SM 14

Service
Polo Estate 1998 ➤

Heating, air conditioning
Edition 11.1999
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Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
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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 © 2011 Volkswagen AG, Wolfsburg 00056406320

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80 - Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
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1 Servicing heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
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1.1 Servicing heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
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1.2 Passenger compartment heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
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1.3 Removing fresh air blower -V2- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
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1.4 Removing and installing dust and pollen filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.5 Removing vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1.6 Removing and installing heated air and fresh air controls . . . . . . . . . . . . . . . . . . . . . . . . . .13
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1.7 Checking ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
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2 Removing and installing heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

2.1 Removing and installing heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
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3 Dismantling and assembling heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

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3.1 Dismantling and assembling heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
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4 Dismantling and assembling heated air and fresh air controls . . . . . . . . . . . . . . . . . . . . . . . .23
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4.1 Dismantling and assembling heated air and fresh air controls . . . . . . . . . . . . . . . . . . . . . . . .23
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5 Installing and adjusting cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

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5.1 Installing and adjusting cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
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87 - Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
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1 Notes on repair work to vehicles with air conditioning and on handling refrigerant . . . . . . . .30
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1.1 Notes on repair work to vehicles with air conditioning and on handling refrigerant . . . . . . . .30
1.2 Safety precautions when working on vehicles with air conditioning and when handling
refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
2 Air conditioner with manual controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
2.1 Air conditioner with manual controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
2.2 Air conditioning and heating - Passenger compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
2.3 Removing and installing heating and air conditioning controls . . . . . . . . . . . . . . . . . . . . . . . .37
2.4 Dismantling and assembling heating and air conditioning controls . . . . . . . . . . . . . . . . . . . .40
2.5 Installing and adjusting heating and air conditioning cables . . . . . . . . . . . . . . . . . . . . . . . .42
2.6 Air conditioning and heating system - Engine compartment . . . . . . . . . . . . . . . . . . . . . . . .46
2.7 Removing and installing air conditioner compressor bracket, engine code: APE . . . . . . . .53
2.8 Servicing magnetic coupling -N25-; Sanden unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
2.9 Removing magnetic coupling from compressor and refitting again . . . . . . . . . . . . . . . . . . . .65
3 Servicing refrigerant circuit, which may only be performed at workshops with specially trained
personnel (specialist repair workshop for air conditioning systems) . . . . . . . . . . . . . . . . . .68
3.1 Servicing refrigerant circuit, which may only be performed at workshops with specially trained
personnel (specialist repair workshop for air conditioning systems) . . . . . . . . . . . . . . . . . .68
3.2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
3.3 Renewing refrigerant circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
3.4 Checking high pressure sender -G65- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
3.5 Removing and installing heater and air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
3.6 Dismantling and assembling evaporator housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
3.7 Removing expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
3.8 Removing and installing condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
4 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
4.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
4.2 Refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
4.3 Refrigerant oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Contents i
Heating, air conditioning - Edition 11.1999
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ii Contents
80 - Heating
1 - Servicing heating system

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1.2 - Passenger compartment heating
Warning!
Always disconnect the battery earth strap before working on the electrical system.
Notes:
◆ Obtain radio anti-theft coding before disconnecting the battery.
1.1 - Servicing heating system 1

◆ Check vehicle equipment (radio, clock, electric windows) as per Workshop Manual and/or Owner's Manual
when reconnecting the battery.
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2 Dust and pollen filter

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◆ With activated charcoal filter

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3 Fresh air and heated air controls
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◆ With fresh air blower switch -E9-

◆ With fresh air and air recirculation switch -E159-
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◆ Dismantling and assembling => Page 23

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◆ Installing and adjusting cables => Page 25

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◆ Installing => Page 21
5 Front passenger's vent

◆ Removing vent => Page 9
6 Fresh air/air recirculation positioning motor -V154-
7 Fresh air blower -V2-
◆ Removing =>Fig. 7 , Removing and installing fresh air blower -V2-
1.2 - Passenger compartment heating 3

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8 Fresh air blower series resistor with overheating fuse -N24-

◆ Removing =>Page 7 , Removing fresh air blower -V2-
9 Central vent
10 Heater
◆ Removing => Page 17
4 80 - Heating
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11 Cables
◆ Removing and installing => Page 25
12 Connecting piece
13 Cover
14 Footwell vent
15 Kick plate
16 Intermediate piece, defrost
◆ Renewing:
- Removing and installing dash panel
dash panel
1.2 - Passenger compartment heating 5

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19 Right vent
6 80 - Heating
1.3 - Removing fresh air blower -V2-
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=> General body repairs interior; Repair group 70; Removing trim under the steering column. Removing trim
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=> General body repairs interior; Repair group 70; Removing and installing centre console. Removing and
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- Remove shelf on passenger side

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=> General body repairs interior; Repair group 70; Removing and installing shelf on passenger side. Removing
and installing shelf on passenger side.
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- Remove foam covering under heater unit.

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- Pull off connectors.

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- Remove series resistor for fresh air blower -item 3-.

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- Pull fresh air blower out downwards.

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1- -> Plenum chamber cover

2- Cover
3- Dust and pollen filter cover
4- Dust and pollen filter
1.3 - Removing fresh air blower -V2- 7

5- Plastic nut, 2.5 Nm
6- Filter housing
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- Starting from the right-hand side of plenum chamber cover, pull rubber seal -1- off upwards to vehicle centre.
- Unclip locking lugs -arrows- on plenum chamber cover and remove plenum chamber cover -2-.
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- -> Press out cover -1- and filter housing clips -A- in direction of arrows and take out filter element with frame
upwards.
- Take filter element out of frame.
Installing
- -> Guide left and right frame edge into the first lamination -arrow- of the new filter element.
8 80 - Heating
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- -> Locate frame lugs -1-
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- -> Install plenum chamber cover -2- and secure locking lugs -arrows-.
- Press on rubber seal -1-.
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1.5 - Removing vent

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Remove centre vent
- -> Remove radio -1-.
1.4 - Removing and installing dust and pollen filter 9

=> Radio, Telephone, Navigation; Repair group 91; Radio systems Radio systems
- Remove tray -2-.
- -> Remove screws -arrows A-.

- Lever out retaining lugs -arrows B- upwards.
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- -> Lift bottom of centre vent up and simultaneously pull it out.

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- Separate connectors to warning lamp switch.

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Removing and installing front passenger's vent

Removing
- -> Lever out -arrows- using a screwdriver and protective support -arrows-.
10 80 - Heating
- Pull vent out.
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- Press vent in lightly until it locates.
Removing and installing driver's vent
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- -> Remove light horis switch -1-.
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- -> Remove screw -arrow-.

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1.5 - Removing vent 11

- -> Lever out -arrows- using a screwdriver and protective support.
- Pull off headlight range control connector.
- Pull vent out. wage es n
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3- Connecting piece
4- Cover
5- Kick plate
6- Spreader rivet
7- Heater
8- Bolt
9- Defrost intermediate piece
- Remove shelf on passenger side
12 80 - Heating
Removing
- Remove screw -1-.

- Pull footwell vent -2- out towards the driver's side footwell -arrow A-.
1.6 - Removing and installing heated air and fresh air controls
Removing
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- -> Press down with fingertips in compartment -1-.

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1.5 - Removing vent 13

AG. Volkswagen AG d
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agen - Edition o11.1999
es n
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spec
es, in part or in w
t to the co
rrectness of i
- -> Remove screws -arrows-.
l purpos
Now carry out the following work:
nf
ercia
orm
m
atio
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n in
or c
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installing centre console. C py
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Prote AG.
- -> Release cables on controls -arrows-.

- Pull off connectors -1- and -2-.
As soon as the controls have been removed check the function of the heated air and fresh air cables.
- -> To do this move the eyes of the centre cable to and fro in direction of arrow.
- Replace damaged or stiff cables.
14 80 - Heating
Installing
Notes:
◆ Cable sleeves are colour coded.

