Removing fan housing — VW

Remove fluid reservoir for windscreen washer system:

=> Electrical system; Repair group 92; Windscreen washer system
Electrical system
Windscreen washer system

Detach hose clamp -2- and pull off air hose -3-.
Open clips -arrows- and remove air filter cover -1-.

If fitted, unscrew hexagon nuts -arrows- from bracket for exhaust gas recirculation valve and solenoid valve for boost pressure limiting -1-.
Remove bracket for exhaust gas recirculation valve and solenoid valve for boost pressure limiting -1-.

Unscrew nuts with washers -arrows-.
Pull fan housing -1- forwards.

Unlock and disconnect the two connectors behind the fan housing -arrow-.

Unlock and pull off connectors -arrows- on series resistor for fresh air blower -1-.

Pull off vacuum hose -1- from two-way valve for fresh and recirculating air flap -2-.
Remove fan housing from engine compartment.

Note:

On vehicles with 5-cylinder diesel engines the fan housing must be dismantled before removal due to the overall height of the intake manifold.
On vehicles with petrol engine, remove cleaning aperture cover
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80-42
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Removing vacuum unit for fresh and recirculating air flap

Pull hose -1- off vacuum unit -2-.
Unscrew cross-head screws -arrows-.
Unhook vacuum unit for recirculating air flap from joint.

Removing two-way valve for fresh and recirculating air flap -N63-

Pull off connector -1-.
Pull hose -2- off two-way valve for fresh and recirculating air flap -3-.
Unscrew cross-head screw -arrow-.

Removing fresh air blower relay - 4th speed -J407-.

Pull relay -1- off relay base.
Connection -2- to intake pipe or brake servo.

Removing series resistance for fresh air blower with overheating fuse -N24-.

Pull off connector -1-.
Unscrew cross-head screws -arrows-.
Withdraw series resistor for fresh air blower -2- upwards out of fan housing.

Removing and installing fresh air blower -V2-

Pull connector -2- off fresh air blower -1-.

Unscrew cross-head screws -arrows-.
Remove blower housing -1- complete with fresh air blower from fan housing -2-.

Withdraw fresh air blower -1- from blower housing -2-.

Push rubber bearing brackets -arrows- on fresh air blower -1-.
Align fresh air blower -1- so that when installing in the blower housing -3- the connector -2- and opening -4- align.

Hold rubber bearing brackets securely when installing.

Press fresh air blower into the blower housing.
The projecting lugs of the rubber bearing brackets must be seated accurately in the openings of the blower housing -arrows-.

Removing cleaning aperture cover.

Open Velcro lock -arrow- and pull off noise insulation mat -1-.

Open clamping locks -3-.
Push cleaning aperture cover -2- to the right and remove.

Note:

When installing, insert the cover so that the locking lugs are in the guides -1-.