Service

Workshop Manual
Octavia II 2004 ➤
Octavia II 2010 ➤
Heating, Air conditioning
Edition 11.2011

Service Department. Technical Information

 Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups

Repair Group
80 - Heating
82 - Supplementary heating
87 - Air conditioning system
 Octavia II 2004 ➤ , Octavia II 2010 ➤
Heating, Air conditioning - Edition 11.2011

Contents

80 - Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Summary of components, disassembling and assembling the heater unit . . . . . . . . . . . . 1
1.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Disassembling and assembling the heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Dash panel vent and air guide ducts, ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Removing and installing centre vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Removing and installing the right/left side vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Removing and installing rear vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 Removing and installing the rear duct of the right and left footwell . . . . . . . . . . . . . . . . . . 6
2.5 Remove and install footwell vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.6 Inspecting ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.7 Removing and installing air intake grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Heater control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Removing and installing heater control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Plug connections on the rear side of the heater control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Removing and installing flex shaft for positioning unit of air distribution flaps . . . . . . . . . . 10
3.4 Removing and installing the bowden wire for temperature flap . . . . . . . . . . . . . . . . . . . . . . 11
4 Components on the heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.1 Removing and installing fresh air blower V2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 Removing and installing series resistor for fresh air blower with overheating fuse N24 . . 13
4.3 Removing and installing dust pollen filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.4 Removing and installing the control motor of the re-circulating air flap V113 . . . . . . . . . . 14
4.5 Removing and installing the control unit for temperature flap . . . . . . . . . . . . . . . . . . . . . . 15
4.6 Removing and installing heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.7 Removing and installing heating element for additional air heating Z35 . . . . . . . . . . . . . . 19
5 Removing and installing the heating unit from the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.1 Removing and installing heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

82 - Supplementary heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1 Auxiliary heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.1 Types of installed auxiliary heatings, general notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2 Safety measures when working on vehicles fitted with auxiliary heating. . . . . . . . . . . . . . . 24
1.3 Notes when operating the auxiliary heating on vehicles with diesel engine. . . . . . . . . . . . . 25
1.4 Rules of cleanliness when working on the auxiliary heating and the fuel system . . . . . . . . 25
1.5 General notes when working on vehicles fitted with auxiliary heating . . . . . . . . . . . . . . . . 26
2 Description of the function and control of auxiliary heating as well as the radio remote
control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.1 Description of the function and control of auxiliary heating . . . . . . . . . . . . . . . . . . . . . . . . 28
2.2 Operation (activation) of the auxiliary heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3 Descriptions of the functions of the radio control Telestart T91 . . . . . . . . . . . . . . . . . . . . . . 29
2.4 Replacing the battery of the radio remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3 Repairing the auxiliary heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1 Summary of components of auxiliary heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.2 Type plate of auxiliary heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.3 removing and installing ambient temperature sensor G17 . . . . . . . . . . . . . . . . . . . . . . . . 34
3.4 Removing and installing auxiliary heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.5 Removing and installing lengthened exhaust pipe (only on vehicles with diesel engine up to
CW 45.05) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.6 Removing and installing silencer with bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.7 Removing and installing holder for auxiliary heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.8 Removing and installing cover for auxiliary heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.9 removing and installing coolant shut-off valve of heating system N279 . . . . . . . . . . . . . . 38

Contents i
 Octavia II 2004 ➤ , Octavia II 2010 ➤
Heating, Air conditioning - Edition 11.2011

3.10 Removing and installing radio receiver for auxiliary heating R64 . . . . . . . . . . . . . . . . . . . . 38
4 Components of auxiliary heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.1 Summary of components of auxiliary heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.2 Removing and installing air intake silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.3 Removing and installing circulating pump V55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.4 Removing and installing exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5 Disassembling and assembling auxiliary heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.1 Components of the inner auxiliary heating, Thermo Top V . . . . . . . . . . . . . . . . . . . . . . . . 43
5.2 Components of the inner auxiliary heating, Thermo Top VEVO . . . . . . . . . . . . . . . . . . . . 45
5.3 Removing and installing auxiliary heating control unit J364 . . . . . . . . . . . . . . . . . . . . . . . . 46
5.4 Plug assignment at control unit for auxiliary heating J364 Thermo Top V/VEVO . . . . . . . . 47
5.5 Removing and installing, checking the temperature sensor G18 and the overheating sensor
G189 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.6 Removing and installing glow plug with flame monitoring Q8 on Thermo Top V . . . . . . . . 49
5.7 Removing and installing glow plug with flame monitoring Q8 on Thermo Top VEVO . . . . 49
6 Fuel supply of auxiliary heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.1 Summary of components of fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.2 Removing and installing the dosing pump V54 with its component parts . . . . . . . . . . . . . . 53
6.3 Check fuel flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.4 Checking the function of the fuel shut-off valve N109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

87 - Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

1 Instructions and safety measures for repair work on vehicles with air conditioning and when
using refrigerant R 134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.1 Notes regarding the odours coming from the heating and air conditioning unit . . . . . . . . . . 58
2 Description of the air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.1 Operation of the air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.2 Structure of the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.3 Parts of the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.4 Extractor, filler and measurement valves for quick couplings of the AC service station on the
refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.5 Parts for securing the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.1 Refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.2 Refrigerant oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4 Repairing the air conditioning system - engine compartment . . . . . . . . . . . . . . . . . . . . . . 69
5 Removing and installing parts of the air conditioning system - engine compartment . . . . . . 73
5.1 Removing and installing dessicator cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5.2 Replacing dessicator cartridge / fluid reservoir with dessicator . . . . . . . . . . . . . . . . . . . . . . 76
5.3 Removing and installing AC compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.4 Running-in instructions of the AC compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.5 Inspecting the pressure relief valve on the AC compressor . . . . . . . . . . . . . . . . . . . . . . . . 78
5.6 Removing and installing the expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.7 Removing and installing the cover plate for expansion valve . . . . . . . . . . . . . . . . . . . . . . . . 81
5.8 Removing and installing the condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
6 Removing and installing the heating and air conditioning unit from the vehicle . . . . . . . . . . 83
7 Climatic, air conditioning system with manual control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
7.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
7.2 Overview of control motors at the heating and air conditioning unit - right-hand drive . . . . 91
7.3 Removing and installing heating and air conditioning system control with control unit for air
conditioner/Climatic J301 up to MY 08 (CW 44.08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
7.4 Removing and installing heating and air conditioning system control with control unit for air
conditioner/Climatic J301 as of MY 09 (CW 45.08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
7.5 Plug connections at the control for heating and air conditioning system . . . . . . . . . . . . . . 93

ii Contents
 Octavia II 2004 ➤ , Octavia II 2010 ➤
Heating, Air conditioning - Edition 11.2011

7.6 Disassembling and assembling the heating and air conditioning unit (Climatic, air conditioning
system with manual control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
7.7 Removing and installing evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
7.8 Removing and installing, testing condensation water drain . . . . . . . . . . . . . . . . . . . . . . . . 96
7.9 Removing and installing the control motor of temperature flap V68 . . . . . . . . . . . . . . . . . . 97
7.10 Removing and installing the Footwell vent temperature sender G192 . . . . . . . . . . . . . . . . 99
7.11 Removing and installing the middle vent temperature sender G191 . . . . . . . . . . . . . . . . . . 99
7.12 Removing and installing the evaporator vent temperature sender G263 . . . . . . . . . . . . . . 100
8 Climatronic - Air conditioner with automatic regulation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
8.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
8.2 Overview of control motors at the heating and air conditioning unit - right-hand drive . . . . 105
8.3 Function of the Control and display unit for air conditioner/Climatronic E87 with Climatronic
control unit J255 up to MY 08 (CW 44.08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
8.4 Function of the Control and display unit for air conditioner/Climatronic E87 with Climatronic
control unit J255 as of MY 09 (CW 45.08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
8.5 Removing and installing Control and display unit for air conditioner, Climatronic E87 with
Climatronic control unit J255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
8.6 Plug connections on the control unit for Climatronic J255 . . . . . . . . . . . . . . . . . . . . . . . . 109
8.7 Disassembling and assembling heating and air conditioning unit (Climatronic) . . . . . . . . . . 111
8.8 Removing and installing left footwell vent temperature sender G261 . . . . . . . . . . . . . . . . 112
8.9 Removing and installing Right footwell vent temperature sender G262 . . . . . . . . . . . . . . 112
8.10 Removing and installing left vent temperature sender G150 and right vent temperature
sender G151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
8.11 Removing sunlight penetration photosensor G107 and sunlight penetration photosensor 2
G134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
8.12 Removing and installing the control motor of the re-circulating air flap V113 . . . . . . . . . . 113
8.13 Remove and install control motor of air flow flap V71 or control motor of air flow flap and re-
circulating air flap V71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
8.14 Removing and installing the defroster flap control motor V107 . . . . . . . . . . . . . . . . . . . . . . 115
8.15 Removing and installing the left temperature flap control motor V158 . . . . . . . . . . . . . . . . 116
8.16 Removing and installing right temperature flap control motor V159 . . . . . . . . . . . . . . . . . . 118
8.17 Removing and installing the control motor of central flap V70 . . . . . . . . . . . . . . . . . . . . . . 119
8.18 Fresh air blower control unit J126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
8.19 Air quality sensor G238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Contents iii
 Octavia II 2004 ➤ , Octavia II 2010 ➤
Heating, Air conditioning - Edition 11.2011

iv Contents
 Octavia II 2004 ➤ , Octavia II 2010 ➤
Heating, Air conditioning - Edition 11.2011

80 – Heating
1 Summary of components, disassem‐
bling and assembling the heater unit
⇒ „1.1 Summary of components“, page 1
⇒ „1.2 Disassembling and assembling the heater unit“,
page 3

1.1 Summary of components

1 - Dash panel
❑ Removing and installing
⇒ Body Work; Rep. gr.
70
2 - Centre vent
❑ removing and installing
⇒ page 5
3 - Outer dash panel vent
❑ removing and installing
⇒ page 5
4 - Re-circulating air flap con‐
trol motor -V113-
❑ removing and installing
⇒ page 14
5 - Footwell vent front passen‐
ger side
❑ removing and installing
⇒ page 7
6 - Flex shaft
❑ for positioning unit for air
distribution flaps
❑ removing and installing
⇒ page 10
7 - Series resistor for fresh air
blower with overheating fuse -
N24-
❑ removing and installing
⇒ page 13
8 - Fresh air blower -V2-
❑ removing and installing
⇒ page 13
9 - Shield for heater unit
❑ removing and installing ⇒ page 2
10 - Dust and pollen filter
❑ Also filter version with odour insert, see ⇒ Catalogue of Original Parts
❑ removing and installing ⇒ page 14
11 - Rear duct of right footwell
❑ removing and installing ⇒ page 6
12 - Center rear duct
❑ Removing and installing ⇒ Body Work; Rep. gr. 68

1. Summary of components, disassembling and assembling the heater unit 1

 Octavia II 2004 ➤ , Octavia II 2010 ➤
Heating, Air conditioning - Edition 11.2011

13 - Center rear vent

❑ removing and installing ⇒ page 6
14 - Air deflector
❑ for center rear vent
15 - Rear duct of left footwell
❑ removing and installing ⇒ page 6
16 - Screws, 1.5 Nm
❑ 8 pieces
17 - Heater control
❑ removing and installing ⇒ page 9
18 - Adapter for heater control
19 - Heating element for air auxiliary heating -Z35-
❑ removing and installing ⇒ page 19
20 - Heat exchanger
❑ removing and installing ⇒ page 15
❑ replace coolant after changing the heat exchanger
21 - Footwell vent driver's side
❑ removing and installing ⇒ page 7
22 - Bowden wire for temperature flap
❑ removing and installing ⇒ page 11
23 - Heating
❑ removing and installing ⇒ page 21
❑ disassembling and assembling ⇒ page 3
24 - Intermediate piece for defroster duct
❑ placed onto the distributor housing and secured with a clip on the cross member - dash panel
❑ for removing, take out dash panel
25 - Intermediate piece for dash panel vents
❑ placed onto the distributor housing
❑ for removing, take out dash panel
26 - Vent duct
❑ for window blower in the door
❑ Part of the cover

Remove shield for heating and air conditioning unit

– Unscrew the plastic screws -2- and remove the shield -1-.

2 Rep. gr.80 - Heating

 Octavia II 2004 ➤ , Octavia II 2010 ➤
Heating, Air conditioning - Edition 11.2011

Fitting position of the seal for heater unit/engine compartment

– First of all insert seal for heater unit/engine compartment -1-
into the front wall -2- and then pull the sealing lip -3- into the
groove of the heat exchanger.

Note

In order to prevent water leaking into the interior of the vehicle,

pay attention to the fitting position.

1.2 Disassembling and assembling the heater unit

1 - Positioning unit for temper‐

ature flap
❑ removing and installing
⇒ page 15
2 - Support
3 - Cover
4 - Re-circulating air flap con‐
trol motor -V113-
❑ removing and installing
⇒ page 14
5 - Housing for air inlet
❑ with re-circulating air
flap
6 - Heater unit
7 - Fresh air blower -V2-
❑ removing and installing
⇒ page 13
8 - Series resistor for fresh air
blower with overheating fuse -
N24-
❑ removing and installing
⇒ page 13
9 - Dust and pollen filter
❑ Also filter version with
odour insert, see ⇒
Electronic Catalogue of
Original Parts
❑ removing and installing
⇒ page 14
10 - Cover
❑ for dust and pollen filter
11 - Heat exchanger
❑ removing and installing ⇒ page 15
12 - Heat exchanger trim panel
13 - Heating element for air auxiliary heating -Z35-
❑ only fitted on certain models
❑ removing and installing ⇒ page 19

1. Summary of components, disassembling and assembling the heater unit 3

 Octavia II 2004 ➤ , Octavia II 2010 ➤
Heating, Air conditioning - Edition 11.2011

14 - Distributor housing

4 Rep. gr.80 - Heating

 Octavia II 2004 ➤ , Octavia II 2010 ➤
Heating, Air conditioning - Edition 11.2011

2 Dash panel vent and air guide ducts,

ventilation
⇒ „2.1 Removing and installing centre vent“, page 5
⇒ „2.2 Removing and installing the right/left side vent“,
page 5
⇒ „2.3 Removing and installing rear vent“, page 6
⇒ „2.4 Removing and installing the rear duct of the right and left
footwell“, page 6
⇒ „2.5 Remove and install footwell vent“, page 7
⇒ „2.6 Inspecting ventilation“, page 7
⇒ „2.7 Removing and installing air intake grid“, page 8

2.1 Removing and installing centre vent

Removing
– Use disassembly wedge -3409- to carefully lever out in the
area of the retaining clips -arrows-.
– Unplug connector from warning light switch.
Install
When installing, ensure that the retaining clips are correctly fitted,
if necessary bend them slightly.
– After installing check the vents for easy adjustment.

2.2 Removing and installing the right/left

side vent
Removing
– Open all the fins of the vent.
– Use disassembly wedge -3409- to carefully lever out in the
area of the retaining clips -arrows-.
– Swivel the vent towards the center out of the opening.
Make sure when removing the side vent that the controls for
the adjustment are not damaged.
Install
When installing, pay attention,
♦ that the retaining clips are correctly fitted, if necessary bend
slightly,
♦ that the controls for the adjustment are not damaged.
– After installing check the vents for easy adjustment.

2. Dash panel vent and air guide ducts, ventilation 5

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2.3 Removing and installing rear vent

Removing
– Use disassembly wedge -3409- to carefully lever out in the
area of the retaining clips -arrows-.
Install
– Clip the vent back into the assembly opening.
– After installing check the vents for easy adjustment.

2.4 Removing and installing the rear duct of

the right and left footwell

Note

Proceed in the same way to remove the rear ducts on either side,
but reversed.

Removing
– Remove the front passenger or driver's seat ⇒ Body Work;
Rep. gr. 72 .
– Remove the centre console ⇒ Body Work; Rep. gr. 68 .
– Remove the attachments of the front floor covering ⇒ Body
Work; Rep. gr. 70 .
– Lift up floor covering, unclip rear duct from cross member and
pull off from heater unit.
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

When installing the rear duct make sure that the rear duct is first
of all pushed onto the heater unit -arrow- and then clipped into
the cross member.

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2.5 Remove and install footwell vent

⇒ „2.5.1 Removing and installing the footwell vent on the driver's
side“, page 7
⇒ „2.5.2 Removing and installing the footwell vent on the front
passenger side“, page 7

2.5.1 Removing and installing the footwell

vent on the driver's side
Removing
– Remove the bottom part of the dash panel insert and the trim
panel on the driver's side ⇒ Body Work; Rep. gr. 70 .
– Unscrew fixing screw -2- and remove footwell vent -1-.
Install
Installation is carried out in the reverse order.

2.5.2 Removing and installing the footwell

vent on the front passenger side
Removing
– Remove the glove compartment ⇒ Body work; Rep. gr. 70 .
– Unscrew fixing screw -2- and remove footwell vent -1-.
Install
Installation is carried out in the reverse order.

Note

On vehicles with glove compartment cooling, pay attention to the

correct position of the hose.

2.6 Inspecting ventilation

– Remove rear bumper ⇒ Body Work; Rep. gr. 63 .

2. Dash panel vent and air guide ducts, ventilation 7

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– The sealing lips -1- in the ventilation frame must be free and
close independently.
– Check fitting position.

Note

For Octavia the two ventilation frames are located on the right
vehicle side, for Octavia Combi one ventilation frame is located
on the right side and one ventilation frame is located on the left
vehicle side.

2.7 Removing and installing air intake grid

Removing
– Remove the cooling water tank cover ⇒ Body Work; Rep. gr.
64 .
– Screw out screws -arrows- (1.3 Nm) and remove the cover
-1-.

– Unscrew the fixing nuts -arrows- (2.5 Nm) and remove the air
intake grid upwards.
Install
Installation is carried out in the reverse order.

Note

The gasket must be correctly positioned at the air intake grid.

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3 Heater control
⇒ „3.1 Removing and installing heater control“, page 9
⇒ „3.2 Plug connections on the rear side of the heater control“,
page 9
⇒ „3.3 Removing and installing flex shaft for positioning unit of air
distribution flaps“, page 10
⇒ „3.4 Removing and installing the bowden wire for temperature
flap“, page 11

3.1 Removing and installing heater control

Removing

Note

♦ The heater control consists of two separate housings. Before

removing the heater control, bring the rotary knobs into the
following position:
♦ Heat regulator to „cold“
♦ Blower to „0“
♦ Direction of vent to „footwell“

– Vehicles with mobile phone holder - slacken mobile phone

holder ⇒ Electrical System; Rep. gr. 91 .
– Carefully lever out the covering -1- using the disassembly
wedge -3409- .
– Screw out screws -3- (1.5 Nm) and remove the heater control
-2- from the dash panel.
– Disconnect plug.
Install
Installation is carried out in the reverse order. Make sure that the
rotary knobs have the same position as during the removal.

3.2 Plug connections on the rear side of the

heater control
Special tools and workshop equipment required
♦ Measuring tool set -V.A.G 1594/C-

3. Heater control 9
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16-pin plug connection is not assigned.

5-pin plug connection, T5
1 - 3. Blower stage
2 - 2. Blower stage
3 - 1. Blower stage
4 - 4. Blower stage
5 - Terminal X

20-pin plug connection, T20c

3 - Re-circulating air flap control motor -V113-
6 - Re-circulating air flap control motor -V113-
8 - Rear window heater
11 - Control unit for heated driver seat -J131-
15 - Control unit for heated front passenger seat -J132-
16 - Terminal 75 seat heating (optional)
18 - Terminal 30
19 - Terminal 15
20 - Terminal 31

3.3 Removing and installing flex shaft for

positioning unit of air distribution flaps
Removing
– Remove the glove compartment ⇒ Body work; Rep. gr. 70 .
– Remove the heater control ⇒ page 9 .
– Press the catch pegs -1- of the flex shaft in
-the direction of the arrow- and pull the flex shaft out of the
adapter -2- of the heater control.

