golf 3 ac

87-16

A/C controls and mechanical components, servicing

A/C and heating system components, passenger compartment

WARNING!

Parts marked with an asterisk (*) can be serviced only after the A/C refrigerant system has been discharged by a certified technician using EPA-approved refrigerant recovery and recycling equipment safety measures, page 87-1 .

1 - Instrument panel

Removing and installing Repair Manual, Body, Repair Group 70

2 - Retaining strap

3 - Evaporator housing*

With evaporator

With fresh/recirculating air flap

Assembly page 87-28

87-17

4 - Seal*

5 - Fresh air blower series resistance -N24-

Removing/installing (with A/C) Fig. 1

6 - Fresh air/recirculating flap vacuum servo*

7 - Vacuum hose

Vacuum hose layout page 87-42

8 - Seal

9 - Fresh air blower -V2-

Removing/installing (with A/C) Fig. 2

10 - A/C evaporator temperature switch -E33-

Vehicles up to 07.93

Prevents evaporator from freezing

Located behind cover -16-

Insert sensor tube of temperature switch into evaporator 330 mm (13.0 in.)

Removing/installing Fig. 3

Switch opens (compressor OFF): below -2 C (28F)

87-18

11 - Seal

Always replace

12 - Intermediate connecting duct

With seal

13 - Plug

14 - A/C switch -E35-

From 08.93 (1994 m.y.): revised to include A/C switch -E35- and fresh air/recirculating flap switch -E159-

Verify correct part number

15 - A/C control head trim

16 - Cover

Replacing: first remove instrument panel Repair Manual, Body, Repair Group 70

17 - A/C control head

Removing/installing page 80-17

87-19

18 - Control cables

Remove footwell air outlet -20- before removing

Installing/adjusting (with A/C) page 87-24

19 - Rear footwell air ducts

20 - Footwell air outlet

Remove center console before removing

21 - Central flap lever

22 - Temperature flap lever

23 - Footwell/defrost flap lever

Lever and flap are one piece

24 - Heater (air distribution) box*

Do not disassemble any further

87-20

25 - Heater core*

To install:

- Install seals around perimeter of heater core so there are no gaps and glue in place.

- If heater core does not lock into place during

installation, fasten to heater box using screws through tabs on top of heater core.

- After removing heater core, drain entire cooling system and refill with new coolant.

26 - Vacuum hose clip

27 - Seal*

28 - Intermediate connecting duct

29 - Relay

Vehicles up to 07.93:

A/C relay -J32- (control number 13)

Vehicles from 08.95:

VR6, engine code AAA: relay for A/C shutoff -J365- (control number 147)

Diesel, engine code 1Z: A/C clutch cut-off relay -J246- (control number 38)

87-21

30 - A/C cut-off control module -J314-

Only on Diesel vehicles with engine code AAZ

Above relay plate

Control number 129

31 - Seal

Always replace

32 - Not applicable for US/Canada

33 - Heater fuse -S23-

87-22

CAUTION!

Part numbers are for reference only. Always check with your Parts Department for latest parts information.

Fig. 1 Removing and installing fresh air blower series resistance -N24- (with A/C)

- Remove glove compartment.

- Disconnect connector -2- and remove screw -3-.

- Remove series resistance -1-.

- Install in reverse order of removal noting following:

- Apply adhesive Part No. AMV 176 000 05 or equivalent to mating surface before installing.

Fig. 2 Removing and installing fresh air blower -V2- (with A/C)

- Disconnect connector -1-.

- Remove 5 screws (arrows) and remove fresh air blower -2- downward.

87-23

Note:

Wire connector -5- can temporarily be bridged during troubleshooting procedures.

Fig. 3 Removing and installing A/C evaporator temperature switch -E33-

1 - A/C evaporator temperature switch -E33- and cover

2 - Rubber grommet

3 - Sensor tube and tape

Install tape on sensor tube 330 mm (13.0 in.) from end to mark insertion depth of tube into evaporator

4 - Self-tapping screw

5 - Wire connector

87-24

Control cables, installing and adjusting (with A/C)

Notes: Install cable ends identified with colored bands to control head levers.

Install cables to control head before installing on evaporator/heater box levers.

