which processes the signal from the high
pressure sender -G65- and activates the compressor via the
compressor regulator valve, air conditioning -N280- .
♦ The cooling power cannot be tested once the High pressure
sender -G65- is removed, the Climatronic control unit -J255- /
Air conditioning control unit -J301- will not activate the
compressor⇒ Vehicle diagnostic, testing and information sys‐
tem VAS 5051.
♦ Different fitting locations depending on the engine, for vehicles
with 2.0 litre Diesel engine, the High pressure sender -G65-
for example is not fitted on the coolant hose from the expan‐
sion valve to the condenser; it is fitted instead to the tube from
the compressor to the condenser.
♦ On vehicles with 4-cyl. engines, the connector of the High
pressure sender -G65- may be removed without first removing
other components (access from above).
– Remove the sound proofing element (if fitted) ⇒ Bodywork,

exterior fitting work; Rep. gr. 50 .
– Disconnect the connector -A-.

3.3.1 Pin allocation on the High pressure

sender -G65-
Contact -1-: Earth.
Contact -2-: Signal output (square-wave signal on the Climatronic
control unit -J255- / Air conditioning control unit -J301- ).
Contact -3-: to the Onboard supply control unit -J519- .
Note
♦ If the pin -A- is disconnected the compressor is not activated.

♦ The high pressure sender -B- is the electronic control unit that
generates a rectangular wave signal whose duty cycle
changes with the pressure change in the refrigerant agent cir‐
cuit ⇒ page 59 .
3.3.2 The pressure signal of the High pres‐

sure sender -G65- .
-A- Pressure in the high pressure side of the refrigeration agent
circuit in bar (absolute pressure)
-B- Provides the duty cycle of the rectangular wave signal
-C- Characteristic curve

Note
♦ The Climatronic control unit -J255- / Air conditioning control

unit -J301- activates the compressor when there is no condi‐
tion to deactivate the compressor (activating the Compressor
regulation valve, air conditioning -N280- ) ⇒ Vehicle diagnos‐
tic, testing and information system VAS 5051.
♦ With a duty cycle greater than 12 % (equivalent to approx. 1.2
bar absolute pressure) and less than 78 % (equivalent to about
32 bar absolute pressure).
♦ If duty cycle is less than 12 % or greater than 78 %, the com‐
pressor is not activated (the Compressor regulation valve, air
conditioning -N280- is not activated).
♦ The duty cycle and the calculated pressure on the control and
indication panel Climatronic control unit -J255- / Air condition‐
ing control unit -J301- is displayed on the measurement values
block ⇒ Vehicle diagnostic, testing and information system
VAS 5051.
♦ An absolute pressure of 0 bar represents an absolute vacuum.
The normal ambient pressure is therefore equivalent to ap‐
prox. 1Protected
bar absolute pressure. In general most manometer
scales represent atmospheric pressure as not
0 bar meaning
or accept an
permitted unless authorised by SEAT S.A. SEAT S.A does guarantee any liability with
absolute pressure
respect to the of 1 bar of(this
correctness can inbethisrecognised
information if there
document. Copyright by SEAT is S.A.
a -1 on the scale).
♦ The Climatronic control unit -J255- / Air conditioning control
unit -J301- sends a signal along the comfort data bus to the
engine control unit, depending on the pressure calculated in
the refrigeration circuit, while the compressor is activated, to
request a higher refrigerant ventilator speed. The request cal‐
culated by the Climatronic control unit -J255- / Air conditioning
control unit -J301- is displayed on the measurement values
VAS 5051.
♦ Currently, the request for a higher refrigerant ventilation speed
is sent for the following duty cycle:
♦ Pressure in the refrigerant circuit lower than approx. 9 bar (6
bar when the pressure was more than 9 bar) without require‐
ment.
♦ Pressure in the refrigerant circuit higher that approx. 9 bar (6
bar) to approx. 20 bar, depending on the pressure of 30 to 100
% of the requirement.
♦ Pressure in the refrigerant circuit higher than approx. 20 to 100
% of the requirement.
♦ The signal generated by the High pressure sender -G65- may
also be used for engine management. The control and indi‐
cation panel Climatronic control unit -J255- / Air conditioning
control unit -J301- sends the information over the comfort sys‐
tem data bus to the engine control unit (the torque required for
compressor operation depends on the pressure in the refrig‐
eration circuit). Depending on engine control unit version,
signal is displayed as duty cycle in measurement value block
⇒ Vehicle diagnostic, testing and information system
VAS 5051

This image appears on the screen of the oscilloscope (for exam‐

ple in the self diagnosis -VAS 5051- ) when the limit conditions
are fulfilled:
– When the ignition is turned on (positive on the pin „3“ and earth
on the pin „1“ on the High pressure sender -G65- ).
– Oscilloscope adjustment: 5 V/Div. = (5V per DC voltage unit)
5 ms/Div. (5 milliseconds per unit).
– Measurement cable (signal cable) on the pin „2“ connected to
the High pressure sender -G65- .
– Measurement cable (screened) to contact „1“ (earth on High
pressure sender -G65- ).
Note
♦ The figure shows that the signal that is being transmitted when
a pressure of approx. 7 bar absolute pressure is applied to the
refrigeration circuit that is equivalent to a duty cycle of 25%
(setting when the engine is stationary, an ambient temperature
of 30℃ and a correctly filled refrigerant circuit).
♦ The amplitude of the
permitted unless pulses
authorised -A- S.A.
by SEAT depends
SEAT S.Aon
doesthe pressure
not guarantee in any liability with
or accept
the refrigeration circuit
respect (if the pressure
to the correctness of information increases,
in this document.the margin
Copyright by SEAT S.A.
is made wider -A-).
♦ The length -B- of the signals is always 20 milliseconds (corre‐
sponding to a frequency of 50 Hertz).
♦ The duty signal is the result of the relationship between the
width of the pulse -A- and the length of the signal -B-.
♦ For this test, the test cables from the auxiliary measurement
set -VAG 1594C- may be used as can a cable adapted for this
purpose. This requires, for example, one connector -A- or
-B- each (with original part number 1J0 973,703 and 1J0
973,803 and the corresponding plug contacts), two commer‐
cially available sockets for banana plugs -C- and two wires
with a cross section of 0.5 mm2.
3.4 O-rings for refrigerant circuit

♦ The O-rings may only be used once, replace them every time
they are removed.
♦ Lightly oil the O-rings with oil from the refrigerant circuit just
before fitting.
♦ Ensure that the O-rings sit correctly into the corresponding
tubes or grooves.

♦ Work in a clean area (even small impurities such as a hair for

example can cause leaks).
Note
♦ Only fit O-rings that are resistant to the refrigeration agent

R134a and to the corresponding oil. These O-rings are easily
identified by their colour to avoid possible confusion (currently
„red“, „purple“ or „violet“): ⇒ Spare parts catalogue .
♦ The measurements -a- and -b- are different, depending on the
fitting position of the O-rings ⇒ Spare parts catalogue .
♦ In addition to the colour-coded O-ring seals, use is also made
of black O-ring seals for certain connections.
3.5 Compressor on its holder: Removing

and installing
Note
♦ The compressor can be detached from the support and re-

attached without opening up refrigerant pipes.
♦ Following is the description of the removal and fitting of the
compressor for a 2.0 litre petrol engine and a „Denso“ type „7
SEU 16“ compressor. There may be small differences in ve‐
hicles with a different engine or different compressor (depend‐
ing on the engine concerned it may be necessary to remove
or detach other auxiliary groups)
♦ The refrigerant circuit must not be emptied; nor should the
flexible tubes and the tubes for the refrigerant on the com‐
pressor be disconnected.
♦ Do not unfasten refrigerant pipes and corresponding clips.
♦ After detaching, use wire for example to attach compressor to
longitudinal member. Never leave hanging from refrigerant
pipes.
♦ Before removing the Poly-V belt, mark the direction of rotation
using chalk or a marker. Running a used belt in the opposite
direction could destroy it.
♦ Depending on the engine fitted and the country, different com‐
pressors are fitted ⇒ Parts catalogue .
3.5.1 Removing the holder

– Remove the upper engine protection ⇒ Engine, mechanics;
Rep. gr. 13 . permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

– Remove the centre sound proofing element ⇒ Bodywork, ex‐

– Mark the direction of rotation on the Poly-V belt (the diagram

shows the position for a 4 cylinder. engine).
– Release the Poly-V belt (the diagram shows the position for a
4 cylinder engine) and remove ⇒ Engine, Mechanics; Rep.
gr. 13 .
– Disconnect the connection to the Compressor regulation
valve, air conditioning -N280- on pin -1-.

– Unscrew the attachment bolts -arrows- (25 Nm).
– Detach the compressor and use wire, for example, to secure
it to the vehicle.
3.5.2 Install the holder

lowing:

– Before fitting the compressor, check the correct positioning of

the two sleeves -arrow- on the support or on the compressor.
– Fit accordingly, a washer on the attachment bolts -arrows-

(torque 25 Nm).
– Check carefully following fitting of the Protected
compressor, the secure
fitting of the refrigerant tubes. They must be secured inbythe
permitted unless authorised SEAT S.A. SEAT S.A does not guarantee or accept any liability with
supports designed for them (depending on thetoengine
respect type).
the correctness of information in this document. Copyright by SEAT S.A.
– After attaching the compressor, also check the refrigerant

pipes and corresponding holders to ensure adequate clear‐
ance from other components. Also ensure that there is suffi‐
cient space between the belt, the support and the pulley.
3.6 Check the activation signal for the Com‐

pressor regulation valve, air condition‐
ing -N280-
– Remove the upper protective cover of the engine (e.g. in ve‐
hicles with 4-cyl. engine, the connector can be accessed from
above) ⇒ Engine, mechanics; Rep. gr. 13 .
– Remove the sound proofing ⇒ Bodywork, exterior fitting work;
Rep. gr. 50 .
– Disconnect the connection to the Compressor regulation
valve, air conditioning -N280- on pin -1-.

– Re-establish the connection using the adapter cable from the

auxiliary measurement set -VAG 1594C- between the con‐
nector -A- and the connector -B- on the regulation valve.
Note
♦ During the activation of the Compressor regulation valve, air

conditioning -N280- , the current measured by the control and
indication panel Climatronic control unit -J255- / Air condition‐
ing control unit -J301- is displayed in the measurement values
VAS 5051.
♦ Use can also be made of an improvised adapter cable for this
test. This requires, for example, one connector -A- or -B- each
(with original part number 1J0 973,702 and 1J0 973,802 and
the corresponding plug contacts), two commercially available
sockets for banana plugs -C- and two wires with a cross sec‐
tion of 0.5 mm2.

– Connect the measurement cables -VAS 5051/8- to the adapter

cables.
– Test cable(signal) to contact -2-.
– Test cable (screen, earth) to contact -1-.
– Adjust in the self diagnosis -VAS 5051- the operation mode:
DSO (digital memory oscilloscope).
– Adjustment 5V/Div = 0.5ms/Div (5 volts DC and 0.5 millisec‐
onds per unit).
– Start engine.
– Adjust the temperature on the passenger and driver sides in
the Climatronic control unit -J255- / Air conditioning control unit
-J301- .
Vehicles fitted with Climatronic:
– Activate and deactivate in the Climate control unit -J255- using
the keys „Auto“ and „Off/On“ or „Econ“, the activation of the
Compressor regulation valve, air conditioning -N280- .
Vehicles fitted with Climatic:
– Activate and deactivate in the Air conditioning control unit -
J301- using the keys „AC“ and selecting the speed „1“ for the
Fresh air blower -V2- , the activation of the Compressor reg‐
ulation valve, air conditioning -N280- .
The adjustment function of the Climatronic control unit -J255- / Air
conditioning control unit -J301- is displayed on the oscilloscope
screen:
– In operation mode „OFF“ or „Econ“ without any rectangular
wave signal (the regulation valve is not activated).

– In the operation mode „Auto“ with the temperature control at

the minimum, there is a rectangular wave signal with a pulse
width -A- of between 75 % and 100% (the regulation valve is
activated).
– With the button „AC“ pressed, the speed „1“ of the Fresh air
blower -V2- selected and with the temperature control at min‐
imum, there is a rectangular wave signal with a pulse width
-A- of between 75 % and 100% (the regulation valve is acti‐
vated).

Note
♦ The figure shows a signal with a duty cycle of approx. 80%.

♦ The amplitude of the pulse -A- depends on the desired cooling
power, the on-board voltage, etc. (in the field -A-, the flow is
controlled via air conditioning system compressor regulating
valve -N280- from the Climatronic control unit -J255- / air con‐
ditioning control unit -J301- .
♦ The length -B- of the signals is always 2 milliseconds (corre‐
sponding to a frequency of 500 Hertz).
♦ The duty signal is the result of the relationship between the
width of the pulse -A- and the length of the signal -B-.
– Depending on the adjustment in the Climatronic control unit -

J255- / Air conditioning control unit -J301- and the magnitudes
of the environment conditions measured, the amplitude of the
rectangular wave signal (duty cycle between 100% and more
than 30%, the regulation valve is activated in such a way that
enough power is directed to the compressor to reach the
specified temperatures).
Note
♦ With the setting of the lowest temperature, the air conditioning

system compressor regulating valve -N280- is controlled in
such a way that the maximum permissible flow of current flows
with approx. 0.65 A through the air conditioning system com‐
pressor regulating valve -N280- (highest power of the com‐
pressor).
♦ During regular operation, the controlling period depends on
the required cooling output, the on-board voltage, etc. How‐
ever, the controlling continues until an average current inten‐
sity of approx. 0.3 A flows.

4 Replacing the compressor pulley
Note
Depending upon the engine type and date of production different

versions of compressor or from different manufacturers may be
fitted.
4.1 Replacing pulley (compressor, make

„Denso“, version „1“)
Note
♦ This type of pulley is fitted, for example, for the compressor

type „7 SEU 16“.
♦ Depending on the design of the compressor and the engine
version, different versions of the pulley are fitted ⇒ Spare parts
catalogue .
♦ To remove and replace the compressor pulley ⇒ page 69
1 - Bolt.
❑ replace
❑ Tightening torque: 20
Nm
❑ Loosening and tighten‐
ing ⇒ page 69
2 - Drive plate
❑ Different versions ⇒
Parts catalogue
⇒ page 69
❑ Activated for excess tor‐
que (for example if the
compressor
Protected becomes
difficult
permitted to power)
3 - Circlip
❑ replace
❑ Fit by the correct side
(flat side facing the com‐
pressor)
⇒ page 69
4 - Pulley
❑ The rubber element acts
in case of excess torque
(in case the compressor
becomes difficult to op‐
erate) and the pulley
moves freely without op‐
erating the compressor
Parts catalogue

⇒ page 69
Note
Under certain conditions (for exam‐

ple, engine trouble) the rubber ele‐
ment may be activated even if there
is no problem with the compressor
or the refrigerant circuit.
5 - Compressor
❑ Depending on the engine version and on the country there are different versions ⇒ Parts catalogue
❑ Clean the compressor bracket before fitting the pulley
4.2 Removing and refitting the compressor

pulley („Denso“ brand compressor, ver‐
sion „1“)
Note
♦ If the protection has been activated by an overload, check,

before replacing the pulley, the movement of the compressor.
If the movement of the compressor is difficult, replace it com‐
pletely.
♦ The operation of the overload protection of the version „1“ is
described as an example in the self-learning program.
♦ To remove the pulley, it may be necessary to loosen the en‐
gine compressor, depending on the engine version
⇒ page 62 .
♦ The compressor can be detached from the support and re-
attachedProtected
without opening
by copyright. up refrigerant
Copying pipes. purposes, in part or in whole, is not
for private or commercial
♦ Before removing the Poly-V belt, mark the direction of rotation
using chalk or a marker. Running a used belt in the opposite

direction could destroy it.
♦ Depending on the engine fitted and the country, different com‐
pressors are fitted ⇒ Parts catalogue .
4.2.1 Preparation work

Rep. gr. 50 .
– Loosen the Poly-V belt and remove it ⇒ Engine, mechanics;
Rep. gr. 13 .
– Detach the compressor from the engine ⇒ page 62 .
4. Replacing the compressor pulley 69

4.2.2 Removing and fitting the pulley

– Unscrew the bolt -A- (tightening torque: 20 Nm).
Note
♦ To loosen and tighten the bolt -A- secure the drive plate -B-.
♦ Replace the bolt -A- (fitted with fixing agent).
♦ If the pulley cannot be removed with the compressor in place,
loosen the compressor from the engine ⇒ page 62 .
– Move the drive plate -A- using 2 screwdrivers -B- uniformly and
very carefully.
Note
♦ Note when moving the drive plate -A- avoid damaging the pul‐
ley collar -C-.
♦ There are different versions of the pulley -C- and the drive
plate -A-, for this reason, note the type carefully ⇒ Spare parts
catalogue .
– Remove circlip -A-.

– Remove the pulley -B-.
Note
♦ Replace the circlip -A-.

♦ Take special care when fitting the circlip -A- that it is not bent
any more than is necessary for fitting.
♦ Fit the circlip -A- on the correct side, the side with the insertion
rebate -C- should be on the side facing away from the com‐
pressor (the flat side faces the compressor).
♦ Ensure that the circlip is correctly seated in the groove in the
compressor bracket.
♦ Clean the compressor bracket before fitting the pulley The
pulley must be easy to fit. (Fitting should be completed without
having to apply any significant force).

4.3 Replacing pulley (compressor, make

„Denso“, version „2“)
Note
♦ Depending on the design of the compressor and the engine

version, different versions of the pulley are fitted ⇒ Spare parts
catalogue .
♦ To remove and to replace the compressor pulley
⇒ page 72
1 - Circlip
❑ Remove carefully using
a small screwdriver or a
large nosed pliers (take
care of the pulley)
⇒ page 72
2 - Drive plate
❑ This is screwed onto the
compressor power shaft
Parts catalogue
❑ The overload rubber el‐
ement acts in case of
excess torque (in case
the compressor be‐
comes difficult to oper‐
ate) and the pulley
⇒ page 72
Nm
3 - Circlip
❑ replace
❑ Fit by the correct side
(flat side facing the com‐
pressor)
⇒ page 72
4 - Spacer
❑ Dimensions: 17.5 x 10 x

3 mm
5 - Rubber buffer element
❑ 6x, ensure correct installation ⇒ page 72
❑ These separate the pulley from the compressor operation axle, absorb vibrations and noise
❑ Damp the rubber buffer elements slightly for fitting, for example using a wheel fitting paste or even a
soap solution (lubrication for fitting)
6 - Pulley
❑ The pulley is made from plastic and is quite fragile, for this reason manipulate it with due care.
❑ Different versions ⇒ Parts catalogue
7 - Compressor
4.4 Removing and refitting the compressor

pulley („Denso“ brand compressor, ver‐
sion „2“)
Note
♦ Note the comments for removal of the pulley version „1“ be‐
cause these are also valid for the removal of version „2“
⇒ page 69 .
♦ Carry out the preparation work as described for the removal
of the pulley version „1“ ⇒ page 69 .
♦ The pulley is made from plastic and is quite fragile, for this
reason manipulate it with due care.
♦ If the drive plate -C- protection against overload has been ac‐
tivated, the drive plate may be levered easily following the
removal of the circlip -A- from the pulley -D-.
♦ To reduce the noise, the pulley drive plate -A- can incorporate
a plastic disk -B- ⇒ Spare parts catalogue . This disk -B- re‐
duces the rattling noise of the pulley, which may occur in
Diesel engine vehicles in „Econ“ mode (activation of the com‐
pressor cancelled) (the noise is barely perceptible when the
air conditioning is full on).

4.4.1 To remove and fit the pulley version „2“

Removal:
– Remove the plastic disk -B- from the pulley -A- ( if fitted)
– Remove the circlip -A- for example, carefully using a small

screwdriver or a large nose pliers (take special care not to
damage the pulley).
– Hold the compressor shaft -B- with an ordinary hexagonal
wrench or a socket from the shock absorber kit -T10001- (de‐
pending on the compressor version) and turn the drive plate
-C- with the pulley -D- in the direction of the arrow -E- (35 Nm
tightening torque)
– Remove the drive plate -C-.
– Remove circlip -A-.

– Remove the pulley -B-.
Installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Note
♦ Replace the circlip -A-.

♦ Clean the compressor bracket before fitting the pulley.
♦ Take special care when fitting the circlip -A- that it is not bent
any more than is necessary for fitting.
– Fit the pulley -B-.

– Fit the circlip -A- on the correct side, the side with the insertion
rebate -C- should be on the side facing away from the com‐
pressor (the flat side faces the compressor).
– Fit the rubber buffer elements -D- as shown in the diagram to
the pulley -B-.
– Damp the rubber buffer elements -D- slightly for fitting, for ex‐
ample using a wheel fitting paste or even a soap solution
(lubrication for fitting).
Note
The rubber buffer elements must be fitted to the pulley in such a

way that the arrow points to the exterior. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Fit the drive plate -C- onto the rubber buffer elements -D- (refer
to the figure E87–10005), to the plate is at the same level as
the compressor shaft -B-.
– Screw in the nut for the drive plate -C- rotating it in

-the direction of the arrow- -F- onto the compressor shaft -B-.
– Tighten the drive plate -C- to 35 Nm (on the pulley -D-). Turn
it with a commercially available strap wrench (with fabric strap)
in the direction of arrow -F- for this purpose. Hold fast the
compressor shaft -B- with an ordinary hexagonal wrench or a
socket from the shock absorber kit -T10001- .
– Replace the circlip -A-.
– Fit the circlip -A- (with rubber washer).