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– Pull off flex shaft -1- with sudden motion from the positioning
unit of the air distribution flaps -2-.
Install
The flex shaft can only be installed in one way on the positioning
unit and on the heater control.
When installing, however, the positioning unit and the rotary knob
of the heater control must be in a certain position relatively to each
other, otherwise this will result in malfunctions.
– Fit flex shaft onto positioning unit of air distribution flaps and
lock in place.
– Use the flex shaft to move the defrost flap into vertical position
(open).
– Fit heater control onto adapter and set air distribution knob to
„Defrost function“.
– In this position, insert flex shaft into heater control and lock in
place.
– Position heater control onto the adapter.

Note

♦ In this position, insert flex shaft into control and lock in place.
f the dash panel is installed and the position of the defrost flap
is not visible, run fresh air blower at maximum speed.
♦ If air also flows out of the defrost vent in the „defrost function“
position and not out of the footwell vents, the flex shaft is cor‐
rectly installed. If this is not the case, remove the flex shaft
from the heater control and turn the rotary knob 1/2 turn (180°).
Then reinsert the flex shaft. Repeat check.

3.4 Removing and installing the bowden

wire for temperature flap
Removing
– Remove left footwell vent ⇒ page 7 .
– Remove the side cover of the centre console on the left side
⇒ Body Work; Rep. gr. 68 .
– Fit rotary knob of heater control fully into the position „cold“.
– Remove the heater control ⇒ page 9 .
– Remove flex shaft for positioning unit of air distribution flaps
from the adapter ⇒ page 10 .
– Release the catch -4- of the Bowden wire cover -1- and take
the Bowden wire cover out of the adapter.
– Release the ball -2- from the lever -3- of the control.

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– Unclip Bowden wire at the positioning unit for temperature flap

-1- and at the heater unit -2-.
Install

Installation is carried out in the reverse order. Make sure that the
Bowden wire is positioned below the hook -arrow-.
– Fit on heater control and check whether it is possible to easily
turn the temperature knob from „cold“ to „warm“.

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4 Components on the heater unit

⇒ „4.1 Removing and installing fresh air blower V2 “, page 13
⇒ „4.2 Removing and installing series resistor for fresh air blower
with overheating fuse N24 “, page 13
⇒ „4.3 Removing and installing dust pollen filter“, page 14
⇒ „4.4 Removing and installing the control motor of the re-circu‐
lating air flap V113 “, page 14
⇒ „4.5 Removing and installing the control unit for temperature
flap“, page 15
⇒ „4.6 Removing and installing heat exchanger“, page 15
⇒ „4.7 Removing and installing heating element for additional air
heating Z35 “, page 19

4.1 Removing and installing fresh air blower

-V2-
Removing
The fresh air blower -V2- is accessible from the front passenger
side of the footwell.
– Remove glove compartment on front passenger side ⇒ Body
Work; Rep. gr. 70 .
– Remove shield -1- from heater unit ⇒ page 1 and footwell vent
on front passenger side ⇒ page 7 .
– Separate plug connection -3- at the fresh air blower -V2- .
– Unscrew screw -4- for fresh air blower -V2- (if present).
– Release catch -2-, turn fresh air blower -V2- in
-direction of arrow- and remove.
Install
Installation is carried out in the reverse order.

Note

If the catch -2- is defective, screw in screw -4- (1 Nm).

4.2 Removing and installing series resistor

for fresh air blower with overheating fuse
-N24-
Removing

DANGER!

The series resistor for fresh air blower with overheating fuse -
N24- can be hot - risk of burning!
Before removing the series resistor for fresh air blower with
overheating fuse -N24- , allow it to cool down.

– Switch off the ignition and all electrical components.

– Remove shield from heater unit ⇒ page 1 .

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– Disconnect plug connection at series resistor for fresh air

blower with overheating fuse -N24- -1-.
– Press the catch in -the direction of the arrow- and take the
series resistor for fresh air blower with overheating fuse -N24-
out of the heater unit.
Install
Installation is carried out in the reverse order.

4.3 Removing and installing dust pollen filter

Removing
– Remove shield -2- from heater unit, see ⇒ page 2 .
– Release cover -3- in the -direction of the arrow A- and remove
in the -direction of the arrow B-.
– Remove dust and pollen filter from the heater unit downwards.
Install

Installation is carried out in the reverse order.

Note

Pay attention to the fitting position of the dust and pollen filter.

4.4 Removing and installing the control mo‐

tor of the re-circulating air flap -V113-
Removing
– Switch off the ignition and all electrical components.
– Remove the storage compartment in the dash panel on the
front passenger side ⇒ Body Work; Rep. gr. 70 .

Note

The position of the re-circulating air flap must not be changed.

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– Remove cover -1-.

– Disconnect the plug connection from the control motor of the
re-circulating air flap -V113- -2-.
– Remove the control motor of the re-circulating air flap - V113-
-2- from the mounts.
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

♦ After installing the control motor, it is necessary to test the op‐

eration of the re-circulating air flap.
♦ Carry out the function „Initiate basic setting“ with the Vehicle
diagnosis, measurement and information system -VAS 5051- .

4.5 Removing and installing the control unit

for temperature flap
Removing
– Switch off the ignition and all electrical components.
– Left-hand drive - remove the side cover of the centre console
on the driver's side ⇒ Body Work; Rep. gr. 68 .
– Right-hand drive - remove storage compartment on front pas‐
senger side ⇒ Body Work; Rep. gr. 70 .
– Remove left footwell vent ⇒ page 7 .
– Unclip the control cable at the positioning unit for temperature
flap -2-.
– Release the catch -1- and press the control unit for tempera‐
ture flap in -the direction of the arrow- up to the stop.
– Pull off positioning unit for temperature flap.
Install
Installation is carried out in the reverse order.

Note

After installing, it is necessary to test the operation of the tem‐

perature flap. It must be possible to adjust the rotary knob from
the position „cold“ into position „warm“ in a smooth and easy way.

4.6 Removing and installing heat exchanger

Special tools and workshop equipment required
♦ Hose clamp -MP 7-602 (3094)-
♦ Hose clamp -T30096 (3093)-
♦ Pneumatic gun, commercially available
Removing
– On vehicles with air conditioning system, switch on the ignition
and set the highest possible temperature.

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– Switch off the ignition, all the electrical consumers and dis‐
connect the battery-earth strap ⇒ Electrical System; Rep. gr.
27 .

DANGER!

The coolant temperature can be over 100 °C when the engine

is warm. The cooling system is under pressure - risk of scald‐
ing!
Before repairs, reduce pressure and temperature if necessary.

– Pinch off coolant hose -1- with the hose clamp -MP 7-602- .
– Pinch off coolant hoses -2- and -3- with hose clamp -T30096- .

Note

If the heat exchanger is replaced, the coolant must be replaced.

In this case, drain the coolant ⇒ Engine; Rep. gr. 19 .

– Separate the quick couplings at the heat exchanger.

– Place the hose -1- a little onto the upper connection.

– Hold a container -2- below the lower connection -3-.
– Carefuly blow with a pneumatic gun the remaining coolant out
of the heat exchanger into the container -2-.

– Unscrew screw -1- between the heat exchanger connections

(hexagon; 6 mm).
– Remove the side cover of the centre console on the left side
⇒ Body Work; Rep. gr. 68 .
– Remove left footwell vent ⇒ page 7 .
– Right-hand drive vehicles with air conditioning system - re‐
move temperature flap control motor -V68- ⇒ page 97 .

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– Unscrew screws -1- and remove the heat exchanger trim pan‐
el.
– Cover the floor covering in the area below the heat exchanger
with a liquid impermeable foil and absorbent paper.

– Depending on the type of heat exchanger - open hose clamps

-1-

or -A- and pull the coolant pipes out of the heat exchanger.
– Remove the heat exchanger out of the heater unit.
Install
Installation is performed in the reverse order, pay attention to the
following points:

– Install only heat exchanger with undamaged and correctly

positioned gasket -A- and -B-.

Note

♦ An incorrectly stuck on gasket can be rolled into the heater unit

when sliding in the heat exchanger.
♦ If the gasket is damaged or incorrectly installed, the cold air
can flow around the heat exchanger.

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– On a removed heat exchanger, check the heater unit (through

the assembly opening -A-) for contamination.
– If necessary, remove dirt or coolant residues drained from the
heat exchanger.
– Carefully slide the heat exchanger into the heater unit.

Note

Always replace the gasket rings -2-.

– Moisten new gasket rings -2- with coolant before installing.

– Insert gasket rings in the connections -3- of the heat exchang‐
er.
– Press the coolant pipes -1- into the connections -3-.

– Push the hose clamps -1- over the connection point. They
must easily turn on the coolant pipes/flange-heat exchanger.
– Hose clamps -1-

or -A- must be attached as shown in the fig.

Note

In case of deformation of the hose clamps, these must be re‐

placed.

– Tighten hose clamps -1- or -A- to 1.5 Nm.

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– Screw in screw -1- between the heat exchanger connections.

Make sure that the screw engages into the provided hole, if
necessary press flange into the direction of the centre of the
vehicle.

– After installing the grommet -C-, check for correct seating in

the bulkhead plenum chamber.
– If necessary, seal the flanges of the coolant pipes to the heat
exchanger -A- and the expansion valve to the evaporator -B-
with grommet -C- against penetration of ambient humidity with
silicone glue sealing mass.
– Pay attention to the sequence when connecting the battery ⇒
Electrical System; Rep. gr. 27 .

Note

Check the coolant circuit for leaktightness, while paying particular

attention to the connection between the coolant pipes and the
heat exchanger.

4.7 Removing and installing heating ele‐

ment for additional air heating -Z35-

Note

♦ The heating element for additional air heating -Z35- is only

fitted to certain models.
♦ Check with ⇒ Vehicle diagnostic tester.

Removing

DANGER!

The heating element for additional air heating -Z35- can be hot
- risk of burning!
Before removing the heating element for additional air heating
- Z35- , allow it to cool down.

– Remove the side cover of the centre console on the left side
⇒ Body Work; Rep. gr. 68 .
– Remove left footwell vent ⇒ page 7 .

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Note

If the lever is positioned opposite the left temperature flap in such

a way that the top screw -A- is covered by the lever -C-, switch
on the ignition and perform another adjustment of the tempera‐
ture.

– Disconnect battery earth strap ⇒ Electrical System; Rep. gr.

27 .
– Unscrew the screws -A- from the cover -B- and remove the
cover.
Vehicles manufactured up to 10.06

– Unscrew fixing nut for supply voltage -3- (6 Nm) and for earth
connection -4- (6 Nm).
– Disconnect the plug connections -5- from the heating element
for additional air heating -Z35- .
Vehicles manufactured as of 11.06

– Unscrew the fixing nut for the earth connection -A- (9 Nm).
– Disconnect the plug -B- with the strip -2- from the heating el‐
ement for additional air heating -Z35- -C-.
All vehicles
– Push the heating element for additional air heating - Z35- out
of the heater unit.
Install
Installation is performed in the reverse order, pay attention to the
following points:
– Pay attention to the sequence when connecting the battery ⇒
Electrical System; Rep. gr. 27 .

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5 Removing and installing the heating

unit from the vehicle
Special tools and workshop equipment required
♦ Hose clamp -MP7-602 (3094)-
♦ Hose clamp -T30096 (3093)-
♦ Pneumatic gun, commercially available
⇒ „5.1 Removing and installing heater unit“, page 21

5.1 Removing and installing heater unit

A second mechanic is required occasionally for removing and in‐
stalling the heater unit.
– Disconnect battery earth strap ⇒ Electrical System; Rep. gr.
27 .
– Removing the dash panel ⇒ Body Work; Rep. gr. 70 .
– Separate the rear duct of the right and left footwell ⇒ page 6 .

DANGER!

The coolant temperature can be over 100°C when the engine

is warm. The cooling system is under pressure - risk of scald‐
ing!
Before repairs, reduce pressure and temperature if necessary.

– Pinch off coolant hose -1- with the hose clamp -MP 7-602- .
– Pinch off coolant hoses -2- and -3- with hose clamp -T30096- .

Note

If the heat exchanger is replaced, the coolant must be replaced.

In this case, drain the coolant ⇒ Engine; Rep. gr. 19 .

– Separate the quick couplings at the heat exchanger.

– Place the hose -1- a little onto the upper connection.

– Hold a container -2- below the lower connection -3-.
– Carefuly blow with a pneumatic gun the remaining coolant out
of the heat exchanger into the container -2-.
– Cover the floor covering in the vehicle interior with a liquid im‐
permeable foil and absorbant paper.

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1 - Screw, 4.5 Nm
2 - Screws, 4,5 Nm
3 - Cable strap
4 - Heater unit
❑ Removing:
– Remove footwell vent
on driver's side.

– Remove the intermedi‐

ate pieces for defrost
duct and dash panel
vents.

– Disconnect the plug

connections from the
heater unit.

– Remove wiring loom

from holder - Pos. 5.

– Release screws - Pos. 6

and 7 - from holder -
Pos. 5 -.

– Holder - Pos. 5.

– Remove the control unit

for data bus diagnostic
interface -J533- (attach‐
ed in the area of the
steering column to the
bracket - Pos. 19 -) ⇒
Electrical System; Rep.
gr. 90 .

– Release screws - Pos. 1

and 2 - from cable clip -
Pos. 3 -.

Note

– Release screws - Pos. 18 and 20 - and remove from holder - Pos. 19 -.

Vehicles up to CW 44.08:

– Remove holder - Pos. 15 and 17.

– Remove supports - Pos. 10 and 12.

Vehicles as of CW 45.08 (MY 09 Facelift):

– Remove the central pipe/dash panel - Pos. 8 ⇒ Body Work; Rep. gr. 70 .

All vehicles:

– Remove heater unit.

❑ Installing:
Installation is performed in the reverse order, pay attention to the following points:

– Install the seal to the front wall from the passenger compartment and then guide the heat exchanger
flange through the seal ⇒ page 23 .

– Top up coolant ⇒ Engine; Rep. gr. 19 .

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5 - Bracket, right
6 - Screws, 8 Nm
7 - Screws, 8 Nm
8 - Central pipe/dash panel
9 - Screws, 8 Nm
10 - Right support
❑ As of CW 45.08 welded to the central pipe Pos. 8
11 - Screws, 20 Nm
12 - Left support
❑ As of CW 45.08 welded to the central pipe Pos. 8
13 - Screws, 8 Nm
14 - Screws, 8 Nm
15 - Support
❑ As of CW 45.08 welded to supports Pos. 10 and Pos. 12
16 - Screws, 2 Nm
17 - Support
18 - Screws, 8 Nm
19 - Bracket, left
20 - Screws, 9 Nm

Seal for heater unit/engine compartment

Note

Pay attention to the fitting position of the seal -1-.

1 - Seal - it must be placed all around in the front wall

2 - Front wall
3 - Bead - it must be placed all around in the groove of the heat
exchanger flange

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82 – Supplementary heating
1 Auxiliary heating
⇒ „1.1 Types of installed auxiliary heatings, general notes“, page
24
⇒ „1.2 Safety measures when working on vehicles fitted with aux‐
iliary heating.“, page 24
⇒ „1.4 Rules of cleanliness when working on the auxiliary heating
and the fuel system“, page 25
⇒ „1.5 General notes when working on vehicles fitted with auxili‐
ary heating“, page 26

1.1 Types of installed auxiliary heatings,

general notes
Types of auxiliary heatings installed as standard
Petrol engines „Thermo Top V“
Diesel engines up to CW 44.2010 „Thermo Top V“
Diesel engines as of CW 45.2010 „Thermo Top VEVO“
Both heatings are nearly identical, they differ only in the type of
fuel delivery to the combustion chamber:
♦ Thermo Top V - burner insert with Venturi nozzle, the fuel in‐
jection is assisted by the suction effect.
♦ Thermo Top VEVO - the fuel is mixed with the air in the evap‐
orator. The same system is used for the auxiliary heating
Thermo Top C (available as original accessories).
Further information and description of function:
♦ ⇒ Self-study programme No. 79 ; Auxiliary heating
♦ ⇒ Owner's manual Octavia II
♦ Contact assignment ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations
As of CW 22.2011, a radio remote control is part of the scope of
delivery of the auxiliary heating installed as standard.
♦ Description of the function of the radio remote control
⇒ page 29 and Operating Instruction ⇒ Operating Instruction
Octavia II .
♦ Replacing the battery of the radio remote control
⇒ page 30 .

Note

When replacing, pay attention to the correct part numbers see ⇒

Electronic Catalogue of Original Parts . The fuel pump for Thermo
Top V, located on the fuel tank, has a different part number than
for Thermo Top VEVO.

1.2 Safety measures when working on ve‐

hicles fitted with auxiliary heating.
♦ The auxiliary heating must not be on or be switched on in areas
where there is a risk of fire or explosion.

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♦ The auxiliary heating must not be on or be switched on (also

not via a preselected switch-on time) in closed rooms without
exhaust gas suction.
♦ Observe the relevant and applicable safety measures and the
rules for cleanliness when working on the fuel system ⇒ En‐
gine; Rep. gr. 20 .
♦ The engine must not be started as well as the auxiliary heating
must not be switched on if parts of the fuel system (e.g. dosing
pump, fuel line, fuel gauge sender) are removed or opened.

WARNING

The cooling system is under pressure, the coolant temperature

can be over 100°C when the engine is warm - risk of burning!
Before repairs, reduce pressure and temperature if necessary.

Vehicles with start-stop system:

♦ On vehicles with activated start-stop system (recognizable by
a message in the dash panel insert), the engine can start au‐
tomatically if required.
♦ It is therefore necessary to ensure that the start-stop system
is deactivated when carrying out work on the vehicle (ignition
switched off; if required switch ignition on again).
Conditions for the activation/deactivation of the start-stop system
⇒ Operating Instruction Octavia II .

1.3 Notes when operating the auxiliary heat‐

ing on vehicles with diesel engine.
If PME or RME fuel (methyl ester of plants or rapeseed) is refueled
during the cold season, it may cause malfunctions of the auxiliary
heating.
Reasons:
– If PME or RME fuel (methyl ester of plants or rapeseed) is
refueled during the cold season, it may cause malfunctions of
the auxiliary heating. The deposits can lead to malfunctions
during the combustion process (no more flame formation and
deflagration in the combustion chamber) after prolonged op‐
eration with PME or RME fuel.

1.4 Rules of cleanliness when working on

the auxiliary heating and the fuel system
Carefully observe the following five rules for cleanliness when
working on the fuel system:
♦ Thoroughly clean the connection points and their surroundings
before releasing.
♦ Place removed parts on a clean surface and cover. Do not use
fuzzy cloths!
♦ Carefully cover or seal opened or removed components if the
repair is not carried out immediately.
♦ Only install clean parts: Remove spare parts from their wrap‐
ping immediately before installing. Do not use any parts which
have been stored unwrapped (e.g. in tool boxes).
♦ On an open fuel system, the following is not allowed:
– Working with compressed air.

1. Auxiliary heating 25
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– Start the engine.

– Switch on auxiliary heating.
– Avoid moving the vehicle.