◆ Check cables before installing replace tight or damaged cables.
AG. Volkswagen AG d
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◆ All flaps must audibly move onto stops
ss a
when turning controls. c
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un
pt
- -> Angle wire end of cable -1- and press onto actuating arm -2- -arrow-.
an
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- -> Press cable for footwell/defrost, cable for temperature flap and cable for central flap -1- into locking device
com
tio
-2- until it engages. n in
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Footwell/defrost flaps cable markings:

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Central flap cable markings:
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Left-hand drive: yellow op Vo
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Temperature flap cable markings: red

Left-hand drive: beige
Right-hand drive: white
1.7 - Checking ventilation
Notes:
◆ The stale air escapes via ventilation openings in the luggage compartment trim.
◆ If the ventilation is to function properly the ventilation openings must not be covered.
◆ The ventilation frames are located in side panel behind the bumper.
1.6 - Removing and installing heated air and fresh air controls 15
Checking
- -> The sealing lips -1- in the ventilation frame -2- must be free to move and close of their own accord.
2 - Removing and installing heater unit

2.1 - Removing and installing heater unit
AG. Volkswagen AG d
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nform
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ion
c
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ate
do
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Prote AG.
16 80 - Heating
Warning!
Notes:
n AG. Volkswagen A
◆ Obtain radio anti-theft coding beforeolkdisconnecting
swa
ge the battery.
G do
es n
ot g
◆ Check vehicle equipment (radio,d bclock,
y V electric windows) as per Workshop
ua
ran
Manual and/or Owner's Manual
or
ise
tee
th or
au ac
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un
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ab
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cial p
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Prote AG.
Removing
Perform following work first:
- Remove dash panel
dash panel
- Seal coolant hoses in engine compartment and remove from heat exchanger.
2.1 - Removing and installing heater unit 17

- Seal heat exchanger to prevent coolant from running out
1 Hexagon nut
◆ In engine compartment
◆ Qty. 3
◆ 4 Nm
2 Bulkhead
3 Heater AG. Volkswagen AG d
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◆ Dismantling and assembling heater unit => VoPage
lksw 19 oes
not
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4 Guide pin ris
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c
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Prote AG.
Installing
- Place heater against bulkhead and push threaded studs through the corresponding holes.
- At the same time, make sure that the heater is sitting firmly on the guide pin -item 4 -
- Fit nuts onto studs from engine compartment and tighten onto bulkhead
- Check coolant level and top up.
18 80 - Heating
3 - Dismantling and assembling heater

3.1 - Dismantling and assembling heater
AG. Volkswagen AG d
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1 Heat exchanger
◆ Draincoolant
l purpos
◆ Renewing: Remove dash panel and heater unit

◆ After removal renew complete coolant
nform
ercia
2 Fillister head self-tapping screw

m
3 Air distribution housing

a
com
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◆ Do not dismantle further

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6 Fresh air blower -V2-
Co
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◆ Removing => Page 7 gh ht
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Prote AG.
3.1 - Dismantling and assembling heater 19

AG. Volkswagen AG d
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7 Series resistor -N24-

rrectne
◆ Removing =>Page 7 , Removing and installing fresh air blower -V2-

ss o
9 Central flap lever

cial p
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◆ Installing and adjusting => Fig. 1

form
mer
10 Temperature flap lever

atio
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◆ Note correct part number

n
c
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11 Base plate
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=> Fig. 2
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20 80 - Heating
-> Fig.1 Installing and adjusting lever for central flap
- The central flap pinion has an adjustment marking. Fit the lever so that the lever marking and the pinion
marking align with one another -arrows-.
AG. Volkswagen AG d
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-> Fig.2 Installation position of heat exchanger seal/bulkhead
ss
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The seal between the heat exchanger and the bulkhead has a fitting mark.
ab
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Fit the seal -1- so that the fitting mark on the seal and the mark on the base plate -2- align with one another
, is n
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-3-.
hole
spec
es, in part or in w
Installing fresh/recirculating air flap positioning motor -V154-

t to the co

rrectness of i
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- Remove dash panel.
- Remove heater unit partially and pull to side rearwards.

nform
mercia
at
Notes:
om
ion
c
in t
or
◆ A new positioning motor is supplied in the end position "recirculation".

his
ate
◆ The positioning motor is easier to install in the middle position.

do
priv
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for
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To put the positioning motor in the middle position, proceed as follows:

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- Connect voltage supply connector to positioning motor. gh ht
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- Switch on ignition. cop Vo
by lksw
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Prote AG.
- Operate push button for fresh air/recirculating air.
3.1 - Dismantling and assembling heater 21

When the centre position has been reached
- Pull voltage supply connector off positioning motor.
Installing
- -> Place positioning motor -2- onto the fresh air/air recirculation lever -arrow B-.
Position fresh/recirculating air flap leverGmanually, depending on position of positioning motor. To do this, the
A . Volkswagen
fresh air blower -V2- must be removed
lkswagen => Page 7A.G does
n
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db ran
- Turn positioning motorri -2- in direction
se
of -arrow D-. tee
ho
- Fit securing screws
aut -3-. or
ac
- Connect voltagess supply connector.
ce
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ab
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mer
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c
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22 80 - Heating
n AG. Volkswagen A
Heating,
G do air conditioning - Edition 11.1999
lkswage es n
Vo ot g
y u
4 - Dismantling and assembling heated air and fresh air controls
b ara
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4.1 - Dismantling and assembling heated air and fresh air controls
ce
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un
pt
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d
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ab
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cial p
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mer
atio
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c
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Prote AG.
1 Controls
◆ Including fresh air blower switch -E9- and fresh air/air recirculation switch
-E159-
2 Light conductor
3 Coloured filter
4 Trim panel
5 Fresh air control light bulb -L16-
◆ 12V, 1.2W
◆ Removing:
- Unclip trim panel -item 8 - and rotary control -item 6 -.
- Pull out bulb with aid of fuel hose.
6 Rotary control
◆ For blower speed
◆ To remove: Use pliers with suitable plastic or rubber protection for jaws
4.1 - Dismantling and assembling heated air and fresh air controls 23
AG. Volkswagen AG d
agen oes
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7 Rotary control
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◆ For air distribution

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8 Trim panel
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9 Rotary control
, is n
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◆ For interior temperature

hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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t.
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Prote AG.
24 80 - Heating
5 - Installing and adjusting cables

5.1 - Installing and adjusting cables
AG. Volkswagen AG d
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Notes:
cial p
f inform
mer
◆ Attach cables to removed controls first and then attach cables to heater levers.
atio
m
◆ The outer cables are colour coded.

o
n
c
◆ Check cables before installing, replace tight or damaged cables.

i
or
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◆ When turning control knobs all flaps must be heard to contact the stops.
te
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t.
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Cop py
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rig ht
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Prote AG.
5.1 - Installing and adjusting cables 25

AG. Volkswagen AG d
agen oes
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ris nte
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aut ra
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un
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
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com
tion in
r
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thi
1 Central flap cable

s
iva
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◆ From air distribution rotary control to central flap

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◆ Cable sleeve marking:

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t.
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Left-hand drive: yellow
Co
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Right-hand drive: grey
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ht ht
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◆ Adjusting cable at central flap => Fig. 3 py by
co Vo
by lksw
2 Footwell/defrost flap cable cted agen
Prote AG.
◆ From air distribution rotary control to footwell/defrost flap
◆ Adjusting cable at footwell/defrost flap => Fig. 2
26 80 - Heating
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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nl
pt
du
an
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ab
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
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ion
c
in t
or
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ate
do
priv
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for
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t.
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Prote AG.
3 Fresh air and heated air controls

4 Temperature flap cable
◆ From temperature rotary control to temperature flap
◆ Cable sleeve retainer marking:
◆ Adjusting cable at temperature control flap => Fig. 1

-> Fig.1 Adjusting cable at temperature flap
Prerequisites:
• The heated air and fresh air blower controls are installed. n AG. Volkswagen AG do
lkswage es n
o ot g
Adjusting byV ua
d ran
ir se tee
tho
or
- Turn temperature rotary control knob to left sonto
au stop. ac
- Attach centre wire of cable -1- to the temperature flap lever -2-. s
ce
le
- Push temperature flap lever -2- onto stop -arrow A- and secure outer cable -1- with clip -3-.
un
pt
an
d
- Turn temperature rotary control knob to left and right onto stops.
itte
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ab
ility
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When turning, both flap end stops mustbe reached.
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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te
sd
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-> Fig.2 Adjusting cable at footwell/defrost flap
pr
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fo
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t.
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Cop py
Prerequisite:
t. rig
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• The heated air and fresh air blower controls are installed. cted agen
Prote AG.
Adjusting
- Turn air distribution rotary knob to left onto stop.