– Clean the pulley drive plate -A- and stick the plastic disk -B-
centred over the drive plate (only in compressors without a
rubber washer in the circlip).
4.5 Pulley: Replacing (compressor make „Zexel“)
Note
♦ Follow the instructions for the removal of the pulley in the compressor make „Denso“, version „1“; these
instructions are also valid for this compressor ⇒ page 69 .
♦ Carry out preparation work in the same way as for the removal of the pulley in the compressor make „Denso“,
version „1“ ⇒ page 69 .
1 - Bolt.
❑ replace
❑ To release and tighten
the bolt, the pulley
should be held with a
strap wrench
❑ Clean the thread on the
compressor axle ( and
where applicable on the
bolt) removing fixing
agents from old threads
before bolting
❑ Fit the bolt prepared
with thread fixing agent
(e.g. with D 000 600 A2)
⇒ Parts catalogue
Nm
2 - Bolt.
strap wrench
❑ Tightening torque: 5 Nm
3permitted
- Drive plate

ate) and the pulley
❑ With a rubber element to
separate the pulley from

the compressor opera‐

tion axle, absorb vibrations and noise.
4 - Circlip
❑ replace
❑ Install in correct position. The inlet chamfer -A- shows away from the compressor (flat side to the com‐
pressor)
❑ Take special care when fitting the circlip that it is not bent any more than is necessary for fitting
5 - Pulley
6 - Compressor
4.6 Removing and fitting the pulley (com‐

pressor brand „Zexel“)
Note
♦ Follow the instructions for the removal of the pulley in the

compressor make „Denso“, version „1“,these instructions are
also valid for this compressor
♦ Carry out preparation work in the same way as for the removal
of the pulley in the compressor make „Denso“, version „1“
4.6.1 Removing drive plate
Note
♦ Compressors with the part number 1K0 820 803 from index
„N“ have the disk grooves on the drive plate fastened to the
grooves on the compressor shaft.
♦ Compressors with the part number 1K0 820 803 to index „L“
have the disk grooves on the drive plate free from the grooves
on the compressor shaft. In these compressors it is possible
that the drive plate grooves wear down and can no longer drive
the compressor. In this case, check whether the compressor
moves easily, and replace the drive plate if necessary (using
the repair kit 1 K0 898 814) ⇒ Parts catalogue
– Hold the pulley -A- using a strap wrench (with a braided strap)
and release the bolt -B-

Note
♦ If the protection against overloading the drive plate is active

-D-, the pulley turns freely without driving the compressor.
Check ease of movement in the compressor by turning it by
its bolt -B-; should movement be difficult, replace the com‐
pressor with the pulley. If the compressor does move easily,
remove the bolts -C- and remove the drive plate. To do this,
the clutch plate hub must be held in place by pliers to remove
bolt -B-.
♦ The bolt -B- cannot be released if the pulley grooves are worn
(the compressor shaft turns with the bolt). In this case, remove
the bolts -C- and tighten the drive plate with the disk -A- (flat
side facing outwards), the washers -B- and the bolts -C- (in‐
cluded in the repair kit 1 K0 898 814 ⇒ Parts catalogue ) on
the compressor shaft
– Remove the bolt -D- then.

– Remove the disk -A- and remove the drive plate -A-.
Note
♦ If the drive plate -A- is fastened to the compressor shaft, fit

three long bolts -C- through the orifices in the clutch plate
-A- on the pulley -D- and separate the drive plate -A- with a
normal bolt -B- (bolt with M8 thread, flat in front and with a
resistance of min. 10.9). At the same time, hold the pulley
-D- with a normal strap wrench (with a braided strap).
♦ When the drive plate -A- has already been replaced once and
has been pasted with sealing agent D 154 102 A1, it may occur
that the plate connects itself with the compressor shaft in such
a way that it will not be able to be separated. In this case the
complete compressor must be replaced.
– If the pulley must be replaced, release the circlip and remove

the pulley
– Clean the grooves of the compressor shaft and examine it;
replace the compressor if there are signs of wear in the
grooves
Caution
Do not use compressed air for cleaning, as the dirt particles

can reach the compressor shaft seal and damage it.
4.6.2 Fit the drive plate
Caution
Do not use compressed aircorrectness

for cleaning, asinthe dirt particles
respect to the of information this document. Copyright by SEAT S.A.
can reach the compressor shaft seal and damage it.

– Clean the grooves of the compressor shaft -B-, the pulley -A-
and the grooves of the drive plate -C- with a normal cleaning
product (eliminate the rust, worn particles, old adhesive and
other material).
– Clean the thread of the compressor shaft -B- and the three
threads of the pulley -A- eliminating the leftover bolt fastening
paste (e.g with a thread tapping bolt).
– Clean the grooves of the compressor shaft -B-; replace the
compressor if there are signs of wear in the grooves
– Examine the grooves in the drive plate -C-; replace the drive
plate if there are signs of wear in the grooves.
– Fit the pulley and its circlip (if removed)
– Apply sealant „D 154 102 A1“ on the grooves of the compres‐
sor shaft -B- and the grooves of the drive plate -C- ⇒ Parts
catalogue
Note
♦ Apply sealant in moderation, taking care that it does not reach

the compressor shaft seal -B- (in the compressor interior).
♦ The sealant is also adhesive; once dry, the drive plate cannot
be detached.
♦ The sealant hardens out after a certain period. Therefore, the
drive plate must be mounted to the connection within 5 mi‐
nutes after applying the sealing agent and the bolts -C- and
-B- must also be tightened to the specified tightening torque
within this time period.
– Re-install all components in reverse order of the removal op‐

erations.
– Wait for an hour (after fitting the drive plate) before starting the
engine.
Note
The sealant requires an hour approx to reach the required resist‐

ance.
4.7 Pulley: Replacing (compressor make „Sanden“)

Note
♦ Follow the instructions for the removal of the pulley in the compressor make „Denso“, version „1“,these
instructions are also valid for this compressor.
♦ Carry out preparation work in the same way as for the removal of the pulley in the compressor make „Denso“,
version „1“.

1 - Conical hexagon bolt

❑ replace
the hexagonal bolt, the
pulley should be held
with a strap wrench
❑ Clean the thread of the
hexagonal bolt and the
thread of the compres‐
sor axle to remove fixing
agents from old threads
before bolting
❑ Fit the hexagonal bolt
prepared with thread fix‐
ing agent (e.g. with D
000 600 A2) ⇒ Parts
catalogue
Nm
2 - Bolt.
strap wrench
❑ Tightening torque: 4.5
Nm
3 - Drive plate
ate) and the pulley
❑ With a rubber element to
separate the pulley from the compressor operation axle, absorb vibrations and noise.
4 - Washer
5 - Circlip
❑ replace
❑ Install in correct position. The inlet chamfer -A- shows away from the compressor (flat side to the com‐
pressor)
❑ Take special care when fitting the circlip that it is not bent any more than is necessary for fitting
6 - Pulley
7 - Compressor

5 Air conditioning with manual control:

Climatic
5.1 Air conditioning and heating - Passen‐

ger compartment
Note
♦ Disconnect the battery before removing any components

marked with ** ⇒ Rep. gr. 27 .
♦ A plate fitted in the engine compartment indicates the type of
refrigerating agent and amount in the system.
♦ When the control lamp does not illuminate after pressing the
AC button, a fault saved in the control unit may be at hand.
Call up the error memory with the Vehicle diagnosis, testing
and information system -VAS 5051B- (or successor models).
If the fault „Initial commissioning of the air conditioning com‐
pressor not performed“ is stored, the basic settings and ad‐
justment „Initial commissioning of the air conditioning com‐
pressor “ must be performed in the guided fault finding or in
the guided functions.
♦ If a new air conditioner control unit -J301- is installed, the set‐
ting „Initial commissioning of the air conditioner compressor“
must be performed in the guided fault finding or in the guided
functions.

1 - Instrument panel **
2 - Centre vent
⇒ page 97
3 - Right hand side vent
⇒ page 97
4 - Heating and air conditioning
regulator unit, Climatic control
-J301-
❑ With fresh air and air re‐
circulation flap switch -
E159- .
❑ With button for heated
rear window -E230-
❑ With switch for fresh air
blower -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
control unit -J301-
❑ Removing and fitting permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
⇒ page 84 respect to the correctness of information in this document. Copyright by SEAT S.A.
5 - Servomotor for the fresh

air / air recirculation flap -V113-
❑ Check: ⇒ Vehicle diag‐
nostic, testing and infor‐
mation system
VAS 5051
⇒ page 11
❑ Replacing: initiate the basic settings with the self diagnosis -VAS 5051X-
9 - Passenger side foot well cover
10 - Air temperature sender, evaporator outlet -G263-
11 - Sealing plug
5. Air conditioning with manual control: Climatic 81

15 - Securing bolt
❑ 8x
16 - Control unit of the heater / main board
17 - Front left foot well vent
18 - Servomotor for the temperature flap -V68-
❑ Check: ⇒ Vehicle diagnostic, testing and information system VAS 5051
❑ Replacing: initiate the basic settings with the self diagnosis -VAS 5051X-
19 - Flexible shaft
20 - Temperature sender for footwell area vent -G192-
21 - Temperature sender, central vent -G191-

5.2 Air conditioning (Climatic): Disassembling and assembling
1 - Servomotor for temperature

flap -V68-
❑ Removing and installing
2 - Spring retainer
3 - Bolts
❑ Unscrew the bolts to
separate the air distrib‐
utor body and the evap‐
orator.
4 - Cover
5 - Servomotor for air recircu‐
lation flap -V113-
⇒ page 11
6 - Air inlet housing
❑ With air recirculation
flap.
7 - Upper section of the evap‐
orator housing
❑ Evaporator housing:
dismantling and assem‐
bling
8 - Lower section of the evap‐
orator housing
❑ Evaporator housing:
dismantling and assem‐
bling
9 - Evaporator
❑ Removing and installing
10 - air temperature sender,
evaporator -G263-
⇒ page 119
11 - glove box cooling nozzle
12 - glove box cooling hose
❑ With activated charcoal filter.
16 - Cover
❑ For dust and pollen filter.
17 - Heat exchanger

18 - Heat exchanger covering

5.3 Air conditioning control unit -J301- : re‐

moving and fitting
The removal and fitting of the Air conditioning control unit -J301-
are carried out in the same manner as those for the Heating
control unit -J65- ⇒ page 29 .
5.4 Connectors for the Air conditioning con‐

trol unit -J301-

♦ template -V.A.G 1598/47-2-
5.4.1 Pin allocation of the multiple connectors

on the rear of the Air conditioning control
unit -J301-
20 pin connector
3 - Temperature sender, central vent -G191-
5 - High-pressure sender -G65-
7 - CAN, low
8 - CAN, high
12 - Right hand side heated seat (optional)
13 - Left hand side heated seat (optional)
15 - Terminal 75 heated seat (optional equipment)
16 - Compressor control valve, air conditioning -N280-
19 - Terminal 30A
20 - Terminal 31

16 pin connector
1 - Servomotor for the temperature flap -V68- , heat
4 - Temperature sender for footwell area vent -G192-
5 - Potentiometer - servomotor for temperature flap -G92-
7 - + 5 V for the Potentiometer for the servomotor of the temper‐
ature flap -G92-
8 - Earth for the Potentiometer - servomotor for temperature flap
-G92- , Temperature sender, centre vent -G191- , Potentiometer
- servomotor for temperature flap -G92- and Air temperature
sender, evaporator sender -G263-
9 - Servomotor for air recirculation flap -V113- , open
10 - Servomotor for air recirculation flap -V113- , closed
11 - Servomotor for the temperature flap -V68- , cool
5 pin connector
1 - 3rd blower speed
2 - 2nd blower speed
3 - 1st blower speed
4 - 4th blower speed
5 - Terminal X
5.5 Removing and fitting temperature flap

control motor -V68-
5.5.1 Removal:
– Removing the dashboard ⇒ Rep. gr. 70 .
– Removing the data bus diagnosis interface -J533- ⇒ Rep. gr.
97 .
– Unscrew the bolts -1- and -3- (tightening torque 10 Nm).

– Remove the holder -2-.

– Mark the connector -C- for the servomotor (possible confusion
with other similar connectors).
– Detach the connector -C- of the temperature flap servomotor
-V68- .
– Remove the cover -A-.
– Unscrew the fastening bolts -D- and remove the servomotor
of the temperature flap -V68- -B-.
– Release the lever -E- of servomotor from connecting rod -D-
5.5.2 Installing
Install in reverse order. The following should be taken into ac‐
count:
– Place the cable harness so that it does not come into contact
with moving components (e.g servomotor lever).
Note
After installing temperature flap control

Protected by copyright. motor
Copying for private-V68- , check
or commercial op‐in part or in whole, is not
purposes,
eration of temperature
permitted flap.
– Checking: Vehicle diagnostic, testing and information system

-VAS 5051X-
– Replacing: with the Vehicle diagnosis, testing and information
system -VAS 5051X- , start basic setting
5.6 Removing and installing air recirculation

flap control motor -V113-
5.6.1 Removal:
– remove the recirculation flap servomotor -V113- ⇒ page 115
5.7 Removing and installing footwell vent

temperature sender -G192-
The removal and fitting of the Temperature sender, foot well area
vent -G192- is done in the same way as for the Air temperature
sender, left hand side foot well zone -G261- ⇒ page 119 .
5.8 Removing and installing centre vent

The removal and fitting of the Temperature sender, centre vent -
G191- is done in the same way as the Air temperature sender,
left hand side vent -G150- ⇒ page 101 .

6 Air conditioning with automatic con‐

trol: Climatronic
Note
♦ If there is a fault in the system, first consult the fault memory

of the control and indication panel Climatronic control unit -
J255- ⇒ Vehicle diagnostic, testing and information system
VAS 5051.
♦ If no fault is detected, then consult the measurement values
block of the Climatronic control unit -J255- and activate, if
necessary, the component concerned using the activator di‐
agnostic function ⇒ Vehicle diagnostic, testing and information
system VAS 5051.
♦ Repair work on the refrigeration agent circuit are described
from page ⇒ page 162 .
♦ Once repair work is finished carry out the following work:
– Consult the fault memory of the panel Climatronic control unit

-J255- and erase the faults that appear.
– Check the coding of the control and indication panel Clima‐
tronic control unit -J255- .
– Check the adaptation of the control and indication panel Cli‐
matronic control unit -J255- .
– Perform basic adjustment for the air conditioning ⇒ Vehicle
diagnostic, testing and information system VAS 5051.
6.1 Components located outside the pas‐
senger compartment
6.1.1 Component extensions „1“
6. Air conditioning with automatic control: Climatronic 87

1 - Information plate
❑ With data about the type
and amount of refrigera‐
tion agent
2 - Plenum chamber water
drainage
❑ Both sides of the ple‐
num chamber
❑ Verification, cleaning
⇒ page 92
3 - Rear window heater -Z1-
❑ The request is sent by
the Climatronic control
unit -J255- via the data
bus, the Heated rear
window -Z1- is activated
by the Onboard network
control unit -J519- ⇒ Ve‐
hicle diagnostic, testing
and information system
VAS 5051
heated rear window ⇒
work; Rep. gr. 64 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
4 - Forced ventilation
❑ Fitted in the rear, under‐
neath the rear bumper
❑ Sealing lips in vent
opening must move
freely and close by
themselves
❑ To ensure proper func‐
tioning of passenger
compartment ventila‐

tion, air ducts must not

be blocked by luggage compartment lining
❑ check ⇒ page 92
5 - Liquid tank
❑ This may only be removed when the refrigerant circuit is empty; bring the vehicle to a support workshop
specialised in air conditioning work
6 - Condenser
❑ This may only be removed when the refrigerant circuit is empty; bring the vehicle to a support workshop
specialised in air conditioning work
❑ Different versions depending on the vehicle equipment ⇒ Air conditioning - with refrigeration agent R134a
SEAT ⇒ Spare parts catalogue
❑ Removing and refitting the refrigerant tubes ⇒ page 168
❑ Removing and fitting the condenser ⇒ page 169
7 - Stone deflector
❑ Only fitted with certain optional equipment ⇒ Spare parts catalogue
8 - exterior temperature sensor -G17-
❑ For access to the thermosensor, remove the fog light grill: ⇒ Front bumper moulding; Rep. gr. 63
❑ Remove the connection from the temperature sensor and extract it from the allotment in the air conduit
❑ The measurement value from the Outside temperature sensor -G17- is analysed by the Control unit with
indication lamps in the instrument panel -J285- and transmitted over the comfort system data bus to the
Climatronic control unit -J255- ⇒ Vehicle diagnostic, testing and information system VAS 5051
❑ Check activation and operation ⇒ page 64
10 - Compressor
❑ Detaching and attaching compressor from support ⇒ page 62
❑ Refrigerant pipes: detaching/attaching at compressor ⇒ page 165
❑ Compressor: removing and fitting ⇒ page 166
❑ Depending on the engine, the design of the compressor may vary ⇒ Spare parts catalogue
❑ Removing and fitting the Poly-V belt : ⇒ Engine, mechanics; Rep. gr. 13
❑ Replace the pulley ⇒ page 68

6.1.2 Component extensions „2“
1 - Condensation drain
❑ Verification, removing
2 - Expansion valve
❑ Removing and refitting
the refrigerant tubes
⇒ page 172
⇒ page 174
3 - Radiator fan -V7-
❑ The request for fan cut-
in is transmitted by the
Climatronic control unit -
J255- over the comfort
system data bus to en‐
gine control unit. The
engine control unit then
activates the ventilators
directly through the
Coolant ventilator con‐
trol unit -J293- ⇒ En‐
gine, mechanics; Rep.
gr. 19
❑ The corresponding con‐
trol unit activates, for ex‐
ample, the Coolant ven‐
tilator -V7- (through the
Coolant ventilator con‐
trol unit -J293- ) accord‐
ing to the power re‐
quired (and depending
on the engine fitted)
⇒ Vehicle diagnostic,
testing and information
system VAS 5051,
⇒ Current flow dia‐
grams, Electrical fault

finding and Fitting loca‐

tions
❑ Different versions are fitted according to the vehicle equipment. ⇒ Spare parts catalogue
❑ Check the activation of the Climatronic control unit -J255- ⇒ Vehicle diagnostic, testing and information
system VAS 5051
❑ Operation, removing and fitting ⇒ page 57
❑ The measurement value of the sender is viewed by the function „Read measurement block values“ of
the Climatronic control unit -J255- ⇒ page 58 and ⇒ Vehicle diagnostic, testing and information system
VAS 5051
❑ Used by specialised air conditioning workshops, to measure, empty and fill
❑ Hood with seal, always screw into place
❑ Used by specialised air conditioning workshops, to measure, empty and fill
❑ Hood with seal, always screw into place
7 - Fresh air inlet cover
❑ Check the correct positioning, ensure that water does not enter into the air conditioning inlet
8 - Fresh air inlet grill
❑ Check the correct positioning, ensure that impurities (for example leaves) does not enter into the air
conditioning inlet
9 - Fresh-air intake duct temperature sensor -G89-
❑ Removing and fitting, check the resistance value ⇒ Vehicle diagnostic, testing and information system
VAS 5051
❑ Only fitted in vehicles with automatic climate control until model year 2006 (gradually phased out in model
year 2006)
Note
♦ During the model

permittedyear
unless 2006 the
authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
thermosensor - fresh
respectair intake
channel -G89- was gradually
phased out; vehicles without this
can only have control and indi‐
cation panels, Climatronic con‐
trol unit -J255- , with the part
number from index „M“.
♦ If vehicles without thermosensor
- fresh air intake channel -G89-
have a control and indicator pan‐
el, Climatronic control unit -
J255- , with the part number up
to index „L“, an entry is made in
the fault memory.

6.2 Air outlet vent: testing

– Test the air flow ducts to the air outlet vent -A- in the luggage
compartment for correct air flow *left and right).
♦ The seal edges -B- in the air outlet vent -A- should be free to
move and close alone.
♦ Plugged air outlet ducts or stuck seal edges may cause the
windows of the vehicle to fog up.
Note
♦ In the diagram, the air outlet vent is shown with the rear bump‐
er moulding removed. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ For the forced air system, 2 air outlets

respect tohave been fitted -A-. in this document. Copyright by SEAT S.A.
the correctness of information
♦ So that the seal edges -B- close correctly, the air outlet vent
-A- must be fitted with the rayons -C- facing downwards.
♦ To ensure proper operation of passenger compartment venti‐
lation, vent openings left -A-, right -B- and at the rear -C- in
luggage compartment lining are never to be sealed off.
6.3 Plenum chamber water drainage: test‐

ing and cleaning

Note
♦ Due to the regular accumulation in the plenum chamber

(leaves, branches, etc.) drainage channel -arrow-, the drain‐
age of the plenum chamber may be affected. In car washes or
in heavy rain, the level of water may rise in the plenum cham‐
ber and water may enter into the air inlet for the air conditioning
(heating) where it will be blown to the evaporator by the air
inlet turbine.
♦ If the water drains -arrow- (right and left of the plenum cham‐
ber) are blocked by leaves, the water may accumulate and
freeze and the drains will be blocked. After a short period of
time the engine heat and exhaust system heat will melt the ice
in the drains and by the time the vehicle is brought to a garage
the ice may no longer be there.
6.4 Cover and grill for the air inlet: checking,

removing and fitting
6.4.1 Removing and installing panel

– Remove the windscreen washers and the windscreen trim
(plenum chamber cover) ⇒ Electric system; Rep. gr. 92 .
– Remove the cover -A- moving it downwards.
Note
Make sure that the cover -A- is fitted correctly. When the cover is
not fitted correctly, water can run into the intake opening of the air
conditioner (heater).
6.4.2 Removing and installing air intake grille

– Remove the cover -A- moving it downwards.
– Unscrew nuts -B-.
– Remove the cover grill -C-.
♦ Make sure that the cover grille -A- is fitted correctly. When the
cover is not fitted correctly, water can run into the intake open‐
ing of the air conditioner (heater).
♦ Check the seal underneath the cover grill for damage and if
necessary replace it.