1.5 General notes when working on vehi‐

cles fitted with auxiliary heating
♦ The auxiliary heating is available in different versions; there‐
fore when replacing pay attention to the exact assignment ⇒
Electronic Catalogue of Original Parts .
♦ There is a second type plate located in the engine compart‐
ment at the lock carrier. In case of uncertainty of the type of
auxiliary heating, pay attention to the type plate attached to
the auxiliary heating as well as the part number of the auxiliary
heating control unit -J364- , which is shown in the function
„Self-diagnosis“ ⇒ Vehicle diagnostic tester.
♦ Switch off the ignition before disconnecting or connecting the
battery as this could otherwise damage the control units, see
⇒ Electrical System; Rep. gr. 27 Chapter „Work sequence
when disconnecting and reconnecting the battery“.
♦ The control unit for auxiliary heating -J364- and other compo‐
nents are equipped with a self-diagnosis system; inspect
⇒ Vehicle diagnostic tester.
♦ Certain inspections may cause the control unit to detect and
store a fault. It is therefore necessary to interrogate the fault
memory after having completed all inspections and repairs,
and if necessary delete ⇒ Vehicle diagnostic tester.
♦ If there is too little fuel in the fuel tank (fuel gauge is in the red
field), the control unit for auxiliary heating -J364- does not
switch on the auxiliary heating.
♦ A minimum voltage of 11.5 V is required for perfect functioning
of the electrical components.
♦ The fuel lines (pipes and hoses) from the fuel tank to the aux‐
iliary heating must be routed flush with the underfloor in such
a way that they do not come in contact with those parts which
become warm and they must be protected against heat. If it
heats up, the operation of the auxiliary heating could be im‐
paired.
♦ If parts of the fuel system were removed or replaced, make
sure that all the components for the fuel removal of the auxil‐
iary heating are properly installed.
♦ The function of the auxiliary heating must be inspected after
finishing the repair work on the auxiliary heating or the fuel
system.
♦ If the auxiliary heating is replaced by a new one, it must run at
full load mode for at least 10 minutes before handing it over to
the customer. There can still be lubricant residues in or on the
components of the auxiliary heating fitted at the factory, which
evaporate after it is switched on for the first time. The smoke
which occurs may worry the customer and he might look upon
the auxiliary heating as defective.

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Note

In the event of complaints about the operation of the auxiliary

heating on vehicles with diesel engine at the start of the heating
period - it is probably caused by frozen fuel in the line from the
fuel tank to the auxiliary heating (summer diesel is still present in
the fuel system of the auxiliary heating).

Safety measures ⇒ page 24 .

1.5.1 Starting conditions of the auxiliary heat‐

ing
♦ Engine type is O.K. (diesel/petrol)
♦ Auxiliary heating coded in Gateway
♦ No undervoltage shut-off
♦ No Crash shut-off
♦ No fuel reserve operation
♦ No fault code entries which prevent the start-up

Note

The AC button does not influence the auxiliary heating operation.

1. Auxiliary heating 27
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2 Description of the function and con‐

trol of auxiliary heating as well as the
radio remote control
Other information and further description of function:
♦ ⇒ Self-study programme No. 79 ; Auxiliary heating
♦ ⇒ Owner's manual Octavia II
♦ Contact assignment ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations
⇒ „2.1 Description of the function and control of auxiliary heating“,
page 28
⇒ „2.2 Operation (activation) of the auxiliary heating“, page 29
⇒ „2.3 Descriptions of the functions of the radio control Telestart
T91“, page 29
⇒ „2.4 Replacing the battery of the radio remote control “,
page 30

2.1 Description of the function and control of

auxiliary heating
Switching on
Starting the auxiliary heating is carried out optionally via the re‐
mote control, the instant heat button -E537- (if present, installed
as of CW 22.11), a corresponding programming in the dash panel
insert or direct switch-on in the cover of the air conditioning ac‐
tuator. The auxiliary heating is switched on automatically via the
vehicle electronics, if all the necessary requirements are present
⇒ page 27 . Detailed description for programming as well as
switching on/off the auxiliary heating ⇒ Operating Instruction Oc‐
tavia II .
First of all the functional testing of the fresh air blower -V2- and
the combined glow plug with flame monitoring -Q8- is carried out,
then the glow plug with flame monitoring -Q8- passes through the
preheating phase.
The subsequent start procedure depends, among other things,
on the coolant temperature and can therefore vary over time. In
addition, the fuel is supplied, the glow plug with flame monitoring
-Q8- is gradually switched off and the flame detector is activated.
After completing the initial phase, the device is burning at full load
and the additional load control (operating mode, full load, partial
load and control pause) is based on the following thresholds of
the coolant temperature.
♦ Change from full load to partial load: approx. 82 °C
♦ Change from partial load to control pause: approx. 88 °C
If the coolant temperature drops during the control pause and
within 15 minutes to below 71 °C, the heater unit starts in the full
load mode.
The reference resistance of the glow plug with flame monitoring
-Q8- is automatically redefined depending on the device in order
to compensate the age-related changes during the start-up phase
or during the afterrun at regular intervals.
As a result of this calibration process, the affected processes can
also take a long time.

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Switching off
After the maximum possible duration of 60 min has elapsed or
after manual shutdown by remote control or instant heat button -
E537- , the auxiliary heating is switched off.
The auxiliary heating switches off when at least one of the defined
switching requirements is no longer fulfilled ⇒ page 27 .
After switching off, the operation of the dosing pump -V54- is im‐
mediately stopped.
The combustion air blower -V6- and the glow plug with flame
monitoring -Q8- continue to operate within a limited period of time,
in order to completely burn the remaining fuel in the system and
to cool the burner components.
The afterrun of the circulating pump -V55- is also carried out.
The afterrun of the heater unit can last different lengths of time
depending on the software version and the load level at the time
of shutdown.
175 seconds when switching off from full load mode
110 seconds when switching off from partial load mode
Depending on the software versions in the control unit, this can
lead to deviations of the above after-running times.

2.2 Operation (activation) of the auxiliary

heating
Starting the auxiliary heating is carried out optionally via the re‐
mote control, the instant heat button -E537- (if present), a corre‐
sponding programming in the dash panel insert or direct switch-
on in the cover of the air conditioning actuator. The auxiliary
heating is switched on automatically via the vehicle electronics, if
all the necessary requirements are present ⇒ page 27 .
Detailed description for switching on and operating the auxiliary
heating ⇒ Operating Instruction Octavia II .

2.3 Descriptions of the functions of the radio

control Telestart T91
As of CW 22.2011, a radio remote control is part of the scope of
delivery of the auxiliary heating installed as standard.
The Webasto heater units Thermo Top V/VEVO or the vehicle
blower can be switched on and off wireless over a great distance
with the radio control Telestart T91. A modus change must be
performed at the sender in order to switch on the vehicle blower
(ventilating the vehicle interior).
After switching on, the auxilary heating switches off automatically
after the expiration of the selected engaging duration or by means
of the automatic heating.
An optimal signal transfer is obtained in a cleared area or from
elevated locations. As a result, the operation of the auxiliary heat‐
ing becomes possible if the distance from the vehicle is up to 600
m. Due to poor weather conditions, in heavily developped areas
or as a result of a weak battery, the reception is restricted ac‐
cordingly.

2. Description of the function and control of auxiliary heating as well as the radio remote control 29
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Note

♦ Detailed description of the function of the radio remote control

⇒ Operating Instruction Octavia II .
♦ If the radio remote control is replaced, carry out the adaptation
with ⇒ Vehicle diagnostic tester.

2.4 Replacing the battery of the radio re‐

mote control

Note

♦ Observe the fitting position of the battery (see symbol „+“ on

the cover -1-).
♦ Only use a battery of the same type with a voltage of 3V.
♦ The adaptation is ensured, a new adaptation is not necessary.

– Place a coin in the gap of the cover -1- and unlock the cover
by turning -arrow- and remove it.
– Replace battery, insert cover and lock it by turning to the right.

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3 Repairing the auxiliary heating

⇒ „3.1 Summary of components of auxiliary heating“, page 31
⇒ „3.2 Type plate of auxiliary heating“, page 32
⇒ „3.3 removing and installing ambient temperature sensor G17
“, page 34
⇒ „3.4 Removing and installing auxiliary heating“, page 34
⇒ „3.5 Removing and installing lengthened exhaust pipe (only on
vehicles with diesel engine up to CW 45.05)“, page 36
⇒ „3.6 Removing and installing silencer with bracket“, page 37
⇒ „3.7 Removing and installing holder for auxiliary heating“, page
37
⇒ „3.8 Removing and installing cover for auxiliary heating“, page
37
⇒ „3.9 removing and installing coolant shut-off valve of heating
system N279 “, page 38
⇒ „3.10 Removing and installing radio receiver for auxiliary heat‐
ing R64 “, page 38

3.1 Summary of components of auxiliary heating

1 - Radio receiver for auxiliary

water heating -R64-
❑ mounted as of CW
22.10
❑ removing and installing
⇒ page 38
2 - Fuel gauge sender -G-
❑ Removing and Installing
⇒ Engine; Rep. gr. 20
❑ Fitting location: under
the rear seat bench on
the fuel delivery unit
3 - Roof aerial for signal recep‐
tion from the radio remote con‐
trol of the auxiliary heating
❑ removing and installing
⇒ Electrical System;
Rep. gr. 91
4 - During operation of the aux‐
iliary heater -N279-
❑ the heater coolant shut‐
off valve is controlled by
the auxiliary heater con‐
troller -J364-
❑ Fitting location: at the
bulkhead in the engine
compartment
❑ Functional testing with
⇒ Vehicle diagnostic
tester
❑ removing and installing
⇒ page 38
❑ not fitted on all engines
see ⇒ page 38

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5 - Fresh air blower relay -J13-

❑ only vehicles without Climatronic
❑ check ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
❑ Fitting location: additional relay holder under the dash panel
6 - Fuse carrier
7 - Coolant temperature sender -G62-
❑ before removing, reduce pressure in cooling system if necessary
8 - Battery
9 - Ambient temperature sensor -G17-
❑ removing and installing ⇒ page 34
❑ check ⇒ Vehicle diagnostic tester
❑ Fitting location: below the front left bumper
10 - Circulating pump -V55-
❑ removing and installing ⇒ page 41
11 - Auxiliary heating with auxiliary heating control unit -J364-
❑ removing and installing ⇒ page 34
❑ Fitting location: below the front right bumper
❑ the type plate is located at the auxiliary heating as well as at the lock carrier ⇒ page 32
12 - Exhaust system of auxiliary heating
❑ removing and installing ⇒ page 42
13 - Dosing pump -V54-
❑ removing and installing ⇒ page 53
❑ Check fuel flow rate ⇒ page 54

3.2 Type plate of auxiliary heating

The type plate is attached to the auxiliary heating and its duplicate
to the lock carrier.
Type plate at the auxiliary heating
Version for petrol engines

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Version for diesel engines up to CW 44.2010

Version for diesel engines as of CW 45.2010

Type plate at lock carrier

Version for petrol engines

Version for diesel engines up to CW 44.2010

3. Repairing the auxiliary heating 33

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Version for diesel engines as of CW 45.2010

3.3 removing and installing ambient temper‐

ature sensor -G17-
The outside temperature sensor -G17- is located behind the bot‐
tom grid of the front left bumper.
Removing
– Except vehicles RS and Scout - depending on the fitting loca‐
tion of the sensor, remove the air guide grid from the front left
bumper ⇒ Body Work; Rep. gr. 63 , if necessary put a finger
through the grid of the bumper.
– Vehicles RS and Scout - remove bumper ⇒ Body Work; Rep.
gr. 63 .
– Unclip ambient temperature sensor -G17- -1- from the bracket
-arrows- and disconnect the plug connection.
Install
Installation is carried out in the reverse order.

3.4 Removing and installing auxiliary heat‐

ing
Removing

Note

If the auxiliary heating is replaced, first connect the diagnostic unit

⇒ Vehicle diagnostic tester and the function „replace control unit“
is called up under the guided functions.

Special tools and workshop equipment required

♦ Hose clamps -MP7-602 (3094)-
– Disconnect the battery-earth cable with the ignition off ⇒ Elec‐
trical System; Rep. gr. 27 .
– Remove front bumper ⇒ Body Work; Rep. gr. 63 .
– Remove the front right wheelhouse liner ⇒ Body Work; Rep.
gr. 66 .

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– Removing windshield washer reservoir ⇒ Electrical System;

Rep. gr. 92 .
– Separate the exhaust system (only diesel engines).

WARNING

The cooling system is under pressure, the coolant temperature

can be over 100°C when the engine is warm - risk of burning!
Before repairs, reduce pressure and temperature if necessary.

– Pinch off coolant hoses -1- and -2- with hose clamps -MP7-602
(3094)- .
– Pull out coolant hoses -1- and -2- from the auxiliary heating.
– Extracting fuel line ⇒ page 40 .
– Disconnect plug connections of auxiliary heating.

– Remove fixing screw -1- (8 Nm).

– Remove fixing nut -2- (8 Nm).

3. Repairing the auxiliary heating 35

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– Slacken clamp -3- at coolant hose from the front frame side
rail and remove fixing nut -1- (15 Nm).
– Remove auxiliary heating -2-.
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

♦ Pay attention to correct connection of hoses according to con‐

nection plan ⇒ Engine; Rep. gr. 19 .
♦ If the auxiliary heating is not replaced, connect the diagnostic
unit ⇒ Vehicle diagnostic tester after installing and the function
„unlock heater unit“ is called up under the guided functions.
♦ After installing the auxiliary heating, top up the refrigerant cir‐
cuit and ventilate ⇒ Engine; Rep. gr. 19 .
♦ Pay attention to the sequence when connecting the battery
earth strap ⇒ Electrical System; Rep. gr. 27 .
♦ If the auxiliary heating is replaced by a new one, it must run at
full load mode for at least 10 minutes before handing it over to
the customer. There can still be lubricant residues in or on the
components of the auxiliary heating fitted at the factory, which
evaporate after it is switched on for the first time. The smoke
which occurs may worry the customer and he might look upon
the auxiliary heating as defective.

3.5 Removing and installing lengthened ex‐

haust pipe (only on vehicles with diesel
engine up to CW 45.05)
Removing
– Release screw -7- (6 Nm), slacken clamp -5- (7 Nm) and re‐
move exhaust tailpipe -6-.
– Release screws -3- (6 Nm) and -4- (23 Nm), slacken clamp
-1- (7 Nm) and remove middle exhaust pipe -2-.
Install
Installation is carried out in the reverse order.

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3.6 Removing and installing silencer with

bracket
Removing
– Slacken exhaust pipe from silencer -4-.
– Remove screw -1- (7 Nm) and lay the exhaust pipe aside.
– Remove screw -2- (7 Nm) and remove silencer -4-.
– Remove screws -3- from silencer bracket (6 Nm).
– Slacken bracket from the centering tabs and remove.
Install
Installation is carried out in the reverse order.

3.7 Removing and installing holder for aux‐

iliary heating
• The auxiliary heating is removed.
Removing
– Remove screws -1- and remove holder -2-.
Install
Installation is carried out in the reverse order.

3.8 Removing and installing cover for auxil‐

iary heating
• The auxiliary heating is removed.
Removing
– Mark the fitting location of the supports for the coolant hoses,
remove screw -1- (4 Nm) and take out the supports.
– Unclip cover at the catches -arrows- and pull over the catch
pegs -2-.
Install
Installation is carried out in the reverse order.

3. Repairing the auxiliary heating 37

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3.9 removing and installing coolant shut-off

valve of heating system -N279-

Note

The coolant shut-off valve of the heating system -N279- is not

fitted on all engines (see connection diagram for coolant hoses
⇒ Engine; Rep. gr. 19 ).

Removing
Special tools and workshop equipment required
♦ Hose clamps -MP7-602 (3094)-

WARNING

The cooling system is under pressure, the coolant temperature

can be over 100°C when the engine is warm - risk of burning!
Before repairs, reduce pressure and temperature if necessary.

– Remove engine cover and intake pipe to exhaust turbocharger

⇒ Engine; Rep. gr. 21 .
– Pinch off coolant hoses -B- with hose clamps -MP7-602
(3094)- and pull off the hoses from the coolant shut-off valve
of heating system -N279- -1-.
– Disconnect plug connection at coolant shut-off valve of heat‐
ing system -N279- .
– Release fixing nuts -A- (10 Nm) and remove coolant shut-off
valve of heating system -N279- -1-.
Install
Installation is carried out in the reverse order.
Diagnosis of coolant shut-off valve of heating system -N279-
For fault finding use the ⇒ Vehicle diagnostic tester in the function
„Targeted fault finding“.

3.10 Removing and installing radio receiver

for auxiliary heating -R64-
The radio receiver for auxiliary heating -R64- is located behind
the right luggage compartment trim panel.
– Remove right luggage compartment trim panel ⇒ Body Work;
Rep. gr. 70 .
– Disconnect plug of antenna socket and plug from radio re‐
ceiver for auxiliary heating -R64- .
– Release the fixing screws and remove the radio receiver with
holder.
– Press the latch clip and push the radio receiver out of the
holder.
– Installation is performed in the reverse order, pay attention to
the following points:

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Note

When replacing the radio receiver, adapt the new radio receiver
with the ⇒ Vehicle diagnostic tester in the function „Targeted fault
finding“ to the auxiliary heating.

3. Repairing the auxiliary heating 39

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4 Components of auxiliary heating

⇒ „4.1 Summary of components of auxiliary heating“, page 40
⇒ „4.2 Removing and installing air intake silencer“, page 40
⇒ „4.3 Removing and installing circulating pump V55 “,
page 41
⇒ „4.4 Removing and installing exhaust system“, page 42

4.1 Summary of components of auxiliary heating

1 - Auxiliary heating with auxil‐

iary heating control unit -J364-
❑ removing and installing
⇒ page 34
2 - Fuel line with quick coupling
3 - Air intake silencer
❑ removing and installing
⇒ page 40
4 - Exhaust System
❑ removing and installing
⇒ page 42
5 - Circulating pump -V55-
❑ removing and installing
⇒ page 41
6 - Exhaust tail pipe
7 - Protective part

4.2 Removing and installing air intake si‐

lencer
Removing
– Remove front bumper ⇒ Body Work; Rep. gr. 63 .

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– Screw out the screw -A- and detach the air intake silencer
-B- from the intake manifold.
Install
Installation is carried out in the reverse order.

4.3 Removing and installing circulating

pump -V55-
Removing
Special tools and workshop equipment required
♦ Hose clamps -MP7-602 (3094)-

WARNING

The cooling system is under pressure, the coolant temperature

can be over 100°C when the engine is warm - risk of burning!
Before repairs, reduce pressure and temperature if necessary.

– Remove noise insulation ⇒ Body Work; Rep. gr. 50 and front

part of right wheelhouse liner ⇒ Body Work; Rep. gr. 66 .
– On vehicles where the plug is not directly located at the circu‐
lating pump housing (up to CW 01.10) - Remove bumper ⇒
Body Work; Rep. gr. 63 .
– Vehicles up to CW 01.10 - Disconnect the plug -2- from the
control unit and expose the cable to the pump -1-.

– Vehicles as of CW 02.10 - Disconnect the plug -1- from the

pump -2-.

4. Components of auxiliary heating 41

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– Disconnect the coolant hoses from the hose clamps -MP

7-602 (3094)- .
– Slacken clamps -1- and pull off the coolant hoses from the
circulating pump -V55- .
– Release screw -2- and remove circulating pump -V55- .
Install
Installation is performed in the reverse order, pay attention to the
following points:
– After installing the circulating pump, top up the refrigerant cir‐
cuit and ventilate ⇒ Engine; Rep. gr. 19 .