- Attach wire end of cable -1- to footwell/defrost flap lever -3-, arrow -A-.
- Press footwell/defrost flap lever onto stop arrow -C- and attach outer cable -1- with clip -2-, arrow -B-.
- Turn air distribution rotary control knob to left and right onto stops.
When turning, both flap end stops must be reached.
28 80 - Heating
-> Fig.3 Adjusting cable at central flap
Prerequisites:
• Central flap lever is correctly adjusted

=> Page 21 , Fig. 1 .
• Heated air and fresh air blower
agen controls areAinstalled.
AG. Volkswagen G d
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olks t gu
byV
Adjusting ris
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ara
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- Turn air control knob to left distribution
ss rotary onto stop. c
- Attach centre wire of cable -2- to the central flap lever -1- .
ce
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un
pt
- Press centre flap lever onto stop arrow -A- and attach outer cable -2- with clip -3-.
an
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ab
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cial p
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mer
atio
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c
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Prote AG.

87 - Air conditioning
1 - Notes on repair work to vehicles with air conditioning and on handling

refrigerant
1.1 - Notes on repair work to vehicles with air conditioning and on handling refrigerant
The assemblies and pipe work system of the air conditioner are filled with refrigerant R134a (tetrafluoroethane,
CF3-CH2F or CH2F-CF3).
At present the R134a refrigerant pressure vessels are labelled with the following trade names:
- H-FKW 134a
- SUVA 134a
- ARCTON 134a
These trade names may vary from country to country.

Further information:
. Volkswag
◆ The appropriate faultksfinding
wage programme
n AG can
en AG
doebe
s n found in, Fault finding "Heating, Air conditioner - binder 2".
◆ The valid currentbyflowVol diagrams can be found in,otCurrent gu
ara
flow diagrams, Electrical fault finding and Fitting
locations binder.
ir se
d
nte
◆ Servicing uevacuated
tho refrigerant circuit, which may only bee operformed
ra by trained personnel at specialist repair
workshops
ss
a
=>Page 68 . c
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nl
pt
du
an
Warning!
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Before working on the electrical system disconnect the battery earth strap.
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Notes:
h re
hole
spec
◆ When reconnecting the battery check the vehicle equipment (radio, clock, electric windows) according to
es, in part or in w
t to the co
Workshop Manual and/or Owner's Manual.

◆ A notice on the lock carrier plate in the engine compartment provides information concerning the refrigerant
used and the capacity.
rrectness of i
l purpos
1.2 - Safety precautions when working on vehicles with air conditioning and when handling
refrigerant R134a
nform
mercia
at
om
io
The following safety precautions must be observed for the refrigerant (in some countries additional regulations
n
c
in t
r
may apply):
o
his
ate
do
riv
If it is necessary to evacuate the refrigerant circuit during repairs to the vehicle, the vehicle must be taken to a
p
cum
or
specialist workshop!
f
en
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Only specialist workshops are equipped with suitable service stations and trained personnel to evacuate the
c by lksw
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refrigerant competently. Prote AG.
Notes:
◆ It is recommended that an eye wash bottle be kept nearby. Should liquid refrigerant contact the eyes, eyes
must be thoroughly rinsed with water for approx. 15 minutes.
◆ Then apply eye drops and contact a doctor immediately, even if eyes do not hurt. The doctor must be
informed that the frost bite has been caused by refrigerant R134a.
30 87 - Air conditioning
AG. Volkswagen G d
agenHeating, air Aconditioning
oes - Edition 11.1999
olksw not
byV gu
a
◆ If, in spite of these safety measures, ise refrigerant comes into contact with other
d ran body parts, these areas
tee must
or
also be immediately thoroughly uthrinsed with cold water for at least 15 minutes. or
a ac
ss
Only work on the refrigerant circuit in well ventilated rooms. The refrigerant is not to be stored in shafts or
ce
le
un
pt
openings leading to cellars.
an
d
itte
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rm
ab
Reasons:
pe
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, is n
Refrigerant is odourless and colourless and heavier than air and therefore displaces oxygen. If, even after taking
h re
hole
precautions, refrigerant escapes there is a danger of asphyxiation without advance warning in poorly ventilated
spec
rooms/pits.
es, in part or in w
t to the co
Precautions:
rrectness of i
Before working on a refrigerant circuit ensure that there are no cellar openings, pits or shafts within 5 m. Any
available extraction systems to be in operation.
l purpos
Do not weld, braze or soft-solder parts of the charged air conditioner.
nform
ercia
This also applies to welding and soldering work on the vehicle when the danger exists that parts of the air
m
a
com
t
conditioner will heat up. During paintwork, object temperatures in the drying oven or in its pre-heating zone
ion in
must not exceed 80° C.
r
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Reason:
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High pressure is the result of heat in the system and this may lead to the pressure relief valve operating. During
t.
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electrical welding invisible ultra-violet rays are produced, these penetrate hoses and breakdown the refrigerant.
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Precautions: by c lksw
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Prote AG.
Damaged or leaking air conditioner components are not to be repaired by soldering/welding, they must always
be renewed, first evacuate refrigerant from refrigerant circuit using refrigerant evacuation station (take vehicle
to specialist workshop).
1.2 - Safety precautions when working on vehicles with air conditioning and when handling
refrigerant R134a 31
AG. Volkswagen AG d
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2 - Air conditioner with manual controls ol not
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2.1 - Air conditioner with manual controls ss au ra
c
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un
pt
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es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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t.
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Cop py
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Prote AG.
2.2 - Air conditioning and heating - Passenger compartment
Warning!
Notes:

AG. Volkswagen AG d
agen oes
olksw not
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h
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le
un
pt
an
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
ercia
◆ Components marked with an * can only be repaired in specialist workshops, this is because the refrigerant
m
a
com
ti
must first be extracted with service station V.A.G 1885.

on in
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1 Air duct
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◆ In plenum chamber
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◆ Removing and installing yri
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=> Page 7
op Vo
by c lksw
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3 Heating and air conditioning controls Prote AG.
◆ With installed air conditioner switch -E35-

◆ With fresh and recirculated air flap switch -E159-
◆ Removing and installing =>Page 37
◆ Dismantling and assembling => Page 40
2.2 - Air conditioning and heating - Passenger compartment 33

AG. Volkswagen AG d
agen oes
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y V gu
d b ara
rise nte
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au ra
ss c
ce
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nl
pt
du
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ility
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es, in part or in w
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4 Dash panel
l purpos

nform
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dash panel
m
at
om
ion
5 Front passenger's vent

c
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ate
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t.
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7 Fresh air blower -V2- t. Cop py
rig
◆ Removing => Fig. 1
gh ht
pyri by
Vo
o
8 Fresh air blower series resistor with overheating fuse -N24-
c by lksw
cted agen
Prote AG.
◆ Removing =>Fig. 1 , Removing and installing fresh air blower -V2-
9 Central vent
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10 Heating and air conditioning* ss
ce
le

un
pt
an
d
◆ Dismantling and assembling evaporator housing => Page 88

itte
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rm
ab
11 Cables
pe
ility
◆ Installing and adjusting => Page 42

ot
wit
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12 Connecting piece
hole
spec
13 Cover
es, in part or in w
14 Footwell vent
t to the co

15 Kick plate
rrectness of i
16 Intermediate piece, defrost

l purpos
◆ Renewing:
◆ Draincoolant
- Removing and installing dash panel
nform
ercia
m
a
com
ti
dash panel
on in
r
te o
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cum
fo
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t.
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Cop py
t. rig
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by c lksw
cted agen
Prote AG.

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spec
t to the co
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17 Heat exchanger*
o
cial p
f i
◆ Removing => Page 88 , Dismantling and assembling evaporator housing.

nform
◆ After renewal replace coolant complete

mer
atio
18 Heat exchanger/bulkhead seal*

om
n
c
◆ Dismantling and assembling evaporator housing => Page 88

i
or
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=> Page 21 , Fig. 2

i
o
pr
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19 Right vent
en
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t.
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Co
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-> Fig.1 Removing fresh air blower -V2-
es, in part or in w
t to the co
1- Heater and air conditioner
2- Fresh air blower -V2-
3- Series resistor with overheating fuse for fresh air blower -N24-
rrectness of i
l purpos
Removing
nf
ercia
orm
m
atio
m

o
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or c
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sd
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cu
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=> General body repairs interior; Repair group 70; Removing and installing centre console. Removing and en
ng
t.
yi Co
installing centre console. . Cop py
rig
ht ht
rig by
py
- Remove shelf on passenger side co Vo
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cted agen
Prote AG.
- Pull connector off series resistor.

- Remove fresh air blower series resistor -item 5-.
- Pull fresh air blower out downwards.
2.3 - Removing and installing heating and air conditioning controls
Removing
- -> Unclip tray -1- with a screwdriver.