7 Air conditioning control and regula‐

tion components in the passenger
compartment
Note
♦ If there is a fault in the system, first consult the fault memory

of the Climatronic control unit -J255- ⇒ Vehicle diagnostic,
testing and information system VAS 5051.
♦ If no fault is detected, then consult the measurement values
block of the Climatronic control unit -J255- and activate, if
necessary, the component concerned using the activator di‐
agnostic function ⇒ Vehicle diagnostic, testing and information
system VAS 5051.
♦ Repair work on the refrigeration agent circuit is described from
page ⇒ page 162 .
♦ Once repair work is finished carry out the following work:

-J255- and erase the faults that appear.
– Check the coding of the Climatronic control unit -J255- .
– Check the adaptation of the Climatronic control unit -J255- .
– Perform basic adjustment for the air conditioning ⇒ Vehicle
♦ Electrical verification of the different servomotors, potentiom‐
eters and senders is described in the fault localisation guide
VAS 5051.
7.1 Air conditioning: passenger compart‐

ment, removing and fitting
7.1.1 Component extensions

1 - Temperature sender for the

left hand side air vent -G150-
❑ Not fitted in vehicles
with manual climate
control
⇒ page 101
2 - Diagnostics connection
❑ Finish the air condition‐
ing self-diagnosis ⇒ Ve‐
hicle diagnostic, testing
and information system
VAS 5051
3 - Accelerator mechanism
❑ The deactivation of the
J255- compressor Kick-
Down (through the
Compressor regulation
valve, air conditioning -
N280- ) is performed at
the request of the en‐
gine control unit (infor‐
mation is exchanged
over the data bus). The
measurement values
block for the Climatronic
control unit -J255- can
be used to check the ac‐
tual state ⇒ Vehicle di‐
agnostic, testing and in‐
formation system
VAS 5051
4 - Flexible condensation
drainage tube
❑ Verification, removing
5 - LeftProtected
seat thermosensor
by copyright. Copying-G59- and
for private left heated
or commercial seat
purposes, -Z6-
in part or in,whole,
driver's
is not heated seat back -Z7-
❑ permitted
Thermal unlessor heated
authorised seats
by SEAT are
S.A. SEAT not
S.Afitted
does notin every
guarantee orvehicle
accept any(optional
liability with equipment)
❑ Heated seats are controlled by the heated front seats control unit -J774- ⇒ Current flow diagrams, Elec‐
trical fault finding and Fitting locations
❑ The activation of the seat heating may be seen in the measurement values block of the Climatronic control
unit -J255- , test ⇒ Vehicle diagnostic, testing and information system VAS 5051
❑ Repairing the thermal seat ⇒ Bodywork, interior fitting work; Rep. gr. 74
6 - Right seat thermosensor -G60- and right heated seat -Z8- , passenger's heated seat back -Z9-
❑ Thermal or heated seats are not fitted in every vehicle (optional equipment)
❑ Heated seats are controlled by the heated front seats control unit -J774- ⇒ Current flow diagrams, Elec‐
trical fault finding and Fitting locations
❑ The activation of the seat heating may be seen in the measurement values block of the Climatronic control
unit -J255- , test ⇒ Vehicle diagnostic, testing and information system VAS 5051
❑ Repairing the thermal seat ⇒ Bodywork, interior fitting work; Rep. gr. 74
7 - Defroster vent
Rep. gr. 70
7. Air conditioning control and regulation components in the passenger compartment 95

9 - Control unit with indication unit in instrument panel -J285-

❑ With the Outside temperature indicator -G106-
❑ The outside temperature emitted by the Climatronic control unit -J255- is displayed.
❑ If the temperature reading is incorrect, check the measurement values of the temperature sensors ⇒ Ve‐
hicle diagnostic, testing and information system VAS 5051
❑ The measurement value from the Outside temperature sensor -G17- is analysed by the Control unit in
the instrument panel and transmitted over the comfort system data bus to the Climatronic control unit -
J255- ⇒ Vehicle diagnostic, testing and information system VAS 5051
10 - Defroster vent
❑ For windscreen
11 - Photosensor for solar radiation -G107- and Photosensor 2 for solar radiation -G134-
❑ Removing and fitting ⇒ page 97 ⇒ Bodywork, interior fitting work; Rep. gr. 70
12 - Thermo sensor - dashboard -G56-
❑ Fitted in the Climatronic control unit -J255- , this cannot be replaced separately
13 - Climatronic control unit -J255-
❑ Different versions (with the button OFF , with or without thermal seat regulator, with or without radio /
navigation system or radio and navigation with large controls panel), allocation ⇒ Spare parts catalogue
❑ The Temperature sensor - Dashboard -G56- is incorporated into the control and indication panel Clima‐
tronic control panel -J255-
❑ Note the additional instructions for the control and indication panel ⇒ page 97
❑ The self-diagnosis of the Climatronic control unit -J255- must be carried out as described in the guided
fault finding⇒ Vehicle diagnostic, testing and information system VAS 5051
❑ The illumination of the push buttons and the indication areas is done using LEDs, they may not be
replaced
14 - Dash panel
permitted unlessvent (centre
authorised by SEATleft)
Rep. gr. 70
15 - Dash panel vent (centre right)
Rep. gr. 70
16 - Air conditioning with evaporator and removable parts
❑ Air duct in the air conditioning and the vehicle ⇒ page 146
❑ Air conditioning components located in passenger compartment ⇒ page 113
❑ Air conditioning: removing and fitting ⇒ page 176
17 - Defroster vent
❑ Passenger's side window
❑ Removing and fitting: ⇒ page 97 and ⇒ Bodywork, interior installation work; Rep. gr. 70
Rep. gr. 70
19 - air temperature sender, right vent -G151-

7.2 Removing and installing dash panel

vent
– Extract the vent using a lever -U-30800- ⇒ Bodywork, interior
fitting work; Rep. gr. 70
Note
The instrument panel vents can only be fitted in one defined way.
7.3
permitted unlessPhotosensor for S.Asolar
does notradiation -G107-
authorised by SEAT S.A. SEAT guarantee or accept any liability with
and Photosensor 2 for solar radiation -

G134- removal and fitting

– Lever out carefully the photosensor for solar radiation -A- from
the de-icing vent for the windscreen.
– Remove the contact -B-.
7.4 Control unit for Climatronic -J255- , func‐

tion, removing and fitting
– Removing and installing Climatronic control unit -J255-
⇒ page 98

Note
♦ The control and indication panel Climatronic control unit -

J255- may be described in the current circuit diagrams as
Control unit for Climatronic -J255- .
♦ When replacing a control and indication panel Climatronic
control unit -J255- , note the exact allocation ⇒ Spare parts
catalogue .
♦ Different versions of the Climatronic control unit -J255- exist
in vehicles with a button for deactivation of the air conditioning
regulation ( OFF ), with or without regulator for the thermal
seats, with or without radio and navigation system (or radio
with large controls). Part number identification letters must
therefore be carefully noted ⇒ Parts catalogue .
♦ After fitting the Climatronic control unit -J255- , carry out the
basic adjustment setting following the instructions ⇒ Vehicle
♦ If a new Climatronic control unit -J255- and the basic adjust‐
ment has not been done, the regulation of the Climatronic
control unit -J255- is limited and recorded as a fault in the fault
memory ⇒ Vehicle diagnostic, testing and information system
VAS 5051.
♦ The illumination of the indication fields and the control buttons
takes place in the Climatronic control unit -J255- using LEDs;
they cannot be replaced.
♦ Check, in case of a false measurement from the Temperature
sensor - dashboard -G56- , the moulding of the Climatronic
control unit -J255- , (ensure it is not covered).
♦ Functions selected are indicated by the activation of light-
emitting diodes (LEDs) in the various buttons of the Clima‐
tronic control unit -J255- .
♦ Following replacement of the Climatronic control unit -J255- ;
always carry out the following operations:
♦ Perform basic setting.
♦ test the coding.
♦ check adjustment if necessary.
♦ interrogate fault memory ⇒ Vehicle diagnostic, testing and in‐

formation system VAS 5051.
♦ The temperature indication on the control panel of the Clima‐
tronic control unit -J255- (in °C or °F) is defined by the coding.
The indication may be changed as described below:
♦ With the ignition on, press both keys AUTO and ECON and keep
them pressed for several seconds.
♦ The temperature indication changes from °C to F ° or vice ver‐
sa.
7.4.1 Operating and display unit Climatronic

control unit -J255- removing and fitting
7.4.2 Removal:
– Check the coding and the adaption of the Climatronic control
unit -J255- using the function „replace control unit“ of the gui‐
ded fault finding (if the Climatronic control unit -J255- is to be

replaced) ⇒ Vehicle diagnostic, testing and information system

VAS 5051.
On vehicles with no radio navigation system or radio with large
control panel.
– Remove the moulding underneath the Climatronic control unit
-J255- in the centre element of the dashboard) ⇒ Bodywork,
interior fitting work; Rep. gr. 68 .
On vehicles with radio navigation system or radio with large con‐
trol panel
– Remove the radio or navigation system ⇒ Radio, telephone,
navigation; Rep. gr. 91 .
Continued for all vehicles
– Loosen the Climatronic control unit -J255- securing bolts lo‐
cated in the lower part of the control panel.
– Insert a hand underneath (or from above) into the centre con‐
sole and release the Climatronic control unit -J255- from the
centre console.
– Release the Climatronic control unit -J255- connectors by lift‐
ing the insert tabs and removing them.
Note
♦ The Climatronic control unit -J255- is secured to the centre

console by two bolts.
♦ Check, in case of a false measurement from the Temperature
sensor - dashboard -G56- , the moulding of the Climatronic
control unit -J255- , (ensure it is not covered).
♦ When replacing the Climatronic control unit -J255- note the
correct allocation (for example with or without regulator for
thermal seats, etc ). ⇒ Spare parts catalogue .
♦ Installing
Install in reverse order of removal.
-J255- and erase the faults that Protected
appear⇒ Vehicle
by copyright. diagnostic,
Copying for private or commercial purposes, in part or in whole, is not
testing and information systempermitted
VAS 5051.
– Carry out the basic settings, the coding, adaption and, if nec‐
essary, the actuator diagnosis of the Climatronic control unit -
J255- ⇒ Vehicle diagnostic, testing and information system
VAS 5051.

7.5 Flexible condensation drainage tube:

removing, testing and fitting
Note
♦ In this vehicle there is only one condensation drain fitted.

♦ On the condensation drainage valve -C- there is no flap.
♦ Check in case of a complaint of humidity in the passenger
compartment, apart from the condensation drainage, the fol‐
lowing components:
♦ plenum chamber water drainage ⇒ page 92 .
♦ the correct fitting of the plenum chamber cover and the cover
for the air inlet opening, also check for damage ⇒ page 93 .
♦ the correct fitting of the dust and pollen filter and if it is dirty
⇒ page 120 .
♦ the forced ventilation vents in the boot ⇒ page 92 .
♦ the operation of the air retention flap ⇒ page 124 and the air
recirculation flap ⇒ page 115 ⇒ Vehicle diagnostic, testing and
information system VAS 5051.
♦ The signal for the detection of windscreen washers in the Cli‐
matronic control unit -J255- ⇒ Vehicle diagnostic, testing and
information system VAS 5051.
♦ Check the temperature of the evaporator air outlet using the
measurement of the Air temperature sender, evaporator -
G263- in the conditions of use described by the client, or the
conditions of use described below in the Climatronic control
unit -J255- ⇒ Vehicle diagnostic, testing and information sys‐
tem VAS 5051.
♦ Select the lowest temperature possible for the passenger and
driver side
♦ A medium level of the fresh air blower (approx. 7 V) ⇒ Vehicle
diagnostic, testing and information system VAS 5051
♦ If the measurement value of the sender is too low (for an at‐
mospheric temperature above 0°C, less than 0°C for a long
period of time) or too high (even if the air conditioning functions
correctly above about 10°C, for example), see the notes for
the refrigeration performance test ⇒ page 152 .
7.5.1 Removing, testing

– Remove the glove compartment and the central console ⇒
Bodywork, interior fitting work; Rep. gr. 68 .

– Fold the floor covering back in the area of the condensation

drainage hose until the tube can be seen ⇒ Bodywork, interior
– Check the correct positioning of the condensation drainage
tube -B- (eliminate any folding for example) and ensure that it
is clean.
– Cover the area under the passage -D- (for the drainage of the
condensation water -C-) using absorbent paper (so that water
does not go under the carpet).
– Remove the condensation water drain -B-.
– Check if the condensation water drainage tube of the air con‐
ditioning -A- is clean, for example use a piece of wire.
– Check the distance between noise insulation mat attached to

the middle tunnel and the condensed water drainage
Protected valve
-C- on the opening in the floor plate -D-.permitted
An adequate sizebyofSEAT S.A. SEAT S.A does not guarantee or accept any liability with
unless authorised
the clearance must be provided so that the condensed water
can flow out of the water drainage -C- valve.

♦ Installing
Install in reverse order, observing following:
– Fit the condensation drainage -B- so that it is not bent or trap‐
ped.
– Ensure during fitting of the floor mat that the condensation
drainage tube is not crushed -B-.
7.6 Outlet temperature sender -G150- : Re‐

moving and installing
– Remove the driver side lower lining ⇒ Bodywork, interior fitting
work; Rep. gr. 70 .
– Remove the connection -A- from the temperature sensor.
– Rotate the thermosensor -B- by approx. 90°.
– Remove the temperature sensor -B- from the air duct.
7.6.1 Installing
– Install in reverse order of removal.
– Note that while fitting the seal -C- is correctly seated.
7.7 Right outlet temperature sender -

G151- : Removing and installing
work; Rep. gr. 68 .
– Remove the connection -A- from the temperature sensor.

– Rotate the thermosensor -B- by approx. 90°.
– Remove the temperature sensor -B- from the air duct.
7.7.1 Installing
– Install in reverse order of removal.

8 Air conditioning system with automat‐

ic regulation „Climatronic“ 03.2009 ►
Note
♦ The operating unit is fitted with a warning lamp that shows the
activation of the selected function. Furthermore, the display of
the radio or the navigation system shows the selected function
when briefly pressing one of the buttons or a controller.
♦ When the control lamp does not illuminate after pressing the
AC button, a fault saved in the control unit may be at hand.
Call up the error memory with the Vehicle diagnosis, testing
and information system -VAS 5051B- (or successor models).
If the fault „Initial commissioning of the air conditioning com‐
pressor not performed“ is stored, the adjustment „Initial com‐
missioning of the air conditioning compressor “ must be
performed.
♦ In the main menu of the instrument panel, you are able to
switch the temperature unit (°C or °F) that appears on the dis‐
play of the radio or navigation system. The main menu opens
via the rocker button on the windscreen wiper lever (or via the
multi-function steering wheel). In the next step, select the con‐
figuration, units and temperatures.
♦ Pressing the AUTO button will cancel all settings which deviate
from automatic operation.
♦ Deviations from automatic operation ⇒ appropriate operating
instructions.
♦ Activate the OFFpermitted
button, Climatronic turned off. The heater
and ventilation do not begin with their ofoperation.

respect to the correctness information in this document. Copyright by SEAT S.A.
♦ Deactivate the OFF button, Climatronic turned on.

♦ Activate the AC button, air conditioner compressor turned off.
The heating and ventilation operations continue to be control‐
led automatically.
♦ Deactivated AC button; air conditioner compressor adapts it‐
self in such a way that only a minimum quantity of air flows.
The heating and ventilation operations continue to be control‐
led automatically.
8.1 Procedure for testing and adjusting

components
Select „guided fault finding“ in the vehicle diagnosis testing and
information system -VAS 5051- .
Once you have consulted all of the control units:
– Press the „Go to“ button.
– Select „Selection of components and functions“.
– Select „Bodywork“.
– „Heater, ventilation and air conditioning (Rep.-Group 01,
80...87)“.
– Select „01 - Systems capable of self-diagnosis“.
– Select „Climatronic“ or „Climatic“.
– „Select“ Functions"
8. Air conditioning system with automatic regulation „Climatronic“ 03.2009 ► 103

– „Basic setting“.
– „Initial commissioning of the air conditioner compressor“
– „Check the cooling performance“.
– „Read measured value block“.
– „Encoding“
8.2 Mode of function of the Air-conditioning

control unit and display, Climatronic -
E87- with the Climatronic control unit -
J255-
Note
♦ The operating Protected

unit is byfitted withCopying
copyright. a warning lamp
for private that shows
or commercial purposes,the
in part or in whole, is not
activation of the selected function. Furthermore, the display of
the radio or the navigation system shows the selected function

when briefly pressing one of the buttons or a controller.

♦ In the main menu of the instrument panel, you are able to
switch the temperature unit (°C or °F) that appears on the dis‐
play of the radio or navigation system. The main menu opens
via the rocker button on the windscreen wiper lever (or via the
multi-function steering wheel). In the next step, select the con‐
figuration, units and temperatures.
♦ When an Air-conditioning control unit and display, Climatronic
-E87- is fitted with a new Climatronic control unit -J255- , the
basic setting and adjustment of the „Initial commissioning of
the air conditioner compressor“ should be carried out in the
guided fault finding or in the guided functions.

1 - Button for de-icing the wind‐

screen
2 - Upper air distribution button
3 - Centre air distribution but‐
ton
4 - Interior temperature sensor
5 - Lower air distribution button
6 - Lower air distribution button
❑ Pressing this air recircu‐
lation button prevents
polluted air from enter‐
ing the passenger com‐
partment.
7 - Rear window heating button
8 - Right rotary knob for interior
temperature
9 - Button for the right seat
heating (option)
10 - AC button.
❑ You can switch the cool‐
ing mode on or off by
pressing the AC button.
❑ The illuminated control
lamp of the button is an
indication that the air
conditioner compressor
is turned on.
11 - DUAL button.
❑ When the control lamp Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
of the button illuminates, permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
different temperatures respect to the correctness of information in this document. Copyright by SEAT S.A.
can be set on the left
and right sides.
❑ By pressing the Dual button, the control lamp goes out and the temperature setting of the drivers side
is also taken over on the passengers side.
12 - Blower controller
❑ The blower speed is changed by briefly pressing the button.
13 - Automatic climate control button OFF
❑ Switching the automatic climate control on and off
14 - AUTO button
❑ Pressing AUTO button causes the Climatronic to maintain the selected interior temperature completely
automatically. In doing so, it varies the temperature of the air flowing out, the speed of the blower and
the air distribution automatically.
15 - Interior temperature control rotary knob
16 - Button for the seat heating (option)
17 - Screen on the display of the radio or radio / navigation system
❑ Temperature in the left area
18 - Screen on the display of both areas with the vent outflows
19 - Screen on the display of the radio or radio / navigation system
❑ Temperature in the right area

8.3 Air-conditioning control unit and display,

Climatronic -E87- with Climatronic con‐
trol unit -J255- Removing and installing
Note
♦ The Climatronic control unit -J255- and the air-conditioning/

Climatronic control unit and display -E87- constitute a single
unit, which cannot be disassembled.
♦ When an Air-conditioning control unit and display, Climatronic
-E87- is fitted with a new Climatronic control unit -J255- , the
basic setting and adjustment of the „Initial commissioning of
the air conditioner compressor“ should be carried out in the
guided fault finding or in the guided functions.
8.3.1 Removal:
♦ Lever -U 30800-
– Remove trim frame of the radio unit or the radio / navigation
system⇒ Rep. gr. 91 .
– Loosen the bolts -arrows- (1.5 ± 0.2 Nm).
– Put the tool U-30800 onto the side of the spacing's without
scratching the dash panel and the centre venting unit Air-con‐
ditioning control unit and display, Climatronic -E87- clip out
and remove the dash panel.
– Unplug the connector -1- of the Air-conditioning control unit
and display, Climatronic -E87- by releasing the fuse -arrow-.

8.3.2 Installing
Note
When an Air-conditioning control unit and display, Climatronic -

E87- is fitted with a new Climatronic control unit -J255- , the basic
setting and adjustment of the „Initial commissioning of the air
conditioner compressor“ should be carried out in the guided fault
finding or in the guided functions.
The installation is performed in the reverse order and when con‐

sidering the tightening torques of the screws of 1.5 ± 0.2 Nm.
8.4 Connectors for the Climatronic control

unit -J255-
8.4.1 Pin allocation for the multi-connectors A,

B, and C at the back of the Climatronic
control unit -J255-
♦ template -1598/47-2-

20-pin connector, in the current circuit diagram T20c -A-

1 - Photosensor 2 for solar radiation -G134- or photosensor for
solar radiation -G107- , signal
3 - Photosensor 2 for solar radiation -G134- or photosensor for
solar radiation -G107- , signal
4-
5 - Can High
6 - CAN, low
7 - Not used
8 - Not used
9 - + 5V for photosensor 2 for solar radiation -G134- or photo‐
sensor for solar radiation -G107-
10 - Heated driver seat regulator -E94- (optional equipment)
11 - Heated passenger seat regulator
permitted -E95-
unless authorised (optional
by SEAT equipment)
12 -
13 - Air temperature sender -G150-
14 - air temperature sender, right vent -G151-
15 - Not used
16 - Not used
17 - Earth signal for photosensor for solar radiation -G107- , pho‐
tosensor 2 for solar radiation -G134- , sender for the vent air
temperature -G150- and sender for the right vent air temperature
-G151- and control motor for the indirect venting flap -V213-
19 - Terminal 31
20 - Terminal 30a; without supplementary heating terminal 15
16-pin connector, in the current circuit diagram T16g -B-

1 - + 5V for servomotors
2 - Temperature flap control motor potentiometer -G220-
3 - Potentiometer for right temperature flap control motor -G221-
4 - Defroster flap control motor potentiometer -G135-
5 - Central flap control motor potentiometer -G112-
7 - Air recirculation flap control motor potentiometer -G143-
8 - Air temperature sender, foot well zone vent -G261-
9 - Air temperature sender, right foot well zone vent -G262-
14 - Potentiometer earth signal

16-pin connector, in the current circuit diagram T16f -C-

1 - Temperature flap control motor -V158- , cold
2 - Temperature flap control motor -V158- , warm
3 - Servomotor for the de-icing flap -V107- , closed
4 - Servomotor of the de-icing flap -V107- , open
5 - Central flap control motor -V70- , direct vent
6 - Central flap control motor -V70- , footwell
9 - Air recirculation flap control motor -V113- , open
10 - Air recirculation flap control motor -V113- , closed
11 - Servomotor for right temperature flap -V159- , cold
12 - Servomotor for right temperature flap -V159- , hot
15 - Control unit for fresh air blower -J126-
16 - Control unit for fresh air blower -J126- , signal
8.5 Climatronic: Passenger compartment
Note
♦ Disconnect the battery before removing any components

marked with ** ⇒ Rep. gr. 27 .
♦ A label indicates the type and quantity of refrigerant used.