4.4 Removing and installing exhaust system

Removing
Special tools and workshop equipment required
♦ Torque wrench
– Slacken fixing clamp -1- (7 Nm), remove screws -2- and -3- (7
Nm).
– Remove exhaust system.
Install
Installation is performed in the reverse order, pay attention to the
following points:

WARNING

The exhaust system must be aligned in such a way that it does

not come in contact with the wiring loom.

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5 Disassembling and assembling aux‐

iliary heating
⇒ „5.1 Components of the inner auxiliary heating, Thermo Top V“,
page 43
⇒ „5.2 Components of the inner auxiliary heating, Thermo Top
VEVO“, page 45
⇒ „5.3 Removing and installing auxiliary heating control unit J364
“, page 46
⇒ „5.4 Plug assignment at control unit for auxiliary heating J364
Thermo Top V/VEVO“, page 47
⇒ „5.5 Removing and installing, checking the temperature sensor
G18 and the overheating sensor G189 “, page 48
⇒ „5.6 Removing and installing glow plug with flame monitoring
Q8 on Thermo Top V“, page 49
⇒ „5.7 Removing and installing glow plug with flame monitoring
Q8 on Thermo Top VEVO“, page 49

5.1 Components of the inner auxiliary heat‐

ing, Thermo Top V
For disassembling the auxiliary heating, remove it from the vehi‐
cle ⇒ „3.4 Removing and installing auxiliary heating“, page 34 .

5. Disassembling and assembling auxiliary heating 43

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1 - Cover for auxiliary heating

control unit -J364-
❑ removing - separate the
fuel supply and unlatch
the cover from the latch
clips
2 - Temperature sensor -G18-
❑ remove and install, test
⇒ page 48
3 - Overheating sensor -G189-
❑ remove and install, test
⇒ page 48
4 - Fuel shut-off valve -N109-
❑ only on vehicles with
diesel engine as of CW
45.05
❑ Component of the com‐
bustion pipe, cannot be
replaced individually
❑ Inspect proper opera‐
tion ⇒ page 55
5 - Combustion pipe
6 - Heat exchanger
7 - 7 Nm
8 - Retaining spring
9 - 4 Nm
10 - Gasket
❑ replace after each re‐
moval
❑ Check fitting position
11 - Cover
❑ removing and installing ⇒ page 37
12 - Coolant hose supports
13 - 4 Nm
14 - Retaining plate
15 - Coolant hose supports
16 - Retaining clip
17 - Glow plug with flame monitoring -Q8-
❑ pay attention to correct position
❑ remove and install, test ⇒ page 49

Note

18 - Heating element for fuel preheating -Z66- (only diesel engines)

❑ Inspect proper operation ⇒ Vehicle diagnostic tester
19 - Housing
❑ the combustion air blower -V6- and the housing cannot be disassembled
20 - Auxiliary heating control unit -J364-
❑ removing and installing ⇒ page 46

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21 - 4 Nm

5.2 Components of the inner auxiliary heat‐

ing, Thermo Top VEVO
For disassembling the auxiliary heating, remove it from the vehi‐
cle ⇒ page 34

1 - Cover for auxiliary heating

control unit -J364-
2 - Temperature sensor -G18-
❑ remove and install, test
⇒ page 48
3 - Overheating sensor -G189-
❑ remove and install, test
⇒ page 48
4 - Retaining bracket for retain‐
ing spring of glow plug with
flame monitoring -Q8-
❑ pay attention to correct
position
5 - Glow plug with flame moni‐
toring -Q8-
❑ pay attention to correct
position
❑ removing and installing
⇒ page 49
6 - Retaining spring for glow
plug with flame monitoring -
Q8-
❑ pay attention to correct
position
7 - Combustion pipe
8 - Heat exchanger
9 - 7 Nm
10 - Retaining spring
11 - 4 Nm
12 - Gasket
❑ replace after each re‐
moval
❑ Check fitting position
13 - Cover
❑ removing and installing ⇒ page 37
14 - Coolant hose supports
15 - 4 Nm
16 - Retaining plate
17 - Coolant hose supports
18 - Housing
❑ combustion air blower -V6- and housing cannot be disassembled

5. Disassembling and assembling auxiliary heating 45

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19 - Auxiliary heating control unit -J364-

❑ removing and installing ⇒ page 46
20 - 4 Nm

5.3 Removing and installing auxiliary heat‐

ing control unit -J364-
Removing
– Remove cover for control unit ⇒ Item 1 (page 44) .
– Unplug connector -A- and -C- and release screws -arrows-.
– Remove cover.
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

When assembling the wiring loom of the connector -C- must be

in the recess -B-.

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5.4 Plug assignment at control unit for auxiliary heating -J364- Thermo Top V/
VEVO

Con‐ Pin No. Connection designation

nec‐
tor
1 1 Heating control unit -J162- (only vehicles
without air conditioning system)
2 Radio receiver for auxiliary water heating -
R149-
3 Heating control unit -J162- (only vehicles
without air conditioning system)
4 CAN bus Low
5 Dosing pump -V54-
6 Coolant shut-off valve of the heating system
-N279- (only on certain vehicles)
7 CAN bus High
8 Fresh air blower relay -J13-
2 1 Battery + (tml. 30)
2 Battery - (tml. 31)

5. Disassembling and assembling auxiliary heating 47

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Con‐ Pin No. Connection designation

nec‐
tor
3 1 Glow plug with flame monitoring -Q8- +
2 Glow plug with flame monitoring -Q8- -
4 1 Fuel shut-off valve -N109- (as of CW 45.05
Thermo Top V, diesel engines)
2 Fuel shut-off valve -N109- (as of CW 45.05
Thermo Top V, diesel engines)
3 Heating element for fuel preheating -Z66-
(Thermo Top V, only diesel engines)
4 Heating element for fuel preheating -Z66-
(Thermo Top V, only diesel engines)
5 2 Temperature sensor -G18- +
3 Overheating sensor -G189- +
6 Temperature sensor -G18- -
7 Overheating sensor -G189- -
6 2 Circulating pump -V55- -
3 Circulating pump -V55- +

5.5 Removing and installing, checking the

temperature sensor -G18- and the over‐
heating sensor -G189-

Note

Proper functioning can be checked using the ⇒ Vehicle diagnostic

tester in the function „Targeted fault finding“.

Removing
– Release screw -1- and remove retaining spring -2-.
– Pull out temperature sensor -G18- -3- and overheating sensor
-G189- -4- using a set of pointed pliers.
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

♦ Pay attention to the correct location of the retaining spring

-2-.
♦ The sensors cannot be replaced individually.

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5.6 Removing and installing glow plug with

flame monitoring -Q8- on Thermo Top V

Note

♦ The diesel version is shown on the figure.

♦ For the diesel version, the heating element for fuel preheating
-Z66- (Pos. -A-) is installed firmly at the combustion chamber.
The cables are connected with the cables of the glow plug with
flame monitoring -Q8- . In the case of this version the complete
combustion pipe must be replaced, if the glow plug with flame
monitoring -Q8- is defective.

Removing
– Remove housing with combustion air blower -V6- ⇒ page 43 .

– Raise the clip -A- on both sides using a suitable screwdriver

and remove the glow plug -B- with flame monitoring -Q8- .
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

♦ The glow plug -B- must be fixed in the exact position with the
clip -A- in the ceramic housing. A faulty position can cause
problems during the combustion (e.g. build-up of smoke).
♦ The non-insulated connecting lines to the glow plug must not
touch or rest against any other components (risk of short cir‐
cuit).
♦ Proper functioning of the glow plug with flame monitoring -Q8-
can be checked using the ⇒ Vehicle diagnostic tester in the
function „Targeted fault finding“.

5.7 Removing and installing glow plug with

flame monitoring -Q8- on Thermo Top
VEVO
Removing
– Remove housing with combustion air blower -V6- ⇒ page 45 .
– Pull out retaining spring -1- -arrow-.
– Remove retaining bracket -2-.
– Remove glow plug with flame monitoring -Q8- Pos. -3-. -3-.
Install
Installation is performed in the reverse order, pay attention to the
following points:

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Note

♦ Observe the fitting position of the retaining spring -1- as well

as the retaining bracket -2-.
♦ The non-insulated connecting lines to the glow plug must not
touch or rest against any other components (risk of short cir‐
cuit).
♦ Proper functioning of the glow plug with flame monitoring -Q8-
can be checked using the ⇒ Vehicle diagnostic tester in the
function „Targeted fault finding“.

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6 Fuel supply of auxiliary heating

Note

♦ Observe safety measures ⇒ page 24 .

♦ Observe rules for cleanliness ⇒ page 25 .
♦ Fuel lines must be secured only with spring strap clips. The
use of clamp-type or screw-type clips is not allowed.
♦ Use pliers for spring strap clips to remove and fit the spring
strap clips.
♦ If parts of the fuel system were removed or replaced, make
sure that all the components for the fuel removal of the auxil‐
iary heating are properly installed.
♦ The fuel line (pipes and hoses) from the fuel tank to the aux‐
iliary heating must be routed in such a way that it does not
come in contact with those parts which become warm and it
must be protected against heat. If it heats up, the operation of
the auxiliary heating could be impaired.

⇒ „6.1 Summary of components of fuel supply“, page 52

⇒ „6.2 Removing and installing the dosing pump V54 with its
component parts“, page 53
⇒ „6.3 Check fuel flow rate“, page 54
⇒ „6.4 Checking the function of the fuel shut-off valve N109 “,
page 55

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6.1 Summary of components of fuel supply

1 - Quick coupling
2 - Auxiliary heating
3 - Quick coupling
4 - Dosing pump -V54-
❑ removing and installing
⇒ page 53
5 - Fuel delivery unit
❑ Removing and Installing
⇒ Engine; Rep. gr. 20
❑ Connection of the fuel
line to the fuel delivery
unit ⇒ page 52

Connection of the fuel line to the fuel delivery unit

The fuel removal of the auxiliary heating is performed via the con‐
nection to the fuel delivery unit -arrow-.

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6.2 Removing and installing the dosing pump -V54- with its component parts

WARNING

The fuel line is under pressure! Place cleaning cloths around

the connection point before detaching hose connections. Then
reduce the pressure by carefully removing the hose.

1 - Gasket at fuel reservoir

2 - Plug connection of dosing
pump -V54-
3 - Clips
4 - Quick coupling
5 - Bracket for dosing pump -
V54-
6 - Dosing pump -V54-
❑ Dosing pump and rela‐
ted components are a
replacement part
❑ different versions, see
⇒ Electronic Catalogue
of Original Parts
❑ Removing:

Note

– Disconnect plug con‐

nection - Pos. 2 - 2 - of
the dosing pump -V54- .

– Slacken fuel hose at the

quick coupling - Pos. 4 -.
4.

– Remove the cables from

the cable straps - Pos. 3.
3.

– Unhook bracket for dos‐

ing pump -V54- - Pos. 5
- at fuel reservoir.

– Slacken the bottom

hose clamp at the con‐
nection on the fuel delivery unit and pull out the fuel extraction pipe - Pos. 7.
❑ Installing:
Installation is performed in the reverse order, pay attention to the following points:

Note

7 - Fuel extraction pipe

6. Fuel supply of auxiliary heating 53

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The correct position of the fuel extraction pipe

Note

If the auxiliary heating operates without problems with a full fuel

tank and in the event problems occur when operating with a partly
filled fuel tank (fault message „No flame formation“ or „Repeated
flame-out“), this indicates a fault in the routing of the fuel extrac‐
tion pipe (the pipe -A- is located outside the banking up housing
-D-).

6.3 Check fuel flow rate

Special tools and workshop equipment required
♦ ⇒ Vehicle diagnostic tester
♦ Commercial measuring glass
Test requirements
• Voltage at the dosing pump -V54- : approx. battery voltage
⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations.
• Resistance of dosing pump -V54- : approx. 5.2 Ω ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations.
• No fault in fault memory ⇒ Vehicle diagnostic tester.
• Ambient temperature below 25°C.
• Coolant temperature below 30°C.
• Fuel lines are not damaged or leaking.
• Fuel reservoir is filled adequately (fuel gauge in the dash panel
insert is not at the red level).
Test sequence

WARNING

The fuel line is under pressure! Place cleaning cloths around

the connection point before detaching hose connections. Then
reduce the pressure by carefully removing the hose.

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– Disconnect fuel line at the dosing pump -V54- and close with
suitable means.

– Call up the guided function „check fuel flow rate“ with the ve‐
hicle diagnosis, measurement and information system, open
the fuel line and at the same time hold the measuring glass.
After approx. 30 seconds the fuel line is filled and ventilated.
– Close fuel line.
– Empty measuring glass.
– Call up the guided function „check fuel flow rate“ with the ve‐
hicle diagnosis, measurement and information system, open
the fuel line and at the same time hold the measuring glass.
After approx. 120 seconds the fuel delivery is finished.
– Reconnect the fuel line.
Nominal flow rate: 22 to 28 ml.
– If the nominal rate is not achieved, replace dosing pump -V54-
⇒ Item 6 (page 53) .

6.4 Checking the function of the fuel shut-off

valve -N109-

Note

Fuel shut-off valve -N109- Pos. -B- only on Thermo Top V as of

CW 45.2005 on vehicles with diesel engines.

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– Remove the fuel line from the auxiliary heating ⇒ page 40 .

Close the removed fuel line or place the end of the removed
fuel line in a small vessel if necessary (a small quantity of fuel
can escape during the following actuator diagnosis. This can
also be avoided by disconnecting the plug from the dosing
pump located at the fuel tank.
– For example, connect the hand vacuum pump -VAS 6213- at
the fuel line to the auxiliary heating -A-.
– Connect the ⇒ Vehicle diagnostic tester and select the function
„actuator diagnosis of the auxiliary heating“ in the targeted
fault finding, do not start yet.
– Using the hand vacuum pump -VAS 6213- , generate an over‐
pressure of approx. 1.5 bar.
– Wait approx. 1 minute, the overpressure indicated on the pres‐
sure gauge of the pump must remain.
– Activate the actuator fuel shut-off valve -N109- in the function
„Actuator diagnosis“, while doing so observe the display on the
pressure gauge of the hand vacuum pump.
– As soon as the fuel shut-off valve -N109- is actuated, the
pointer on the pressure gauge of the hand vacuum pump must
drop.

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87 – Air conditioning system

1 Instructions and safety measures for repair work on vehicles with air
conditioning and when using refrigerant R 134a
Safety measures must be observed for refrigerant R 134a (additional directives may apply in individual coun‐
tries):
Refrigerant must not be released into the environment, it must be drained off from the refrigerant circuit using
an exhaust system or A/C service station. The drained off refrigerant is processed on site or is returned to the
manufacturer for ecological disposal (different or additional directives may apply in certain countries).
If unpleasant odours come from the heating and air conditioning unit, it must be cleaned with e.g. the ultrasonic
air conditioning system cleaning device -VAS 6189B- . When cleaning, proceed according to the enclosed
instruction. Other information, see ⇒ page 58 .
If during repairs on the vehicle it is necessary to drain the refrigerant circuit, the vehicle must be entrusted to
a service centre!
Reasons:
Only the service centres have suitable A/C service stations and properly trained personnel where the refrig‐
erant can be drained off professionally.

In order to carry out professional work on air conditioning systems for vehicles, you must have completed a
training course on the air conditioning system including general knowledge (possibly with a corresponding final
test) and you must be able to implement these elements in practice, see ⇒ Air conditioning system with
refrigerant R134a; Rep. gr. 00 General notes on the air conditioning system.
Only these workers are recognised as qualified to pursue the activities on air conditioning systems for vehicles.
Alternative or additional regulations may be valid in certain countries.

Note

All the safety measures when working on vehicles with air condi‐
tioning system, when using the refrigerant as well as to the below-
mentioned chapters can be found in the Workshop Manual „Air
conditioning system with refrigerant R134a“ ⇒ Air conditioning
system with refrigerant R134a; Rep. gr. 00 technical data.

♦ General notes on the air conditioning system

♦ General instructions for refrigerant circuit
♦ Legal texts and legal regulations
♦ Refrigerant circuit
♦ Working with the A/C service station
♦ Detect leaks in the refrigerant circuit
♦ Removing contaminants from the refrigerant circuit
♦ Complaints
♦ Check the pressure in the refrigerant circuit (with the A/C serv‐
ice station)
♦ Replace components of the refrigerant circuit

1. Instructions and safety measures for repair work on vehicles with air conditioning and when using refrigerant R 134a 57
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Caution

Do not buckle or sharply bend the refrigerant lines.

There is a foil in the refrigerant lines which could be damaged.
Refrigerant lines must not be bent over a smaller radius R =
100 mm.

Vehicles with start-stop system:

♦ On vehicles with activated start-stop system (recognizable by
a message in the dash panel insert), the engine can start au‐
tomatically if required.
♦ It is therefore necessary to ensure that the start-stop system
is deactivated when carrying out work on the vehicle (ignition
switched off; if required switch ignition on again).
Conditions for the activation/deactivation of the start-stop system
⇒ Operating Instruction Octavia II .

1.1 Notes regarding the odours coming from

the heating and air conditioning unit
Numerous methods for cleaning the evaporator, which differ in
their use and effect, are offered on the market. It is currently rec‐
ommended to clean the evaporator of Škoda vehicles using the
ultrasonic air conditioning system cleaning device -VAS 6189B- .
When cleaning, proceed according to the enclosed instruction. If
additional procedures are tested and approved by Škoda in the
course of time, the corresponding notes can be found in the
Workshop Manual ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00 .

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2 Description of the air conditioning

system

Note

Detailed description of the function of the air conditioning system

can be found in the Workshop Manual „Air conditioning system
with refrigerant R134a“ ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00 technical data.

⇒ „2.1 Operation of the air conditioning system“, page 59

⇒ „2.2 Structure of the refrigerant circuit“, page 59
⇒ „2.3 Parts of the refrigerant circuit“, page 61
⇒ „2.4 Extractor, filler and measurement valves for quick cou‐
plings of the AC service station on the refrigerant circuit“,
page 63
⇒ „2.5 Parts for securing the refrigerant circuit“, page 64

2.1 Operation of the air conditioning system

The temperature in the passenger compartment is influenced by
radiant heat through the window and by the contact heat emitted
by metallic parts. In order to provide agreeable temperatures for
the passengers on very hot days, some of the ambient heat must
be evacuated.
As it is a well known fact that heat spreads towards colder tem‐
peratures, an aggregate that generates lower temperatures has
been fitted to the vehicle, i.e. the evaporator. Liquid refrigerant is
continuously evaporated in this aggregate. The heat required for
this operation is drawn from the air flowing through the evapora‐
tor.
The refrigerant gas together with the absorbed heat is pumped
out of the evaporator by the AC compressor. The AC compres‐
sor's compression work increases the heat content and the tem‐
perature of the refrigerant. It is now considerably higher than the
ambient air temperature.
The high-temperature refrigerant and its heat content flow to the
condenser. There, because of the temperature difference be‐
tween the refrigerant and the ambient air, the refrigerant releases
heat into the ambient air via the condenser. The evaporated re‐
frigerant is therefore liquified.
The refrigerant is also a heat conveyor. As it will be re-used, it is
again pumped to the evaporator.

2.2 Structure of the refrigerant circuit

Note

The parts marked with an * must only be repaired in specialist service centres which have suitably trained
personnel and are fitted out for working on the refrigerant circuit.