- -> Pull trim off controls -arrows-.
AG. Volkswagen AG d
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- -> Remove screws -arrows-.

t to the co

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nform
mercia

a
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Cop py
ht. rig
rig ht
py by
co Vo
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Prote AG.
- -> Release cables on controls -arrows-.

- Pull off connectors -1- and -2-.
AG. Volkswagen AG d
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As soon as the controls have been removed check the function of the heated air and fresh air cables.
y li
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ab
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ility
- -> To do this move the eyes of the centre cable to and fro in direction of arrow. ot
wit
, is n
- Replace damaged or stiff cables.
h re
hole
spec
Installing
es, in part or in w
t to the co
Notes:
rrectness of i
◆ Cable sleeves are colour coded.
◆ Check cables before installing replace tight or damaged cables.
l purpos
nform
mercia
a
com
tion in
r
te o
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Cop py
t. rig
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◆ All flaps must audibly move onto stops when turning controls.
- -> Angle wire end of cable -1- and press onto actuating arm -2- -arrow-.
- -> Press cable for footwell/defrost, cable for temperature flap and cable for central flap -1- into locking device
-2- until it engages.
Footwell/defrost flaps cable markings:

2.3 - Removing and installing heating and air conditioning controls 39

Central flap cable markings:
Left-hand drive: yellow agen
AG. Volkswagen AG d
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Right-hand drive: grey Volksw not
gu
y
Temperature flap cable markings: red ise
d b ara
nte
Left-hand drive: beige uthor eo
ra
Right-hand drive: white ss a c
ce
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un
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an
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2.4 - Dismantling and assembling heating and air conditioning controls
ab
ility
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t to the co
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cial p
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mer
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1 Heating and air conditioning controls

◆ With installed air conditioner switch -E35-
◆ With switch for fresh and recirculated air flap -E159-
◆ Removing =>Page 37
2 Light conductor
3 Coloured filter
4 Trim panel
5 Fresh air control light bulb -L16-
◆ 12V, 1.2W
◆ Removing:
- Unclip trim panel -item 8 - and rotary control -item 6 -.
- Pull out bulb with aid of fuel hose.
AG. Volkswagen AG d
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6 Rotary control
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◆ For blower speed

hole
spec
es, in part or in w
7 Rotary control
t to the co
◆ For air distribution

rrectness of i
8 Trim panel
9 Rotary control
l purpos
◆ For interior temperature

nform
mercia
a
com
tion in
r
te o
thi
s
iva
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cum
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2.4 - Dismantling and assembling heating and air conditioning controls 41

2.5 - Installing and adjusting heating and air conditioning cables
AG. Volkswagen AG d
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es, in part or in w
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nf
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Notes:
◆ The outer cables are colour coded.

◆ Check cables before installing, replace tight or damaged cables.
◆ First connect cables to removed controls then adjust and secure cables to levers on air conditioner.
◆ When turning control knobs all flaps must be heard to contact the stops.
1 Central flap cable

◆ From air distribution rotary control to central flap
Left-hand drive: yellow
Right-hand drive: grey
◆ Adjusting cable at central flap => Fig. 3
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es, in part or in w
t to the co
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nform
mercia
a
com
tion in
r
te o
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t.
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Cop py
t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.
2 Footwell/defrost flap cable

◆ From air distribution rotary control to footwell/defrost flap
◆ Replacing:
- Remove controls for heating and air conditioning system
=> Page 37
=> General body repairs; Repair group 70; Removing trim under the steering column. Removing trim under the
steering column.
- Unclip cable on heater and air conditioner unit.

◆ Adjusting cable at footwell/defrost flap => Fig. 2
2.5 - Installing and adjusting heating and air conditioning cables 43

AG. Volkswagen AG d
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3 Heating and air conditioning controls

nform
ercia
m
at
om
4 Temperature flap cable

ion
c
in t
r
◆ From temperature rotary control to temperature flap

o
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e

at
do
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p
cum
or

f
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t.
◆ Adjusting cable at temperature flap => Fig. 1
yi Co
Cop py
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rig ht
py by
co Vo
by lksw
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Prote AG.
agen Heating,
AG. Volkswagen AG
doesair conditioning - Edition 11.1999
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-> Fig.1 Adjusting cable atisetemperature
db flap ara
nte
or eo
h
Prerequisites: aut ra
ss c
ce
e
nl
• Controls for heating and air conditioning are installed.
pt
du
an
itte
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erm
ab
Adjusting
ility
ot p
wit
- Turn temperature rotary control knob to left onto stop.
, is n
h re
- Attach centre wire of cable -1- to the temperature flap lever -2-.
hole
spec
- Push temperature flap lever -2- onto stop -arrow A- and secure outer cable -1- with clip -3-.
es, in part or in w
- Turn temperature rotary control knob to left and right onto stops.
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
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for
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Cop py
t. rig
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Vo
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by c lksw
cted
-> Fig.2 Adjusting cable at footwell/defrost flap
agen
Prote AG.
Prerequisite:
Adjusting
- Turn air distribution rotary knob to left onto stop.
- Attach wire end of cable -1- to the temperature flap lever -3-, arrow -A-.
- Press footwell/defrost flap lever onto stop arrow -C- and attach outer cable -1- with clip -2-, arrow -B-.
When turning,both flap end stops must be reached.
-> Fig.3 Adjusting cable at central flap

Prerequisite:
• Central flap lever is correctly adjusted
=> Page 21 .
2.5 - Installing and adjusting heating and air conditioning cables 45

AG. Volkswagen AG d
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Adjusting byV
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- Turn air distributionthrotary
o r control knob to left onto stop. eo
- Attach centre wire
ss au
of cable -2- to the central flap lever -1- . ra
c
- Press footwell/defrost flap lever onto stop arrow -A- and attach outer cable -2- with clip -3-.
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2.6 - Air conditioning and heating system - Engine compartment
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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atio
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Prote AG.
Warning!
Notes:
◆ Components marked with an * can only be repaired in specialist workshops, this is because the refrigerant
AG. Volkswagen AG d
must first be extracted with service station V.A.G 1885.
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es, in part or in w
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nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1 Evacuating and charging valve*

◆ Low pressure side
2 Expansion valve*
◆ Opening must be sealed sufficiently to stop ingress of water
◆ Under the plenum chamber cover
2.6 - Air conditioning and heating system - Engine compartment 47

AG. Volkswagen AG d
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t to the co
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4 Ambient temperature switch -F38-

mer
◆ Removing =>Fig. 3
atio
om
5 Heat exchanger opening

n
c
i
or
n thi
◆ Switches off magnetic coupling -N25- at low ambient temperature (off at 2°C, on at 7°C).
te
sd
a
◆ Held in clip in centre of plenum chamber

iv
o
pr
cum
r
6 Plenum chamber cover

fo
en
ng
t.
yi
Co
Cop py
7 Coolant temperature sender for air conditioner switch-off -G62-
t. rig
gh ht
yri by
◆ -G62- switches off magnetic coupling -N25- at excessively high coolant temperatures(off at 119°C, on
op Vo
by c lksw
at 112°C).
cted agen
Prote AG.
AG. Volkswagen AG d
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ility
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nform
mercia
at
om
ion
c
in t
or
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ate
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8 Radiator fan control unit -J293-
um
for
en
g
9 Condenser*
n
t.
yi Co
op
10 Pressure relief valve*
C py
t. rig
gh ht
yri
◆ Checking => Page 80 , Fig. 4 p by
co Vo
by lksw
11 Magnetic coupling -N25-* cted agen
Prote AG.
◆ Manufacturer: Sanden
◆ Servicing magnetic coupling -N25- => Page 60
12 High pressure sender -G65-
◆ Removing and installing:
◆ Removing => Fig. 2
- Tightening torque 8 Nm
- Renew O ring seal (note Part No.).
◆ The high pressure sender can be removed without evacuating the refrigerant system.

