Dismantling and assembling evaporator housing for front seats and rear seats — VW

Warning!
Always disconnect the battery earth strap before working on the electrical system.
Notes:

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

To prevent the ingress of dampness all components of the refrigerant circuit which have been opened must be sealed with suitable plugs.
Components underlined can be renewed after first removing the evaporator with heater.

Perform following work first:

Extract refrigerant with Service station V.A.G 1885.

Note:

Draining the refrigerant into the environment is a punishable offence.

Drain coolant.
Remove dash panel.

=> General body repairs, interior; Repair Group 70; Removing and installing dash panel
General body repairs, interior
Removing and installing dash panel

Remove heater and air conditioner unit.

Evaporator housing for front seats

Fresh air blower -V2-
Before installing coat contact surfaces with AMV 176 000 05

Series resistor -N24-
Housing, upper part
With fresh air and recirculating air flap
Before installing coat contact surfaces with AMV 176 000 05

Intake ring
Evaporator
With funnel to guide the temperature switch -E33- sensor pipe

Gasket
Intake housing
With recirculating air flap

Vacuum unit for fresh and recirculating air flap
Ventilated: Fresh air operation
Vacuum hose connection diagram => Page
87-42

Evaporator temperature switch -E33-
Insertion depth of sensor tube: 330 mm
Task: prevents icing up
Switching temperatures: opens at or below -20 C

Housing, lower part
Before installing coat contact surfaces with AMV 176 000 05

Double vacuum unit for central flap
Vacuum hose connection diagram => Page
87-42

Air distribution housing
Vacuum unit for footwell/defrost flap
Vacuum hose connection diagram => Page
87-42

Heat exchanger
Gaskets must be bonded gap-free all around.
After removal replace complete coolant.

Gasket
Temperature flap cable
Heating and air conditioning controls
Vacuum hoses
Vacuum hose connection diagram => Page
87-42

2. Evaporator housing for rear seats

Air duct
2nd evaporator
Do not dismantle further

Temperature sensor -G18-
Insertion depth : marked 50 mm

2nd evaporator air conditioning control and regulating unit -J127-
Relay position:

=> Current flow diagrams, Electrical fault finding and Fitting locations

2nd evaporator fresh air blower relay

Water drain pipe
Grommet
Lip valve
Connector
Release connection using release tool => Page
87-139
, Fig.
5

O rings
13 mm; 1.9 mm
Qty. 2

O rings
10.8 mm; 1.8 mm
Qty. 2

Connector
Release connection using release tool => Page
87-139
, Fig.
5

Blower for 2nd evaporator
Before installing coat contact surfaces with AMV 176 000 05

5/8" thread - 18 UNF
O rings
7.9 mm; 1.8 mm
Qty. 2

Refrigerant circuit solenoid valve
-N43-
Open when current is supplied
Only on air conditioning systems with 2nd evaporator

O rings
14 mm; 1.8 mm
10.8 mm; 1.8 mm
Qty. 2

O rings
7.9 mm; 1.8 mm
17.2 mm; 1.8 mm
Qty. 2

Socket head screw
7 Nm

Expansion valve for rear evaporator
Opening must be sealed sufficiently to stop ingress of water
The same component as the front evaporator

Series resistance -N6- with overheating fuse for 2nd evaporator