2. Description of the air conditioning system 59

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HP = High-pressure side
LP = Low-pressure side

1 - Regulating valve for com‐

pressor of air conditioning sys‐
tem - N280- *
2 - AC compressor*
3 - Belt pulley
❑ with anti-lock device
4 - Oil drain plug*
5 - Pressure relief valve*
6 - High-pressure sender -
G65-
7 - Connection with valve*
8 - Condenser*
9 - Fluid container with dessi‐
cator cartridge*
10 - Extractor, filler and meas‐
urement valve*
❑ High-pressure side
11 - Screw cap
12 - Expansion valve*
13 - Evaporator*
14 - Extractor and measure‐
ment valve*
❑ Low-pressure side
15 - Screw cap
16 - Shock absorber*
❑ for damping of pressure
fluctuations
❑ only fitted on certain
models

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2.3 Parts of the refrigerant circuit

AC compressor
Engine dependent AC compressors manufactured by the firms
Denso, Zexel and Sanden are used. They differ only in the ver‐
sion.
Externally controlled AC compressors with variable displacement
are driven by the engine's ribbed V-belt. It does not have a mag‐
netic clutch.
The belt pulley/compressor shaft grip occurs via a driver clutch.
The displacement of the AC compressor is controlled via an ex‐
ternally driven regulating valve with PWM signal on the suction
side in accordance with the required cooling output.
The AC compressor continues operating with a minimum power
supply requirement even when the air conditioning system is off.
The AC compressor sucks refrigerant gas from the evaporator,
compresses it and transfers it to the condenser.

Note

The AC compressor contains refrigerant oil, which can be mixed

with the R 134a refrigerant at all temperatures.

Condenser
The condenser dissipates heat from the compressed refrigerant
gas into the ambient air.
During this process the refrigerant gas condenses and liquifies.

Fluid reservoir
The fluid reservoir -3- is bolted to the condenser or is its compo‐
nent.
It gathers the liquid drops and conveys them to the expansion
valve in a constant flow.
Humidity, that has penetrated into the refrigerant circuit during
assembly, is bound by a dessicator cartridge integrated in the fluid
reservoir.

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Expansion valve
The expansion valve atomizes incoming refrigerant and controls
the flow in accordance with the different pressures in such a way
that, depending on the heat transport, the vapour only becomes
gaseous at the outlet of the evaporator.

Evaporator
The liquid refrigerant evaporates in the evaporator. The heat re‐
quired for this operation is drawn from the air flowing through the
evaporator fins.
The air cools down the evaporator. The refrigerant evaporates
and is sucked in with the absorbed heat as gas by the AC com‐
pressor.
The externally regulated AC compressor allows a variable air out‐
let temperature of 1 to 11°C.
Pipes and hoses of the refrigerant circuit
The mixture of refrigerant oil and refrigerant R 134a corrodes cer‐
tain metals (e.g. copper) and alloys and dissolves certain hose
materials.
Therefore only original spare parts may be used.

Note

Pay attention to the prescribed tightening torques for the screwed

connections.

O-ring seals
These O-rings seal off the connection points between the indi‐
vidual components of the refrigerant circuit.
Only use O-rings that are resistant to refrigerant R 134a and re‐
lated refrigerant oils. Original spare parts offer this guarantee.
Black and coloured O-rings are fitted.
O-ring seals:
♦ Only use once, replace.
♦ Pay attention to correct diameter -a- and -b-.
♦ Moisten with refrigerant oil before inserting.

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2.4 Extractor, filler and measurement valves

for quick couplings of the AC service
station on the refrigerant circuit

WARNING

Before removing the extractor and filler valves, the refrigerant

must be drained off with the aid of the A/C service station.
If the refrigerant circuit is not opened within 10 minutes after
draining it off, pressure can arise in the refrigerant circuit due
to the post-evaporation. Drain the refrigerant once again.

Note

♦ Only use valves and connections that are resistant to refrig‐

erant R134a and related refrigerant oils.
♦ Different connections (outside diameter) for the high-pressure
and low-pressure side guarantee that the quick-coupling
adapters are not interchanged.
♦ Carefully screw in the handwheel of the service coupling after
connecting the A/C service station and only so far until the
valve of the service connection is safely opened (observe the
pressure gauge, do not over-press the valve).
♦ After disconnecting the quick-coupling adapter tighten the
caps to prevent any dirt from penetrating.

Special tools and workshop equipment required

♦ Socket inserts -T10364-

Arrangement in the vehicle, see ⇒ page 69 .

Extractor, filler and measurement connections with Schrader
valve

Note

♦ Carefully tighten the valve core -2- because of the low tight‐
ening torque.
♦ These valves are available in different versions. Therefore
they have different tightening torques. If the valve core -2- has
a thread of VG5 (5.2 x 0.7 mm, tyre valve) the tightening torque
is 0.4±0.1 Nm, a valve core with a thread of M6 x 0.75 mm has
a tightening torque of 0.9±0.1 Nm and a valve core with a
thread of M8 x 1.0 mm has a tightening torque of 2.0±0.2 Nm.

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High-pressure side
1 - Service coupling in the refrigerant line
2 - Extractor, filler and measurement valve
3 - Sealing ring
4 - Cap

Low-pressure side
1 - Service coupling in the refrigerant line
2 - Extractor and measurement valve
3 - Sealing ring
4 - Cap

2.5 Parts for securing the refrigerant circuit

Pressure relief valve
The pressure relief valve is located on the AC compressor and
opens in the event of overpressure. The refrigerant does not flow
out completely.
If the valve was opened the adjoining area is also covered in oil.
Opening pressure: 4 ±0.4 MPa (40±4 bar)
Closing pressure: at least 3.1 MPa (31 bar)

Note

If the pressure relief valve was opened, determine the cause of

the overpressure in the system and eliminate it.

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Belt protection for blocked AC compressor

The AC compressor operates continuously via a driver clutch
-2- and -3- in the belt drive, whether or not the air conditioning
system is switched on.
If the AC compressor blocks, the rubber elements -3- will shear
off or the driver disc -2- will become deformed depending on the
compressor temperature (it depends on the temperature).
In any case the belt pulley of the AC compressor can rotate while
the driver disc/compressor shaft is at a standstill.
Replace the AC compressor.
Various AC compressors with a differently designed anti-lock de‐
vice are fitted engine dependent ( ⇒ page 67 ).

Note

♦ This anti-lock device applies for the Denso AC compressor.

♦ The anit-lock device for the AC compressors Zexel and San‐
den is designed differently.

High-pressure sender -G65-

The high-pressure sender -G65- determines the pressure in the
refrigerant circuit and transmits the values to the Air conditioning
system control unit -J301- (climatic) or to the Climatronic control
unit -J255- .
The following are shifted via these control units:
♦ The radiator fan -V7- switches to the next speed in the event
of a pressure rise in the refrigerant circuit
♦ Reduction of the compressor output if the pressure is too high,
3.2 MPa (32 bar), e.g. too little engine cooling
♦ Reduction of the compressor output if the pressure is too low,
0.2 MPa (2 bar), e.g. refrigerant loss
Air conditioning system control unit -J301- (Climatic) or Clima‐
tronic control unit -J255- (Climatronic)

The air conditioning system control unit -J301 - is integrated in

the heating and air conditioning system control.
It processes information such as ambient temperature, actual and
required interior temperature, evaporator temperature, pressure
in the refrigerant circuit, engine load and driving conditions.
Depending on the required cooling output the air conditioning
system control unit -J301 - sends a PWM signal (pulse width
modulated) to the regulating valve of the AC compressor.

Note

♦ On vehicles fitted with Climatronic, the Climatronic control unit

-J255- takes over these functions.
♦ As of MY 09, different arrangement of actuating elements and
displays.

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Regulating valve for compressor of air conditioning system -

N280-
Depending on the required cooling output the regulating valve
-arrow- (component of the AC compressor, cannot be replaced
separately) receives a PWM signal from the air conditioning sys‐
tem control unit - J301- or Climatronic control unit -J255- and
regulates the displacement of the AC compressor via the suction
pressure (position of the articulated disc).
This guarantees that the output of the AC compressor does not
exceed the requirements.

Note

Depending on the type of manufacturer, the regulating valve can

be constructively designed differently.

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3 Contents
⇒ „3.1 Refrigerant R134a“, page 67
⇒ „3.2 Refrigerant oil“, page 67

3.1 Refrigerant R134a

Refrigerant circuit
525 ± 25 g refrigerant R 134a (for all AC compressors)

Note

♦ Fill the refrigerant circuit on the high-pressure side only.

♦ Always fill the refrigerant circuit up to the top tolerance limit
(there will still be some refrigerant in the filling hoses).

3.2 Refrigerant oil

As refrigerant oil is strongly hygroscopic (it absorbs humidity),
protect open cans against penetrating humidity and immediately
seal tight after use.

Note

♦ Refrigerant oils from the containers which were opened for a

longer period of time, cannot be used.
♦ Because of its chemical properties, refrigerant oil must not be
disposed of with engine oil or gearbox oil. The refrigerant oil
must be disposed of as oil of unknown origin.
♦ The total volume of refrigerant oil is contained in the spare part
AC compressor.

Manufacturer Part number of AC com‐ Filling capacity Part number of refrigerant oil
pressor
Denso 1K0 820 803 F 180 ± 10 cm3 G 052 300 A2
1K0 820 803 E 140 ± 10 cm3
1K0 820 859 M,S 140 ± 10 cm3
1K0 820 859 N,H,P,T 90 ± 10 cm3
1K0 820 808 A, 90 ± 10 cm3
8J0 260 805 90 ± 10 cm3
Zexel 1K0 820 803 H 120 ± 10 cm3 G 052 154 A2
Sanden 1K0 820 803 G 110 ± 10 cm3 G 052 154 A2
1K0 820 859 F,G,Q 110 ± 10 cm3
1K0 820 808 B, 110 ± 10 cm3
Delphi 5N0 820 803 110 ± 10 cm3 G 052 154 A2
5N0 820 803 A,B,C 110 ± 10 cm3

Oil distribution
The oil, which before the first activation of the air conditioning system was located in the AC compressor's oil
pan, is distributed as follows in the refrigerant circuit:

3. Contents 67
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Oil distribution
♦ AC compressor approx. 50 %

♦ Condenser approx. 10 %

♦ Air intake hose approx. 10 %

♦ Evaporator approx. 20 %

♦ Fluid reservoir approx. 10 %

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4 Repairing the air conditioning system - engine compartment

Note

♦ The parts marked with an * must only be repaired in specialist service centres which have suitably trained
personnel and are fitted out for working on the refrigerant circuit.
♦ Comply with the safety measures when working on vehicles with air conditioning system and when using
refrigerant R 134a and observe the instructions for working on the refrigerant circuit ⇒ Air conditioning
system with refrigerant R134a; Rep. gr. 00 technical data.
♦ The engine must not be started if the refrigerant lines are not connected to the AC compressor and the AC
compressor is shut off with plugs (risk of overheating because of the internal refrigerant oil circuit).
♦ If the refrigerant circuit was separated, it is not always necessary to replace the dessicator, see
⇒ page 76 .
♦ If the earth strap of the battery was disconnected, pay attention to the sequence when connecting it ⇒
Electrical System; Rep. gr. 27 .

⇒ Fig. “„Remove refrigerant lines from the AC compressor““ , page

71
⇒ Fig. “„Remove the refrigerant lines from the condenser““ , page
72
⇒ Fig. “„Removing and installing, inspecting high pressure sender
-G65- ““ , page 72

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Summary of components

1 - Ambient temperature sen‐

sor -G17-
❑ removing and installing
⇒ page 34
❑ check ⇒ Vehicle diag‐
nostic tester
❑ Fitting location: below
the front left bumper at
the bumper support
2 - Fluid container with dessi‐
cator cartridge*
❑ removing and installing
⇒ page 73
❑ Replace fluid reservoir
(dessicator cartridge),
if… ⇒ page 76
3 - Regulating valve for com‐
pressor of air conditioning sys‐
tem - N280- *
❑ Elements of the AC
compressor, do not re‐
place individually

Note

4 - AC compressor*
❑ various manufacturers:
⇒ page 67 ; Contents
❑ Removing and installing
the refrigerant lines
⇒ page 71
❑ Belt protection for
blocked AC compressor
⇒ page 64
❑ Removing and installing
AC compressor ⇒ page 77
❑ Running-in instruction ⇒ page 78
5 - Condenser*
❑ Removing and installing the refrigerant lines ⇒ page 72
❑ Removing and installing the condenser ⇒ page 81
6 - High-pressure sender -G65-
❑ function ⇒ page 64
❑ removing and installing ⇒ page 72
❑ inspect ⇒ Vehicle diagnostic tester in the function „Targeted fault finding“
7 - Pressure relief valve*
❑ Replace O-ring (⇒ Electronic Catalogue of Original Parts ).
❑ Tightening torque: 10 Nm
❑ function ⇒ page 64
❑ check ⇒ page 78
8 - Extractor and filling valve*
❑ High-pressure side
❑ for exhausting, filling and measuring

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❑ Contents ⇒ page 67
❑ always screw on cap with gasket
❑ Description, removing and installing ⇒ page 63
9 - Clamp
10 - Retaining clip
11 - Exhaust valve*
❑ Low-pressure side
❑ for exhaust and measurement only
❑ always screw on cap with gasket
❑ Description, removing and installing ⇒ page 63
12 - Expansion valve*
❑ removing and installing ⇒ page 80
13 - Holder for refrigerant lines
14 - 20 Nm

Remove refrigerant lines from the AC compressor

Note

♦ Empty the refrigerant circuit with the aid of the A/C service
station.
♦ After disconnecting, shut off the refrigerant lines and the AC
compressor connections with suitable caps to protect them
from the penetration of ambient humidity.

1 - 23 Nm
2 - Connection fitting for high-pressure line
♦ Torsion stop with sleeve
3 - Connection fitting for low-pressure line
♦ Torsion stop with sleeve
4 - O-ring (low-pressure side)
♦ replace (⇒ Electronic Catalogue of Original Parts )
5 - Fitting sleeve
6 - Groove for O-ring
7 - O-ring (high-pressure side)
♦ replace (⇒ Electronic Catalogue of Original Parts )

4. Repairing the air conditioning system - engine compartment 71

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Remove the refrigerant lines from the condenser

1 - Connection fitting for condenser
2 - O-rings
♦ replace (⇒ Electronic Catalogue of Original Parts )
3 - Connection fitting for refrigerant line
♦ Torsion stop with sleeve
4 - 10 Nm
5 - Fitting sleeve
6 - Groove for O-ring

Note

Shut off refrigerant line and condenser connection.

Removing and installing, inspecting high pressure sender -G65-

– Switch off the ignition and all electrical components.
– Unplug 3-pin connector from high pressure sender -G65- -1-.
– Unscrew high pressure sender.
Tightening torque: 8 Nm
– Replace O-ring (⇒ Electronic Catalogue of Original Parts ),
moisten with refrigerant oil and carefully insert.

Note

♦ The refrigerant circuit remains closed, connection to valve.

♦ The high pressure sender -G65- -1- can also be fitted accord‐
ing to engine variant on another point close to the condenser.

Functional test
The function of the high pressure sender -G65- is checked via
self-diagnosis of the air conditioning system control unit -J301-
⇒ Vehicle diagnostic tester.

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5 Removing and installing parts of the

air conditioning system - engine com‐
partment

Note

Detailed description of the air conditioning system, instructions

for repair work and when using the refrigerant R134a can be
found in the Workshop Manual „Air conditioning system with re‐
frigerant R134a“ ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00 technical data.

⇒ „5.1 Removing and installing dessicator cartridge“, page 73

⇒ „5.2 Replacing dessicator cartridge / fluid reservoir with dessi‐
cator“, page 76
⇒ „5.3 Removing and installing AC compressor“, page 77
⇒ „5.4 Running-in instructions of the AC compressor “,
page 78
⇒ „5.5 Inspecting the pressure relief valve on the AC compressor“,
page 78
⇒ „5.6 Removing and installing the expansion valve“, page 80
⇒ „5.7 Removing and installing the cover plate for expansion
valve“, page 81
⇒ „5.8 Removing and installing the condenser“, page 81

5.1 Removing and installing dessicator car‐

tridge
On condensers:
♦ „Denso“ the container is a component part with the dessicator
of the condenser and cannot be replaced individually.
♦ „Showa“ and „Fujikoki“ the dessicator is replaced together with
the container ⇒ page 74 .
♦ „Modine“ the container is a component part of the condenser.
The dessicator and the strainer can be replaced
⇒ page 74 .

Note

♦ The condensers can be mutually exchanged.

♦ Repairs must only be carried out in specialist service centres
which have suitably trained personnel and are fitted out for
working on the refrigerant circuit.
♦ If the refrigerant circuit was separated, it is not always neces‐
sary to replace the dessicator, see ⇒ page 76 .
♦ All opened components of the refrigerant circuit must be pro‐
tected from the penetration of ambient humidity with suitable
plugs.
♦ When replacing, pay attention to the prescribed volume of re‐
frigerant oil in the refrigerant circuit see „Air conditioning sys‐
tem with refrigerant R134a“ ⇒ Air conditioning system with
refrigerant R134a; Rep. gr. 00 technical data, chapter „Re‐
placing components of the refrigerant circuit“.

5. Removing and installing parts of the air conditioning system - engine compartment 73
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5.1.1 Condensers manufactured by Showa

and Fujikoki
Removing
– Drain the refrigerant circuit with the aid of the A/C service sta‐
tion.
– Put lock carrier in service position ⇒ Body Work; Rep. gr. 50 .
– Release fixing screws for the radiator ⇒ Engine; Rep. gr. 19 .
– Attach radiator with workshop tools (cable strap or welding
wire) to workshop crane -V.A.G 1202 A- and lifting device
-2024 A- and unhook radiator from lock carrier. Coolant hoses
and refrigerant lines remain connected.
– Unscrew screw -1- (if necessary, remove expanding rivet) and
remove retaining clip -2-.
– Unscrew screws -5- and pull out the fluid reservoir with des‐
sicator -3- towards the top.
Install
Installation is carried out in the reverse order. Pay attention to the
following:

♦ Replace O-rings -4-.

♦ First tighten the screws -5- and then the screw -1- to 5 Nm.
♦ Fill the refrigerant circuit with the aid of the A/C service station.

5.1.2 Condensers manufactured by Modine

Removing
– Release top protective cap -1- from dessicator reservoir.
– Drain the refrigerant circuit with the aid of the A/C service sta‐
tion.

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– Press the screw cap -1- into the fluid reservoir.

– Remove Seeger ring -arrow- and pull the screw cap -1- out of
the reservoir with the aid of a screw M12 -2-.

– Pull the dessicator bag out of the reservoir using a commer‐

cially available pick-up tool -arrow-.

– Make a welding wire (Ø 2 mm) as shown in the illustration.

a - 380 mm
b - max. 7 mm
c - max. 6 mm

Note

To avoid damaging the condenser, absolutely hook the welding

wire onto the strainer as shown in the illustration.

– Carefully pull the strainer -2- with the welding wire -1- out of
the condenser.
Install
Installation is performed in the reverse order, pay attention to the
following points:
– Insert a new strainer into the reservoir and then insert a new
dessicator bag.

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– Check the fluid reservoir -2- via the opening for contamination
or damage to the sealing surfaces.
– Replace the screw cap -1- with the relevant gasket. Slightly
moisten the gasket of the screw cap with refrigerant oil before
installing.
Pay attention to the correct fit of the gasket in the screw cap -1-.
– Insert Seeger ring -arrow-.