1 - Instrument panel **
❑ Removing and fitting ⇒
Rep. gr. 70
2 - Sunlight penetration photo‐
sensor -G107- or sunlight pen‐
etration photosensor 2 -G134-
❑ Check: Vehicle diagno‐
sis, testing and informa‐
tion system -VAS 5051-
(or successor models).
❑ Function: Regulation of
the temperature flap
and the fresh air blower
depending on the inten‐
sity of light.
❑ Emergency operation
with a malfunction: the
J255- continues to work
with a fixed value.
⇒ page 97
3 - Central vent:
⇒ page 106
4 - Right hand side vent
5 - Dash panel vent, right side
⇒ page 97
6 - air temperature sender, Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
right vent -G151- respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ Check: Vehicle diagno‐

sis, testing and informa‐
tion system -VAS 5051-
(or successor models).
7 - Climatronic control unit -J255-
❑ The Climatronic control unit -J255- and the air-conditioning/Climatronic control unit and display -E87-
constitute a single unit, which cannot be disassembled.
❑ Check: Vehicle diagnosis, testing and information system -VAS 5051- (or successor models).
❑ Replacing: Implementation of the basic settings and the adjustment „Initial commissioning of the air
conditioner compressor“ in the guided fault finding or in the guided functions of the vehicle diagnostic,
testing and information system -VAS 5051- (or successor models) ⇒ page 103 .
8 - Servomotor for air recirculation flap -V113-
❑ Replacing: Take over the basic settings with the vehicle diagnostic, testing and information system -VAS
5051- (or successor models) ⇒ page 103
9 - Footwell vent, passenger's side
10 - Fresh air blower -V2- with blower control unit -J126-
❑ Fresh-air blower -V2- removing and fitting ⇒ page 121
❑ Control unit for fresh air blower -J126- removing and fitting ⇒ page 121

11 - Connection
12 - Baffle plate for heater unit
13 - Joint mouth
❑ For centre console air duct.
❑ To remove, centre console must be removed ⇒ Rep. gr. 68 .
❑ With activated charcoal filter.
15 - Air duct for right rear footwell
16 - Guide tube for the footwell, left side
17 - Evaporator outlet temperature sender -G263-
18 - right temperature flap servomotor -V159-
19 - Auxiliary air heater element -Z35- **
❑ Checking
20 - Heat exchanger
21 - Central flap control motor -V70-
❑ Check: Vehicle diagnosis, testing and information system -VAS 5051B- (or successor model).
❑ unless
Replacing: Take over theS.Abasic settings
guarantee with theanyvehicle
liability withdiagnostic, testing and information system -VAS
permitted authorised by SEAT S.A. SEAT does not or accept
5051B-
respect (or successor
to the correctness model)
of information ⇒ page
in this document. 103 by SEAT S.A.
Copyright
22 - Footwell vent, driver's side

23 - Servomotor for temperature flap -V158-
24 - Air temperature sender, foot well zone vent -G261-
❑ Removing ⇒ page 119
25 - Servomotor for de-icing flap -V107-
26 - Heater unit and air conditioning system


❑ Removing ⇒ page 120
28 - Side vent
29 - Air temperature sender -G150-

9 Air conditioning components

Note the comments for the control and regulation of the passen‐
ger compartment components ⇒ page 94 .
Note
♦ Air duct in the air conditioning and the vehicle ⇒ page 146 .
♦ Air conditioning: removing and installing ⇒ page 176 .
1 - Air conditioning with evap‐

orator
❑ This may only be re‐
moved when the refrig‐
erant circuit is empty;
bring the vehicle to a
support workshop spe‐
cialised in air condition‐
ing work
❑ Air conditioning: remov‐
ing and fitting
⇒ page 176
❑ Air conditioning: dis‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
mantling and assem‐ permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
bling ⇒ page 185 respect to the correctness of information in this document. Copyright by SEAT S.A.
2 - Servomotor for de-icing flap

-V107-
❑ With the Potentiometer
on the de-icing flap ser‐
vomotor -G135-
❑ Lever colour code: Blue
colour
⇒ page 136
3 - Air temperature sender, left
foot well zone vent C1157 -
G261-
⇒ page 119
4 - Central flap control motor -
V70-
❑ With potentiometer for
central flap servomotor -
G112-
9. Air conditioning components 113

⇒ page 117
❑ Only intended for vehicles with diesel engine, see ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations
❑ Checking operation ⇒ Vehicle diagnostic, testing and information system VAS 5051
❑ From 11/06 it has been replaced by two relays High temperature relay -J360- and Low temperature relay
-J359- , see⇒ Current flow diagrams, Electrical fault finding and Fitting locations
7 - Servomotor for the left hand side temperature flap. -V158-
❑ With Servomotor potentiometer for the left hand side temperature flap. -G220-
❑ Lever colour code: White
8 - Servomotor for air retention flap -V71-
❑ With potentiometer for dynamic pressure flap servomotor -G113-
❑ With the Potentiometer on the air recirculation flap servomotor -G143-
11 - Air inlet opening with air recirculation / air retention (fresh air) flap
13 - fresh air blower control unit -J126- and Fresh air blower -V2-
❑ The Fresh air blower -V2- is fitted with the Fresh air blower control unit -J126- and cannot be replaced
separately
❑ Checking ⇒ Vehicle diagnostic, testing and information system VAS 5051
❑ Heed replacement intervals
permitted⇒ Maintenance ; Booklet
16 - Servomotor for the right hand side temperature flap -V159-
❑ With Servomotor potentiometer for the right hand side temperature flap -G221-
17 - Refrigerant agent tubes to the heat exchanger
18 - Grommet
❑ To make airtight the passage for the refrigerant tubes and cooling agent in the transverse panel to the
engine compartment
19 - Connection for condensation drain
❑ Check the condensation drainage, remove and fit the condensation drainage flexible tube ⇒ page 100

9.1 Servomotor for air recirculation flap -

V113-
Note
♦ Different variations of the servomotor for the air recirculation

flap -V113- in vehicles with manual and automatic climate
control ⇒ Parts catalogue The version for vehicles with man‐
ual climate control has, for example, a final switch and no
potentiometer.
♦ Different variations of the servomotor for the air recirculation
flap -V113- in vehicles with automatic climate control with or
without servomotor for dynamic pressure flap -V71- ⇒ Parts
catalogue At the end of model year 2007 the servomotor for
dynamic pressure flap -V71- will be gradually phased out; in
vehicles without servomotor -V71- , the dynamic pressure flap
(fresh air flap) is operated through a cam disk and a lever by
the servomotor for the air recirculation flap -V113- .
⇒ page 124
♦ Check the function of the servomotor as follows: connect both
contacts „5“ and „6“ to a plug of the control motor to a 12 V
direct current voltage source. Control motor then moves only
in one direction as far as stop. Interchanging positive and neg‐
ative reverses direction. Use adapter cable for this purpose
⇒ page 117 .
♦ Following the fitting of a new servomotor, carry out the basic
adjustment of the air conditioning⇒ Vehicle diagnostic, testing
♦ With the function „basic adjustment“ additional tests can be
done for the activation of the air conditioning electric compo‐
nents, for example, that they are not mixed up⇒ Vehicle diag‐
nostic, testing and information system VAS 5051.
9.1.1 Removal:
– Remove glove compartment ⇒ Interior body installation work;
Rep. gr. 68 .
– Mark the connector -A- (to avoid confusion, if several connec‐
tions are removed at the same time).
– Release the inserts -C- and -D- for the support -B- in the air
inlet opening and then remove the support -B- (backwards).

– Remove the servo motor -A- from the air inlet.
9.1.2 Installing
– Check the axle of the airpermitted
recirculation flap -C-
unless authorised before
by SEAT fitting
S.A. SEAT the not guarantee or accept any liability with
S.A does
servo motor -A-. respect to the correctness of information in this document. Copyright by SEAT S.A.
– Adjust the axle -C- so that the joining element from the servo‐
motor -D- can be fitted.
– Fit the servo motor using the joining element -D- onto the axle
-C- and the inlet opening allotments -B-.
– Fit the support -A-, taking into account that the support guide
-B- is fitted correctly into the allotment in the air inlet opening
-C- and that the support correctly inserts into both slots -D- and
-E-.
– With both motor actuators, check that the bracket -A- keeps
these in their position. When they are not installed free of play,
eliminate the play at hand with a little foam that is applied to
the inner side of the fixing points -F- of the bracket -A-.
the following:
– Consult the fault memory of the Climatronic control unit -J255-
and erase the faults that appear⇒ Vehicle diagnostic, testing
– Carry out the basic adjustment and diagnostic of the air con‐
ditioning actuators the consult the fault memory once again
VAS 5051.
Note
In case of complaint with regard to moisture in the interior, check

the air recirculation flap as well. This must be closed completely.

9.2 Preparing adapter cables for control mo‐

tor actuation
– Connect to the pins „5“ and „6“ of a plug -A- (part number 8D0
972 706 or 6Q0 972 706) a 0.25 mm2 cable each ⇒ Parts
catalogue .
– Connect commercially available banana plug -B- to other end
of each wire.
9.3 Central flap control motor -V70-
Note

⇒ page 117 .
9.3.1 Removal: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove the instrument panel ⇒ Bodywork, interior fitting
work; Rep. gr. 70 .
– Insert a hand into the opening on the left between the air con‐
ditioning and the centre tunnel (cross beam of the instrument
panel) and disconnect the connector -A-.
– Mark the connector -A- (to avoid confusion, if several connec‐
tions are removed at the same time).
– Unscrew bolts -B-.
– Remove the servo motor -C-.
9.3.2 Installing
– Fit the pivot -D- into the allotment -E-
the following:


VAS 5051.
9.4 Removing and installing right tempera‐

ture flap control motor -V159-
Note

⇒ page 117 .
♦ Following the fitting of a new servo motor, carry out the basic
setting of the air conditioning. ⇒ Vehicle diagnostic, testing and
information system VAS 5051
9.4.1 Removal:
work; Rep. gr. 68 .
– Remove the air vent for the passenger foot well -A- (for better
access to the servo motor -B-).
– Unscrew bolts -B-. respect to the correctness of information in this document. Copyright by SEAT S.A.
– Remove the servo motor -C-.


9.4.2 Installing
Note
The lever -E- on the servomotor and the connecting rod -D- are
colour coded. These are black on the right temperature flap con‐
trol motor -V159- .

the following:
VAS 5051.
9.5 Removing and installing the evaporator

outlet temperature sender -G263-
– Remove the glove compartment and the central console ⇒
Bodywork, interior fitting work; Rep. gr. 68 .
– Rotate the sender -B- 90° and remove it from the air condi‐
tioning.
9.6 Removing and fitting left footwell vent

– Remove the instrument panel ⇒ Bodywork, interior fitting
work; Rep. gr. 70 .
– Insert a hand into the opening on the left between the air con‐
ditioning and the centre tunnel (cross beam of the instrument
panel) and disconnect the connector -A-.
tioning.

9.7 Air temperature sender, right hand side

foot well zone vent -G262- : removing
and fitting
work; Rep. gr. 68 .
tioning.
9.8 Dust and pollen filter: removing and fit‐

ting
Note
♦ Replacement interval for dust and pollen filter ⇒ Maintenance ;

Booklet .
♦ Clean the area around the dust and pollen filter in air condi‐
tioner (heating) shaft before fitting a new filter.

– Cover the floor mat with paper in the area of the dust and pol‐
len filter.
– Remove the bolts -A- (not fitted in all vehicles, attaching the
cover -B-, when inserts -D- are not used).
– Move the cover -B- in the direction of the arrow -C- and remove
the cover.

– Remove the dust and pollen filter -A- from the opening -B- of
the air conditioning (of the heating).
– Clean the air conditioning (heating) by the opening -B- (for ex‐
ample using a vacuum cleaner) after the removal of the dust
and pollen filter.
9.9 Removing and installing fresh air blower

control unit -J126- and fresh air blower -
V2-
9.9.1 Removal:
work; Rep. gr. 68 .
– Cut the cable ties to those fitted in the fresh air turbine housing
cables -C-
– Release the block -B- and rotate the fresh air blower housing
-C- in -the direction of the arrow-.

Note
♦ The join between the fresh air turbine housing -C- and the
heating system may be sealed by a sealing paste, in which
case it will be necessary to rotate the housing with more force.
♦ In the casing -C- the Fresh air blower -V2- and the Fresh air
blower control unit -J126- are fitted and cannot be replaced
separately ⇒ Parts catalogue .
WARNING
The heat diffuser of the fresh air blower control unit -J126- can
get very hot.
– Remove the fresh air turbine housing -C- fromrespect
the air condi‐
tioning.
Caution
Do not touch the wheel of the fresh air blower -V2- ; the use of
force on the wheel or movement of the counterweights can
cause imbalance which could lead to malfunction.
– Disconnect the connector -D-.
9.9.2 Installing
the following:
Note
♦ On installation, check correct positioning of fresh-air turbine in

air conditioner unit.
♦ Following the installation, check the correct positioning of the
fresh air blower casing in the air conditioning and the operation
of the Fresh air blower control unit -J126- .
– Consult the fault memory of the control and indication panel

Climatronic control unit -J255- and erase the faults that ap‐
pear. ⇒ Measurement, information and diagnosis of vehicles
system VAS 5051 in "Guided fault finding" function.
– Carry out the basic setting and diagnosis of the air conditioning
actuators the consult the fault memory once again. ⇒ Meas‐
urement, information and diagnosis of vehicles system VAS
5051 in "Guided fault finding" function.

9.9.3 Removing and fitting fresh air blower

control unit -J126-
Note
♦ The fresh air blower control unit -J126- can only be replaced
separately in the version which is not firmly attached to the fan
itself (gradual introduction from model year 2007).
♦ There are different spare parts for the fresh air blower control
unit -J126- ; note the correct assignation ⇒ Parts catalogue .
♦ With the ignition connected and the fresh air blower -V2- acti‐
vated, the fresh air blower control unit -J126- connects the
„positive“ contact „4“ of the connector -C- to contact „1“of con‐
nector -B-. The fresh air blower -V2- speed is controlled by the
fresh
Protected by air blower
copyright. control
Copying unit
for private -J126- via
or commercial the inearth
purposes, part or connection
in whole, is not
between
permitted contact
unless authorised „2“S.A.
by SEAT of SEAT
connector -B-guarantee
S.A does not and contact „3“liability
or accept any of con‐with
nector -C- ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations and ⇒ Vehicle diagnostic, testing and infor‐

mation system VAS 5051 in the function "Guided fault finding".
Removal:
– Remove glove compartment ⇒ Bodywork, interior fitting work;
Rep. gr. 68 .
– Detach the connectors -B- and -C-.
WARNING
The heat diffuser of the fresh air blower control unit -J126- can
get very hot.

– Remove the fresh air blower control unit -J126- -D- from its
housing in the fresh air blower -V2-
Installing
the following:
Note
♦ When fitting, bear in mind that the fresh air blower control unit
-J126- -D- sits correctly in the housing of the fresh air blower
-V2- .
♦ After fitting, test operation of the fresh air blower control unit -
J126- and the fresh air blower -V2- .


9.10 Removing and installing air flow flap

control motor -V71- with potentiometer
for air flow flap control motor -G113-
• From 05/07, the components Servomotor for the air retention
flap -V71- with the Potentiometer - servomotor for the air re‐
tention flap -G113- is replaced by a cam system, see ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations
⇒ page 128
Note

direct current voltage source. Control motor
Protected by then moves
copyright. Copying only

⇒ page 117 .
♦ Test, after installing a new servomotor, the activation by the
Climatronic control unit -J255- and the operation of the servo‐
motor (correct position for the air recycling and fresh air op‐
tions) ⇒ Vehicle diagnostic, testing and information system
VAS 5051.
♦ The dynamic pressure flap servomotor -V71- can only be re‐
moved in the position„maximum fresh air mode“ and can only
be assembled in this position. If the servo motor is stopped in
any other position and it may not be moved into the position
of „fresh air option“, it may only be extracted and disassembled
with difficulty.
♦ Different versions of the servomotor in vehicles fitted with
heating or air conditioning (with end of run switches and po‐
tentiometers) ⇒ Parts catalogue .
9.10.1 Removal:
work; Rep. gr. 68 .
– Turn the ignition on, select the Climatronic control unit -J255-
in „de-icing“ mode, (in this mode the servomotor will position
itself in the fresh air option) and wait until the servomotor rea‐
ches its final position „fresh air option“.

– Release the inserts -D- and -E- for the support -A- in the air
inlet opening and then remove the support -A-.
– Disconnect the Servomotor for the air recirculation flap -V113-
⇒ page 115 .
– Mark the connector to the Servomotor for the air recirculation
flap -V113- (to avoid confusing with the connector to the dy‐
namic pressure flap servomotor -V71- ).
– Remove the servo motor -A- from the air inlet.
Note
♦ The junction between the servomotor and air retention flap

cogwheels is designed in such a way that the servomotor may
only be removed in one position „fresh air option“.
♦ If the servo motor is in any other position and cannot be
moved, it may not be extracted without first loosening the al‐
lotment points -B-, ensure to avoid any damage to the cog‐
wheel -C- during this operation.
9.10.2 Installing
Note
♦ The servo motor is supplied as a spare in the position of „fresh

air option“, only when the cogwheel -A- is at the limit -B- may
it be inserted correctly into the cogwheel for the fresh air / air
retention flap. If the servo motor was removed in any other
position or moved while being extracted, it may not be refitted.
♦ If the servo motor cogwheel -A- is not at the limit -B- „fresh air
option“, connect an adapter cable ⇒ page 117 or an auxiliary
cable from the auxiliary measurement set -VAG 1594C- to the
contacts 5 and 6 of the servo motor through a 5 A fuse to a 12
V battery.
– The servomotor will move to the limit in one direction; swap‐
ping the poles will make it move in the other direction.
– Wait until the cogwheel -A- of the servomotor reaches the limit
-B- „fresh air option “(see diagram).
– Check before trying to fit a new servomotor, the retention flap

opening in the air inlet and the cogwheel -C- (the air retention
flap is open, fresh air service).
– Connect the dynamic pressure flap servomotor -V71- to the
vehicle cable harness (check connectors are correctly as‐
signed).

– Open the air recirculation flap -E-.

– Insert a hand into the air inlet opening for the air recirculation
and move the air retention flap -A- into the position „fresh air
option“ (the opening for the air recirculation option is closed).
– Fit the servo motor -B- in the opposition direction to the arrow
on the allotments -C- and onto the cogwheel -D-
– In order to move the cogwheel on the servo motor -A- onto the
cogwheel of the air retention flap, the curved teeth -C- of the
servo motor cogwheel must coincide with space between the
teeth -D- of the cogwheel on the air retention flap axle -B-.
– Fit the Servomotor for the air recirculation flap -V113-
⇒ page 115 .

– Fit the support -A-, taking into account that the support guide
-B- is fitted correctly into the allotment in the air inlet opening
-C- and that the support correctly inserts into both slots -D- and
-E-.
– With both motor actuators, check that the bracket -A- keeps
these in their position. When they are not installed free of play,
eliminate the play at hand with a little foam that is applied to
the inner side of the fixing points -F- of the bracket -A-.
Note
♦ The position of the dynamic pressure flap servomotor -V71-

and the air recirculation flap servomotor -V113- (and the cor‐
responding flaps) is not visible when the glove compartment
is mounted, therefore, check operation before mounting the
glove box.
♦ Ifpermitted
the two notched
unless authorisedwheels (on
by SEAT S.A. theS.Aservomotor
SEAT dynamic
does not guarantee pres‐
or accept any liability with
sure flap servomotor -V71- and the air retention flap) are
incorrectly mounted, this may be observed as the air retention

flap does not reach the end limits (it may be detected through
the „basic settings adjustment“ as a fault) or the servomotor
does not operate correctly, it works in starts.
– Following fitting the servo motor, carry out a basic setting of

the air conditioning and consult the fault memory of the air
conditioning ⇒ Vehicle diagnostic, testing and information sys‐
tem VAS 5051.
– Activate the dynamic pressure flap servomotor -V71- and the

air recirculation flap servomotor -V113- with the Climatronic
control unit -J255- as described below, until the notched wheel
is at the limit „air recirculation mode“ (the figure shows the re‐
tained air flap-A- at the limit for „fresh air mode“) and check
the position of the retained air flap. This must be closed.
– First select the function „air recirculation“ in the Climatronic
control unit -J255-
The air recirculation flap servomotor -V113- opens the flap -E-
and the dynamic pressure flap servomotor -V71- sets the air
retention flap -A- in the position „air intake for air recirculation
mode“.
Wait until both servo motors have reached their final position.
– Select the function „fresh air option“ for example in mode „de-
ice“ (in this mode, the servo motors will always position them‐
selves in the fresh air mode).
The dynamic pressure flap servomotor -V71- sets the air retention
flap -A- in the position „air intake for the closed air recirculation
mode“, the air recirculation flap servomotor -V113- sets the flap
-E- to the position specified by the Climatronic control unit -J255- .
Wait until both servo motors have reached their final position.
the following:

Note
♦ The position of the air retention flap -A- is visible when the air
recirculation flap -E- is closed through the air inlet opening in
the plenum chamber (remove the plenum chamber cover).
♦ For controlling the air retention, the fresh air intake duct is
partially closed by the air retention flap -A- at a high speed
(from approx. 80 km/h) by the Climatronic control unit -J255-
(the position for the re-circulated-air flap -E- is determined by
the operating and display unit Climatronic control unit -J255- ).
♦ When switching from fresh air mode to recirculation mode or
vice versa, in order to reduce the change of noise of the fresh
air blower -V2- due to the different air intake, the dynamic
pressure flap servomotor -V71- and the air recirculation flap
servomotor -V113- are activated as follows:
♦ Switching from fresh Protected
air mode to recirculation
by copyright. mode:
Copying for private the re‐purposes, in part or in whole, is not
or commercial
circulation flap -E- opens
permittedfirst,
unlessthen thebyfresh
authorised airSEAT
SEAT S.A. ductS.Aisdoesclosed
not guarantee or accept any liability with
using the air retention flap -A-.to the correctness of information in this document. Copyright by SEAT S.A.
respect
♦ Switching from recirculation mode to fresh air mode: the fresh

air duct is opened using the air retention flap -A- then the re‐
circulation flap -E- is closed.
♦ In partial air recirculation mode, the air recirculation flap -E-
and the Climatronic control unit -J255- put the air retention flap
-A-into a centre position (the fresh air duct and the air recir‐
culation collection ducts are both slightly open at the same
time). In this way, a better refrigeration is achieved for certain
ranges of temperature and, at the same time, fresh air is taken
in.
9.11 Removing and fitting air recirculation

flap control motor -V113- - vehicles with‐
out air flow flap control motor -V71-
Removal:
– Remove glove compartment ⇒ Bodywork, interior fitting work;
Rep. gr. 68 .

– Unscrew bolts -B-.

– Release the servomotor -A- from its housing -D-
– Release the pivot -E- of the servomotor from the cam disk
housing -F-
– Mark the connector -C- (to avoid confusion, if several connec‐
tions are removed at the same time) and unplug it.
– Remove the servomotor -A-.
Installing
– Check the controlling and function of the re-circulated-air flap

-C- and the air retention flap (fresh air flap) -B- by turning the
cam disk -A-. Ensure that the pinion of the lever sits correctly
into the grooves of the cam disk -A-.
– Position the cam disk -A- so that the servomotor fastening el‐
ement can be fitted.
Note
Vehicles without dynamic pressure flap servomotor -V71- have

the air recirculation flap and the dynamic pressure flap (fresh air
flap) operated by the air recirculation flap servomotor -V113- via
the cam disk. To shorten the time required to reach the air circu‐
lation mode as much as possible, the cam disk has been designed
so that the air recirculation flap is open and the dynamic pressure
flap is closed at both extremes of the servomotor position. In fresh
air intake mode (recirculation flap closed and dynamic pressure
flap open), the servomotor for the air recirculation flap -V113- is
roughly at the mid-point.