After connecting control cables to control head levers, fasten cables to control head using clips.

Adjust cables with control head installed.

When control knobs are turned stop to stop, flaps must move and audibly contact stops.

1 - Temperature flap cable

Connects temperature control knob to temperature flap

Blue sleeve, 585 mm (23.0 in.) long

Adjusting Fig. 1

87-25

2 - Footwell/defroster flap cable

Connects air flow distribution knob (upper control lever) to footwell/defroster flap

Black sleeve, 488 mm (19.2 in.) long

Adjusting Fig. 2

3 - Central flap cable

Connects air flow distribution knob (lower control lever) to central flap

Black sleeve, 639 mm (25.2 in.) long

Adjusting Fig. 3

87-26

Fig. 1 Adjusting temperature flap cable

- Install A/C control head in instrument panel.

- Adjust temperature control knob to full cold.

- Connect temperature flap cable (blue sleeve) to temperature flap lever.

- Push lever in direction of arrow to stop.

- Hold lever in this position and install cable retaining clip.

Fig. 2 Adjusting footwell/defroster flap cable


- Adjust air flow distribution knob to defrost position.

- Connect footwell/defroster flap cable (black sleeve) to footwell/defroster flap lever.



87-27

Fig. 3 Adjusting central flap cable


- Adjust air flow distribution knob to defrost position.

- Connect central flap cable (black sleeve) to central flap lever.



87-28

Evaporator housing, assembly

CAUTION!

Part numbers are for reference only. Always check with your Parts Department for latest parts information.

To remove evaporator housing for disassembly:

- Discharge A/C refrigerant system page 87-92 .

- Drain engine coolant.

- Remove instrument panel and support bracket.

- Remove heater box/evaporator housing.

1 - Seal

2 - Upper evaporator housing

Seal grooves and contact surfaces with silicone sealant, Part No. AKD 476 KD5 05, or equivalent

87-29

3 - Evaporator

4 - Funnel

To guide sensor tube for A/C evaporator temperature switch -E33-

5 - Air intake ring

6 - Lower evaporator housing

Seal grooves and contact surfaces with silicone, sealant Part No. AKD 476 KD5 05, or equivalent

87-30

A/C and heating system components, engine compartment

WARNING!

Parts marked with an asterisk (*) can be serviced only after the A/C refrigerant system has been discharged by a certified technician using EPA-approved refrigerant recovery and recycling equipment safety measures, page 87-1 .

1 - Dust and pollen filter

Where applicable

2 - Plenum cover

Removing/installing page 80-1 item - 3 -

3 - Evaporator water drain valve

Located behind bulkhead insulation


4 - Heater core connections and vacuum hose guide

87-31

5 - Fresh air/recirculating flap two-way valve -N63-

Valve open when voltage applied


6 - Coolant Fan Control (FC) control module -J293-

With fuse -S88- (1993 m.y.)

With fuses -S107- and -S108- (1994 m.y. )

Connector terminal identification:

09.93 Fig. 5

10.93 Fig. 6

7 - Vacuum reservoir

Insert vacuum hose 30 mm (1.2 in.) into reservoir


8 - Vacuum hose


87-32

9 - A/C thermal switch -F163- and third speed coolant Fan Control (FC) thermal switch -F165-

A/C thermal switch -F163- only on vehicles with engine codes AAA, AAZ, ABA, ACC

F163 switches A/C clutch -N25- off at high engine coolant temperature; OFF (switch open) above 119

C (246 F); ON (switch closed) below 112 C (234 F)

Third speed coolant fan control thermal switch -F165- only on vehicles with 3-speed coolant fan motor

F165 switches radiator coolant fan to 3rd speed as engine coolant temperature increases; 3rd speed ON (switch closed) above 112 C (234 F); OFF (switch open) below 108 C (226 F)

Removing and installing (engine code AAA) Fig. 3

Removing and installing (engine code ABA) Fig. 4

87-33

10 - Condenser*

11 - Pressure relief valve*

Checking Fig. 11

12 - A/C clutch -N25-*

13 - Ambient temperature switch -F38-

Switches A/C clutch -N25- OFF when outside temperature is too low

Switch opens (compressor OFF): below 2 C (36 F)

Switch closes (compressor ON): above 7 C (45 F)

Installation location ( 07.95) Fig. 8

Installation location (08.95 ) Fig. 9

14 - A/C pressure switch -F129-

Checking Fig. 10

8 Nm (71 in. lb)

Always replace O-ring seal (note Part No.)