– Screw in the protective cap -1-.

– Re-install the remaining component parts which were re‐
moved.
– Fill the refrigerant circuit with the aid of the A/C service station.

5.2 Replacing dessicator cartridge / fluid

reservoir with dessicator
The dessicator cartridge / fluid reservoir with dessicator has to be
replaced, if:
♦ the coolant circuit was blown through or flushed
♦ the AC compressor has blocked
♦ the system has been opened as of an undetermined time
(creeping leakage)
The dessicator cartridge / fluid reservoir with dessicator must not
be replaced, if:
♦ after an accident the fluid reservoir is not damaged
♦ the repair at the refrigerant circuit is performed for a short pe‐
riod (within the specified repair time) and the vehicle is not
older than 5 years
♦ for the repair of other components, the refrigerant circuit must
be opened for a short period and the vehicle is not older than
5 years

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5.3 Removing and installing AC compressor

Note

♦ Repairs must only be carried out in specialist service centres

which have suitably trained personnel and are fitted out for
working on the refrigerant circuit.
♦ Attachment of the bracket for auxiliary units -4- ⇒ Engine; Rep.
gr. 13 .
♦ If the AC compressor only has to be removed from the bracket
-4- because of the removal of other components, the refriger‐
ant circuit must not be opened and the AC compressor with
connected refrigerant lines must be attached free of stress to
the body.

Removing
– Drain the refrigerant circuit with the aid of the A/C service sta‐
tion.
– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 50 .
– Remove the V-ribbed belt ⇒ engine; Rep. gr. 13 .
– Unplug connector -2-.
– Removing refrigerant lines -1- from the AC compressor
⇒ page 69 .
– Release screws -3- and remove AC compressor.
Install

Note

♦ The total volume of refrigerant oil is contained in the spare part

AC compressor.
♦ When replacing, pay attention to the prescribed volume of re‐
frigerant oil in the refrigerant circuit see „Air conditioning sys‐
tem with refrigerant R134a“ ⇒ Air conditioning system with
refrigerant R134a; Rep. gr. 00 technical data, chapter „Re‐
placing components of the refrigerant circuit“.

Installation is carried out in the reverse order. Pay attention to the

following:
– Before fitting the new AC compressor rotate it 10 times by
hand.

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– When installing make sure that the dowel sleeves -5- are fitted.
Tighten screws -3- to 25 Nm.
– Attach refrigerant lines -1- to the AC compressor ⇒ page 69 .

Note

The engine must not be started if the refrigerant lines are not
connected to the AC compressor and the AC compressor is shut
off with plugs (risk of overheating because of the internal refrig‐
erant oil circuit).

– Replace fluid reservoir with dessicator ⇒ page 73 .

– Fill the refrigerant circuit with the aid of the A/C service station.
– Comply with the running-in instructions for the AC compressor
⇒ page 78 .

5.4 Running-in instructions of the AC com‐

pressor
After the initial filling of the refrigerant circuit or if after blowing
through the refrigerant circuit new refrigerant oil was filled in
( ⇒ page 67 ), the whole volume of refrigerant oil is in the AC
compressor.
To avoid damaging the AC compressor, the AC compressor must
be loaded as follows:
– Position the rotary switch for air distribution on „person flow“.
– Open all dash panel vents.
– Position the fresh-air blower switch at least on speed 3.
– Position rotary switch for temperature selection on the left stop
(minimum temperature).
With Climatronic select the temperature „LO“.
– Start engine.
– Switch on air condition system once idle stabilisation has been
achieved (after approx. 5 seconds).
With Climatronic set to operating mode „AUTO“.
– Run engine without interruption for at least 5 minutes at idle
speed.
– Subsequently switch off engine.
This shuts off the oil distribution in the refrigerant circuit and the
AC compressor can be fully loaded.

5.5 Inspecting the pressure relief valve on

the AC compressor
♦ Task: Protects the refrigerant circuit from excessive pressure.

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DANGER!

There is a risk through icing.

The pressure relief valve drains the coolant while the engine is
running and if an excesssive pressure exists in the refrigerant
circuit.
Switch off engine.

Inspecting the pressure relief valve on the AC compressor

The pressure relief valve -arrow- has operated if refrigerant oil
sticks in the immediate vicinity:
♦ In this case, the vehicle must be repaired in a specialist service
centre which has suitably trained personnel and is fitted out
for working on the refrigerant circuit.

Note

The position of the pressure relief valve varies for the different AC
compressors. The function is however the same.

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5.6 Removing and installing the expansion valve

Note

♦ Repairs must only be carried out in specialist service centres which have suitably trained personnel and are
fitted out for working on the refrigerant circuit.
♦ Before removing, empty the refrigerant circuit with the aid of the A/C service station.
♦ All opened components of the refrigerant circuit must be protected from the penetration of ambient humidity
with suitable plugs.
♦ The O-rings must be replaced ⇒ Electronic Catalogue of Original Parts and before installing moisten with
refrigerant oil.
♦ On certain engines remove the intake hose to the exhaust turbocharger, the DPF cover and if necessary
the intake hose to the air filter for an easier access to the engine cover ⇒ Engine, corresponding repair
group .

1 - Screws, 12 Nm
2 - Refrigerant lines on expan‐
sion valve
3 - O-ring
4 - Expansion valve
❑ Removing:
– Vehicles with cover
plate in front of the ex‐
pansion valve - remove
cover plate for expan‐
sion valve ⇒ page 81 .

– Release screws - Pos. 1

- and pull the refrigerant
lines - Pos. 2 - out of the
expansion valve.

– Release screws - Pos. 9

- and remove the expan‐
sion valve from the heat-
protection insulation -
Pos. 6 -. 6.
❑ Installing:
– Installation is carried out
in the reverse order.

Note

5 - O-ring
6 - Heat-protection insulation
7 - O-ring
8 - O-ring
9 - Screws, 5 Nm
10 - Connection pipes
❑ for heat exchanger

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5.7 Removing and installing the cover plate

for expansion valve
– Detach hoses from heat exchanger see ⇒ page 21 .
– Remove nut -1- (6 Nm).
– Release the clamps -2- and remove the cover plate -3-.

5.8 Removing and installing the condenser

Note

♦ Repairs must only be carried out in specialist service centres which have suitably trained personnel and are
fitted out for working on the refrigerant circuit.
♦ Before removing, empty the refrigerant circuit with the aid of the A/C service station.
♦ All opened components of the refrigerant circuit must be protected from the penetration of ambient humidity
with suitable plugs.
♦ When replacing, pay attention to the prescribed volume of refrigerant oil in the refrigerant circuit see „Air
conditioning system with refrigerant R134a“ ⇒ Air conditioning system with refrigerant R134a; Rep. gr. 00
technical data, chapter „Replacing components of the refrigerant circuit“.

Removing
– Remove the lock carrier ⇒ Body Work; Rep. gr. 50 and secure
the radiator, for example with wire, so that the intake hoses
are not excessively strained.
– Removing refrigerant lines at the condenser ⇒ page 69 .
– Release fixing screws -4- and -6- and remove condenser.

5. Removing and installing parts of the air conditioning system - engine compartment 81
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Summary of components

1 - Condenser
❑ secured with 5 screws at
the radiator
2 - Sealing strips
❑ Stick at top, at bottom
and at the sides of the
condenser
❑ they are no longer fitted
in vehicles manufac‐
tured after 03.06
3 - Support

Note

4 - Screw, 5 Nm
5 - Radiator
6 - Screws, 5 Nm
❑ 4 pieces
7 - Fluid reservoir with dessi‐
cator
❑ removing and installing
⇒ page 73

Install
Installation is performed in the reverse order, pay attention to the
following points:
– First tighten the screw -4-, subsequently the screws on the
right and on the left side of the condensor.

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6 Removing and installing the heating

and air conditioning unit from the ve‐
hicle
(Climatic, air conditioning system with manual control and Clima‐
tronic)
Special tools and workshop equipment required
♦ Hose clamp -MP7-602 (3094)-
♦ Hose clamp -T30096 (3093)-
♦ Pneumatic gun, commercially available
Removing and installing

Note

♦ Repairs must only be carried out in specialist service centres

which have suitably trained personnel and are fitted out for
working on the refrigerant circuit.
♦ A second mechanic is required occasionally for removing and
installing the heating and air conditioning unit.
♦ On certain engines remove the engine cover, the intake hose
to the exhaust turbocharger, the DPF cover and if necessary
the intake hose to the air filter for an easier access to the ex‐
pansion valve ⇒ Engine, corresponding repair group .

– Drain the refrigerant circuit with the aid of the A/C service sta‐
tion.
– Disconnect battery earth strap ⇒ Electrical System; Rep. gr.
27 .
– Removing the dash panel ⇒ Body Work; Rep. gr. 70 .
– Separate the rear duct of the right and left footwell ⇒ page 6 .

DANGER!

The coolant temperature can be over 100 °C when the engine

is warm. The cooling system is under pressure - risk of scald‐
ing!
Before repairs, reduce pressure and temperature if necessary.

– Pinch off coolant hose -1- with the hose clamp -MP7-602
(3094)- .
– Pinch off coolant hoses -2- and -3- with hose clamp -T30096
(3093)- .

Note

If the heat exchanger is replaced, the coolant must be replaced.

In this case, drain the coolant ⇒ Engine ⇒ Rep. gr. 19 .

– Separate the quick couplings at the heat exchanger.

– Vehicles with cover plate in front of the expansion valve - re‐
move cover plate for expansion valve ⇒ page 81 .

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– Place the hose -1- a little onto the upper connection.

– Hold a container -2- below the lower connection -3-.
– Carefuly blow with a pneumatic gun the remaining coolant out
of the heat exchanger into the container -2-.

– Release screws -1- of refrigerant lines -2-.

– Remove the refrigerant lines from the expansion valve -3-.
– Shut off the openings of the refrigerant lines and expansion
valve.
– Cover the floor covering in the vehicle interior with a liquid im‐
permeable foil and absorbant paper.

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1 - Screw, 4.5 Nm
2 - Screws, 4,5 Nm
❑ 2 pieces
3 - Cable strap
4 - Air Conditioning
❑ Removing:
– Remove footwell vent
on driver's side.

– Remove the intermedi‐

ate pieces for defrost
duct and dash panel
vents.
– Disconnect the plug
connections from the
heating and air condi‐
tioning unit.

– Remove wiring loom

from holder - Pos. 5.

– Release screws - Pos. 6

and 7 - from holder -
Pos. 5 -.

– Remove holder - Pos. 5.

– Remove the control unit

for data bus diagnostic
interface -J533- (attach‐
ed in the area of the
steering column to the
bracket - Pos. 19 -) ⇒
Electrical System; Rep.
gr. 90 .

– Release screws - Pos. 1

and 2 - from cable clip - Pos. 3 -.

Note

– Release screws - Pos. 18 and 20 - and remove from holder - Pos. 19 -.

Vehicles up to CW 44.08:
– Remove holder - Pos. 15 and 17.

– Remove supports - Pos. 10 and 12.

Vehicles as of CW 45.08 (MY 09 Facelift):

– Remove the central pipe/dash panel - Pos. 8 ⇒ Body Work; Rep. gr. 70 .

All vehicles:

– Remove the heating and air conditioning unit.

❑ Installing:
Installation is performed in the reverse order, pay attention to the following points:

– First of all install the seal to the front wall from the passenger compartment and then guide the heat
exchanger flange and the refrigerant connection through the seal ⇒ page 86 .

– Pay attention to the fitting position of the seal ⇒ page 87 .

6. Removing and installing the heating and air conditioning unit from the vehicle 85
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– Attach the refrigerant lines to the expansion valve ⇒ page 80 .

– Top up coolant ⇒ Engine; Rep. gr. 19 .

– Fill the refrigerant circuit with the aid of the A/C service station.

5 - Bracket, right
6 - Screws, 8 Nm
7 - Screws, 8 Nm
8 - Module carrier
9 - Screws, 8 Nm
10 - Right support
❑ As of CW 45.08 welded to the central pipe Pos. 8
11 - Screws, 20 Nm
12 - Left support
❑ As of CW 45.08 welded to the central pipe Pos. 8
13 - Screws, 8 Nm
14 - Screws, 8 Nm
15 - Support
❑ As of CW 45.08 welded to supports Pos. 10 and Pos. 12
16 - Screws, 2 Nm
17 - Support
18 - Screws, 8 Nm
19 - Bracket, left
20 - Screws, 8 Nm

Install seal
– Insert the seal -1- from the passenger compartment into the
front wall -2-.
Pay attention to the correct positioning of the reinforcement
(wire hanger) -3- in the seal -1-.

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Seal of heating and air conditioning unit/engine compartment

Note

Pay attention to the fitting position of the seal -1-.

1 - Seal - it must be placed all around in the front wall

2 - Front wall
3 - Wulst - it must be placed all around in the groove of the heating
and air conditioning unit
4 - Bead - it must be placed all around in the groove of the heat
exchanger flange
5 - Reinforcement (wire hanger) - it must be placed all around in
the groove of the seal

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7 Climatic, air conditioning system with

manual control

Note

♦ As of CW 46.10, the temperature in the vehicle interior is con‐

trolled manually. As of this date, some temperature senders
are no longer fitted (see below).
♦ At first glance, the manual air-conditioning unit of the semi-
automatic air conditioning system can be identified on its
operating unit for air conditioning system, which has no nu‐
merical value of the set interior temperature.
♦ Detailed description of the function of the air conditioning sys‐
tem ⇒ Owner's manual Octavia II (depending on the model
year).

⇒ „7.1 Summary of components“, page 89

⇒ „7.2 Overview of control motors at the heating and air condi‐
tioning unit - right-hand drive“, page 91
⇒ „7.3 Removing and installing heating and air conditioning sys‐
tem control with control unit for air conditioner/Climatic J301 up
to MY 08 (CW 44.08)“, page 92
⇒ „7.4 Removing and installing heating and air conditioning sys‐
tem control with control unit for air conditioner/Climatic J301 as of
MY 09 (CW 45.08)“, page 92
⇒ „7.5 Plug connections at the control for heating and air condi‐
tioning system“, page 93
⇒ „7.6 Disassembling and assembling the heating and air condi‐
tioning unit (Climatic, air conditioning system with manual con‐
trol)“, page 95
⇒ „7.7 Removing and installing evaporator“, page 96
⇒ „7.8 Removing and installing, testing condensation water
drain“, page 96
⇒ „7.9 Removing and installing the control motor of temperature
flap V68 “, page 97
⇒ „7.10 Removing and installing the Footwell vent temperature
sender G192 “, page 99
⇒ „7.11 Removing and installing the middle vent temperature
sender G191 “, page 99
⇒ „7.12 Removing and installing the evaporator vent temperature
sender G263 “, page 100

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7.1 Summary of components

Note

Summary of components - Control motors on right-hand drive vehicles ⇒ page 91 .

1 - Dash panel
❑ Removing and installing
⇒ Body Work; Rep. gr.
70
2 - Centre vent
❑ removing and installing
⇒ page 5
3 - Outer dash panel vent
❑ removing and installing
⇒ page 5
4 - Re-circulating air flap con‐
trol motor -V113-
❑ inspect ⇒ Vehicle diag‐
nostic tester in the func‐
tion „Targeted fault find‐
ing“
❑ removing and installing
⇒ page 14
5 - Footwell vent front passen‐
ger side
❑ removing and installing
⇒ page 7
6 - Flex shaft
❑ for positioning unit for air
distribution flaps
❑ removing and installing
⇒ page 10
❑ no longer fitted as of MY
09 (CW 45.08)
7 - Series resistor for fresh air
blower with overheating fuse -
N24-
❑ removing and installing
⇒ page 13
8 - Fresh air blower -V2-
❑ removing and installing ⇒ page 13
9 - Shield for heating and air conditioning unit
❑ removing and installing ⇒ page 1
10 - Evaporator vent temperature sender -G263-
❑ removing and installing ⇒ page 100
11 - Dust and pollen filter
❑ removing and installing ⇒ page 14
12 - Rear duct of right footwell
❑ removing and installing ⇒ page 6

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13 - Center rear duct

❑ Removing and installing ⇒ Body Work; Rep. gr. 68
14 - Center rear vent
❑ removing and installing ⇒ page 6
15 - Air deflector
❑ for center rear vent
16 - Rear duct of left footwell
❑ removing and installing ⇒ page 6
17 - Screws, 1.5 Nm
❑ up to MY 08 (CW 44.08) 8 pieces
❑ as of MY 09 (CW 45.08): 4 pieces
18 - Control for heating and air conditioning system
❑ removing and installing ⇒ page 92
19 - Adapter for heater control
❑ no longer fitted as of MY 09 (CW 45.08)
20 - Heating element for air auxiliary heating -Z35-
❑ removing and installing ⇒ page 19
21 - Heat exchanger
❑ removing and installing ⇒ page 15
❑ replace coolant after changing the heat exchanger
22 - Footwell vent driver's side
❑ removing and installing ⇒ page 7
23 - Control motor for temperature flap -V68-
❑ inspect ⇒ Vehicle diagnostic tester in the function „Targeted fault finding“
❑ removing and installing ⇒ page 97
24 - Footwell vent temperature sender -G192-
❑ no longer fitted as of CW 46.2010
❑ inspect ⇒ Vehicle diagnostic tester in the function „Targeted fault finding“
❑ removing and installing ⇒ page 99
25 - Heating and air conditioning unit
❑ removing and installing ⇒ page 83
❑ disassembling and assembling ⇒ page 95
26 - Positioning motor of front air distribution -V145-
❑ the removal and installation is the same for the central flap control motor -V70- ⇒ page 119
❑ Vehicles as of MY 09 (CW 45.08)
27 - Vent duct
❑ for window blower in the door
❑ Part of the cover
28 - Intermediate piece for defroster duct
❑ placed onto the distributor housing and secured with a clip on the cross member - dash panel
❑ for removing, take out dash panel
29 - Middle vent temperature sender -G191-
❑ no longer fitted as of CW 46.2010
❑ inspect ⇒ Vehicle diagnostic tester in the function „Targeted fault finding“
❑ removing and installing ⇒ page 99

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30 - Intermediate piece for dash panel vents

❑ placed onto the distributor housing
❑ for removing, take out dash panel

7.2 Overview of control motors at the heating and air conditioning unit - right-
hand drive

1 - Re-circulating air flap con‐

trol motor -V113-
❑ inspect ⇒ Vehicle diag‐
nostic tester in the func‐
tion „Targeted fault find‐
ing“
❑ removing and installing
⇒ page 14
2 - Positioning motor of front air
distribution -V145-
❑ the removal and instal‐
lation is the same for the
central flap control mo‐
tor -V70- ⇒ page 119
3 - Control motor for tempera‐
ture flap -V68-
❑ inspect ⇒ Vehicle diag‐
nostic tester in the func‐
tion „Targeted fault find‐
ing“
❑ removing and installing
⇒ page 97

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7.3 Removing and installing heating and air

conditioning system control with control
unit for air conditioner/Climatic -J301-
up to MY 08 (CW 44.08)
Removing

Note

♦ The heater control consists of two separate housings. Before

removing the heater control, bring the rotary knobs into the
following position:
♦ Heat regulator to „cold“
♦ Blower to „0“
♦ Direction of vent to „footwell“

– Switch off the ignition and all electrical components.