AG. Volkswagen AG d
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◆ The high pressure sender -G65- supplies information to the radiator fan control unit -J293- and to the
engine control unit.
Function:
rrectness of i
◆ Switches radiator fan -V7- to next higher speed when pressure increases in refrigerant circuit.
◆ The high pressure sender -G65- can be checked via engine control unit self-diagnosis.
l purpos
◆ Checking air conditioner high pressure sender -G65- => Page 81

◆ Switches off conditioning system when pressure is excessive (for example, insufficient engine cooling).
◆ Switches off conditioning system when pressure is too low (for example, loss of refrigerant).
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
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ility
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13 Fluid reservoir with drier* spec

es, in part or in w
t to the co
14 Evacuating and charging valve*
◆ High pressure side
15 Water drain valve
rrectness of i
◆ Removing and installing => Fig. 1

l purpos
◆ Valve lips must not be sealed with underseal

nf
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-> Fig.1 Removing and installing water drain valve
1- Water drain valve

2- Bulkhead
3- Water drain pipe, on evaporator housing
4- Mounting plate
◆ Install water drain valve with opening of lip seal facing downwards.
◆ Water drain valve must not be clogged with underbody sealant.
lkswage es n
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a ac
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ce
e
nl
pt
du
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ility
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es, in part or in w
t to the co
rrectness of i
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nf
ercia
-> Fig.2 Removing high pressure sender -G65-

rm
m
atio
m
- Pull off connector -1-.

o
n in
or c
- Unscrew high pressure sender -2-.

thi
te
- Replace seal.
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Prote AG.
Fig3. Removing ambient temperature switch -F38-
- -> Pull off connector -1-.

- Unclip ambient temperature switch -3- from retainer -2-.
2.7 - Removing and installing air conditioner compressor bracket, engine code: APE
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Special tools, workshop equipment, test and measuring appliances and aux. items required
rrectness of i
◆ Torque wrench V.A.G 1331 (5 - 50 Nm)

l purpos
Notes:
nform
ercia
◆ The compressor bracket and related components can be removed and installed without having to open the
refrigerant circuit.
m
a
com
◆ To remove the ribbed belt:

ion in
r
te o
thi
=> Workshop manual Engine, Mechanics; Repair group 13; Dismantling and assembling engine. Dismantling
s
iva
do
and assembling engine.

r
rp
cum
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en
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t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
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Prote AG.
53
AG. Volkswagen AG d
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1 Alternator, compressor and P.A.S. vane pump bracket s
ce
le
un
pt
an
d
itte
Removing
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erm
ab
ility
ot p
- Pull lock carrier forwards.

wit
is n
h re
ole,
=> General body repairs; Repair group 50; Body front; lock carrier servicing position Body front lock carrier
spec
servicing position
t to the co
- Removing alternator
rrectne
=> Electrical system; Repair Group 27; Removing and installing alternator Removing and installing alternator
- Removing P.A.S. vane pump

ss o
cial p
f in
=> Repair Group 48; Removing and installing P.A.S. vane pump Removing and installing P.A.S. vane pump
form
mer
atio
- Take compressor off bracket and secure to body with suitable item (e.g. welding wire) =>Fig. 1
om
- Unbolt bracket from cylinder block

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AG. Volkswagen AG d
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nf
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atio
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Cop py
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Prote AG.
Installing
◆ When installing observe:

- Renew securing bolts.
- Observe securing bolts tightening sequence.
◆ Tightening sequence:
First tighten hexagon bolt item - 3 -, then hexagon bolt item - 5 - and then tighten hexagon bolts item
- 2 - and item - 4 - last.
2 Hexagon bolt M10x55

◆ 45 Nm
◆ Before turning in, clean thread and coat with locking fluid D 000 600 A2.
55
AG. Volkswagen AG d
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mer

atio
m
◆ 45 Nm
o
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te

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◆ 45 Nm
um
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op
5 Hexagon bolt M10x100 C py
t. rig
gh
◆ 45 Nm
ht
pyri by
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c by lksw
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Prote AG.
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6 Refrigerant hoses
rrectness of i
7 Compressor
l purpos
◆ Removing:
- First remove P.A.S. vane pump
nform
ercia
=> Repair Group 48; Removing and installing P.A.S. vane pump Removing and installing P.A.S. vane pump
m
at
om
io
- Loosen hexagon bolts - 8 - a couple of turns and knock-back threaded sleeve from compressor. Then
n
c
in t
r
remove hexagon bolts.

o
his
te
- Take compressor off bracket and secure to body with suitable item (e.g. welding wire) =>Fig. 59 .
a
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for

en
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◆ 45 Nm Cop py
t. rig
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pyri by
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57
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pe
ility
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es, in part or in w
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l purpos
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op
9 Ribbed belt
C py
t. rig
gh ht
◆ Removing and installing pyri by
Vo
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Prote AG.
=> Repair group 13; Dismantling and assembling engine; Removing and installing ribbed belt Dismantling and
assembling engine Removing and installing ribbed belt
◆ Ribbed belt routing

=> Fig. 2
10 Tensioner
11 Tensioning element for tensioner
-> Fig.1 Securing air conditioner compressor to body
If the compressor is removed without opening the refrigerant circuit, the compressor should be secured to the
body with suitable material, for example, welding wire.
When doing this, ensure the refrigerant hoses on the compressor are not stressed.
AG. Volkswagen AG d
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-> Fig. 2 Ribbed belt routing

rrectness of i
l purpos
Note:
nform
ercia
When installing the belt ensure it is correctly seated in the pulley.

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Cop py
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pyri by
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59
2.8 - Servicing magnetic coupling -N25-; Sanden unit
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Special tools, workshop equipment, test and measuring appliances and aux. items required
itte
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erm
ab
ility
◆ V.A.G 1331 Torque wrench (5...50 Nm)

ot p
wit
, is n
h re
Notes:
hole
spec
es, in part or in w
◆ It is not necessary to open the refrigerant circuit to repair the magnetic coupling with the compressor installed.
t to the co
◆ If the compressor has to be removed, take the vehicle to a workshop with trained mechanics (Specialist
workshops for air conditioning), the refrigerant must be evacuated with Service station V.A.G 1885.
rrectness of i
l purpos
nf
ercia
orm
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atio
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n in
or c
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Cop py
t. rig
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pyri by
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by
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un
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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fo
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t.
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Cop py
t. rig
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pyri by
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Prote AG.
Notes:
◆ Removing magnetic coupling from compressor and refitting again =>Page 65 .
2.8 - Servicing magnetic coupling -N25-; Sanden unit 61

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ab
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ot p
wit
is n
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spec
t to the co
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cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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fo
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.
1 Hexagon nut
◆ Self-locking
◆ Replacing
◆ 20 Nm
◆ Loosening and tightening =>Page 65
2 Coupling plate
◆ Pulling off =>Page 66
3 Spacer
◆ To adjust the clearance between coupling and belt pulley
◆ Clearance: 0.4...0.8 mm
◆ Checking distance=>Page 67
4 Circlip
◆ Replacing
- Install correctly:
Flat side faces compressor
◆ Ensure seated correctly in groove
AG. Volkswagen AG d
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.
5 Belt pulley
◆ Pulling off =>Page 66
6 Circlip
◆ Replacing
- Install correctly:
Flat side faces compressor
◆ Ensure seated correctly in groove
7 Magnet windings
◆ Installing =>Page 66
Notes:
An overheating protection is installed in the magnet windings. The overheating protection interrupts the magnet
windings as soon as the magnetic coupling overheats (for example a binding compressor).
8 Retainer
◆ With screw
9 Retainer
2.8 - Servicing magnetic coupling -N25-; Sanden unit 63

AG. Volkswagen AG d
Polo Estate 1998 ➤ ksw
agen oes
not
ol
Heating, air conditioning - Edition 11.1999 d byV gu
ara
ise nte
or eo
h
aut ra
ss c
ce
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
10 Retainer
11 Bolt
12 Compressor
13 Threaded bush
2.9 - Removing magnetic coupling from compressor and refitting again
Special tools, workshop equipment, testers, measuring instruments and auxiliary items required
AG. Volkswagen AG d
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◆ -> 3212 Two hole pin wrench

un
pt
an
d
◆ Two arm puller

itte
y li
◆ Three arm puller
erm
ab
ility
◆ Depth gauge
ot p
◆ V.A.G 1331 Torque wrench (5...50 Nm)
wit
is n
h re
ole,
Notes:
spec
t to the co
◆ It is not necessary to open the refrigerant circuit to remove and refit the magnetic clutch.
rrectne
ss o
cial p
◆ On vehicles with a Diesel engine, remove the charge air cooler.

inform
mer
=> Workshop manual Engine, Mechanics; Repair group 21; Charging. Charging.
atio
om
n
c
i
or
n thi
te
sd
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cum
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fo
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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Prote AG.
-> Loosening and tightening hexagon nut
- Tightening torque: 20 Nm
Remove hexagon nut.
Use commercially available 2 hole pin wrench 3212 -A- with a pin diameter of 4 mm to counter-hold.
2.9 - Removing magnetic coupling from compressor and refitting again 65