87-34

15 - Receiver drier*

16 - Sight glass*

Not applicable to all vehicles

17 - High and low-pressure service valves*

18 - Expansion valve*

Insulator, installing and checking Fig. 1

87-35

Insulation is used around expansion valve to prevent moisture (condensation) build-up and to protect expansion valve from high engine compartment temperatures and the resulting decrease in A/C system cooling performance.

Fig. 1 Installing and checking expansion valve insulator

1 - Insulator

2 - Expansion valve

- Install insulator -1- over expansion valve -2- (arrow).

- Check insulator for damage and proper fit, and replace if necessary.

Fig. 2 Removing and installing evaporator water drain valve

1 - Water drain valve

2 - Bulkhead

3 - Water drain tube (on evaporator housing)

4 - Mounting recess

- To remove, carefully pull water drain valve -1- from drain tube -3-.

- Install water drain valve so that valve flap opens from bottom.

- Make sure valve flap is free of dirt, wax or undercoating; clean if necessary.

87-36

CAUTION!

Cooling system may be under pressure. Relieve system pressure before removing any engine coolant temperature sensors or switches.

Note:

Fig. 3 Removing and installing A/C thermal switch -F163- and third speed coolant Fan Control (FC) thermal switch -F165- (2.8 liter VR6 engine code AAA)

1 - Clip

2 - Engine coolant regulator housing

3 - O-ring

4 - A/C cut-out thermal switch -F163- and third speed coolant fan control thermal switch -F165-, brown

5 - Engine coolant temperature (ECT) sensor -G2- and after-run coolant fan control thermal switch -F87-, yellow

6 - Engine coolant temperature (ECT) sensor -G62-, blue

- Carefully relieve cooling system pressure.

- Disconnect harness connector from thermal switch -4-.

- Remove clip -1- and pull thermal switch from housing.

- Install in reverse order of removal.

Refill coolant to proper level after removing and installing A/C switches or sensors.

87-37

CAUTION!

Cooling system may be under pressure. Relieve system pressure before removing any engine coolant temperature sensors or switches.

Note:

Refill coolant to proper level after removing and installing A/C switches or sensors.

Fig. 4 Removing and installing A/C cut-out thermal switch -F163- (2.0 liter engine code ABA)

1 - Clip

2 - Connection

3 - O-ring

4 - A/C cut out thermal switch -F163-

5 - Harness connector

Fig. 5 Connector terminal identification of coolant Fan Control (FC) control module -J293- ( 09.93)

87-38

Fig. 6 Connector terminal identification of coolant Fan Control (FC) control module -J293- (10.93 )

Fig. 7 Removing and installing vacuum reservoir

1 - Vacuum hose

Insert into reservoir 30 mm (1.2 in.)

2 - Rubber grommet


4 - Nut

5 - Wheel housing liner

- Remove wheel housing liner Repair Manual, Body, Repair Group 66.

- Remove vacuum hose -1- and nut -4- from reservoir.

- Remove reservoir.

- Install in reverse order of removal.

87-39

Fig. 8 Installation location of ambient temperature switch -F38- ( 07.95)

1 - Bolt, M8

Tightening torque: 15Nm (11 ft lb)

2 - Mounting bracket

3 - Horn bracket

4 - Plastic clip

5 - Ambient temperature switch -F38-

6 - Horn

Note:

Removing and installing right-hand plenum cover page 80-1 , item - 3 -.

Fig. 9 Installation location of ambient temperature switch -F38- (08.95 )

1 - Ambient temperature switch

2 - Plastic clip

87-40

Functions

Switches A/C clutch -N25- OFF if system pressure is too low (low refrigerant charge). Switching occurs between terminals 1 (T4a/1) and 2 (T4a/2).

Switches A/C clutch -N25- OFF if system pressure is too high. Switching occurs between terminals 1 (T4a/1) and 2 (T4a/2).

Switches coolant fan -V7- to second speed when A/C system pressure increases. Switching occurs between terminals 3 (T4a/3) and 4 (T4a/4).