– Vehicles with mobile phone holder - slacken mobile phone
holder ⇒ Electrical System; Rep. gr. 91 .
– Carefully lever out the covering -1- using the disassembly
wedge -3409- .
– Screw out screws -3- (1.5 Nm) and remove the heater control
-2- from the dash panel.
– Disconnect plug.
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

♦ The rotary knobs must be in the same position as for the re‐
moval.
♦ Check the function of the control unit for air conditioner/Cli‐
matic -J301- after the installation.
♦ When replacing, carry out the function „Initiate basic setting“
with the ⇒ Vehicle diagnostic tester.

7.4 Removing and installing heating and air

conditioning system control with control
unit for air conditioner/Climatic -J301- as
of MY 09 (CW 45.08)
Removing
– Switch off the ignition and all electrical components.
– Vehicles with mobile phone holder - slacken mobile phone
holder ⇒ Electrical System; Rep. gr. 91 .

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– Carefully lever out the covering -1- using the disassembly

wedge -3409- .
– Screw out screws -3- (1.5 Nm) and remove the heater control
-2- from the dash panel.
– Disconnect plug.
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

♦ Check the function of the control unit for air conditioner/Cli‐

matic -J301- after the installation.
♦ When replacing, carry out the function „Initiate basic setting“
with the ⇒ Vehicle diagnostic tester.
♦ If the button AC does no longer function after replacing the
control unit for air conditioner/Climatic -J301- , carry out the
function of the „AC compressor inlet“ with the ⇒ Vehicle diag‐
nostic tester in the targeted fault finding.

7.5 Plug connections at the control for heat‐

ing and air conditioning system
Contact assignment of multipin plug connections on the rear side
of the control for heating and air conditioning system
Special tools and workshop equipment required
♦ Test box -V.A.G 1598/47-
Vehicles up to MY 08 (CW 44.08)

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Vehicles as of MY 09 (CW 45.08)

20-pin plug connection
3 - Middle vent temperature sender -G191-
5 - High-pressure sender -G65-
7 - CAN bus Low (comfort)
8 - CAN bus High (comfort)
12 - Right seat heating (optional)
13 - Left seat heating (optional)
15 - Terminal 75 seat heating (optional)
16 - Regulating valve for compressor of air conditioning system -
N280-
18 - Middle vent temperature sender -G191-
19 - Terminal 30A
20 - Terminal 31
16-pin plug connection
1 - Control motor for temperature flap -V68-
2 - Evaporator vent temperature sender -G263-
3 - Potentiometer - central flap control motor -V70- (vehicles as
of MY 09)
4 - Footwell vent temperature sender -G192-
5 - Potentiometer for temperature flap control motor -G92-
7 - + 5°V for potentiometer for temperature flap control motor -
G92-
8 - Ground for sender
9 - Re-circulating air flap control motor -V113-
10 - Re-circulating air flap control motor -V113-
11 - Control motor for temperature flap -V68-
12 - Central flap control motor -V70- (vehicles as of MY 09)
13 - Central flap control motor -V70- (vehicles as of MY 09)
5-pin plug connection
1 - 3. Blower stage
2 - 2. Blower stage
3 - 1. Blower stage
4 - 4. Blower stage
5 - Terminal 75

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7.6 Disassembling and assembling the heating and air conditioning unit (Cli‐
matic, air conditioning system with manual control)

Note

Summary of components - Control motors on right-hand drive vehicles ⇒ page 91 .

1 - Control motor for tempera‐

ture flap -V68-
❑ removing and installing
⇒ page 97
2 - Support
3 - Cover
4 - Re-circulating air flap con‐
trol motor -V113-
❑ removing and installing
⇒ page 14
5 - Housing for air inlet
❑ with re-circulating air
flap
6 - Housing - top part
7 - Housing - bottom part
8 - Evaporator
❑ removing and installing
⇒ page 96
9 - Hose for glove compart‐
ment cooling
❑ not mounted as of CW
46.10
10 - Series resistor for fresh air
blower with overheating fuse -
N24-
❑ removing and installing
⇒ page 13
11 - Fresh air blower -V2-
❑ removing and installing
⇒ page 13
12 - Dust and pollen filter
❑ removing and installing ⇒ page 14
13 - Cover
❑ for dust and pollen filter
14 - Heat exchanger
❑ removing and installing ⇒ page 15
15 - Heat exchanger trim panel
16 - Heating element for air auxiliary heating -Z35-
❑ only fitted on certain models
❑ removing and installing ⇒ page 19

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17 - Distributor housing
18 - Positioning motor of front air distribution -V145-
❑ the removal and installation is the same for the central flap control motor -V70- ⇒ page 119
❑ as of MY 09 (CW 45.08)

7.7 Removing and installing evaporator

Removing
– Remove heating and air conditioning unit ⇒ page 83 .
– Disassemble heating and air conditioning unit ⇒ page 95 , ve‐
hicles with Climatronic ⇒ page 111 .
– Remove evaporator -A- from the evaporator housing bottom
part.
Install

Note

♦ Before inserting the evaporator, check the condensation water

drain and the evaporator housing, if necessary clean (if re‐
quired also the evaporator).
♦ Check seal -F- (it must be sealed all around).

– Fit holder -C- and seal/insulation -B- onto the pipe connections
of the evaporator -D- and -E-.
– Insert evaporator -A- into the evaporator housing bottom part
as shown in the fig.
– When inserting the evaporator -A- into the evaporator housing
bottom part and when assembling both housing parts, ensure
that the seal -F- is not damaged.

Note

♦ After assembling the housing halves, make sure that the seal/
insulation -B - is correctly fitted in the opening for the access
to both coolant pipes.
♦ Check that the holder -C- is correctly fitted on both coolant
pipes -D- and -E-. If the heat-protection insulation -B- is miss‐
ing or not correctly installed, it may result in a power reduction
of the air conditiong system (tuning modification of the regu‐
lator characteristic of the expansion valve due to heat radia‐
tion).
♦ There is refrigerant oil in the removed evaporator which must
be guided back with the new evaporator into the refrigerant
circuit ⇒ page 67 .

7.8 Removing and installing, testing con‐

densation water drain
– Remove the side cover on the front passenger side ⇒ Body
Work; Rep. gr. 68 .

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– Fold back the floor covering until the condensation water drain
-4- is visible.
– Cover the area below the opening -1- with absorbant paper.
– Carefully pull off the connection angle -2- from the heating and
air conditioning unit -1- and the connection -4- from the open‐
ing -5-.
– Check the condensation water drain -1- and -4- for contami‐
nation; e.g. with a piece of wire.

Note

♦ The connecting pieces -2- and -4- must fit tightly on the pipe
-3-.
♦ When installing pay attention to the correct positioning of the
connecting pieces -2- and -4- in the areas -1- and -5- (torsion
stop).

7.9 Removing and installing the control mo‐

tor of temperature flap -V68-

7.9.1 Left-hand drive

Removing
– Switch off the ignition and all electrical components.
– Remove lower part of the dash panel insert on the driver's side
⇒ Body Work; Rep. gr. 70 .
– Remove left footwell vent ⇒ page 7 .
– Remove the control unit for data bus diagnostic interface -
J533- (attached in the area of the steering column to the
bracket) ⇒ Electrical System; Rep. gr. 97 .
– Release screws - 3 - (10 Nm).
The screws -1- are not released.

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– Press the bracket -1- in the direction of the brake pedal

-arrow- and fasten it there with the cable strap.

– Mark the connector -C- (the design is identical to other con‐

nectors, danger of mix-ups) and subsequently remove it at the
left temperature flap control motor -V158- -B-.
– Removing cover -A-.
– Release the fixing screws -D- (1.4 Nm) and remove the control
motor -B-.
– Slacken the lever -E- of the control motor from the coupling
rod -F-.
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

♦ After installing the control motor, it is necessary to test the op‐

eration of the temperature flap.
♦ Carry out the function „Initiate basic setting“ with the Vehicle
diagnosis, measurement and information system -VAS 5051- .

7.9.2 Right-hand drive

Removing
– Switch off the ignition and all electrical components.
– Remove storage compartment on passenger side ⇒ Body
Work; Rep. gr. 70 .
– Remove left footwell vent ⇒ page 7 .
– Disconnect the plug connection at the control motor.

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– Unscrew screw -1- (1.4 Nm) and unhook the control motor
from the catch -arrow-.
– Slightly turn the control motor and unhook it from the control
cable of the temperature flap.
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

♦ After installing the control motor, it is necessary to test the op‐

eration of the temperature flap.
♦ Carry out the function „Initiate basic setting“ with the Vehicle
diagnosis, measurement and information system -VAS 5051- .

7.10 Removing and installing the Footwell

vent temperature sender -G192-

Note

Is not mounted as of CW 46.2010.

Removing
– Switch off the ignition and all electrical components.
– Remove left footwell vent ⇒ page 7 .
– Rotate footwell vent temperature sender -G192- -2- by 90° and
remove from housing.
– Unplug connector -1-.
Install
Installation is carried out in the reverse order.
When installing, pay attention to the correct seating of the gasket
ring -3-.

7.11 Removing and installing the middle vent

temperature sender -G191 -

Note

Is not mounted as of CW 46.2010.

Removing
– Removing the dash panel ⇒ Body Work; Rep. gr. 70 .

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– Unplug connector -3-.

– Rotate middle vent temperature sender -G191- -1- by 90° and
remove from housing.
Install
Installation is carried out in the reverse order.
When installing, pay attention to the correct seating of the gasket
ring -2-.

7.12 Removing and installing the evaporator

vent temperature sender - G263-
Removing
– Remove the side cover of the centre console on the front pas‐
senger side ⇒ Body Work; Rep. gr. 68 .
– Disconnect plug at evaporator vent temperature sender -
G263- -1-.
– Turn evaporator vent temperature sender -G263- 90° and pull
out.
Install
Installation is carried out in the reverse order.
When installing, pay attention to the correct seating of the gasket
ring.

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8 Climatronic - Air conditioner with au‐

tomatic regulation)

Note

Detailed description of function ⇒ Owner's manual Octavia II .

⇒ „8.1 Summary of components“, page 102

⇒ „8.2 Overview of control motors at the heating and air condi‐
tioning unit - right-hand drive“, page 105
⇒ „8.3 Function of the Control and display unit for air conditioner/
Climatronic E87 with Climatronic control unit J255 up to MY 08
(CW 44.08)“, page 105
⇒ „8.4 Function of the Control and display unit for air conditioner/
Climatronic E87 with Climatronic control unit J255 as of MY 09
(CW 45.08)“, page 107
⇒ „8.5 Removing and installing Control and display unit for air
conditioner, Climatronic E87 with Climatronic control unit J255 “,
page 108
⇒ „8.6 Plug connections on the control unit for Climatronic J255
“, page 109
⇒ „8.7 Disassembling and assembling heating and air condition‐
ing unit (Climatronic)“, page 111
⇒ „8.8 Removing and installing left footwell vent temperature
sender G261 “, page 112
⇒ „8.9 Removing and installing Right footwell vent temperature
sender G262 “, page 112
⇒ „8.10 Removing and installing left vent temperature sender
G150 and right vent temperature sender G151 “, page 113
⇒ „8.11 Removing sunlight penetration photosensor G107 and
sunlight penetration photosensor 2 G134 “, page 113
⇒ „8.12 Removing and installing the control motor of the re-cir‐
culating air flap V113 “, page 113
⇒ „8.13 Remove and install control motor of air flow flap V71 or
control motor of air flow flap and re-circulating air flap V71 “, page
114
⇒ „8.14 Removing and installing the defroster flap control motor
V107 “, page 115
⇒ „8.15 Removing and installing the left temperature flap control
motor V158 “, page 116
⇒ „8.16 Removing and installing right temperature flap control
motor V159 “, page 118
⇒ „8.17 Removing and installing the control motor of central flap
V70 “, page 119
⇒ „8.19 Air quality sensor G238 “, page 120

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8.1 Summary of components

Note

Summary of components - Control motors on right-hand drive vehicles ⇒ page 105 .

1 - Dash panel
❑ Removing and installing
⇒ Body Work; Rep. gr.
70
2 - Sunlight penetration photo‐
sensor -G107 - and Sunlight
penetration photosensor 2 -
G134-
❑ fitted together in one
housing
❑ inspect ⇒ Vehicle diag‐
nostic tester in the func‐
tion „Targeted fault find‐
ing“
❑ Function: Depending on
the intensity of the sun‐
light controls the left and
right temperature flap
and the fresh air blower
❑ Emergency operation in
the event of failure: Cli‐
matronic control unit -
J255- adopts fixed value
❑ removing and installing
⇒ page 113
3 - Air quality sensor -G238-
❑ mounted as of CW
22.09
❑ Description, removing
and installing
⇒ page 120
4 - Air intake grid
❑ removing and installing
⇒ page 8
5 - Centre vent
❑ removing and installing ⇒ page 5
6 - Outer dash panel vent
❑ removing and installing ⇒ page 5
7 - Footwell vent front passenger side
❑ removing and installing ⇒ page 7
8 - Shield for heating and air conditioning unit
❑ removing and installing ⇒ page 1
9 - Dust and pollen filter
❑ removing and installing ⇒ page 14
10 - Rear duct of right footwell
❑ removing and installing ⇒ page 6

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11 - Center rear duct

❑ Removing and installing ⇒ Body Work; Rep. gr. 68
12 - Center rear vent
❑ removing and installing ⇒ page 6
13 - Air deflector
❑ for center rear vent
14 - Rear duct of left footwell
❑ removing and installing ⇒ page 6
15 - Evaporator vent temperature sender -G263-
❑ removing and installing ⇒ page 100
16 - Right temperature flap control motor -V159-
❑ inspect ⇒ Vehicle diagnostic tester in the function „Targeted fault finding“
❑ removing and installing ⇒ page 118
17 - Heating element for air auxiliary heating -Z35-
❑ removing and installing ⇒ page 19
18 - Heat exchanger
❑ removing and installing ⇒ page 15
❑ replace coolant after changing the heat exchanger
19 - Footwell vent driver's side
❑ removing and installing ⇒ page 7
20 - Left temperature flap control motor -V158-
❑ inspect ⇒ Vehicle diagnostic tester in the function „Targeted fault finding“
❑ removing and installing ⇒ page 116
21 - Left footwell vent temperature sender -G261-
❑ inspect ⇒ Vehicle diagnostic tester in the function „Targeted fault finding“
❑ removing and installing ⇒ page 112
22 - Defroster flap control motor -V107-
❑ inspect ⇒ Vehicle diagnostic tester in the function „Targeted fault finding“
❑ removing and installing ⇒ page 115
23 - Heating and air conditioning unit
❑ removing and installing ⇒ page 83
❑ disassembling and assembling ⇒ page 111
24 - Control motor of centre flap -V70-
❑ inspect ⇒ Vehicle diagnostic tester in the function „Targeted fault finding“
❑ removing and installing ⇒ page 119
25 - Vent duct
❑ for window blower in the door
❑ Part of the cover
26 - Intermediate piece for defroster duct
❑ placed onto the distributor housing and secured with a clip on the cross member - dash panel
❑ for removing, take out dash panel
27 - Left vent temperature sender -G150-
❑ inspect ⇒ Vehicle diagnostic tester in the function „Targeted fault finding“
❑ removing and installing ⇒ page 113
28 - Intermediate piece for dash panel vents
❑ placed onto the distributor housing

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❑ for removing, take out dash panel
29 - Right vent temperature sender -G151-
❑ inspect ⇒ Vehicle diagnostic tester in the function „Targeted fault finding“
❑ removing and installing ⇒ page 113
30 - Re-circulating air flap control motor -V113-
❑ mounted up to 05.07. As of 06.07, its function is replaced by the control motor of air flow flap and re-
circulating air flap -V71-
❑ inspect ⇒ Vehicle diagnostic tester in the function „Targeted fault finding“
❑ removing and installing ⇒ page 113
31 - Fresh air intake duct temperature sensor -G89-
❑ only on vehicles manufactured up to 05.05.
❑ inspect ⇒ Vehicle diagnostic tester in the function „Targeted fault finding“
❑ Function: The temperature sensor controls the temperature flap and the fresh air blower according to
the temperature
❑ In case of signal failure, the value from the ambient temperature sensor -G17- is used.
❑ to disassemble, remove dash panel, turn temperature sensor by 90°, remove and disconnect plug con‐
nection
32 - Vehicles up to 05.07: air flow flap control motor -V71- , vehicles as of 06.07: air flow flap control motor and
re-circulating air flap -V71-
❑ inspect ⇒ Vehicle diagnostic tester in the function „Targeted fault finding“
❑ removing and installing ⇒ page 114
33 - Fresh air blower -V2- with fresh air blower control unit -J126-
❑ Removing and installing fresh air blower ⇒ page 13
❑ the control unit cannot be replaced individually
34 - Climatronic control unit -J255-
❑ The Climatronic control unit -J255 - and the Control and display unit for air conditioner, Climatronic -E87-
cannot be disassembled
❑ as of MY 09, different arrangement of actuating elements and displays
❑ Description of the function ⇒ page 101
❑ inspect ⇒ Vehicle diagnostic tester in the function „Targeted fault finding“
❑ removing and installing ⇒ page 108

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8.2 Overview of control motors at the heating and air conditioning unit - right-
hand drive

1 - Control motor of air flow flap

and re-circulating air flap -V71-
❑ inspect ⇒ Vehicle diag‐
nostic tester in the func‐
tion „Targeted fault find‐
ing“
❑ removing and installing
⇒ page 114
2 - Control motor of centre flap
-V70-
❑ inspect ⇒ Vehicle diag‐
nostic tester in the func‐
tion „Targeted fault find‐
ing“
❑ removing and installing
⇒ page 119
3 - Defroster flap control motor
-V107-
❑ inspect ⇒ Vehicle diag‐
nostic tester in the func‐
tion „Targeted fault find‐
ing“
❑ removing and installing
⇒ page 115
4 - Right temperature flap con‐
trol motor -V159-
❑ inspect ⇒ Vehicle diag‐
nostic tester in the func‐
tion „Targeted fault find‐
ing“
❑ removing and installing
⇒ page 118
5 - Left temperature flap con‐
trol motor -V158-
❑ inspect ⇒ Vehicle diag‐
nostic tester in the function „Targeted fault finding“
❑ removing and installing ⇒ page 116

8.3 Function of the Control and display unit

for air conditioner/Climatronic -E87- with
Climatronic control unit -J255- up to MY
08 (CW 44.08)

Note

♦ By pressing the AUTO button all deviating settings from auto‐

matic operation are cancelled.
♦ Detailed description of the function of the air conditioning sys‐
tem ⇒ Owner's manual Octavia II (depending on the model
year).

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1 - Display of the selected in‐

terior temperature, left
2 - Button for re-circulating air
mode
❑ The re-circulating air
mode is switched on by
pressing the button,
thus preventing conta‐
minated outside air from
penetrating into the pas‐
senger compartment.
3 - Button - centre air distribu‐
tion
4 - Button - bottom air distribu‐
tion
5 - Button - top air distribution
6 - Display of the selected in‐
terior temperature, right
7 - Button for defrosting the
windscreen
8 - Button for rear window
heating
9 - Rotary knob for interior tem‐
perature, left
10 - Blower regulator
11 - Interior temperature sen‐
sor
12 - Button ECON
❑ By pressing the button
ECON the AC compres‐
sor is adjusted close to
zero output. The heating
and ventilation opera‐
tion continues to be controlled electronically.
13 - Rotary knob for interior temperature, right
14 - Button AUTO
❑ By pressing the button AUTO the Climatronic maintains the selected interior temperature for the vehicle
fully automatically. To this end the temperature of the expelled air, the blower speed and the air distri‐
bution are automatically changed.