– Plug connector -C- into the servomotor -A-.

– Lay the cable harness to the connector -C- so that it cannot
make contact with any moving parts (e.g. the levers in the in‐
take cavity).
– Insert the pivot -E- of the actuator motor into the cam disk
housing -F-
Note
♦ The pivot of the servomotor shaft -E- must only be fitted in a

position where it can be inserted into the cam disk -F- without
using force. If the pivot -E- can only be inserted with pressure,
check the motor shaft (it may be turned 270° and applied to
the other limit).
♦ If the servomotor shaft pivot -E- is not in a position where it
can be inserted, connect the servomotor to the vehicle cable
harness. Connect the ignition and select the Climatronic con‐
trol unit -J255- on the control and indication panel, on a setting
where the servomotor will be in a central position (e.g. fresh
air intake mode) Wait until the servomotor has reached the
required position then disconnect the ignition.
♦ If the servomotor shaft pivot -E- is not in a position for insertion,
contact „5“ and „6“ of the removed servomotor can be con‐
nected to a 12 V battery (with a 5A fuse) using a cable adapter
(or an auxiliary cable of the auxiliary measurement set -V.A.G
1594/C- ). Allow the servomotor to turn until the shaft is in a
position where it can be inserted freely (roughly in mid-posi‐
tion); the turning direction can be reversed by exchanging the
positive and negative poles.
– Fit the servomotor -A- in its housing -D- authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
permitted unless
– Fit bolts -B-.
the following:
Note
In case of complaint with regard to moisture in the interior, check

the air recirculation flap as well. This must be closed completely.
9.12 Heater element for supplementary air

heater -Z35- : Removing and installing,
vehicles ► 11.2006
• From 11/06 additional air heater control unit -J604- , see
cations

Note
♦ Check operation of additional heating heater element -Z35-

VAS 5051.
♦ Vehicles with diesel engine are currently fitted with an electric
additional heater (heat energy is added to air flow immediately
after exiting from heating system heat exchanger). Check if
the vehicle is fitted with additional heating ⇒ Vehicle diagnos‐
tic, testing and information system VAS 5051.
♦ For vehicles with a petrol engine, no additional heating is fitted.
♦ Replacement air distributor housings all have an opening for
an additional heating element and are supplied as such. For
those vehicles without an additional heating element, the
opening is plugged by the cover of the heat exchanger (differ‐
ent versions)⇒ Parts catalogue .
9.12.1 Removal:
– Disconnect car battery ⇒ Electrical system; Rep. gr. 27 .
– Remove driver side footwell trim ⇒ Rep.
permitted gr. 68by. SEAT S.A. SEAT S.A does not guarantee or accept any liability with
unless authorised
– Unscrew and remove the bolts -1- of the trim -2- -arrow-.
If the lever -1- is in a position that prevents access to the screw
-2- with regard to the temperature flap: Change the position of the
temperature flap via the hot air and outside air control unit, with
vehicles fitted with Climatronic, on the operating and display unit,
e.g. by setting to „Hi“.
– Remove the driver's side footwell air vent ⇒ page 18 .

– Remove the heat exchanger cover -1-; by unscrewing the bolt
-arrow-.

– Unplug electrical connector -2- on heating element for the

supplementary heating -Z35- -1-.
– Remove the heating element for the supplementary heating -
Z35- of the air conditioning system.
Note
The dashboard insert must be pressed in the direction of the seat

so that this does not make contact with the heating element for
the supplementary heating -Z35- when removing it.
– Remove securing nuts for voltage supply -2- and earth con‐
nection (6 ± 1 Nm).
9.12.2 Installing
– Install the heating element for the supplementary heating -
Z35- ; Installation is performed in the reverse sequence to
removal.
Note

so that this does not make contact with the heating element for
the supplementary heating -Z35- whilst the previous is inserted in
its position.
– Check operation once more if necessary⇒ Vehicle diagnostic,

9.13 Heater element for supplementary air

heater -Z35- : Checking. removing and
installing, vehicles 11.2006 ►
9.13.1 Checking auxiliary air heater element -

Z35- with peripherals
Auxiliary air heater element -Z35- and its peripherals (load signal
for alternator terminal DF, low heat output relay -J359- , high heat
output relay -J360- , intake manifold temperature sender -G72- ,
coolant temperature sender -G62- ) can be read via the engine
control unit self-diagnosis.
9.13.2 Checking auxiliary air heater element -

Z35-

♦ Vehicle diagnostic, testing and information system -VAS

5051B- with trigger clamp, 100 A -VAS 5051B/7-
9.13.3 Test requirements

• Intake temperature below 19 °C
• Coolant temperature below 80 °C
• Passenger compartment temperature about 20° C
• Battery voltage higher than 11 V
• Alternator charge not greater than 50 % (terminal DF)
• Engine speed greater than 450 rpm
• Turn rotary knob for interior temperature to end position for
maximum temperature
9.13.4 Checking sequence

– Remove the trim from the centre console and foot well, left
side.
– Using the vehicle diagnostic, testing and information system -
VAS 5051B- and the current clamp 100 A -VAS 5051B/7- ,
measure the power consumption on the earthing cable
-arrow-.
Low heating power ≈ 30 Amps
Mean heating power ≈ 60 Amps
High heating power ≈ 80 Amps
9.13.5 Removing and installing

Removal:
– Remove driver side footwell trim ⇒ Rep. gr. 68 .

Note
If the lever -C- is in a position that prevents access to the screw

-A- with regard to the temperature flap: Change the position of the
temperature flap via the hot air and outside air control unit, with
vehicles fitted with Climatronic, on the operating and display unit,
e.g. by setting to „Hi“.
– Disconnect battery .⇒ Rep. gr. 27

– Remove the bolts -A- from the cover -B-.
Caution
There is a risk of triggering an electric short-circuit.

Before any assembly on the vehicle, disconnect the battery.
– Unscrew the nut -1- (9 ± 1 Nm).

– Disengage the connector rail -arrow-.
WARNING
There is a risk of burns.

The auxiliary air heater element -Z35- may be hot.
Before removing auxiliary air heater element -Z35- , allow it to
cool off.
– Loosen the screw -2- with 1.4 Nm and remove the auxiliary air
heater control unit -Z35- from the blower motor housing.
Note

so that this does not make contact with the heating element when
removing it.
Installing
Note
♦ The dashboard insert must be pressed in the direction of the

seat so that this does not make contact with the heating ele‐
ment for the supplementary heating -Z35- whilst the previous
is inserted in its mount. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ Make sure the earthing cable is routed corrected.

10 Replace components that can only

be removed and fitted with the air
conditioning removed
10.1 Air inlet opening with air retention, fresh

air / air recirculation flap: removing and
fitting
10.1.1 Removal:
70 .
– Remove air conditioner unit ⇒ page 176 .
– Disconnect the connector -A- and remove the cable from its
attachments in the air inlet.
– Mark the wired connection to the connector -B- (to the dynamic
pressure flap servomotor -V71- ) and disconnect (risk of con‐
fusion, as connectors -B- and -C- are identical in shape).
– Mark the cable connection to the connector -C- (to the Servo‐
motor for the air recycling flap -V113- ) and detach it.
– Remove bolts -D-.

– Release the air inlet opening of the air conditioning.
10.1.2 Installing
the following:
ing of the attachment points -F- and -G-.
moving components (e.g. control motor lever).
10. Replace components that can only be removed and fitted with the air conditioning removed 135
10.2 Removing and fitting fresh air intake

duct temperature sensor -G89-
Note
♦ During model year 2006 the thermosensor for fresh air intake
channel -G89- was gradually phased out; vehicles without this
can only have control and indication panels, Climatronic con‐
trol unit -J255- , with the original part number from index „M“.
⇒ Spare parts catalogue
♦ If vehicles without thermosensor - fresh air intake channel -
G89- have a control and indicator panel, Climatronic control
unit -J255- , with the part number up to index „L“, an entry is
made in the fault memory.
10.2.1 Removal:
– Remove the instrument panel completely with the instrument
panel cross beam. ⇒ Bodywork - Interior fitting work; Rep. gr.
70
– Rotate the thermosensor -B- 90° and remove it from the air
inlet opening.
10.2.2 Installing
Re-install all components in reverse order of the removal
permitted opera‐ by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
unless authorised
tions. respect to the correctness of information in this document. Copyright by SEAT S.A.
10.3 Removing and fitting defroster flap con‐

trol motor -V107-
10.3.1 Removal:
70 .

– Mark the connector -C- to the servo motor (danger of confu‐

sion with other connectors of the same type).
– Remove the connector -C- from the Servomotor for the de-
icing flap -V107- .
– Unscrew bolts -A-.
– Remove the servo motor -B-.
10.3.2 Installing
Note
The lever -E- on the servomotor and the connecting rod -D- are
colour coded. These are blue on the defroster flap control motor
-V107- .

the following:
VAS 5051.
10.4 Removing and installing left tempera‐

ture flap control motor -V158-
10.4.1 Removal:
70 .
– Mark the connector -C- to the servo motor (danger of confu‐
sion with other connectors of the same type).
– Remove the connector -C- from the Servomotor for the left
hand side temperature flap -V158- .
– Remove the cover -A-.
– Remove the servo motor -B-.
– Release the lever -E- of servomotor from
permitted connecting
unless rod
authorised by SEAT-D-S.A. SEAT S.A does not guarantee or accept any liability with
10.4.2 Installing
Note
The lever -E- in the servo motor is actually white as is the con‐
nection rod -F-.

the following:
VAS 5051.

11 Air conditioner heat exchanger (heat‐

ing): Removing and installing
♦ Cooling (leak) tester -SAT 1274- (and adaptors)
♦ Clamping tool -U-30042-

♦ Hose clamps up to 40 mm or hose clamps up to 25 mm Pliers
-T20174-
11.1 Preparation work before removing the

heat exchangers
– Protect the driver and front passenger seat with protective
covers.
– Release the pressure in coolant circuit by opening cap on the
coolant expansion tank ⇒ Engine, mechanics; Rep. gr. 19 .
– Remove the components that prevent access to the coolant
hoses to the heat exchangers in the engine compartment -A-
and -B- ⇒ Engine - Mechanics; Rep. gr. 13
11. Air conditioner heat exchanger (heating): Removing and installing 139
– Mark positions of coolant hoses -A- and -B-.
Note
♦ Depending on the engine and the vehicle version, it may be

necessary to release or remove the following components
(upper cover of the engine, air conduit to the throttle and the
intake manifold etc.) ⇒ Engine /Mechanics; Rep. gr. 13
♦ There are different versions of the heat shield -B-. In version
„1“ the nuts need not be removed for panel -A- nor the heat
shield removed -B- from the vehicle (coolant hoses can be
disconnected with the panel in place).
♦ In version „2“ it is necessary to remove the disks -A- and the
clips-C- and release the vehicle heat shield -B-.
♦ For clarity, the illustration shows the heat shield -B- with the
engine removed
– Release the heat shield -B- from the front wall of the wind‐
screen wiper tray (if fitted and when necessary) and place it to
one side (or remove completely).
– Pull back the heat shield hoses -D- and -E- (if fitted) so that
fitting can be performed, for example, of the clamps up to 40
mm pliers -T20174- -F- on the coolant hoses-A- and -B-.

– Mark fitting positions of refrigerant hoses -A- and -B-.
Note
♦ The heat exchanger has been designed for the certain flow
direction of the refrigerant; for this purpose, the hoses must be
connected to the correct side (Hose -A-: Supply from cylinder
head, Hose -B-: Return tube to the water pump).
♦ The position of the refrigerant hoses is the same for vehicles
with heating or air conditioning. This illustration shows the po‐
sition in a vehicle with air conditioner.
13 .
– Cover the area below the tube joints -A- and -B- (e.g with ab‐
sorbent paper).
– Pinch off both coolant tubes leading to the air conditioner
(heating) system heat exchanger (e.g. using the hose clamps
up to ø 40 mm pliers -T20174- ) and detach them.

– Remove the bolt -A-
permitted from
unless the by
authorised sleeve
SEAT S.A. bracket
SEAT S.A-B-does(to move the
coolant tubes and remove the heat exchanger).
– Remove the driver side lower lining ⇒ Bodywork, interior fitting

work; Rep. gr. 68 .
– Remove the vent from the foot well area on the left side
⇒ page 18 .
– For those vehicles with an additional electric heating (Diesel
vehicles only) remove the Additional heating element -Z35-
(with Additional air heating control unit -J604- ) ⇒ page 130 .
11.2 Heating heat exchanger: Removing and

installing
11.2.1 Removal:
– Carry out the preparation work for removal of the heat ex‐
changer ⇒ page 139 .
– Remove the 4 bolts -A- and remove the cover -B-.
Note
♦ This diagram shows the air conditioning version with additional

electric heating
♦ There are different versions of the cover -B- (for vehicles with
or without additional electric heating).
♦ If the lever -C- to the left hand side temperature vent is in a
position that makes it impossible to reach the upper bolt -A-,
turn on the ignition and select a different temperature regula‐
tion on the Climatronic control unit -J255- to the left.
– Cover the floor in the area under the heat exchanger with an
impermeable layer and absorbent paper.
– Remove the bolts -A- and remove the clips -B- from the coolant
tube connections -C- and -D- on the heat exchanger -E-.
– Release the coolant tubes -C- and -D- from the heat exchang‐
er -E- (move the coolant tubes to the transverse panel).
– Pull heat exchanger -E- out of air conditioning (heater).
11.2.2 Installing
lowing:
– Check seals -A- and -B- attached to heat exchanger. Only in‐
stall heat exchangers with intact seals.

Note
♦ A seal that is not correctly fitted may roll up during introduction

of the heat exchanger.
♦ If the seal is damaged or not correctly fitted, cold air may pass
into the heat exchanger.
♦ From model year 2005 the heat exchanger -B- has extra strips
of foam -A-stuck to the corners. These foam strips -A- should
prevent certain knocking noises that may especially occur in
vehicles with diesel engines. Apply these strips with all heat
exchangers (e.g. self-adhesive foam with the spare part num‐
ber 191 819 069 ⇒ Spare parts catalogue )
– With heat exchanger removed, check for contamination of air

conditioning (heater by way of heat exchanger cavity -A-).
– Remove any dirt or remnants of escaped coolant from air con‐
ditioner (heating) unit (e.g. after removing leaking heat ex‐
changer).
– Fit heat exchanger into the air conditioning (heater).
– Remove the old clips -B- form the two coolant tubes -C-.
– Attach new clips -A- (included with delivery of new heat ex‐
changer) to both heat exchanger coolant pipes as shown.
– Lightly humidify the new seals -A- (included with delivery of
new heat exchanger) using coolant.
– Fit the new seals -A- to the connections of the heat exchanger
-D-.
– Insert the two coolant tubes -C- into the connections on the
heat exchanger -D-.
– Re-check position of seals -A- between coolant pipes -C- and
heat exchanger connections -D-.
– Attach the two coolant pipes -C- and -D- with clips -C- to heat
exchanger.
– Tighten bolts at clips -A- to 2.5 Nm.
– Check position of both clips -B- after tightening the bolts -A-;
they must completely surround flange at heat exchanger and
coolant pipe and not make contact with other components.
– Fit the bolt -A- of the connection flange -B- (ensure that the
bolt is tightened on the attachment point designed for this).
– Check the correct positioning
permitted of the
unless authorised grommet
by SEAT S.A. SEAT -C- in the
S.A does trans‐ or accept any liability with
not guarantee
verse panel. respect to the correctness of information in this document. Copyright by SEAT S.A.
– Seal the flanges for the coolant hoses to the heat exchanger
-A- and the pressure release valve (to evaporator) -B- in the
openings of the grommet -C-, for example using silicon sealing
paste (so that it is water tight).

– Re-install components removed in reverse order with the ex‐
ception of the heat exchanger connection cover and the driver
side lower covering.
19 .
Note
♦ The seal of the coolant circuit can be checked in the following

manner, for example:
♦ Bleed coolant circuit.
♦ Carefully open cap at coolant expansion tank (heed relevant
safety precautions) ⇒ Engine, mechanics ; Rep. gr. 19 .
♦ Increase the pressure in the coolant circuit, for example using
the cooling (leak) tester -SAT 1274- (and the adaptors).
Whenbypurging
♦ Protected the coolant circuit, ensure that the heat ex‐
changer is completely purged. If there are still air bubbles in
the heat exchanger, the client may complain of low heating
power in the winter or a different vent air temperatures for the
same setting on the control ⇒ page 160 .

connection between coolant pipes and heat exchanger, ⇒
Engine, mechanics; Rep. gr. 19 .
– Re-install the heat exchanger connection cover and the driver
side lower covering and all other removed components.
12 Basic connection schema for air dis‐

tribution
12.1 Air flow in the vehicle passenger com‐

partment
Note
♦ Air intake, air outlet and air flow in the air conditioning
⇒ page 147 .
♦ Component fitting locations ⇒ page 87 , ⇒ page 94 and
⇒ page 113 .
♦ The passenger compartment is vented by way of two vent
frames (on left and right of luggage compartment in area of
bumper) ⇒ page 92 .
1 - Dash panel
❑ with air ducts to defrost‐
er vents and dash panel
vents on the driver's and
front passenger's side
❑ Removing and fitting : ⇒
work; Rep. gr. 70
2 - Defroster vent
❑ For windscreen
❑ Crushing the intermedi‐
ate piece between the
air conditioning and the Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
air duct on the instru‐ permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
ment panel when instal‐

ling instrument panel

will result in irregular or
inadequate air flow to
the windscreen ⇒ Body‐
work, interior fitting
work; Rep. gr. 70
3 - Defroster vent
❑ Passenger's side win‐
dow
⇒ page 97
vent ⇒ page 97
5 - Dash panel vent (centre
right)

vent ⇒ page 97
6 - Dash panel vent (centre left)
8 - Defroster vent
9 - Intermediate piece/defroster duct
❑ The air is taken from the plenum chamber.
11 - Recirculated-air intake
❑ Air is drawn in beneath glove box from passenger's foot well
12 - Air duct / instrument panel vents
❑ To the vents, left and right side
15 - Sealing plug
17 - Front left foot well vent
18 - Air conditioner unit respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ Air conditioning: removing and fitting ⇒ page 176
12.2 Air intake, air outlet and air flow in the air
conditioning
Note
♦ Air flow and distribution in the vehicle passenger compartment

⇒ page 146 .
♦ Component fitting locations ⇒ page 87 , ⇒ page 94 and
⇒ page 113 .
12. Basic connection schema for air distribution 147

12.2.1 Air intake and air outlet openings
2 - Air intake of the interior (re‐
circulation)
in the front right foot well
4 - Air intake to the dash panel
vent, right-side
5 - Outlet to the centre dash
panel vents (left-side and right-
side)
6 - Air extraction to the dash
panel vent, left-side
in the front left foot well
8 - Outlet to the defroster vents
(the dash panel)
9 - Outlet to rear right footwell
vent
10 - Air extraction to the rear
left foot well vent
sole vents
using a plug.
❑ Use of a vent in the cen‐
tre console still not real‐
ised
sole vents
using a plug.
❑ Use of a vent in the cen‐
tre console still not realised

12.2.2 Air flow in the evaporator housing
1 - Complete evaporator hous‐

ing
2 - Fresh-air flap
❑ Displayed in „open“ po‐
sition
3 - Air recirculation flap
position
❑ With fresh air blower
control unit -J126-
❑ Heed replacement inter‐
vals ⇒ Maintenance ;
Booklet
6 - Evaporator
❑ For thoseunless
vehicles with
permitted authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
heatingrespect
(without air con‐ of information in this document. Copyright by SEAT S.A.
to the correctness
7 - Evaporator housing, lower
element (with separating ele‐
ments)
8 - Air outlet to the air distribu‐
tor body
12.2.3 Routing of air flow in air distribution

housing
Note
For the purpose of displaying the air duct in the air distributor
body, this section is shown along the lines „A“-„A“ and „B“-„B“.


2 - Left temperature flap (driv‐
er's side)
❑ Displayed in „cooling“
position
5 - Right temperature flap (pas‐
senger's side)
tion
6 - Temperature flap in the left
footwell (driver's side)
position
❑ The centre vents (left,
right and middle) and
the vents in the foot well
area are operated by the
cam disks on the servo‐

motor or the shaft.