-> Pulling off coupling plate
- Release coupling plate carefully with two screwdrivers -A- and remove.
AG. Volkswagen AG d
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-> Pulling off belt pulley
y li
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ab
ility
ot p
- Fit commercially available 2 arm puller -A- on shoulder -B- and pull off belt pulley.
wit
is n
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spec
t to the co
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cial p
f inform
mer
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-> Installing magnet windings

um
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- Fit magnet windings onto compressor. Cop py
. rig
- Locate locking pin -C- in recess -A-.
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Prote AG.
AG. Volkswagen AG d
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-> Checking clearance rise nte
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- Clearance: 0.4...0.6 mm s
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Determining dimension "1"

itte
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ility
ot p
- Measure dimension between belt pulley -2- and coupling plate -3- with a depth gauge -1- and note dimen‐
wit
is n
sion.
h re
ole,
spec
Perform measurements at three different locations. The measurements must not deviate.
t to the co
Determining dimension "2"
rrectne
- Separate connector -A- on compressor.
- Attach connector -4- to vehicle battery (terminal +) using an auxiliary cable.
- Measure dimension between belt pulley -2- and coupling plate -3- with a depth gauge -1- and note dimen‐
ss
sion. o
cial p
f
- Determine clearance.
inform
mer
The clearance is the difference between dimension "1" and dimension "2".
atio
om
n
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i
or
Notes:
thi
te
sd
iva
o
pr
◆ The clearance must lie within the permitted tolerances over the complete circumference.
um
r
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◆ The clearance can be measured when the compressor is installed.

en
ng
t.
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◆ If the clearance is outside the specification, remove coupling plate and adjust clearance by removing or
Co
Cop py
installing spacers.
t. rig
gh ht
pyri by
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Prote AG.
2.9 - Removing magnetic coupling from compressor and refitting again 67

3 - Servicing refrigerant circuit, which may only be performed at workshops with

specially trained personnel (specialist repair workshop for air conditioning
systems)
3.1 - Servicing refrigerant circuit, which may only be performed at workshops with specially
trained personnel (specialist repair workshop for air conditioning systems)
3.2 - Tools
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Special tools, workshop equipment, testers, measuring instruments and auxiliary
s items required
ce
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nl
pt
du
an
V.A.G 1885 Service station

itte
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erm
ab
ility
ot p
◆ Scope of delivery: Quick action coupling adapters are included for the high and low pressure side service
wit
connections.
, is n
h re
hole
spec
For further service stations => Binder Volkswagen Workshop Equipment.

es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
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co lksw
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Prote AG.
3.3 - Renewing refrigerant circuit components
AG. Volkswagen AG d
agen oes
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nl
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itte
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erm
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hole
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
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ion
c
in t
or
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ate
do
priv
cum
for
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t.
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Cop py
t. rig
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pyri by
Vo
o
Notes:
c by lksw
cted agen
Prote AG.
◆ Refrigerant must be evacuated with Service station V.A.G 1885 first.

◆ The previously used service stations can still be used =>Binder Volkswagen Workshop Equipment.
◆ Safety measures when working on an evacuated refrigerant circuit =>Page 30 .
◆ All components of the refrigerant circuit which have been opened must be sealed with suitable plugs to
prevent the ingress of humidity/moisture.
◆ The colour coding of O-rings for the R134a refrigerant circuits has been discontinued. Coloured and black
O-rings are used.
◆ Only the components marked with an * can be replaced without opening and evacuating.
3.3 - Renewing refrigerant circuit components 69

AG. Volkswagen AG d
agen oes
olksw not
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rise nte
tho eo
au ra
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nl
pt
du
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1 Evaporator
l purpos
◆ In passenger compartment
◆ Removing => Page 88 , Dismantling and assembling housing
nform
ercia
2 Threaded plate
m
3 O ring
at
om
ion
◆ 10.8 mm; 1.85 mm

c
in t
or
4 Heat insulation
his
ate
do
riv
5 O ring
p
cum
for
en
◆ 7.6 mm; 1.82 mm

ng
t.
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op
6 Evacuating and charging valve C py
t. rig
gh ht
◆ High pressure side yri
p by
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◆ Evacuating therefrigerant into the environment is a punishable offence.
c by lksw
cted agen
Prote AG.
◆ Capacities => Page 99
AG. Volkswagen AG d
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7 Refrigerant hose
n
t.
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op py
◆ From compressor to condenser
. C rig
ht ht
rig
8 Hexagon socket head combi-bolt
py by
co Vo
by lksw
◆ 30 Nm
cted agen
Prote AG.
9 O ring
◆ 14.3 mm; 2.4 mm
10 Refrigerant hose
◆ From compressor to expansion valve
11 Compressor
Designation: SD7 - V16

AG. Volkswagen AG d
agen oes
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ot p
wit
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spec
t to the co
12 Compressor magnetic coupling -N25-

rrectne
Carrying out repairs on the magnetic coupling, with the compressor installed, should only be undertaken
in exceptional circumstances.
◆ Servicing magnetic coupling with compressor removed => Page 60
ss o
cial p
13 Pressure relief valve

f inform
◆ Checking => Fig. 4

mer
14 O ring
atio
om
◆ 10.8 mm; 1.82 mm

c
i
or
n thi
e
15 O ring
t
sd
iva
◆ 10.8 mm; 1.82 mm

pr
cum
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fo
16 3/4" thread - 16 UNF

en
ng
t.
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◆ 35 Nm Cop py
t. rig
17 Condenser
gh ht
pyri by
Vo
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c by lksw
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Prote AG.
AG. Volkswagen AG d
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un
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d
itte
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ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
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cial p
f inform
mer
atio
m
18 5/8" thread - 18 UNF

o
n
c
i
or
n
◆ 15 Nm
thi
te
sd
a
19 O ring
iv
o
pr
c
◆ 7.6 mm; 1.82 mm
um
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fo
en
ng
20 Foam tube
t.
yi Co
op py
21 3/4" thread - 16 UNF t. C rig
gh ht
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◆ 35 Nm
p by
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by c lksw
22 O ring
cted agen
Prote AG.
◆ 10.8 mm; 1.82 mm
23 High pressure sender -G65-*
◆ Removing and installing:
- Tightening torque 8 Nm
- Renew O ring seal (note Part No.).

AG. Volkswagen AG d
agen oes
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V gu
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or eo
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nl
pt
du
an
itte
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ot p
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es, in part or in w
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nform
mercia
at
om
ion
c
in t
or
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ate
◆ The high pressure sender can be removed without evacuating the refrigerant system.
do
priv
◆ The high pressure sender -G65- supplies information to the radiator fan control unit -J293- and to the
um
for
en
engine control unit.

ng
t.
yi Co
Function: t. Cop py
◆ Switches radiator fan -V7- to next higher speed when pressure increases in refrigerant circuit.
rig
gh ht
yri by
◆ The high pressure sender -G65- can be checked via engine control unit self-diagnosis. op Vo
by c lksw
◆ Checking air conditioner high pressure sender -G65- => Page 81 cted agen
Prote AG.
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un
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an
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itte
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ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
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◆ Switches off conditioning system when pressure is excessive (for example, insufficient engine cooling).
cop Vo
by lksw
◆ Switches off conditioning system when pressure is too low (for example, loss of refrigerant). cted agen
Prote AG.
24 O ring
◆ 7.6 mm; 1.82 mm
25 Fluid container with drier
◆ Tasks => Fig. 3
26 O ring
◆ 10.8 mm; 1.82 mm
27 5/8" thread - 18 UNF
◆ 15 Nm
28 Refrigerant pipe

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
Polo Estate 1998 ➤ ut
ho eo
ra
a
Heating, air conditioning - Edition 11.1999ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
29 Hexagon socket head combi-bolt