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8.4 Function of the Control and display unit for air conditioner/Climatronic -E87-
with Climatronic control unit -J255- as of MY 09 (CW 45.08)

1 - Multi-function display of the

radio/the navigation
❑ Serves as a display for
the information by
means of the pop-up
window.
2 - Button - Upper body air flow
3 - Button - Footwell air flow
4 - Button - Re-circulating air
mode with air quality sensor
❑ The Climatronic
switches into the re-cir‐
culating or automatic re-
circulating air mode by
pressing the button,
thus preventing conta‐
minated outside air from
penetrating into the pas‐
senger compartment.
❑ If the air quality sensor
recognizes a considera‐
ble increase in the con‐
centration of pollutants
while the automatic re-
circulating air operation
is switched on, then it is
temporarily switched to
air re-circulating opera‐
tion.
5 - Button - rear window heat‐
ing.
6 - Regulator - Adjustment of
temperature for the right side
7 - Display of the selected in‐
terior temperature, right
8 - Button - Activation and deactivation of the dual mode for the adjustment of temperature DUAL
❑ If the warning light comes on in the button, the temperature for the left and right side can be set separately.
9 - Button - activation and deactivation of the cooling system AC
❑ Button for the activation/deactivation of the AC compressor
10 - Button - direct activation (deactivation) of the auxiliary heating
❑ Only on vehicles equipped with auxiliary heating.
11 - Interior temperature sensor
12 - Regulator - Setting of the blower speed
13 - Button - Deactivation of the Climatronic
14 - Button - automatic operation AUTO
❑ By pressing the button AUTO the Climatronic maintains the selected interior temperature for the vehicle
fully automatically. To this end the temperature of the expelled air, the blower speed and the air distri‐
bution are automatically changed.
❑ By pressing the button AUTO again, the Climatronic switches between „HIGH“ and „LOW“ ⇒ Operating
Instruction Octavia II .

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15 - Regulator - Adjustment of temperature for the left side

Only on vehicles equipped with driver's seat heating.

16 - Display of the selected interior temperature driver's side, left

17 - Button - intensive de-icing of the windscreen
18 - Button - Air flow to the windows

8.5 Removing and installing Control and

display unit for air conditioner, Clima‐
tronic -E87- with Climatronic control unit
-J255-

Note

♦ The Climatronic control unit -J255- and the Control and display
unit for air conditioner/Climatronic -E87- cannot be disassem‐
bled.
♦ As of MY 09 (CW 45.08), different arrangement of actuating
elements and displays, the assembly work is indentical.

Removing
– Vehicles with mobile phone holder - slacken mobile phone
holder ⇒ Electrical System; Rep. gr. 91 .
– Carefully lever out the cover for the radio/navigation and the
heater control using a disassembly wedge -3409- .
– Unscrew the screws -2- and remove the control and display
unit for air conditioner/Climatronic -E87- -1- from the dash
panel.
– Disconnect the plug connections on the control and display
unit for air conditioner/Climatronic -E87- .
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

♦ Test the operation of the control and display unit for air con‐
ditioner/Climatronic -E87- after the installation.
♦ Carry out „Initiate basic setting“ with the ⇒ Vehicle diagnostic
tester.
♦ If the button AC does no longer function after replacing the
Climatronic control unit -J255- , carry out the function of the
„AC compressor inlet“ with the ⇒ Vehicle diagnostic tester in
the targeted fault finding.

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8.6 Plug connections on the control unit for

Climatronic -J255-
Contact assignment of multipin plug connections A, B, and C on
the rear of the control unit for Climatronic -J255-
Vehicles up to MY 08:

Vehicles as of MY 09:

Special tools and workshop equipment required

♦ Test box -V.A.G 1598/47-
20-pin plug connection -A-
1 - Sunlight penetration photosensor 2 -G134- or Sunlight pene‐
tration photosensor -G107- , signal
2 - High-pressure sender -G65-
3 - Sunlight penetration photosensor 2 -G134- or Sunlight pene‐
tration photosensor -G107- , signal
4 - As of CW 22.09: air quality sensor -G238-
5 - CAN bus High (comfort)
6 - CAN bus Low (comfort)
9 - + 5V for sunlight penetration photosensor 2 -G134- or sunlight
penetration photosensor -G107-
10 - Left seat heating (optional)
11 - Right seat heating (optional)
12 - Up to MY 08: terminal 75A, no longer applicable as of MY 09
13 - Left vent temperature sender -G150-
14 - Right vent temperature sender -G151-
16 - Up to MY 08: terminal 30A, no longer applicable as of MY 09
17 - Ground for sender

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18 - Regulating valve for compressor of air conditioning system -

N280-
19 - Terminal 31
20 - Up to MY 08: terminal 15A, no longer applicable as of MY 09:
terminal 30A
16-pin plug connection -B-
1 - + 5V for control motors
2 - Potentiometer for left temperature flap control motor -G220-
3 - Potentiometer for right temperature flap control motor -G221-
4 - Potentiometer for defroster flap control motor -G135-
5 - Potentiometer for central flap control motor -G112-
6 - Potentiometer for re-circulating air flap control motor -G143-
(no longer applicable as of 05.07)
7 - Potentiometer for air flow flap control motor -G113- (no longer
applicable as of 05.07)
8 - Left footwell vent temperature sender -G261-
9 - Right footwell vent temperature sender -G262-
10 - Fresh air intake duct temperature sensor -G89- (no longer
applicable as of 05.05)
11 - Evaporator vent temperature sender -G263-
14 - Signal ground potentiometer
16-pin plug connection -C-
1 - Left temperature flap control motor -V158-
2 - Left temperature flap control motor -V158-
3 - Defroster flap control motor -V107-
4 - Defroster flap control motor -V107-
5 - Central flap control motor -V70- , person flow
6 - Central flap control motor -V70- , footwell
7 - Re-circulating air flap control motor -V113- , re-circulating air
mode actuation
8 - Re-circulating air flap control motor -V113- , fresh air actuation
9 - Air flow flap control motor -V71-
10 - Air flow flap control motor -V71-
11 - Right temperature flap control motor -V159-
12 - Right temperature flap control motor -V159-
15 - Fresh air blower -V2-
16 - Fresh air blower - V2- , signal

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8.7 Disassembling and assembling heating and air conditioning unit (Clima‐
tronic)

Note

Summary of components - Control motors on right-hand drive vehicles ⇒ page 105 .

1 - Control motor of centre flap

-V70-
❑ removing and installing
⇒ page 119
2 - Left temperature flap con‐
trol motor -V158-
❑ removing and installing
⇒ page 116
3 - Defroster flap control motor
-V107-
❑ removing and installing
⇒ page 115
4 - Support
5 - Cover
6 - Re-circulating air flap con‐
trol motor -V113-
❑ removing and installing
⇒ page 113
❑ no longer fitted on vehi‐
cles manufactured as of
05.07 and its function is
replaced by the control
motor -V71-
7 - Control motor of air flow flap
-V71- or control motor of air
flow flap and re-circulating air
flap -V71-
❑ removing and installing
⇒ page 114
8 - Housing for air inlet
❑ with re-circulating air
flap
❑ with stored pressure
flap (Climatronic)
9 - Housing - top part
10 - Housing - bottom part
11 - Evaporator
❑ removing and installing ⇒ page 96
12 - Hose for glove compartment cooling
13 - Fresh air blower -V2- with series resistor for fresh air blower with overheating fuse -N24-
❑ removing and installing ⇒ page 13
14 - Dust and pollen filter
❑ Also filter version with odour insert, see ⇒ Catalogue of Original Parts
❑ removing and installing ⇒ page 14

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15 - Cover
❑ for dust and pollen filter
16 - Heat exchanger
❑ removing and installing ⇒ page 15
17 - Heat exchanger trim panel
18 - Heating element for air auxiliary heating -Z35-
❑ only fitted to certain models
❑ removing and installing ⇒ page 19
19 - Right temperature flap control motor -V159-
❑ removing and installing ⇒ page 118
20 - Distributor housing

8.8 Removing and installing left footwell

vent temperature sender -G261-
Removing
– Switch off the ignition and all electrical components.
– Remove left footwell vent ⇒ page 7 .
– Rotate footwell vent temperature sender -G261- -2- by 90° and
remove from housing.
– Unplug connector -1-.
Install
Installation is carried out in the reverse order.
When installing, pay attention to the correct seating of the gasket
ring -3-.

8.9 Removing and installing Right footwell

vent temperature sender -G262-
Removing
– Left-hand drive - remove the storage compartment in the dash
panel on the front passenger side ⇒ Body Work; Rep. gr. 70 .
– Right-hand drive - remove lower part of the dash panel insert
on the driver's side ⇒ Body Work; Rep. gr. 70 .
– Unplug connector -1-.
– Rotate right footwell vent temperature sender -G262- -2- by
90° and remove from housing.
Install
Installation is carried out in the reverse order.
When installing, pay attention to the correct seating of the gasket
ring -3-.

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8.10 Removing and installing left vent tem‐

perature sender -G150 - and right vent
temperature sender -G151-
Removing
– Removing the dash panel ⇒ Body Work; Rep. gr. 70 .
– Unplug connector -3-.
– Rotate left vent temperature sender -G150- -1- or right vent
temperature sender -G151- -2- by 90° and remove from hous‐
ing.
Install
Installation is carried out in the reverse order.
– Pay attention to the correct fit of the gasket rings -4-.

8.11 Removing sunlight penetration photo‐

sensor -G107- and sunlight penetration
photosensor 2 -G134 -
– Unclip housing with sunlight penetration photosensor -1- with
disassembly wedge -3409- from the dash panel -3-.
– Unplug connector -2-.

8.12 Removing and installing the control mo‐

tor of the re-circulating air flap -V113-

Note

No longer fitted on vehicles manufactured as of 05.07 and its

function is replaced by the control motor -V71- .

Removing
– Switch off the ignition and all electrical components.
– Remove storage compartment on passenger side ⇒ Body
Work; Rep. gr. 70 .

Note

The position of the re-circulating air flap must not be changed.

– Remove the cover for the control motors.

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– Disconnect the plug connection at the control motor of the re-

circulating air flap -V113- -1-.
– Remove control motor of the re-circulating air flap -V113- -1-.
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

♦ After installing the control motor, it is necessary to test the op‐

eration of the re-circulating air flap.
♦ Carry out the function „Initiate basic setting“ with the Vehicle
diagnosis, measurement and information system -VAS 5051- .

8.13 Remove and install control motor of air

flow flap -V71- or control motor of air flow
flap and re-circulating air flap -V71-

Note

The re-circulating air flap control motor -V113- is no longer fitted

on vehicles as of 05.07 and its function is replaced by the control
motor -V71- .

Removing
– Remove the glove compartment ⇒ Body work; Rep. gr. 70 .

Note

The position of the control motor must not be changed.

Vehicles manufactured up to 04.07

– Remove cover -1-.
– Disconnect the plug connection at the control motor of air flow
flap -V71- -2-.
– Remove air flow flap control motor -V71- -2-.
Vehicles manufactured as of 05.07

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– Unscrew fixing screws -1-.

– Rotate the control motor -2- by approx. 15 -arrow-, push out it
of the bushing and remove it towards you.
– Disconnect the plug connection.
Install
Installation is performed in the reverse order, pay attention to the
following points:

– The control motor fits only in one position to the curved wash‐
er.

Note

♦ When replacing, carry out the function „Initiate basic setting“

with the Vehicle diagnosis, measurement and information sys‐
tem -VAS 5051- .
♦ After installing the control motor, perform a functional test.

8.14 Removing and installing the defroster

flap control motor -V107-
⇒ „8.14.1 Left-hand drive“, page 115
⇒ „8.14.2 Right-hand drive“, page 116

8.14.1 Left-hand drive

Removing
– Removing the dash panel ⇒ Body Work; Rep. gr. 70 .
– Remove the footwell vent on the driver's side ⇒ page 7 .
– Remove data bus diagnostic interface control unit -J533- ⇒
Electrical System; Rep. gr. 97 .
– Unscrew screws -3- and nuts -1- (10 Nm) and remove the
support -2-.

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– Unplug connector -C-.

– Unscrew screws -A- and remove control motor -B-.
– Slacken the lever -E- from the coupling rod -D-.
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

♦ After installing the control motor, it is necessary to test the op‐

eration of the defroster flap.
♦ Carry out „Initiate basic setting“ with the ⇒ Vehicle diagnostic
tester.

8.14.2 Right-hand drive

– Removing the dash panel ⇒ Body Work; Rep. gr. 70 .
– Remove the footwell vent on the driver's side ⇒ page 7 .
– Unscrew screws -3- and nuts -1- (10 Nm) and remove the right
support -2-.

– Unplug connector -C-.

– Unscrew screws -A- (only two screws on right-hand drive ve‐
hicles) and remove control motor -B-.
– Slacken the lever -E- from the coupling rod -D-.
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

♦ After installing the control motor, it is necessary to test the op‐

eration of the defroster flap.
♦ Carry out „Initiate basic setting“ with the ⇒ Vehicle diagnostic
tester.

8.15 Removing and installing the left temper‐

ature flap control motor -V158 -
⇒ „8.15.1 Left-hand drive“, page 117
⇒ „8.15.2 Right-hand drive“, page 118

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8.15.1 Left-hand drive

Removing
– Switch off the ignition and all electrical components.
– Remove the footwell vent on the driver's side ⇒ page 7 .
– Remove the control unit for data bus diagnostic interface -
J533- (attached in the area of the steering column to the
bracket) ⇒ Electrical System; Rep. gr. 97 .
– Release screws - 3 - (10 Nm).
The screws (nuts) -1- are not released.

– Press the bracket -1- in the direction of the brake pedal

-arrow- and fasten it there with the cable strap.

– Mark the connector -C- (the design is identical to other con‐

nectors, danger of mix-ups) and subsequently remove.
– Removing cover -A-.
– Release the fixing screws -D- (1.4 Nm) and remove the control
motor -B-.
– Slacken the lever -E- of the control motor from the coupling
rod -F-.
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

♦ After installing the control motor, it is necessary to test the op‐

eration of the left temperature flap.
♦ Carry out the function „Initiate basic setting“ with the Vehicle
diagnosis, measurement and information system -VAS 5051- .

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8.15.2 Right-hand drive

Removing
– Switch off the ignition and all electrical components.
– Remove storage compartment on passenger side ⇒ Body
Work; Rep. gr. 70 .
– Remove the footwell vent on the front passenger side
⇒ page 7 .
– Disconnect the plug connection at the control motor.
– Unscrew screw -1- (1.4 Nm) and unhook the control motor
from the catch -arrow-.
– Slightly turn the control motor and unhook it from the control
cable of the temperature flap.
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

♦ After installing the control motor, it is necessary to test the op‐

eration of the temperature flap.
♦ Carry out the function „Initiate basic setting“ with the Vehicle
diagnosis, measurement and information system -VAS 5051- .

8.16 Removing and installing right tempera‐

ture flap control motor -V159 -
Removing
– Switch off the ignition and all electrical components.
Left-hand drive:
– Remove storage compartment on passenger side ⇒ Body
Work; Rep. gr. 70 .
Right-hand drive:
– Remove lower part of the dash panel insert on the driver's side
⇒ Body Work; Rep. gr. 70 .
All vehicles:
– Remove right footwell vent ⇒ page 7 .
– Disconnect the plug connection at the right temperature flap
control motor -V159- .

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– Unscrew fixing screws -1- and remove right temperature flap

control motor -V159- .
– Slightly turn the control motor to the left and unhook the sup‐
port -2-.
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

♦ After installing the control motor, it is necessary to test the op‐

eration of the right temperature flap.
♦ Carry out the function „Initiate basic setting“ with the Vehicle
diagnosis, measurement and information system -VAS 5051- .

8.17 Removing and installing the control mo‐

tor of central flap -V70-
Removing
– Removing the dash panel ⇒ Body Work; Rep. gr. 70 .
– Disconnect the plug connection at the control motor of centre
flap -V70- .
– Unscrew fixing screws -1- and remove control motor of centre
flap -V70- .
Install
Installation is performed in the reverse order, pay attention to the
following points:

Note

♦ After installing the control motor, it is necessary to test the op‐

eration of the central flap.
♦ Carry out the function „Initiate basic setting“ with the Vehicle
diagnosis, measurement and information system -VAS 5051- .

8.18 Fresh air blower control unit -J126-

Note

The fresh air blower control unit -J126- is not arranged as a sep‐
arate component.

Self-diagnosis and fault indication

The fresh air blower control unit -J126- is equipped with self-di‐
agnosis, which facilitates the fault finding.
For fault finding use the ⇒ Vehicle diagnostic tester in the function
„Targeted fault finding“.
Removing
– Switch off the ignition and all electrical components.
– Remove fresh air blower -V2- ⇒ page 13 .

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– Unplug connector -1-.

– Release the screws -2- and remove the control unit -3-.
Install
Installation is carried out in the reverse order.

8.19 Air quality sensor -G238-

Located in the engine compartment at the air intake grid of the air
conditioning system.
Only available for the Climatronic equipment.
Mounted as of CW 22.09.

8.19.1 Description of the function

♦ The air quality sensor recognises pollutants in the ambient air
(usually petrol and/or diesel exhaust).
♦ The Climatronic control unit -J255- evaluates the signal from
the air quality sensor -G238- . The air conditioning system is
activated depending on the intensity and type of the polluted
ambient air.
If the outside temperature is higher than approx. + 2°C, the air re-
circulating operation is already switched on when there is a slight
increase in the concentration of pollutants.
If the outside temperature is between approx. + 2°C and approx.
- 5°C, the switch-over to the air re-circulating operation occurs
only when there is a considerable increase in the concentration
of pollutants, while at the same time the AC compressor is switch‐
ed on.
If the outside temperature is lower than approx. - 5°C, the switch-
over also occurs only when there is a considerable increase in
the concentration of pollutants and only for approx. 15 s (the AC
compressor is not switched on). If the concentration decreases,
the air conditioning system is again switched-over to fresh air op‐
eration.
♦ The function „automatic re-circulating air mode“ can be switch‐
ed off at any time.
♦ So that the air conditioning system does not always run in the
air re-circulating operation in areas with constantly high air
pollution, the sensor is self-adaptive (it adapts its sensitivity to
the environmental pollution).
♦ In order to avoid a too frequent switching of the re-circulating/
fresh air flap, it is not immediately switched when there is a
slight increase in pollution in the ambient air (the sensor trans‐
mits no request to the Climatronic control unit -J255- ). Here
the filter effect of the activated charcoal insert in the dust and
pollen filter is sufficent.
♦ The air quality sensor -G238- requires approx. 30 s in order to
be operational after switching on the ignition (heating period).
During this period, there is no request from the sensor to the
Climatronic control unit -J255- for „automatic re-circulating air
mode“.

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♦ The air quality sensor -G238- is a highly sensitive electronic

component which can be destroyed through direct contact with
solvents, petrol and certain chemical compounds. Therefore
do not install sensors which can come into contact with such
substances.

8.19.2 Removing and installing the air quality

sensor -G238-
Removing
– Remove the cooling water tank cover ⇒ Body Work; Rep. gr.
64 .
– Remove the air inlet cover of the air conditioning system.
– Unplug the plug -1- from the air quality sensor -G238- .
– Release the catch -2- and rotate the air quality sensor -G238-
-3- by 90° and remove.
Install
Installation is carried out in the reverse order.

Note

Do not place a removed sensor in areas where it can come into

contact with solvents, petrol and certain chemical compounds
(liquids or vapours). This would result in permanent damage of
the sensor.

8. Climatronic - Air conditioner with automatic regulation) 121