7 - Air duct in the left footwell (driver's side)
8 - Air distribution housing with cross section made by the line „A“-„A“
❑ Not fitted in all vehicles, see ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
❑ Only in vehicles with diesel engine, in the function of the vehicle equipment, there is an additional auxiliary
heater.
11 - Air intake for the evaporator housing
12 - Right temperature flap (passenger's side)
❑ Shown in centre position
13 - Flap in the right footwell, (passenger's side)
❑ The centre vents (left, right and middle) and the vents in the foot well area are operated by the cam disks
on the servomotor or the shaft.
14 - Defroster flap
15 - Air distribution housing with cross section made by the line „B“-„B“
16 - Centre flap „centre“
❑ Displayed in „open“ position
❑ The centre vents (left, right and middle) and the vents in the foot well area are operated by the cam disks
on the servomotor or the shaft.
17 - Flap in the air duct to the air duct routing to the vent in the rear centre console
❑ This flap is operated via an actuating arm on the centre flap
18 - Air duct to the air duct routing to the vent in the rear centre console
❑ This duct is currently sealed using a plug.
❑ Use of a vent in the centre console still not realised

13 Refrigeration performance of the air

conditioning: testing
♦ Vehicle diagnosis, testing and information system -VAS 5051
A- (or the Vehicle diagnosis and information Service -VAS
5052- )
♦ Normal thermometer (to measure temperature or a thermom‐
eter with two sensors to measure left and right temperatures
at the same time)
♦ Digital thermometer -SAT 4002-
♦ Leak detector A.A. -SAT 4007B-
♦ Vehicle diagnostic, testing and information system -VAS 5051-
13.1 Test prerequisites

♦ Atmospheric temperature of more than 15℃.
♦ Radiator and condenser clean, if necessary, clean them.
♦ The Poly-V belt for the operation of the compressor is in good
condition, tense and pulley action to the compressor must be
OK.
♦ All air ducts, covers and seals OK and properly fitted
♦ The air flow through the dust and pollen filter is not obstructed
by dirt.
♦ The air intake (in fresh air and air recirculation position) should
be clear of any obstruction or components.
♦ The vehicle should not be in direct sunlight. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ The engine must be warm. respect to the correctness of information in this document. Copyright by SEAT S.A.
♦ The fault memory of the Climatronic control unit -J255- / Air

conditioning control unit -J301- has been consulted and
cleared, the basic adjustment has been completed and the
coding of the Climatronic control unit -J255- / Air conditioning

control unit -J301- ⇒ Vehicle diagnostic, testing and informa‐

tion system VAS 5051 has been checked.
♦ The adaption of the Climatronic control unit -J255- / Air con‐
ditioning control unit -J301- has been checked ⇒ Vehicle
Position in the vehicle.
– Open all dash panel vents
– Close the bonnet.
– Adjust operating mode „Auto“ on the control and indication
panel, Climatronic control unit -J255- .
– Choose temperature preselection „LO“ (for driver and pas‐
senger side) on the control and indication panel, Climatronic
control unit -J255- .
Functions with the engine is running:
♦ The fresh air blower -V2- functions at full speed.
♦ The air conditioner switches to re-circulated-air mode (approx.
1 minute after starting vehicle), the fresh-air intake flaps are
closed and re-circulated-air flap opened, (the air is drawn in
by fresh air blower -V2- in the interior under the dash panel or
the glove compartment).
♦ The radiator fans -V7- operate (activation and speed depend
on the air conditioning circuit pressure and engine tempera‐
ture).
Note
If one of these conditions is not fulfilled for the test, check the fault
memory, carry out a diagnosis of the actuators and then read the
measurement block values ⇒ Vehicle diagnostic, testing and in‐
13.2 Check refrigerating output

– Measure the ambient temperature (must be greater than
15℃).
– Close doors, bonnet, windows and sun roof.
– Open all dash panel vents.
– Select the „Econ“ mode on the Climatronic control unit -J255- .
– The button „AC“ should not be activated.
– Start engine.
– Finish the air conditioning self-diagnosis ⇒ Vehicle diagnostic,
– Select the function „ Read measurement value block“. Check
the corresponding measurement value blocks for the refriger‐
ant circuit pressure ⇒ Vehicle diagnostic, testing and informa‐
tion system VAS 5051.
– Check the indication in the display fields:
13. Refrigeration performance of the air conditioning: testing 153

Ambient temperature in °C Displayed pressure (in bar ab‐

solute)
15 4,7
20 5,6
25 6,6
30 7,6
35 8,8
Note
♦ An absolute pressure of 0 bar represents an absolute vacuum.

The normal ambient pressure is therefore equivalent to ap‐
prox. 1 bar absolute pressure. In general most manometer
scales represent atmospheric pressure as 0 bar meaning an
absolute pressure of 1 bar (this can be recognised if there is
a -1 on the scale).
♦ Pressure in refrigerant circuit depends on atmospheric tem‐
perature. Due to heat radiation from components (for example
the coolant radiator), for a warm engine at normal running
temperature, the indicated pressure is a above the corre‐
sponding atmospheric temperature.
♦ If the displayed pressure is lower than that given in the table:
♦ Check the output signal of the High pressure sender -G65-
⇒ page 58 .
♦ If no fault is found at high-pressure sender, there is not enough
refrigerant in the circuit and vehicle must be taken to a spe‐
cialist air conditioner workshop.
If pressure in refrigerant circuit is OK.

– Switch on the compressor by adjusting the operating mode
„Auto“ on the Climatronic control unit -J255- .
– Select the lowest temperature setting (for driver and passen‐
ger side) on the Climatronic control unit -J255- .
– Adjust air outlet direction on the Climatronic control unit -J255-
to the „dashboard vents“.
blower -V2- is selected along with the lowest possible tem‐
perature.
– Adjust air direction to the „instrument panel vents“

All vehicles (continued):

– Select the function „ Read measurement value block“ ⇒ Vehi‐
cle diagnostic, testing and information system VAS 5051.
– Check in the corresponding indication fields for a duty cycle of
more than 30 % (the Compressor regulation valve, air condi‐
tioning -N280- is activated, the compressor is running), and a
current intensity of more than 0.3 A (current flows through the
Compressor regulation valve, air conditioning -N280- , the
compressor is operating)
– Pressure in the refrigeration circuit rises above value with
compressor off.

Note
♦ The Compressor regulation valve, air conditioning -N280- is

operated by the Climatronic control unit -J255- / Air condition‐
ing control unit -J301- in such a way that the air temperature
reaches the specified value (approx. 2 to 5℃) after the evap‐
orator:
♦ After starting the vehicle, a value greater than 75 % (0.55 A)
is displayed depending on the measured temperature, engine
speed and electrical system voltage.
♦ As soon as the temperature measured by the Air temperature
sender, evaporator output -G263- approaches the specifica‐
tion, the activation is reduced as is the compressor perform‐
ance.
♦ Under certain conditions of use, ice may form on the regulation
valve for the compressor (and on the expansion valve) be‐
cause of humidity on the refrigeration circuit. Due to the for‐
mation of this ice, the regulation of the compressor is inhibited,
the evaporator is cooled too much and will freeze. Freezing of
the evaporator can lead to the following complaints:
♦ After a longer driving period, the air conditioner fails several
times or every now and then (no cooling or heating perform‐
ance). The function of the air conditioner is okay again after
turning off the vehicle and after a brief waiting time.
♦ After a longer driving period, the windows mist up from the
inside, even pressing the „Defrost“ button does not free the
windows from the mist. The function of the air conditioner is
okay again after turning off the vehicle and after a brief waiting
time.
♦ Remedy
♦ Check the measurement value of the Air temperature sender,
evaporator -G263- function „Read measurement block values“
VAS 5051.
♦ If the measurement value is too high under the conditions de‐
scribed by the client (even though the climate control works
correctly above, for example, 10°C, depending on the atmos‐
pheric temperature), test the Air temperature sender, evapo‐
rator output -G263- (the evaporator may freeze because of a
measurement value error).
♦ If the measurement value of the sender is very low under the
conditions described by the client (with an atmospheric tem‐
perature of more than 0℃, less than 0° for a long time), bring
the vehicle to a workshop specialised in air conditioning.
♦ Check the refrigeration tubes from the evaporator (from the
expansion valve) to the compressor (thick tube, low pressure
side) while the engine is running. If the pipe is severely iced
up by the problem described (thin ice layer is permissible), this
is a further indication that the temperature in the evaporator is
too low. Bring the vehicle to a workshop specialised in air con‐
ditioning.
♦ The specialist workshop can determine the error. The required
work (draining the refrigerant circuit, replacing tanks and then
allow the refrigerant circuit to drain forbyminimum
Protected 3 hours)
copyright. Copying can
only be carried out by such specialist workshops.
♦ If, in the corresponding measurement block values, there is
little or no current, check the activation of the Compressor
regulation valve, air conditioning -N280- ⇒ page 64 .

♦ When the pressure displayed in the respective measured val‐

ue block does not change and the controlling of the compres‐
sors is okay, there is a fault in the refrigerant line Bring the
vehicle to a workshop specialised in air conditioning.
– Press the button for air recirculation on the Climatronic control

unit -J255- / Air conditioning control unit -J301- (the symbol for
the „air recirculation mode“ lights).
– Bring the engine speed up to 2.000 rpm (begin timing).
– Select the function „Read measurement block values“ for the
indication group corresponding to the Air temperature sender,
evaporator -G263- .

– Compare measured value indicated in display field (of the Air

temperature sender, evaporator output -G263- ) to values in
the diagram.
A - Air temperature measured by the air temperature sender,
evaporator -G263-
B - Ambient temperature
C - Acceptable tolerance range
The measured air temperature must be within the tolerance range
shown for 5 minutes depending on the atmospheric temperature.
Note
♦ If the required values are not reached, check the measure‐

ment value of the Air temperature sender, evaporator -G263- ,
compare the measurement values in the corresponding indi‐
cation fields:
♦ When the measurement value evaporator outlet temperature
sender -G263- is greater than the measurement value of the
left outlet temperature sender -G150- and des right outlet tem‐
perature sender -G151- (Climatic: Centre outlet temperature
sender -G191- ), check the correct fitting of the evaporator
outlet temperature sender -G263- and perform the electrical
inspection of this sender ⇒ Vehicle diagnostic, testing and in‐
♦ The operation of the air conditioning can be seen for example
by the cooling of the rigid refrigerant tube on the low pressure
side (thick tube).
If the measurement value of the Air temperature sender, evapo‐

rator -G263- (and, with this, the refrigeration power) are correct:
– Compare the measurement value of the evaporator outlet
temperature sender -G263- with the measurement value of the
left outlet temperature sender -G150- and des right outlet tem‐
perature sender -G151- (Climatic: Air temperature sender,
central vent -G191- ).
The measurement value of the left outlet temperature sender -
G150- and the right outlet
respecttemperature sender
to the correctness of -G151-
information (Climatic:
Air temperature sender, central vent -G191- ) are only allowed to
be max. 3°C higher than the value in the displayed field of the
evaporator outlet temperature sender -G263- after 5 minutes.

Note
♦ If the required values are not reached, compare the measure‐

ment values to each other:
♦ If measured value in one of the two display fields is OK, Check
the activation and operation of the left temperature flap ser‐
vomotor -V158- and the right temperature flap servomotor -
V159- . (Climatic: temperature flap control motor -V68- )
⇒ page 158 , ⇒ page 160 and ⇒ Vehicle diagnostic, testing
and information system VAS 5051
♦ Check the correct fitting of the evaporator outlet temperature
sender -G263- , the left outlet temperature sender -G150- and
the right outlet temperature sender -G151- (Climatic: Air tem‐
perature sender, central vent -G191- ) and if their electrical
connections have contact resistance. If necessary, replace a
defective sender.⇒ Vehicle diagnostic, testing and information
system VAS 5051
♦ When no error has been detected on the left outlet tempera‐
ture sender -G150- nor the right outlet temperature sender -
G151- (Climatic: Air temperature sender, central vent -G191-
nor the left temperature flap control motor -V158- and right
temperature flap control motor -V159- (Climatic: temperature
flap control motor -V68- , perform the troubleshooting after in‐
creasing the temperature after the evaporator ⇒ page 158 .
♦ The temperature of the air flow from „centre“ instrument panel
vents can also be measured using a normal thermometer for
example.
♦ If the client complains of different temperatures for the same
settings, this could be due to the following:
♦ The temperature flaps in the air distribution housing are not
closing fully or are not reaching their terminal positions
⇒ page 147 and ⇒ Vehicle diagnostic, testing and information
system VAS 5051.
♦ There is air in the heat exchanger (the heat exchanger heats
irregularly) ⇒ page 160 .
♦ When fitting the heat exchanger, a sponge seal has been dis‐
placed and the air passes around the heat exchanger.
13.3 Locating faults in case of an increase in temperature after the evaporator

– Pinch off both coolant tubes to heating system heat exchanger e.g. using the clamp -U-30042- .
– Repeat cooling performance test ⇒ page 152 .

• If the measurement values deviate in both display fields of the left temperature flap servomotor -V158- ,
the right temperature flap servomotor -V159- (Climatic: Temperature flap servomotor -V68- ) is only less
than 3 °C of the measurement value of the evaporator outlet temperature sender -G263- ? ⇒ Vehicle
diagnostic, testing and information system VAS 5051
↓ ↓
yes no
↓ ↓
Remove the pressure – clip -U-30042- – Check correct installation of sender with meas‐
uredwith
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability value deviation, as well as checking electrical
↓
respect to the correctness of information connections for contact resistance.

Check the activation and

– operation of the left tem‐ – Eliminate the cause of the faulty measurement,
perature flap servomotor -V158- and the right tem‐ replace the faulty sender.
perature flap servomotor -V159- (Climatic: Tem‐
perature flap servomotor -V68- ) ⇒ page 158 and
⇒ page 160 .
↓
Continued on the following page
• Check the activation and operation of the left temperature flap servomotor -V158- and the right temper‐
ature flap servomotor -V159- (Climatic: Temperature flap servomotor -V68- okay?
↓ ↓
yes no
↓ ↓
Check the operation of the temperature
– flap from the side of the – Eliminate the cause of malfunction
air distribution where there is a rise in temperature ⇒ page 147 . ⇒ Vehicle diagnostic, testing and in‐
formation system VAS 5051 ⇒ Cur‐
If necessary, replace the air– distribution housing ⇒ page 176 . rent flow diagrams, Electrical fault
finding and Fitting locations
↓
Repeat cooling performance
– test ⇒ page 152 .
↓
Repeat cooling
– performance test
⇒ page 152 .

14 Check the heating performance of

the air conditioning
Note
♦ When the refrigerant circuit is not purged after filling, air may
accumulate in the heat exchanger of the air conditioner that
will lead to a reduction of the heating performance. Noises are
also possible or the customer complains about different air
temperatures originating from the vents on the driver and pas‐
senger sides.
♦ Solution:
♦ Carry out a long test run at high engine speeds (at least ten
minutes with a minimum engine speed of 2500 rpm). Use low
gears so that the vehicle does not have to be driven quickly.
♦ If a client complains of low heating power at certain engine
speeds, check the fitting of the heating heat exchanger in the
cooling liquid circuit. If the liquid coolant tubes from the engine
have been mixed up (feed and return), the liquid will flow in the
wrong direction through the heat exchanger ⇒ Engine, me‐
chanics; Rep. gr. 19 .

♦ Vehicle diagnostic, testing and information system -VAS 5051-
14.1 Test prerequisites

♦ The liquid coolant circuit must be purged according to the in‐
structions ⇒ Engine, mechanics; Rep. gr. 19 .
♦ All air ducts, covers and seals OK and properly fitted
♦ The air flow through the dust and pollen filter is not obstructed
by dirt.
♦ The engine must be warm.
♦ The fault memory of the Climatronic control unit -J255- / Air
conditioning control unit -J301- has been consulted and
cleared, the basic adjustment has been completed and the
coding of the Climatronic control unit -J255- / Air conditioning
control
Protectedunit -J301-Copying
by copyright. ⇒ Vehicle
for privatediagnostic, testinginand
or commercial purposes, part orinforma‐
in whole, is not
tion system VAS 5051 has been checked.

♦ The adaption of the Climatronic control unit -J255- / Air con‐

ditioning control unit -J301- has been checked ⇒ Vehicle
♦ The vehicle should not be in direct sunlight.
14.2 Checking
– Close the bonnet.
– Close doors, bonnet, windows and sun roof.
– Connect the central diagnosis -VAS 5051- with the 3m cable
-VAS 5051/5A- , with the ignition off, to the 16 pin vehicle di‐
agnosis plug and select the address code „08“ air conditioning
electronics ⇒ Vehicle diagnostic, testing and information sys‐
tem VAS 5051
– Open all dash panel vents.
– Start the engine and operate at the maximum cooling power:


– Temperature preselection at lowest (for driver and passenger
side).
Vehicles fitted with Climatic
perature.
– Read out the measurement block of the left outlet temperature
sender -G150- and the right outlet temperature sender -G151-
(Climatic: Air temperature sender, central vent -G191- ).⇒ Ve‐
hicle diagnostic, testing and information system VAS 5051
♦ Specifications: Temperature max. 12 ℃ (depending on the
ambient temperature), deviations between the measurement
values less than 3 ℃.
– Set the air distribution to instrument panel vents.
– Set the temperature on the left (driver) side of the Climatronic
control unit -J255- / Air conditioning control unit -J301- to the
highest possible setting.
♦ Specifications: in the corresponding display field, the temper‐
ature rises to about that of the engine, in the corresponding
display field for the passenger compartment, the temperature
rises by about 10℃.
– Set the temperature on the right (passenger) side of the Cli‐
matronic control unit -J255- / Air conditioning control unit -
J301- to the highest possible setting.
♦ Specifications: in the corresponding display field the temper‐
ature rises to about that of the engine, the difference between
the display fields is less than 8℃.
– Regulate the temperature selection for the driver side on the
control and indication panel to the lowest possible value.
– Take corresponding measurement values.
♦ Specifications: the temperature for the left side (drivers side)
falls in about 5 minutes to less than 12℃ (depending on the
ambient temperature).
– Carry out this test in the same way for the opposite side.
If readings do not match specifications, check:
– The coolant circuit for air ⇒ Engine, mechanics; Rep. gr. 19
– The correct incorporation of the heat exchanger for heating in
the air conditioning on the cooling circuit ⇒ Engine, mechan‐
ics; Rep. gr. 19 .
– Check the activation and operation of the left temperature flap
servomotor -V158- and the right temperature flap servomotor
-V159- (Climatic: Temperature flap servomotor -V68- ⇒ Vehi‐
cle diagnostic, testing and information system VAS 5051.
– The sponge material seal in the heat exchanger for heating in
the air conditioning must be in good condition ⇒ page 141 .
– The operation of the temperature flaps in the air distribution
housing ⇒ page 147 .
– The coolant thermostat (when the thermostat is faulty the cool‐
ant does not heat sufficiently) ⇒ Engine, mechanics; Rep. gr.
19 .
14. Check the heating performance of the air conditioning 161

15 Refrigeration agent circuit: repairs
Note
system.
♦ On the ELSA website, enter the technical information: ⇒ Air
♦ Refrigerant in refrigerant circuit is never to be topped up (drain,
evacuate and refill circuit).
♦ The compressor is always driven when engine is running;
there is no magnetic clutch. Engine is therefore not to be star‐
ted unless refrigerant circuit has been properly assembled. If,
for example, refrigerant pipes have not been connected to
compressor, heat generation inside compressor with engine
running may lead to destruction of compressor. The interior
heating occurs because the compressor will work with about
0% flow against a fixed resistance (circuit closed).
♦ To stop the compressor being destroyed when the refrigerant
circuit is empty, it is designed such that delivery is reduced to
roughly 0 % and lubrication is maintained by way of an internal
oil circuit with the oil left in the compressor.
♦ Replacement compressors contain the full quantity of refrig‐
erant oil required for the refrigerant circuit: ⇒ Air conditioning
- with refrigerant R134a SEAT
♦ For different types of compressors, different types of refriger‐
ant oil must be used: ⇒ Air conditioning - with refrigerant
R134a SEAT
before fitting ⇒ page 61 .
♦ The stated diameters for the O-ring seals and the tightening
torque also apply to refrigerant pipe/hose unions between the
individual components.
♦ Only install O-rings that have been approved for use with re‐
frigerant R134a. ⇒ Air conditioning - with refrigerant R134a
SEAT ⇒ Spare parts catalogue .
♦ Checking cooling performance ⇒ page 152 .
♦ Check the pressures in the refrigerant circuit ⇒ Air condition‐
ing - with refrigerant R134a SEAT .
♦ All other repair and testing work are not described in this Re‐
pair Manual ⇒ Air conditioning - with refrigerant R134a SEAT .
system.
15.1 Refrigeration agent circuit: repairs

HD = High-pressure end (high density)
LP = Low-pressure side

1 - Compressor control valve,

air conditioning -N280-
❑ Do not remove
❑ Check activation and
operation ⇒ page 64
Note
The Compressor regulation valve,

air conditioning -N280- is operated
by the Climatronic control unit -
J255- / Air conditioning control unit -
J301- ; check the pressure on the
low pressure side of the refrigerant
circuit
2 - Compressor
❑ Detaching and attach‐
ing compressor from
support ⇒ page 62
❑ Refrigerant pipes: de‐
taching/attaching at
compressor
⇒ page 165
❑ To protect the compres‐
sor from damage, the
engine is must NOT to
be started unless refrig‐
erant circuit has been
properly fitted
❑ Loosen the Poly-V belt
andProtected
remove by it ⇒ Engine,
mechanics; Rep.
permitted unless gr. by13
authorised SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Compressor: removing
❑ Depending on the en‐

gine, the design of the

compressor may vary. ⇒ Spare parts catalogue
❑ After fitting the new compressor or filling it with refrigeration oil (after loosening the refrigerant circuit),
the compressor must be operated by hand about ten rotations before putting it in operation for the first
time following work; this is also to avoid damage to the compressor.
3 - Pulley
❑ replace ⇒ page 68
❑ Removing and fitting the Poly-V belt : ⇒ Engine, mechanics; Rep. gr. 13
4 - Oil drain plug
❑ If a cancelling seal is fitted, always replace this
❑ is only allowed to be unscrewed when the compressor is dismantled, to drain the refrigerant oil, turn the
compressor around the pulley to accelerate the drainage of the refrigerant oil.
5 - Pressure relief valve, 10 Nm
❑ Do not remove
6 - Junctionpermitted
withrespect
valve
❑ Test the signal ⇒ page 58
8 - Condenser
❑ Removing and fitting the condenser ⇒ page 169
9 - Liquid tank
❑ Lightly oil the O-rings with oil from the refrigerant circuit just before fitting ⇒ page 61
❑ Replace the O-rings, version ⇒ Spare parts catalogue
❑ Different versions (secured using 1 or 2 bolts, with or without humidity joint in the junction area) ⇒ Spare
parts catalogue
❑ For the charging station; for measurement, emptying and filling
11 - Sealing cap
❑ With gasket
❑ Screw in
13 - Evaporator
❑ Air conditioning with evaporator: removing and fitting ⇒ page 176

❑ For the charging station; for measurement, emptying and filling
WARNING
valves.
15 - Sealing cap
❑ With gasket
❑ Screw in
15.2 Refrigerant pipes at compressor: de‐

taching and attaching
Note
♦ The compressor is always driven when engine is running;

there is no magnetic clutch. Engine is therefore not to be star‐
ted unless refrigerant circuit has been properly assembled. If,
for example, refrigerant pipes have not
Protected been connected
by copyright. to or commercial purposes, in part or in whole, is not
Copying for private
compressor, heat generation permitted
inside unless
compressor
authorised bywith
SEATengine
running may lead to destruction ofrespect
compressor.
♦ The following Fig. shows compressor on a 4-cyl. diesel engine,

the position of the piston can be slightly modified for vehicles
with other engines, the refrigerant lines are dismantled in the
same way.
♦ Seal open pipes and connections on the compressor with suit‐
able conical plugs from the kit -T20017A- (to prevent ingress
of dirt and moisture) ⇒ page 52 .
15.2.1 Removal:
– Empty the refrigerant circuit ⇒ Air conditioning - with refriger‐
ant R134a SEAT .
– Remove the upper engine protection ⇒ Engine, mechanics;
Rep. gr. 19 .
– Remove the centre sound proofing element ⇒ Bodywork, ex‐
– Detach the compressor from the support in those vehicles in
which direct access to the refrigerant tube connection bolts is
not possible with the compressor in place ⇒ page 62 .
– For those vehicles in which the refrigerant tubes are fitted with
extra supports, remove those supports.