Fig. 10 Checking A/C pressure switch -F129-

Red O-ring (10.8 mm x 1.8 mm) must fit properly in groove.

Switch opens (compressor OFF): below 1.2 bar (17.4 psi)

Switch closes (compressor ON): above 2.4 bar (34.8 psi)

Switch opens (compressor OFF): above 32.0 bar (464 psi)

Switch closes (compressor ON): below 24.0 bar (348 psi)

Switch closes (2nd speed ON): above 16.0 bar (232 psi)

Switch opens (2nd speed OFF): below 12.5 bar (181.3 psi)

Switch identified with a green label or marked "R-134a"

To remove, unscrew switch from Schrader valve

Tightening torque: 8 Nm (71 in lb)

87-41

Checking:

If A/C clutch -N25- does not engage with A/C ON:

- Start engine.

- Using a jumper wire, briefly bridge terminal 1 (T4a/1) and terminal 2 (T4a/2) of A/C pressure switch connector.

If A/C clutch -N25- now engages, refrigerant system is discharged (empty).

- Check A/C system for leaks, repair as necessary.

Note:

With A/C pressure switch -F129- removed and connector attached, A/C clutch -N25- should not engage and A/C should not cool.

Fig. 11 Checking pressure relief valve on compressor

Protects refrigerant circuit from excessive pressure

Pressure relief valve tell-tale indicates when valve has been actuated by excessive pressure (adhesive-attached plate (arrow) is pushed out). If so,

repairs must be carried out by an A/C specialist.

87-42

Vacuum hose layout

Note:

Insert vacuum hose into reservoir 30 mm (1.2 in.). Insert vacuum hoses onto plastic lines up to stop, approx. 15 mm (5/8 in.).

1 - Hose

3.5 x 2 x 40 mm

2 - Plastic line

4 x 1 x 540 mm

3 - Plastic line

4 x 1 x 490 mm

4 - Fresh air/recirculating flap two-way valve -N63-

5 - Foam insulator

6 - Check valve

Arrow points to vacuum source

7 - Hose

3.5 x 2 x 40 mm

8 - Vacuum tee connector

87-43

9 - Hose

3.5 x 2 x 40 mm

10 - Plastic line

4 x 1 x 1170 mm

11 - Rubber grommet


13 - Foam insulator

14 - Plastic line

15 - Hose

3.5 x 2 x 130 mm

16 - Plastic line

4 x 1 x 125 mm

17 - Curved hose

18 - Vacuum hose

For fresh air/recirculating flap

87-44

A/C clutch -N25-, assembly

Notes: The illustration (left) shows the correct assembly detail for the A/C clutch -N25-.

The A/C compressor shown (Sanden model SD7 -H15-) is not applicable for all Golf, GTI, Jetta and Cabrio vehicles.

1 - Nut (self-locking)

Removing Fig. 1

Gap between clutch plate and belt pulley, adjusting Fig. 1

Gap between clutch plate and belt pulley, measuring Fig. 2

2 - Clutch plate

Removing Fig. 3

3 - Lock ring

4 - Belt pulley

Removing Fig. 4

Installing Fig. 5

87-45

5 - Bearing assembly

Removing Fig. 6

Installing Fig. 7

6 - Snap ring

7 - Snap ring

8 - Clutch coil

9 - Key

10 - A/C compressor

Refrigerant oil capacity: 115 cc 15 cc (3.9 oz 0.5 oz)

87-46

To adjust gap between clutch plate and belt pulley:

Fig. 1 Removing and installing clutch plate nut, and adjusting gap between clutch plate and belt pulley

- Hold clutch plate using spanner wrench -A- and remove clutch plate nut.

A - Mastercool tool No. 90901 or equivalent

B - Hex head bolt, 1/4 in. (for tool)

- Hold clutch plate and tighten clutch plate nut (self-locking) until gap -a- = 0.7 mm (.028 in. or approx. 1/32 in.).

Fig. 2 Measuring gap between clutch plate and belt pulley

- Measure distance between clutch plate and belt pulley as shown.

- Using a fused 12 Volt power supply, connect 12 V (power (B+) and Ground (GND)) to A/C clutch connector.