◆ 7 Nm
30 Evacuating and charging valve
◆ Low pressure side
◆ Evacuating therefrigerant into the environment is a punishable offence.
◆ Capacities => Page 99
31 O ring
◆ 17 mm; 1.85 mm
32 Bolt
◆ 8 Nm
33 Expansion valve
◆ Engine compartment right
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wit
, is n
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spec
es, in part or in w
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Function
◆ The expansion valve atomizes the instreaming refrigerant and regulates the through flow so that the vapour,
rrectness of i
depending on temperature, becomes a gas only on reaching the outlet side of the evaporator.
l purpos
◆ The expansion valves for R134a refrigerant circuits are marked with a green sticker.
34 O ring
nform
ercia
◆ 14 mm; 1.82 mm
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
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V gu
d by ara
ise nte
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le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
-> Fig.1 Removing evacuating and charging valve, low pressure side
rp
cum
fo
en
ng
t.
yi
- Extract refrigerant circuit with Service station V.A.G 1885 and then renew the valve -3-.
Co
Cop py
t. rig
gh ht
yri by
Notes: op Vo
by c lksw
cted agen
Prote AG.
◆ Draining the refrigerant into the environment is a punishable offence.
◆ To prevent the ingress of dampness all components of the refrigerant circuit which have been opened must
be sealed with suitable plugs.
1 - Connection with external thread and groove for O-ring

2 - O-ring
7.6 mm; 1.82 mm
3 - Extraction and filling valve
4 - O-ring
5 - Cap
lkswage es n
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itte
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ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
-> Fig.2 Removing evacuating and charging valve, high pressure side
- Extract refrigerant circuit with Service station V.A.G 1885 and then renew the valve -3-.
rrectness of i
l purpos
Notes:
◆ Draining the refrigerant into the environment is a punishable offence.
nf
ercia
o
rm
m
atio
om
1 - Connection with internal thread

n in
or c
2 - O-ring thi
te
sd
a
10.8 mm; 1.82 mm

iv
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3 - Extraction and filling valve with groove and internal thread for cap.
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-> Fig.3 Purpose of the fluid reservoir with drier
The fluid reservoir collects the liquid droplets and guides them in a continuous stream to the expansion valve.
Moisture, which has entered the refrigerant circuit during assembly is collected by the dryer in the reservoir.
-> Fig.4 Checking pressure relief

swa
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◆ Task: protects refrigerant
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◆ The pressure relief
authvalve tell-tale indicates if valve has opened. An
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3.4 - Checking high pressure sender -G65-
AG. Volkswagen AG d
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du
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Special tools, testers, measuring instruments and auxiliary items required
Co
Cop py
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These tools and equipment are required to determine if the high pressure sender -G65- is defective or not.
p by
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Prote AG.
If your workshop is a designated service support point with specially trained personal for air conditioning sys‐
tems, then a service station (e.g. V.A.G 1885) can additionally be used to establish if the refrigerant circuit is,
empty, partially charged, charged correctly.
Checking high pressure sender -G65- via engine control unit
Depending on the signal from the high pressure sender-G65-, the engine control unit will, via the radiator fan
control unit -J293-,
- Switch on magnetic coupling -N25-

- Switch off magnetic coupling -N25-
- Switch radiator fan -V7- to second speed if pressure is rising.
- Increase idling speed when air conditioner is switched on.
3.4 - Checking high pressure sender -G65- 81

Notes:
◆ -> The high pressure sender can be removed without the refrigerant first being evacuated.
◆ The high pressure sender -G65- sends information to theG.engine control unit and radiator fan control unit.
A Volkswagen G d
◆ The high pressure sender -G65- can only be checked
lkswagenvia the engineAcontrol
oes unit self-diagnosis.
n
o ot g
yV ua
db ran
◆ Perform check of high pressure sender o-G65-
rise via the engine control unit self-diagnosis
tee using V.A.G 1551
(engine not running) =>Repair groupa01;
ut Self-diagnosis; Reading measured value block
h or 08; Display group
a
057 (value 4 in %). Compare value swith
s table => Page 84 c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Checking high pressure sender -G65- with ignition tester V.A.G 1767
Note:
This test is to be performed on vehicles for which self-diagnosis viagethe

n AGengine
. Volkswacontrol
gen AG unit is not possible.
d wa oes
olks not
yV gu
Assembling tools and equipment ed
b ara
nte
ris
tho eo
- Connect ignition tester V.A.G1767 -1-. Connect au
ss tester earth (black grip) -2- to vehicle earth -3-. r ac
Using a cable from adapter set V.A.G1594A, establish a connection -4- to connector T14/2 of radiator fan
ce
e
nl
pt
control unit -J293-.
du
an
itte
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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rig ht
py by
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Prote AG.
Checking:
- Switch ignition on.

- Press button (arrow) for modulation ratio on ignition tester V.A.G 1767.
- Compare value with table => Page 84

Evaluating test results:
A workshop temperature of between 20°C to 30°C is assumed for the evaluation. The engine is at room tem‐
perature.
Test result Possible cause Fault rectification

of fault
Modulation ra‐ High pressure -
tio 20% to 25% sender -G65-
is OK.
Modulation ra‐ High pressure Renew (refrigerant
tio 90% sender -G65- need not be emp‐
defective tied)
Modulation ra‐ uHigh pressure uRenew (refriger‐
tio 5% sender -G65- ant need not be
defective emptied)
uRefrigerant cir‐ uCharge refriger‐
cuit is empty ant circuit,
=>Page 99
Note:
If the cause of the fault cannot be located, then seek further in the fault memories of the engine control unit.
Measurements to assess the air conditioning system AG. Volkswagen AG d

agen oes
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Prerequisites: d by V gu
ara
rise nte
tho eo
• Thermo-switch for radiator fan -F18- is OK.
s au ra
c
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nl
=> 4-Cyl. engine, mechanics; Repair group 19; Parts of cooling system body side. Parts of cooling system body
pt
du
an
side.
itte
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erm
ab
ility
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es, in part or in w
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nf
ercia
orm
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atio
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n in
or c
-> The following tests are to be performed with high pressure sender -G65- installed.
thi
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Note:
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The compressor will not switch on if the high pressure sender -G65- has been removed or the connector on
Co
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the high pressure sender -G65- has been pulled off.
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The following measurements must be performed to determine the performance of the air conditioning system: Prote
cted AG.
agen
- Check condition of filling, the air conditioner system is switched off when pressure is too low (for example
when refrigerant is lost).
- Check blower switch-on, the radiator fan -V7- is switched to the next highest speed when pressure in the
refrigerant circuit rises.
- Check air conditioner switch-off, the air conditioner is switched off when pressure is excessive (for example
when engine cooling is insufficient).
3.5 - Removing and installing heater and air conditioner
AG. Volkswagen AG d
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nform
mercia
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r
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cum
fo
en
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t.
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Cop py
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Warning!
Notes:


AG. Volkswagen AG d
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◆ The previously used service stations can still be used =>Binder Volkswagen Workshop Equipment. ss c
ce
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◆ All components of the refrigerant circuit which have been opened must be sealed with suitable plugs to
un
pt
prevent the ingress of humidity/moisture.
an
d
itte
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Removing
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- Remove dash panel

t to the co
dash panel
rrectness of i
- Clamp off coolant hoses in engine compartment and disconnect from heat exchanger.
l purpos
- Seal heat exchanger to prevent coolant from running out

- Remove dust and pollen filter together with filter housing =>Page 7 .
nform
ercia
1 Hexagon nut
m
a
com
tio
◆ Qty. 3
n in
r
◆ 4 Nm
te o
thi
s
iva
do
r
rp
cum
fo
en
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t.
yi Co
Cop py
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rig ht
py by
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cted agen
Prote AG.
AG. Volkswagen AG d
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d by ara
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or eo
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ce
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nl
pt
du
an
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erm
ab
ility
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wit
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
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ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
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Prote AG.
2 Bulkhead
3 Heater and air conditioner
◆ Dismantling and assembling evaporator housing =>Page 88
4 Guide pin
Installing
- Place the heater and air conditioner against the bulkhead and push the threaded studs through the
corresponding holes.
- At the same time ensure the heater and air conditioner is sitting firmly on the guide pin -item 4 -.
- Fit nuts onto studs from engine compartment and tighten onto bulkhead.
- Check coolant level and top up.
3.5 - Removing and installing heater and air conditioner 87

kswage es n
3.6 - Dismantling and assembling evaporator housingd by Vo
l ot g
ua
ran
ir se tee
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u or
a ac
ss
ce
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
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h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
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cted agen
Prote AG.
Warning!
Notes:
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
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n
c
or
n thi
e

t
sd
iva
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pr
cum
r
fo

en
ng
t.
yi Co
op py
- Extract refrigerant with Service station V.A.G 1885.
t. C rig
gh ht
pyri by
Vo
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by c
Notes:
lksw
cted agen
Prote AG.
Draining the refrigerant into the environment is a punishable offence.
- Drain coolant.
- Remove dash panel.
dash panel
- Remove heater and air conditioner unit.
3.6 - Dismantling and assembling evaporator housing 89

AG. Volkswagen AG d
agen oes
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byV gu
ara
ed
ris nte
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aut ra
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ce
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un
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an
d
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ab
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ot p
wit
is n
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
r
fo
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t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.