– Remove the bolts -A- and -D-.

– Remove the refrigerant tubes -B- and -E-.
15.2.2 Installing
lowing:
– Replace all O-ring seals -C- and -F-, version ⇒ Parts cata‐
logue .
– Check the fastener -G- (not fitted to all junctions) and the
sleeve -H- for correct seating and damage.
– Tighten bolts -A- and -D- to 25 Nm.
Note
♦ Use is not to be made of O-ring seals from caps of replacement

compressor connections.
♦ Ensure that the O-ring seals seat correctly into the groove
-G- in the tubes of the refrigerant agent.
♦ Following attachment of the refrigerant pipes to the compres‐
sor (and compressor itself), check correct layout, They must
be inserted in holders provided and not make contact

respect towith
the correctness of information in this document. Copyright by SEAT S.A.
other components.
– Empty the refrigerant circuit and refill it ⇒ Air conditioning -

with refrigerant R134a SEAT .
15.3 Compressor: Removing and installing
15.3.1 Removal:
ant R134a SEAT .
– Remove refrigerant pipes from the compressor ⇒ page 165 .
– Detach compressor from support ⇒ page 62 .
15.3.2 Installing
lowing:
Before fitting the compressor ⇒ Air conditioning - with refrigerant
R134a SEAT .

Note
♦ When the compressor is removed, there is still an undefined
amount of refrigeration oil inside, for this reason note the com‐
ments about compressor replacement ⇒ Air conditioning -
♦ Tightening torques ⇒ page 62 and ⇒ page 165 .

♦ Replace all O-ring seals on the opened junctions, version ⇒
Spare parts catalogue .
– Only ever start the engine after the complete assembly of the
refrigerant circuit.
– Following the fitting of a new compressor or refilling the refrig‐
erant oil (after cleaning the refrigerant circuit) and before fitting
the Poly-V belt, operate the compressor by hand for about 10
rotations before restarting the engine to avoid damage to the
compressor.
– Engine as soon as refrigerant circuit has been properly as‐
sembled.
Note
♦ Different compressors depending on country and engine

⇒ page 54 and ⇒ Spare parts catalogue .
♦ The compressor is always powered by a pulley (there is no
magnetic coupling):
♦ To prevent compressor damage when refrigerant circuit is
empty, compressor is provided with an „internal oil circuit“.
There must be a minimum of refrigeration oil in the compressor
for the internal lubrication to work correctly.
♦ Engine is not to be started unless refrigerant circuit has been
properly assembled. If, for example, refrigerant pipes have not
been connected to compressor, heat generation inside com‐
pressor with engine running may lead to destruction of com‐
pressor.
♦ The Compressor regulation valve, air conditioning -N280- is
not activated when refrigerant circuit is empty and compressor
runs at idle with engine.
♦ However, given that there is no refrigerant, the refrigeration oil
necessary for compressor lubrication is not moved.
♦ To avoid damage to the compressor, the lubrication of the
compressor is secured by a „internal lubrication circuit“.
♦ If the engine has to be started when the refrigerant circuit is
empty:
♦ The refrigeration circuit must be assembled completely.

♦ There must be a minimum of 25 % of the required refrigeration

oil for the lubrication circuit.
♦ The engine speed must not go above the 2500 rpm.
♦ The engine must only be used for the minimum amount of time.
– When starting the engine for the first time following the filling
of the refrigeration circuit, note the following:

– Start the engine with the compressor deactivated. (For the

Climatronic system, operation mode „Econ“, for the Climatic
system, the button „AC“ deselected) and wait until the stable
idle engine speed has been reached.
– Temperature selection at lowest (for driver and passenger
side) Climatronic control unit -J255- .
– Now activate the compressor (operation mode „Auto“ and
„Econ“ deactivated) and let run, minimum, 5 min. with the en‐
gine at idle speed.
Vehicles fitted with Climatic
perature.
– Open all instrument panel vents.
15.4 Refrigerant lines of the condenser: Re‐

Note
♦ Depending on the vehicle version, there are different types of

condensers ⇒ Parts catalogue .
♦ Component locations of the High pressure sender -G65- differ
depending on the engine fitted; for vehicles with 2.0 litre diesel
engine the High pressure sender -G65- for example, is not fit‐
ted on the refrigerant tube from the expansion valve to the
condenser; it is fitted instead to the tube from the compressor
to the condenser.
15.4.1 respect Removal:

ant R134a SEAT .
Rep. gr. 50 .
– Remove the connector -A- from the high pressure sender
-B-.


– Remove the refrigerant tubes -B- and -C- from the condenser.
Note
Seal open pipes and connections at compressor with suitable

conical caps from the kit -T20017A- (to prevent penetration of dirt
and moisture).
15.4.2 Installing
lowing:
– Replace all O-ring seals -D- and -E-. Version ⇒ Parts cata‐
logue .
– Check the fastener -G- (not fitted to all junctions) and the
sleeve -H- for correct seating and damage.
Note
-F- in the tubes of the refrigerant agent.
– After attaching the refrigerant pipes, check their routing. They

must be inserted in holders provided and should not make
contact with other components.
– Empty
Protected theCopying
by copyright. refrigerant
for privatecircuit andpurposes,
or commercial refill it in⇒partAir
or inconditioning
whole, is not -
15.5 Removing and fitting the condenser
Note
Depending on the vehicle version, there are different types of

condensers ⇒ Parts catalogue .
15.5.1 Removal:
ant R134a SEAT .
– Remove the front bumper ⇒ Exterior body installation work;
Rep. gr. 63 .
– Remove refrigerant pipes from the condenser ⇒ page 168 .
– Place the lock carrier plate into service position ⇒ Bodywork,
exterior fitting work ; Rep. gr. 50
– Remove the ventilators for the refrigerant -B- with the allot‐
ment ⇒ Engine, mechanics; Rep. gr. 19

– Remove the bolts -A- and release the radiator (with condens‐
er) -B- from the front module -C- ⇒ Engine, mechanics; Rep.
gr. 19 .

– Release the condenser -C- from the radiator -D-.
– Remove the condenser -C- upwards.
15.5.2 Installing
lowing:
– Ensure that the lengths of adhesive are correctly attached
-E- and -F- on the condenser -C- (not in all versions).
Note
♦ Inside the condenser that has been removed, there is refrig‐

eration oil that must be added to the refrigeration circuit (with
the new condenser) ⇒ Air conditioning - with refrigerant R134a
SEAT .
♦ Depending on the version of the vehicle and the water radiator,
there may be a spacer -G- fitted fitted as shown in the diagram.
♦ Depending on the vehicle version there may be a -B- stone
impact protection fitted using clips -C- in the lower part of the
condenser -A-.


15.6 Liquid tank: removing and fitting
Note
♦ There are different versions of the liquid tank -C- and the con‐
denser -B- (one or two securing bolts -D- and -E- for the liquid
tank) ⇒ Parts catalogue .
♦ When the liquid tank has been fixed with two screws, the screw
-E- in the front modules -A-, that do have an opening -F- (In‐
troduction has not been determined), should only be replaced
when the condenser has been removed or drill a hole in the
front area (diameter, approx. 14 mm) (in this case, you should
proceed with great care so that the radiator or condenser is
not damaged when performing the drilling).
♦ Inside the tank that has been removed, there is refrigeration
oil that must be added to the refrigeration circuit (with the new
tank) ⇒ Air conditioning - with refrigerant R134a SEAT .
♦ Adjustment of oil quantity depends on nature of complaint.
♦ If, for example, reservoir has been damaged in an accident
(no loss of refrigerant, no penetration of moisture and dirt into
refrigerant circuit), air conditioner can be serviced by weighing
old and new reservoir without the need for extensive repair
work. Pour refrigerant oil into new receiver until it weighs the
same as the receiver removed.
♦ If an indeterminate amount of refrigerant oil has escaped or
dirt and moisture have penetrated into refrigerant circuit, it
must be cleaned using compressed air and nitrogen ⇒ Air
15.6.1 Removal: respect to the correctness of information in this document. Copyright by SEAT S.A.

ant R134a SEAT .
– Remove the front bumper ⇒ Exterior body installation work;
Rep. gr. 63 .
– Unscrew the bolts -D- and -E- (bolt -E- not always fitted) (tor‐
que 10 Nm).

– Unscrew the bolts -B- (tightening torque: 10 Nm).

– Extract the bracket -C- from the condenser allotment -E- mov‐
ing it downwards -arrow-.
– Extract the tank -D- to above the condenser -E- -arrow-.
15.6.2 Installing
lowing:
Before fitting theunless
permitted tank ⇒ Airbyconditioning
authorised SEAT S.A. SEAT - S.Awith
does refrigerant
not guarantee orR134a
accept any liability with
SEAT . respect to the correctness of information in this document. Copyright by SEAT S.A.
– Clean the support surface of the condenser -C-.

– Replace all O-ring seals -A- and -B-. Version ⇒ Parts cata‐
logue .
Note
♦ Ensure that the O-rings sit correctly into the corresponding
tubes or grooves.
♦ Cover all open junctions.
♦ Keep reservoir closed as long as possible; only remove caps
immediately prior to installation (reservoir contains a desiccant
bag which soon becomes saturated with moisture and thus
unusable when reservoir is open).
15.7 Refrigerant lines, expansion valve: Re‐

ant R134a SEAT .

– Remove the components that impede access to the fastening

bolts of the coolant pipes -A- of the expansion valve
Note

(upper cover of the engine, air conduit toProtected
the throttle andCopying
by copyright. the for private or commercial purposes, in part or in whole, is not
♦ There are different versions of the heat shield -B-. Version „1“
must have the panel nuts removed -A- and the vehicle heat
shield released -B-
clips-C- and release the vehicle heat shield -B-. If the heat
shield -B- disturbs the next job (because of the coolant hoses),
cut the heat shield panel -B- where marked in -D- (e.g. with a
set of angled pliers) and remove it completely.
engine removed
– Release the heat shield -B- (if fitted) from the front wall of the
windscreen wiper tray and place it to one side (or remove
completely).

– Remove the refrigerant tubes -B- and -C-.
Note
Seal open pipes and connections at the expansion valve with

suitable conical caps from the kit (to prevent the entrance of dirt
and moisture).

15.7.1 Installing
lowing:
logue .
– Check the fastener -G- (Fitted to the junction or expansion
valve, not fitted to all junctions) and the sleeve -H- for correct
seating and damage.
Note
-F- in the tubes of the refrigerant agent.
♦ Install refrigerant pipes such that they are not strained.
♦ Depending on the vehicle equipment and the engine fitted,
thermal insulation is fitted to the coolant tubes, which should
not be damaged and should be re-installed after fitting
♦ Check the fitting position of the coolant tubes to the expansion
valve (should not be supported by other parts) and check the
position and condition of other thermal insulation if existing on
the coolant tubes (certain engines do not require them).
15.8 Removing and fitting the expansion

valve
ant R134a SEAT .
– Remove refrigerant pipes from the expansion valve
⇒ page 172 .
– Extract the expansion valve -B- from the thermal protection
insulation -C-
Note
Seal open pipes and connections at evaporator with suitable con‐

ical caps from the kit -T20017A- (to prevent penetration of dirt and
moisture).
15.8.1 Installing
lowing:
logue .
– Ensure that the O-ring seals -D- and -E- sit correctly onto the
connection tubes to the evaporator -F- and -G-.

Note
♦ There are different expansion valve versions (same housing,

but different characteristic curve during regulation). Take care
of the correct assignment for this purpose ⇒ Spare parts cata‐
logue
♦ When the thermal insulation -C- is not fitted or there is not
enough then there may be reduced performance from the air
conditioning (modification of the characteristic regulation
curve due to heat radiation).
15.9 Capacity
Capacities for refrigerant R134a and refrigerant oil: ⇒ Air condi‐
tioning - with refrigerant R134a SEAT
– Empting and filling the refrigerant circuit ⇒ Air conditioning -
Note
system.
♦ Always fill refrigerant circuit as far as upper tolerance limit
(some refrigerant remains in filler hoses).
♦ Refrigerant circuit may only be filled with approved refrigerant
oils ⇒ Spare parts catalogue .
♦ For different types of compressors, different types of refriger‐
ant oil must be used: ⇒ Air conditioning - with refrigerant
R134a SEAT ⇒ Spare parts catalogue .
♦ Any refrigeration oil that has remained in open containers for
a certain time may not be reused because the oil absorbs hu‐
midity and cannotrespect

be used any more.
♦ Other notes ⇒ Air conditioning - with refrigerant R134a SEAT .

16 Removing and fitting air conditioning

unit
♦ Cooling (leak) tester -SAT 1274- (and adaptors)
♦ Clamping tool -U-30042-
16.1 Removal:
ant R134a SEAT .
– Disconnect car battery ⇒ Electrical system; Rep. gr. 27 .
Note
♦ Before disconnecting the battery, consult the anti-theft code of

the radio.
♦ On removal, note down bolt lengths and assignment for re-
installation.
♦ All cable tiesunless
permitted andauthorised
other wiring harness
by SEAT S.A. SEAT S.Afasteners released
does not guarantee or acceptor
any liability with
cut open on removing air conditioner unit are to be re-attached
in same position on installation.

♦ Depending on the vehicle equipment and the engine fitted,
thermal insulation is fitted to the coolant tubes, which should
not be damaged and should be re-installed after fitting
– Mark positions of coolant hoses -A- and -B-.

– Reduce pressure in coolant circuit by opening cap on the cool‐
ant expansion tank. ⇒ Engine, mechanics; Rep. gr. 19

– Remove the components impeding access to the fastening

bolts of the coolant tubes -A- of the expansion valve and the
coolant hoses to the heat exchanger in the engine compart‐
ment.
Note
So as not to damage instrument panel outside lining, the control

panel is only to be placed on a clean workbench covered, for ex‐
– Remove the accelerator pedal module ⇒ Fuel supply system;

Rep. gr. 20 .
– Fold the mat on the driver side and passenger side back so
that it is possible to remove the vents for the foot well ⇒ Body‐
work, interior fitting work; Rep. gr. 70 .
– Remove the two vents from the foot well for the rear area.
– Remove the -V2- ⇒ page 121 .
– Remove
Protected the
by copyright. instrument
Copying for private orpanel and
commercial the crossbeam
purposes, foris the
in part or in whole, not in‐
permitted strument panel
unless authorised (centre
by SEAT tube)
S.A. SEAT ⇒ Bodywork,
S.A does not guarantee or interior
accept any fitting work;
liability with
Rep. gr. 70 .
– Remove the Data bus diagnostic interface -J533- (in the area
of the steering column secured to the bracket -A-) ⇒ Electric
System; Rep. gr. 90 .
Note

(upper cover of the engine, air conduit to the throttle and the
♦ There are different versions of the heat shield -B-. Version „1“
must have the panel nuts removed -A- and the vehicle heat
shield released -B-
clips-C- and release the vehicle heat shield -B-. After detach‐
ing the coolant hoses, remove the heat shield completely
-B-.
engine removed
– Release the heat shield -B- (if fitted) from the front wall of the
windscreen wiper tray and place it to one side (or remove
completely).
16. Removing and fitting air conditioning unit 177

– Pull back the heat shield hoses -D- and -E- (if fitted) so that
fitting can be performed, for example, of the clamps up to 40
mm pliers -T20174- -F- on the coolant hoses-A- and -B-.
– Mark fitting positions of refrigerant hoses -A- and -B-.
Note
♦ The heat exchanger has been designed for the certain flow
direction of the refrigerant; for this purpose, the hoses must be
connected to the correct side (Hose -A-: Supply from cylinder
head, Hose -B-: Return tube to the water pump).
♦ The position of the refrigerant hoses is the same for vehicles
with heating or air conditioning. This illustration shows the po‐
sition in a vehicle with air conditioner.
13 .
– Cover the area below the tube joints -A- and -B- (e.g with ab‐
sorbent paper).
– Pinch off both coolant tubes leading to the air conditioner sys‐
tem heat exchanger (e.g. using the hose clamps up to ø 40
mm -3093- ) and detach them.


– Remove the refrigerant tubes from the expansion valve and
secure them, for example with cable ties, so that they do not
interfere in the fitting work.
Note
♦ Seal the open junctions (to prevent dirt and moisture entering).
♦ To close the open connections on the expansion valve or the
evaporator it may be appropriate, for example the seal hood
of an spare expansion valve or spare evaporator.
– Remove the glove compartment, the shelf on the driver's side,

the centre console and the instrument panel:⇒ Bodywork, in‐
terior fitting work; Rep. gr. 70
Note
The dashboard should only be placed on a clean work surface

(covered for example with clean cardboard) so that its outer lining
is not damaged.
– Remove the accelerator pedal module ⇒ Fuel system; Rep.

gr. 20
– Remove the left and right vents -C-

– Fold the mat on the driver side and passenger side floor back
so that it is possible to remove the vents on the footrest for the
rear -A- andby-B-.
Protected ⇒ Bodywork
copyright. - Interior
Copying for private fitting
or commercial work;
purposes, Rep.
in part or ingr.
whole, is not
70 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Remove the two vents from the footrest for the rear area -A-
and -B-.
– Remove the fresh air blower.
– In vehicles with manual climate control, remove the air condi‐
tioning control ( control unit for air conditioning -J301- ) (do not
remove the main board for operation)
Rep. gr. 70 .
– Remove the data bus diagnosis interface control unit -J533-

(attached to support -A- in the steering column area). ⇒
Electrical system; Rep. gr. 90
– Remove the bolts -B- and release the support -A- for the air
conditioning (the support remains attached to the cable har‐
ness of the vehicle).

– Remove the two bolts -A- in the cable harness support -B-
– Remove the climate control system water condensation drain‐
age hoses.
– Release the attachment of vehicle wiring harness (with cable
ties) from the air conditioning.
– For those vehicles with an additional electric heating (only for
diesel powered vehicles), release the cable connections to the
voltage supply of the Additional heating element -Z35- .
– Unplug all electric connectors between vehicle wiring harness
and electrical components at air conditioner unit.
Note
The „air conditioning“ wiring harness is removed with the air con‐
ditioning.
– Pull out the air conditioning a little bit from the right hand side
(until the bolt -B- in the right hand side support -A- may be
unscrewed).
Note
♦ Pull gently on the air conditioning so that Protected

the support -A- Copying
by copyright. does for private or commercial purposes, in part or in whole, is not
not break. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ To unscrew the bolt -B- insert a hand between the air condi‐
tioning and the floor mat in the right hand side wheel housing
(this is possible if the fresh air turbine has first been removed).
– Remove the bolts -B- and release the support -A- for the air
conditioning (the support remains attached to the cable har‐
ness of the vehicle).
– Release the two brackets for the refrigerant hoses to the heat
exchanger -A- and the expansion valve (to the evaporator)
-B- in the openings of the grommet -C-.
Note
♦ On removing the air conditioning, pay attention to both coolant

pipes to heat exchanger to ensure that they do not catch on
the opening to the plenum chamber or on the sound proofing
mat and are bent or damaged.

– Take out air conditioner unit -A- towards passenger side.
16.2 Installing
lowing:
– To fit the air conditioning unit, the help of a second mechanic
is required.
♦ Check all seals at air conditioner unit for damage prior to in‐
stallation and replace damaged seals.
♦ Check attachment of coolant pipes to heat exchanger.
– Fit the seal -A- (as viewed from the interior to the outside) to
the transversal panel -B-. Take care of the correct fitting posi‐
tion of the reinforcement -C- (wire brace) on the nozzle -A-
– Seek the help of another person to fit the air conditioning unit.

– The second person must insert (from the engine compart‐

ment) the two brackets for the coolant hoses to the heat
exchanger -A- and the expansion valve (to the evaporator)
-B- in the openings of the grommet -C- when fitting the air
conditioning.
Note
♦ When fitting the air conditioning, pay attention to both coolant

pipes to heat exchanger to ensure that they do not catch on
the opening to the plenum chamber or on the sound proofing
mat and are bent or damaged.
– Connect the condensation drain to the connection of the air

conditioning unit and check the correct positioning
⇒ page 100 .
– Re-install components removed with the exception of the driv‐
er sides lower trim in reverse order.
Note
♦ When installing instrument panel, make sure intermediate de-

icer piece is properly positioned on air conditioner unit on
insertion and that defroster vent does not squash intermediate
piece on fitting.
♦ After installing instrument
respect to the panel, check
correctness of information exit direction
in this document. Copyright byand
SEATdis‐
S.A.
tribution of air flow from de-icer vent to windscreen.
– Fit coolant pipes from the expansion valve ⇒ page 172 .
19 .
connection between coolant pipes and heat exchanger
⇒ page 139 , ⇒ Engine, mechanics; Rep. gr. 19 .
– Check the correct positioning of the grommet -C- in the trans‐

verse panel.
– Seal the flanges for the coolant hoses to the heat exchanger
-A- and the pressure release valve (to evaporator) -B- in the
openings of the grommet -C-, for example using silicon sealing
paste (so that it is water tight).
– Refit the lower lining on the driver side as well as any other
components that were removed.
– Test the operation of the air conditioning unit, for example,
using the function „basic setting“ (correct electrical connec‐
tions test) ⇒ Vehicle diagnostic, testing and information sys‐
tem VAS 5051.

17 Replace components that can only

be removed and fitted with the air
conditioning removed
17.1 Air inlet opening with air retention, fresh

air / air recirculation flap: removing and
fitting
Note
♦ The structure of the intake cavity is different in vehicles with

manual and automatic climate control. Vehicles with automatic
climate control have different versions of the intake cavity (with
and without a bracket for the temperature sensor - fresh air
intake conduit -G89- with one or two servomotors for operating
the air recirculation flap and the dynamic pressure/fresh air
flap) ⇒ Parts catalogue
♦ Until the end of model year 2007, the dynamic pressure flap
(fresh air flap) was operated by the dynamic pressure flap ser‐
vomotor -V71- . At the end of model year 2007 the servomotor
for dynamic pressure flap -V71- will be gradually phased out;
in vehicles without servomotor -V71- , the dynamic pressure
flap (fresh air flap) is operated through a cam disk and a lever
by the servomotor for the air recirculation flap -V113- . For this
reason, note the correct assignation of the control and indica‐
tion unit, Climatronic control unit -J255- ; if the assignation or
adaptation are not correct, this situation is detected in the ba‐
sic adjustment and registered as a fault ⇒ Parts catalogue
Removal:
– Remove the instrument panel completely with the instrument
panel cross beam. ⇒ Bodywork - Interior fitting work; Rep. gr.
70
– Remove air conditioning unit.
– Mark the wired connection to the connector -B- (to the dynamic
pressure flap servomotor -V71- ) and disconnect (risk of con‐
fusion, as connectors -B- and -C- are identical in shape).
– Mark the cable connection to the connector -C- (to the Servo‐
motor for the air recycling flap -V113- ) and detach it.