- With clutch engaged, measure distance between clutch plate and belt pulley once again.

- Difference between first and second measurement is gap.

Must be 0.7 mm (.028 in. or approx. 1/32 in.)

- If necessary, adjust gap Fig. 1

87-47

Fig. 3 Removing clutch plate

- Remove front clutch plate using clutch plate puller -1- (Mastercool tool No. 90902 or equivalent - similar tool shown) and 1/4 in. bolts -2-.

Fig. 4 Removing belt pulley

- Using puller 20/10 or equivalent, remove belt pulley.

87-48

Fig. 5 Installing belt pulley

- Using VW 401 and VW 402 thrust plates and VW 412 and VW 441 thrust bushings, press belt pulley onto shaft.

Fig. 6 Removing bearing assembly

- Using VW 401 and VW 402 thrust plates, VW 412 thrust bushing and VW 455 thrust tube, press bearing from pulley.

87-49

Fig. 7 Installing bearing assembly

- Using VW 401 and VW 402 thrust plates and VW 412 and VW 473 thrust bushings, press bearing onto pulley until fully seated.

87-50

A/C compressor bracket, removing and installing - 4-cyl. gasoline (engine codes ABA, ACC)

Note:

The A/C compressor mounting bracket can be removed and installed without discharging the A/C system.


For Generator (GEN) and A/C compressor

Generator (GEN) removing and installing Repair Manual, Electrical Equipment, Repair Group 27

2 - Spring tensioner

3 - Nut-M8

30 Nm (22 ft lb)

87-51

4 - Compressor support

Installing:

- Install support using bolts -5- and -6-; do not tighten.

- Thread bolt -6- into threaded sleeve -7- until support contacts sleeve.

- Tighten bolt -5-; tightening torque 45 Nm (33 ft lb).

- Tighten bolt -6-; tightening torque: 45 Nm (33 ft lb).

5 - Bolt-M10 x 30

45 Nm (33 ft lb)

6 - Bolt-M10 x 30

45 Nm (33 ft lb)

7 - Threaded sleeve

8 - Refrigerant hoses

9 - A/C compressor

Removing from bracket:

- Remove support -4-.

- Loosen bolts -11- but do not remove.

- Drive threaded sleeve -7- back.

- Completely remove bolts -11- then remove compressor from bracket.

87-52

10 - Ribbed drive belt

If used belt is to be reinstalled: mark running direction of belt before removing and reinstall in same running direction

Removing/installing Repair Manual, General, Engine, Repair Group 13

11 - Bolt-M10 x 112

45 Nm (33 ft lb)

12 - Bolt-M8 x 42

25 Nm (18 ft lb)

13 - Tensioner pulley

87-53

A/C compressor bracket, removing and installing - 6-cyl. VR6 (engine code AAA) 08.93

Note:



08.93 page 87-56


Removing:

- Remove A/C compressor - 8 -.

- Remove generator Repair Manual, Electrical Equipment, Repair Group 27.

Installing:

First install bolts - 3 - and - 11 -.

Replacing:

Remove power steering pump bracket Repair Manual, Suspension, Wheels, Brakes And Steering, Repair Group 48.

2 - Washer-8.4 x 16 x 1.6

3 - Bolt-M8 x 28

25 Nm (18 ft lb)

87-54

4 - Socket-head bolt-M8 x 30

25 Nm (18 ft lb)


25 Nm (18 ft lb)


25 Nm (18 ft lb)


8 - Compressor

Removing:

- Remove front bumper Repair Manual, Body, Repair Group 63.

- Loosen lock carrier (radiator support) and pull forward.

- Remove headlight housing Repair Manual, Electrical Equipment, Repair Group 94.

- Remove ribbed belt - 9 -.

- Remove Generator (GEN) Repair Manual, Electrical Equipment, Repair Group 27.

- Loosen bolts - 10 - and drive threaded sleeves back from compressor.

- Remove bolts -10- and remove compressor.