2 Heat exchanger
◆ After removal renew complete coolant
3 Housing, upper part
◆ With fresh air and recirculating air flap
4 Gasket
◆ Installing seal on evaporator =>Fig. 1
5 Evaporator
◆ Installing seal on evaporator connection =>Fig. 2
6 Housing, lower part
agen
AG. Volkswagen AG d
oes Polo Estate 1998 ➤
ksw
y Vol Heating, air
not
g conditioning
ua - Edition 11.1999
db ran
rise te
tho eo
s au ra
c
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
-> Fig.1 Installing seal on evaporator
nform
ercia
The evaporator -A- must be sealed against the housing at top and sides with gasket -B-.
m
a
com
tion in
Note:
r
te o
thi
s
iva
To ensure that the condensed water can drain properly, the bottom side of the evaporator must not be fitted
do
r
rp
c
with a gasket.
um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
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Prote AG.
-> Fig.2 Installing seal on evaporator connection
The refrigerant pipes -C- must be sealed against both housing sections -B- with gasket -A-.
3.6 - Dismantling and assembling evaporator housing 91

3.7 - Removing expansion valve
AG. Volkswagen AG d
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un
Notes:
pt
an
d
itte
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ab

pe
ility
ot
wit
, is n
◆ Only the components marked with an * can be replaced without opening and evacuating.
h re
hole
spec

es, in part or in w
◆ The colour coding of O-rings for the R134a refrigerant circuits has been discontinued. Coloured and black
t to the co
O-rings are used.

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
1 Threaded plate
m
at
om
2 O ring
on
c
in t
r
◆ 10.8 mm; 1.85 mm

o
his
ate
3 Heat insulation*
do
priv
cum
4 Bolts
for
en
ng
◆ 8 Nm
t.
yi Co
op
◆ Qty. 2
C py
t. rig
gh ht
yri
5 O ring p by
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by c lksw
◆ 7.6 mm; 1.82 mm cted agen
Prote AG.
6 Bolt
◆ 8 Nm
7 Refrigerant pipe
◆ From fluid container with drier to expansion valve
3.7 - Removing expansion valve 93

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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8 Refrigerant hose
rm
ab
pe
ility
◆ From expansion valve to compressor

ot
◆ With damper
wit
, is n
h re
9 O ring
hole
spec
◆ 17 mm; 1.85 mm
es, in part or in w
t to the co
10 Expansion valve
◆ Engine compartment right
rrectness of i
11 O ring
l purpos
◆ 14 mm; 1.82 mm
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
horis
eo Polo Estate 1998 ➤
ut
ss a Heating, airra
cconditioning - Edition 11.1999
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing
Note:
Draining the refrigerant into the environment is a punishable offence.
- Remove heat insulation - 4 -.

- Remove bolt - 6 -.
- Pull out refrigerant pipe - 7 - and refrigerant hose - 8 -.
◆ Renew O rings - 5 - and - 9 -.
- Remove bolts - 4 -.
- Remove expansion valve - 10 -.
◆ Renew O rings - 2 - and - 11 -.
3.7 - Removing expansion valve 95

3.8 - Removing and installing condenser
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m
Warning!
o
n
c
i
or
n thi
te
sd
iva
o
pr
Notes:
um
r
fo
en
ng
t.
yi Co
◆ Obtain radio anti-theft coding before disconnecting the battery. Cop py
. rig
ht ht
rig by
py
when reconnecting the battery. co Vo
by lksw
◆ Refrigerant must be evacuated with Service station V.A.G 1885 first. cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op py
◆ All components of the refrigerant circuit which have been opened must be sealed with suitable plugs to t. C rig
gh ht
prevent the ingress of humidity/moisture. yri
p by
o Vo
by c lksw
cted agen
Prote
AG.
- Extract refrigerant with Service station V.A.G 1885.
Note:
Discharging refrigerant into the atmosphere is an offence.
- Remove lock carrier.
=> General body repairs, exterior; Repair group 50; Body front; Removing lock carrier. Body front Removing
lock carrier.
- Remove refrigerant pipes/hoses on condenser and seal.

- Separate fluid container with dryer from condenser and seal pipes.
3.8 - Removing and installing condenser 97

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
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nl
pt
du
an
itte
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ility
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1 Lock carrier
h re
hole
◆ Removing: spec
es, in part or in w
t to the co
=> General body repairs, exterior; Repair group 50; Body front; Removing lock carrier. Body front Removing
lock carrier.
rrectness of i
2 Cooler
3 Condenser
l purpos
4 Bolts
◆ 8 Nm
nform
ercia
◆ Qty. 4
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4 - Capacities
4.1 - Capacities
4.2 - Refrigerant R134a
Compressor Manufacturer Capacities

SD7-V16 Sanden 850+30 Gram
4.3 - Refrigerant oil
The special refrigerant oil (for use with refrigerant circuits R134a only) is no longer obtainable on the refrigerant/
machine oil market.
Refrigerant oil can be obtained using following part

No.; for:
SD7-V16 Compressor; Sanden G 052 154 A2
Type Production period Capacity

Polo Classic / from 10.99 135cm3*
Estate
* This quantity of refrigerant oil is in a replacement compressor and equates to the capacity.
Further information:
The refrigerant oil is very hygroscopic, therefore opened containers must be closed immediately after use to
stop ingress of moisture.
wage
Refrigerant oil, yV
obecause of its chemical properties,
lks es n
ot g must not be disposed of with engine oils or gearbox oils.
d b ua
ran
ir se tee
Oil distribution
ut
ho or
a ac
ss
The oil is distributed through the refrigerant circuit, which is located in the sump of the compressor before initially
ce
le
un
pt
switching the air conditioner system as follows:

an
d
itte
y li
erm
ab
◆ Compressor approx. 50%

ility
ot p
◆ Condenser approx. 10%

wit
is n
◆ Suction hose approx. 10%

h re
ole,
◆ Evaporator approx. 20%

spec
◆ Fluid reservoir approx. 10%

t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
en
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t.
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Cop py
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co lksw
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99
Prote AG.
4.1 - Capacities

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Service

Polo Estate 1998 ➤

Service Department. Technical Information

All rights reserved.

Copyright © 2011 Volkswagen AG, Wolfsburg 00056406320

1.1 Servicing heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2 Removing and installing heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

3 Dismantling and assembling heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

3.1 Dismantling and assembling heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

5 Installing and adjusting cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

5.1 Installing and adjusting cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

1 - Servicing heating system

1.2 - Passenger compartment heating

1.1 - Servicing heating system 1

2 Dust and pollen filter

◆ With activated charcoal filter

◆ With fresh air blower switch -E9-

◆ Removing and installing

◆ Dismantling and assembling => Page 23

◆ Installing and adjusting cables => Page 25

◆ Removing and installing

5 Front passenger's vent

1.2 - Passenger compartment heating 3

8 Fresh air blower series resistor with overheating fuse -N24-

1.2 - Passenger compartment heating 5

◆ First remove the dash panel.

◆ Installing: => Page 19 dismantling and assembling heater

1.3 - Removing fresh air blower -V2-

First carry out the following work:

under the steering column.

- Remove shelf on passenger side

- Remove foam covering under heater unit.

- Pull off connectors.

- Remove series resistor for fresh air blower -item 3-.

- Pull fresh air blower out downwards.

1- -> Plenum chamber cover

1.3 - Removing fresh air blower -V2- 7

1.5 - Removing vent

Remove centre vent

- -> Remove radio -1-.

1.4 - Removing and installing dust and pollen filter 9

- -> Remove screws -arrows A-.

- -> Lift bottom of centre vent up and simultaneously pull it out.

- Separate connectors to warning lamp switch.

Removing and installing front passenger's vent

Removing and installing driver's vent

Interior lights, bulbs, switches Removing and installing lighting switch.

- -> Remove screw -arrow-.

1.5 - Removing vent 11

Removing footwell vent

First carry out the following work:

- Remove trim under the steering column.

- Remove centre console.

- Remove shelf on passenger side

- Remove screw -1-.

- -> Press down with fingertips in compartment -1-.

1.5 - Removing vent 13

Now carry out the following work:

- Remove centre console.

- -> Release cables on controls -arrows-.

◆ Cable sleeves are colour coded.

Footwell/defrost flaps cable markings:

Left-hand drive: green