– Release the air inlet opening of the air conditioning.
Note
♦ Different versions for vehicles with or without fresh-air intake

duct temperature sensor -G89- ⇒ Spare parts catalogue .
♦ During model year 2006 the thermosensor - fresh air intake
channel -G89- was gradually phased out; vehicles without this
can only have control and indication panels, Climatronic con‐
trol unit -J255- , with the part number from index „M“.
♦ If vehicles without thermosensor - fresh air intake channel -
G89- have a control and indicator panel, Climatronic control
unit -J255- , with the part number up to index „L“, an entry is
made in the fault memory.
Installing
the following:
ing of the attachment points -F- and -G-.
moving components (e.g. control motor lever).

18 Air conditioning components: remov‐

ing and fitting
18.1 Air conditioning electrical components: removing and installing
1 - Air conditioning wiring har‐

ness
❑ Different versions (for
example, with or without
connection to the Addi‐
tional heating control
unit -J604- ) ⇒ Parts
catalogue
❑ See ⇒ Current flow dia‐
grams, Electrical fault
finding and Fitting loca‐
tions
❑ Mark connections be‐
fore removing them (the Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
connections for the dif‐ permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
ferent servo motors and

thermo sensors are

identical, danger of con‐
fusion).
❑ Fit the cable branch into
the attachment points
on the housing (using
cable ties, or in the allot‐
ments so that it does not
come into contact with
any moving parts)
Note
♦ During model year 2006 the ther‐

mosensor - fresh air intake chan‐
nel -G89- was gradually phased
out; vehicles without this can on‐
ly have control and indication
panels, Climatronic control unit -
J255- , with the part number from
index „M“.
the fault memory.
18. Air conditioning components: removing and fitting 185

♦ Until the end of model year 2007,

the dynamic pressure flap (fresh
air flap) was operated by the dy‐
namic pressure flap servomotor
-V71- . At the end of model year
2007 the servomotor for dynamic
pressure flap -V71- will be grad‐
ually phased out; in vehicles
without servomotor -V71- , the
dynamic pressure flap (fresh air
flap) is operated through a cam
disk and a lever by the servomo‐
tor for the air recirculation flap -
V113- . For this reason, note the
correct assignation of the control
and indication unit, Climatronic
control unit -J255- ; if the assig‐
nation or adaptation are not cor‐
rect, this situation is detected in
the basic adjustment and regis‐
tered as a fault ⇒ Parts cata‐
logue
2 - Air conditioner unit

❑ Different versions of Climate control in vehicles with manual and automatic climate control⇒ Parts cata‐
logue
❑ Air conditioning: dismantling and assembling ⇒ page 189
❑ Evaporator housing: dismantling and assembling ⇒ page 192
❑ Only intended for vehicles with diesel engine, see ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations
❑ There are different versions of additional air heaters: In vehicles with a diesel engine that have been built
from 2006 (smooth conversion), the heater element for additional air heater -Z35- is activated via the
additional air heating control unit -J604- . In vehicles with a diesel engine that have been built from 2006
(smooth conversion), a 3-stage heater element for supplementary air heater -Z35- is fitted; This element
is controlled by the respective engine control unit via relays and ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
❑ Vehicles with a Diesel engine and the extra equipment for „independent heating“ also now carry a heating
element for additional heating -Z35- In the future (introduction pending) these vehicles will not carry the

heating element for additional heating -Z35- (the„independent heating“ will run the operation of the „ad‐
ditional heating“) ⇒ independent heating; Rep. gr. 01
❑ Check the operation of the control unit for the additional air heating -J604- , carry out self-diagnosis.
4 - Coolant tubes and heat exchanger cover
❑ This diagram shows the version for vehicles with Additional heating element -Z35-
❑ There are different versions for vehicles with or without Additional heating element -Z35- (for vehicles
without the Additional heating element -Z35- this opening for the Additional heating element -Z35- is
covered) ⇒ Parts catalogue
5 - Bolt.
6 - Central flap control motor -V70-
❑ With potentiometer for central flap servomotor -G112-
7 - Servomotor for the left hand side temperature flap. -V158-
❑ With Servomotor potentiometer for the left hand side temperature flap. -G220-
❑ Lever colour code: White
8 - Link rod to left temperature flap servomotor -V158-
❑ Colour code: white (longer than connecting rod to right temperature flap control motor -V159- )
9 - Servomotor for de-icing flappermitted
-V107- unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ With the Potentiometer on the de-icing flap servomotor -G135-
❑ Lever colour code: Blue colour
10 - Connection rod to the Servomotor for the de-icing trap (00710) -V107-
❑ Colour code: Blue colour
11 - Air temperature sender, left foot well zone vent -G261-
13 - Bracket cover for the Servomotor for the air retention flap -V71- and the Servomotor for the air recirculation
flap -V113-
❑ Removing and fitting (see removal of the Servomotor for the air recirculation flap (00716) -V113- )
⇒ page 124
❑ With both motor actuators, check that this bracket keeps it in their position after fitting. When they are
not installed free of play, eliminate the play at hand with a little foam that is applied to the inner side of
the fixing points of the bracket ⇒ page 124 .
❑ The cover is only fitted in the version with dynamic pressure flap servomotor -V71- (the air recirculation
flap -V113- is bolted in the intake cavity in the version without dynamic pressure flap servomotor -V71- )
❑ Until the end of model year 2007, the dynamic pressure flap was operated by the dynamic pressure flap
servomotor -V71- . At the end of model year 2007 the servomotor for dynamic pressure flap -V71- will

be gradually phased out; in vehicles without servomotor -V71- , the dynamic pressure flap (fresh air flap)
is operated through a cam disk and a lever by the servomotor for the air recirculation flap -V113- .
❑ With the Potentiometer on the air recirculation flap servomotor -G143-
15 - Servomotor for air retention flap -V71-
❑ With potentiometer for dynamic pressure flap servomotor -G113-
16 - Sponge material seal
❑ Air conditioning inlet opening seal
17 - Air inlet opening with air recirculation / air retention (fresh air) flap
❑ Different versions in vehicles with or without temperature sensor for fresh air intake conduit -G89-
❑ Different versions (e.g. with or without thermosensor - fresh air intake conduit -G89- , with and without
dynamic pressure flap servomotor -V71- , etc) ⇒ Spare parts catalogue
❑ Until the end of model year 2007, the dynamic pressure flap was operated by the dynamic pressure flap
servomotor -V71- . At the end of model year 2007 the servomotor for dynamic pressure flap -V71- will
be gradually phased out; in vehicles without servomotor -V71- , the dynamic pressure flap (fresh air flap)
is operated through a cam disk and a lever by the servomotor for the air recirculation flap -V113- .
Note
♦ During model year 2006 the ther‐

mosensor - fresh air intake chan‐
nel -G89- was gradually phased
out; vehicles without this can on‐
ly have control and indication
panels, Climatronic control unit -
J255- , with the part number from
index „M“.
the fault memory.

19 - fresh air blower control unit -J126- and Fresh air blower -V2-
❑ The Fresh air blower -V2- is fitted with the Fresh air blower control unit -J126- and cannot be replaced
separately
20 - Servomotor for the right hand side temperature flap -V159-
❑ With Servomotor potentiometer for the right hand side temperature flap -G221-
❑ Lever colour code: Black
21 - Link rod to right temperature flap servomotor -V159-
❑ Colour code: black (shorter than connecting rod to left temperature flap control motor -V158- )
23 - Cable tie
24 - Cable harness support
18.2 Disassembling and assembling the air

conditioning unit
– Remove the electrical components of the air conditioning unit
⇒ page 185 .

1 - Air distributor housing for air

conditioning
❑ In vehicles without heat‐
er element for additional
air heating -Z35- the
opening for the heater
element for additional
air heating -Z35- is
blocked by the cover of
the heat exchanger.
❑ Lightly grease the sup‐
port points and the tem‐
perature flap guides (for
example using G 052
745 A3).
❑ Different versions in ve‐
hicles with manual and
automatic climate con‐
trol⇒ Parts catalogue
❑ The air distribution cas‐
ing in vehicles with man‐
ual climate control has
gears with a cam disk for
operating the air distri‐
bution flaps. Do not dis‐
connect these gears as
the adjustment cannot
be reset.
Note
♦ Vehicles with manual climate

control have the air distribution
flaps operated manually via a
flexible shaft. Vehicles with au‐
tomatic climate control have air
distribution flaps operated by
servomotors.
♦ In vehicles with manual climate
control, the temperature flaps
(left and right temperature flap)
are connected on top of each
other via a shaft. They are oper‐
ated using an actuator motor.
Vehicles with automatic climate
control have left and right tem‐
perature flaps operated by inde‐
pendent servomotors.

2 - Bolt.
3 - Air duct to the air vent in the left foot well
❑ Version „Air conditioning“
5 - Seal ring
❑ Replace
❑ Lightly cover with liquid coolant and fit correctly into place ⇒ page 139
6 - Clip
❑ Replace
❑ Ensure correct seating
7 - Bolt.
❑ Tightening torque: 2.5 Nm
8 - Coolant tubes
❑ Remove and fit at the heat exchanger ⇒ page 139
❑ Fitted between the grommet and the air conditioning unit
10 - Grommet
❑ Before fitting the air conditioning unit, fit this in the transversal panel of the vehicle ⇒ page 176
11 - O ring
❑ Allocation: ⇒ Parts catalogue
12 - O ring
❑ Allocation: ⇒ Parts catalogue
14 - Bolt.
15 - Evaporator housing
❑ Heed replacement intervals ⇒ Maintenance ; Booklet 101
17 - Cover for the dust and pollen filter
❑ Removing and fitting ⇒ page 120 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
18 - Air duct to the air vent in the right foot well
❑ Version „Air conditioning“
19 - Sealing plug

18.3 Evaporator housing: dismantling and

assembling
⇒ page 185 .
– Remove the air conditioning unit evaporator housing
⇒ page 189 .
1 - Lower section of the evap‐

orator housing
2 - Evaporator
❑ Check the insulation, it
must be complete
⇒ page 192 .
⇒ page 192
3 - Clip
4 - Upper section of the evap‐
orator housing
5 - Bolt.
6 - Seal / insulation
❑ Thermal insulation for
the expansion valve
⇒ page 192
7 - Spring retainer
⇒ page 192
18.4 Removing and fitting the evaporator

⇒ page 185 .
– Dismantle the evaporator housing ⇒ page 192 .

– Extract the evaporator -A- from the lower element of the evap‐
orator housing.
Note
♦ Before fitting evaporator, check and if necessary clean con‐

densate drain.
♦ Clean the evaporator housing ( and, if necessary the evapo‐
rator) before fitting the evaporator.
– When fitting the evaporator -A- note the lower section and
when fitting the two housing elements, protect the seal -F-.
– Check the seal -F- before fitting the evaporator (must be se‐
cured all around).
– Fit the support -C- and the seal / insulation -B- onto the con‐
nection tubes of the evaporator -D- and -E-.
– Fit the evaporator -A- as shown in the illustration to the lower
evaporator housing element.
Note
♦ Check following the fitting, the two parts Protected

of the housing, the for private or commercial purposes, in part or in whole, is not
by copyright. Copying
correct positioning of the seal / insulation -B- in
permitted theauthorised
unless passage by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
for the two coolant tubes -D- and -E-. respect to the correctness of information in this document. Copyright by SEAT S.A.
♦ Check the correct seating of the support -C- on the two coolant
tubes -D- and -E-.
♦ When the protective thermal insulation -B- is not fitted or there
is not enough then there may be reduced performance from
the air conditioning (modification of the characteristic regula‐
tion curve due to heat radiation).
♦ Inside the evaporator that has been removed, there is refrig‐
eration oil that must be added to the refrigeration circuit (with
the new evaporator) ⇒ Air conditioning - with refrigerant
R134a SEAT .
18.5 Air conditioning compressor installation

instructions
18.5.1 Installing
– Only start the engine after the complete assembly of the re‐
frigerant circuit.

– After installing a new air conditioner compressor or filling with

fresh refrigerant oil (e.g. after blowing out refrigerant circuit),
turn the Poly-V belt pulley of the compressor 10 revolutions by
hand before starting engine. This will prevent damage to the
air conditioner compressor.
– If possible, the engine must only be started after the refrigerant
circuit has been filled.
Note
♦ The compressor is driven by the Poly-V belt pulley (not equip‐

ped with an electromagnetic clutch):
♦ If the air-conditioner compressor locks, the overload protection
will come off the compressor shaft. A seized air conditioner
compressor cannot always be identified by visible deforma‐
tions in the poly V-belt pulley. Another indication is abraded
rubber material around the V-ribbed belt pulley.
♦ The air conditioner compressor is equipped with a protected
oil supply to prevent any damage if the refrigerant circuit were
Protected by copyright. Copying for private or commercial 3
to be empty. This
permitted means
unless that
authorised about
by SEAT S.A. 40
SEATtoS.A50 cm
does refrigerant
purposes, in part or in whole, is not
oil remain in the compressor.
♦ The engine may only be started once the refrigerant circuit has
been correctly assembled. If, for example, the refrigerant pip‐
ing has not been connected to compressor, the compressor
may overheat if the engine is running (due to internal heating),
and may eventually be destroyed.
♦ Air conditioning system compressor regulating valve -N280- is
not activated when the refrigerant circuit is empty and the air
conditioner compressor idles with the engine.
♦ If the engine must be started with the refrigeration circuit emp‐
ty:
♦ The refrigeration circuit must be assembled completely.
♦ At least 1/4 of the quantity of refrigerant oil specified for this
refrigerant circuit must be in the air conditioner compressor.
♦ The engine speed must not go above the 2500 rpm.
♦ The engine must only be used for the minimum amount of time
Note
When starting the engine for the first time after filling the refriger‐
ant circuit, take note of the following:
– Start engine with air conditioner compressor switched off

(„Econ“ mode) and wait until the idling speed stabilizes.
– Open all instrument panel vents.
– Select the temperature preselection „Lo“ on the operating and
display unit for air conditioner / Climatronic -E87- .
– Now switch air conditioner compressor on („Auto“ mode) and
allow engine to run for at least 5 minutes at idling speed.

19 Capacity
Capacities for refrigerant R134a and refrigerant oil: ⇒ Air condi‐
tioner with refrigerant R134a .
– Drain, empty and fill the air conditioning circuit. ⇒ Air condi‐
tioning - with refrigerant R134a
Note
♦ Depending on the production and engine, the construction of

the compressor may vary. ⇒ Spare parts catalogue
♦ Originally „Denso“ (type„7 SEU 16“ or „7 SEU 17“) compres‐
sors were factory fitted, from model year 2004 other compres‐
sors were also fitted („Sanden“ or „Zexel“). ⇒ Spare parts
catalogue and ⇒ Air conditioning - with coolant R134a
♦ Depending on the type of compressor („6 SEU 14“, „7 SEU 16“
or „7 SEU 17“ different capacities of oil filling for refrigerant
machine circuits have been prepared ⇒ Parts catalogue and
⇒ Air conditioning - with coolant R134a
♦ This compressor is available as a spare part with different oil
capacities; therefore please observe the parts reference
closely ⇒ Spare parts catalogue and ⇒ Air conditioning- with
R134a coolant . The reason for these variations in the amount
of oil lies in the structure of the compressor; these quantities
of oil must be taken into consideration. Too much oil in the
circuit will lead to more intense pressure and a lowering of the
refrigeration output of the system; if there is not enough oil
there may be lubrication problems in the compressor.
♦ Always fill refrigerant circuit as far as upper tolerance limit
(some refrigerant remains in filler hoses).
♦ Refrigerant circuit may only be filled with approved refrigerant
oils: ⇒ Spare parts catalogue
♦ With the compressor types Zexel, Sanden and Denso, differ‐
ent types of refrigerant oil must be used: ⇒ Air conditioning -
with refrigerant R134a ⇒ Spare parts catalogue .
♦ Any refrigeration oil that has remained in open containers for
a certain time may not be reused because the oil absorbs hu‐
midity and cannot be used any more.
♦ Other notes ⇒ Air conditioning - with refrigerant R134a .
19.1 Coolant agent R134a

Air conditioning Manufacturer Total capacity
compressor
7SEU17C
Protected by copyright. Manufacturer: Den‐ 525
Copying for private or commercial ± 25in part
purposes, grammes
or in whole, is not
permitted unless authorised by SEAT S.A.soSEAT S.A does not guarantee or accept any liability with
PXE16 Manufacturer: San‐ 525 ± 25 grammes
den
6CVC 140 Manufacturer: Del‐ 525 ± 25 grammes
phi
DSC17E Manufacturer: Zexel 525 ± 25 grammes
19. Capacity 195

19.2 Refrigerant circuit oil
Note
♦ The special oil that should be used exclusively for circuits with
coolant agent R134a can no longer be purchased (as in the
past) on the oil market for machines with coolant oil.
♦ The coolant oil for machines cannot be used when the con‐
tainer has been left open for longer periods.
Coolant oil reference; for

7SEU17C; Manufacturer: Denso G 052 300 A2
DSC17E; Manufacturer: Zexel G 052 200 A2
6CVC 140; Manufacturer: Delphi G 052 300 A2 or G 052 154
A2
PXE16; Manufacturer: Sanden G 052 154 A2
Type Production time Total capacity1)

1K0 820 803 E from 04.04 140 cm3 ± 10 cm3
Denso
1K0 820 803 G from 04.04 110 cm3 ± 10 cm3
Sanden from 01.05
1K0 820 803 Q
1K0 820 803 H from 04.04 120 cm3 ± 15 cm3
Zexel
Manufacturer: fromunless
permitted 10.09 110
authorised by SEAT cm
S.A. 3 ±S.A
SEAT 10doescmnot3 guarantee or accept any liability with
Delphi respect to the correctness of information in this document. Copyright by SEAT S.A.
1) The spare compressor is filled with the correct amount of oil
Further information
As the coolant oil absorbs damp, containers should be closed im‐
mediately after use, to prevent the penetration of damp.
Due to its chemical properties, the refrigerant oil must not be dis‐
posed of together with engine or gearbox oil.
19.2.1 Oil distribution

The oil in the compressor oil tank prior to the first time the air
conditioner is connected is distributed in the coolant circuit in the
same way:
♦ Compressor 50% approx.
♦ Condenser 10% approx.
♦ Extraction hose 10% approx.
♦ Evaporator 20% approx.
♦ Liquid tank 10% approx.
19.3 Conversion table by relevance

SEAT tool VW / AUDI tool
Clamping tool -U-30042- -3093-
Cooling system tester -SAT -VAG 1274-
1274-
AC charging station -SAT -VAS 6007 A-
4006D-
Tool set -T20017A- -3212- -VW401- -VAG 1616/1-

SEAT tool VW / AUDI tool

Counterhold tool -T20018B- -3415-
Digital thermometer -SAT
4002-
A.C. leak detector using fluo‐
rescent liquid -SAT 4007B-
Electronic leak detector -SAT
4012-
Cooling system tester -SAT
1274-
Lever -U 30800-
Check box with (105) Pins -
VAG 1598/42-
Pressure tester -VAG 1527B-
19. Capacity 197

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Service

Heating and air conditioning

Service Department. Technical Information

All rights reserved.

Copyright © 2015 Seat S.A S01DCXX8S20

87 - Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4.5 Pulley: Replacing (compressor make „Zexel“) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

♦ Air intake ⇒ page 93 , air outlet and routing of air flow in

1.1 Centre vent: Removing and installing

1.2 Vent left and right side: Removing and

1.3 Air duct system in vehicle interior

1. Instrument panel vents and air conduits 1

2 Rep. gr.80 - Heating

14 - Control unit of the heater / main board

1. Instrument panel vents and air conduits 3

1.4 Air intake, air outlet and air flow in the

1.4.1 Air intake and air outlet openings

4 Rep. gr.80 - Heating

1.4.2 Air duct in the air flow duct

1 - Air flow duct complete

1.4.3 Routing of air flow in air distribution

1. Instrument panel vents and air conduits 5

1 - Air distribution housing

6 Rep. gr.80 - Heating

1.5 Contact corrosion

1. Instrument panel vents and air conduits 7

2.1 Heating system components: removing and fitting

1 - Heating control / Heating

8 Rep. gr.80 - Heating

nents: removing and fit‐

2.2 Fresh air blower series resistor with

– Disconnect the connector -A- from the additional resistance

The refrigerator body of the series resistance of the exterior air

– Extract the additional resistance -B- from the heating system.

2.3 Removing and installing fresh air blow‐

force on the respect

10 Rep. gr.80 - Heating

♦ When fitting, pay attention to correct positioning of fresh-air

2.4 Removing and installing fresh air and air

♦ In the self-diagnosis and circuit diagrams for heating and man‐

– Remove the glove compartment: ⇒ Bodywork, interior instal‐

The servomotor is supplied as a spare in the position of „fresh air

Set the wheel of the servomotor in position „fresh air“

12 Rep. gr.80 - Heating

– In order to move the cogwheel on the servomotor -A- onto the

♦ The position of the servomotor (and the flap) is not visible

– Switch on the ignition.

– Actuate the servomotor until the notched wheel -D- is located

2.5 Check the operation of the fresh air and

Fresh air/air recirculation mode key fitted in the heating control

♦ With the air recirculation option there may be fogging of the

14 Rep. gr.80 - Heating

2.5.1 Check the operation of the Servomotor

2.5.2 Check the operation of the electronics of

16 Rep. gr.80 - Heating

♦ If no fault is detected during this test:

2.6 Vents: removing

2.6.1 Driver and passenger side vents: re‐

2.6.2 Ai duct forS.A.theSEATfoot well: Removing andwith

The removal of the ducts is the same for both sides.

– Remove the passenger and driver seats ⇒ Bodywork, interior

2.6.3 Right foot well vent: removing

2.6.4 Remove the vent from the foot well area

18 Rep. gr.80 - Heating