87-55

9 - Ribbed belt

Removing/installing Repair Manual, 2.8 Liter VR6 General Engine, Repair Group 13

10 - Bolt-M10 x 112

45 Nm (33 ft lb)

11 - Bolt-M8 x 20

25 Nm (18 ft lb)

12 - Washer-8.4 x 16 x 1.6

87-56

A/C compressor bracket, removing and installing-6-cyl. VR6 (engine code AAA) 08.93

Note:



For engines up to 08.93 page 87-53

For Generator (GEN), A/C compressor and power steering pump

Removing:

- Remove A/C compressor -8- from bracket.


- Remove power steering pump.

- Remove bracket.

Installing:

- First install bolts -3- and -12-.

2 - Washer-8.4 x 16 x 1.6

87-57

3 - Bolt-M8 x 28

25 Nm (18 ft lb)


25 Nm (18 ft lb)


25 Nm (18 ft lb)


25 Nm (18 ft lb)


8 - A/C compressor

Removing from bracket:

- Remove front bumper Repair Manual, Body, Repair Group 63.

- Loosen lock carrier (radiator support) and pull forward.

- Remove headlight housing Repair Manual, Electrical Equipment, Repair Group 94.

- Remove poly-ribbed belt -9-.


- Loosen A/C compressor bolts -10- approx. 2 turns

and drive threaded sleeves back from compressor.

- Remove bolts -10- and remove compressor.

87-58

9 - Poly-ribbed drive belt

Removing and installing Repair Manual, 2.8 Liter VR6 General, Engine, Repair Group 13

10 - Bolts-M10 x 112

45 Nm (33 ft lb)

11 - Socket-head bolt M8 x 30

25 Nm (18 ft lb)

12 - Bolt-M8 x 20

25 Nm (18 ft lb)

13 - Washer-8.4 x 16 x 1.6

87-59

A/C compressor bracket, removing and installing - 4-cyl. Turbo Diesel (engine codes AAZ, 1Z)

Note:


1 - Bolt-M8 x 22

25 Nm (18 ft lb)



Removing: remove generator -4- and A/C compressor -9-.

3 - Bolt-M8 x 85

25 Nm (18 ft lb)

4 - Generator

Removing/installing Repair Manual, Electrical Equipment, Repair Group 27

5 - Tensioning element


Qty.: 3

25 Nm (18 ft lb)

87-60

7 - Nut-M8

Qty.: 4

30 Nm (18 ft lb)

8 - Bolt-M8 x 85

25 Nm (18 ft lb)

9 - Compressor

Removing:

- Loosen hex-head bolts -11- approx. two turns and drive threaded sleeve back on compressor.

- Remove bolts.

10 - Ribbed belt

Removing/installing Repair Manual, General Engine, Repair Group 13

11 - Bolt-M10 x 112

Qty.: 2

45 Nm (33 ft lb)

12 - Tensioner

Removing:

- Loosen M6x16 socket head bolt on tensioning

roller tensioning element.

- Drive tensioning roller back with rubber hammer.

87-61

A/C compressor bracket, removing and installing - Sanden compressor (engine codes ABA, ACC) 12.95

CAUTION!

Part numbers are listed here for reference only. Always check with your Parts department for the latest information.



Part No. 037 903 139 F

Removing and installing generator Repair Manual, Electrical Equipment, Repair Group 27

2 - Tensioning element

Part No. 037 903 315 C

3 - Nut-M8

Part No. N 902 291 01

30 Nm (22 ft lb)

Qty.: 4

4 - Threaded sleeve

87-62

5 - Refrigerant hose

Expansion valve/compressor

Part No. 1H1 820 743 P

6 - Refrigerant hose

Compressor/condenser

Part No. 1H0 820 721 C

7 - Compressor

Part No. 1H0 820 803 D

To remove, loosen bolt - 9 - approx. two turns and drive threaded sleeve - 4 - back on compressor, then remove bolts

8 - Ribbed belt

Part No. 037 260 849 C

Removing and installing Repair Manual, General Engine, Repair Group 13

9 - Bolt-M10x112

45 Nm (33 ft lb)

Part No. N102 098 01

10 - Bolt-M8x42

25 Nm (18 ft lb)

Part No. N 010 353 3

11 - Tensioner

Part No. 028 145 278 E

golf 3 ac

Documents

ac page

ac clutch

ac controls

ac switch e35

ac relay j32

ac refrigerant system

ac shutoff j365

fresh air blower v2