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Workshop Manual
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Heating, air conditioning
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
01 - Self-diagnosis
80 - Heating
87 - Air conditioning system
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg 00050205120

Polo 1995 ➤
Heating, air conditioning - Edition 06.2004
Contents
01 - Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Self-diagnosis of Climatronic, vehicles 10.99 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Connecting vehicle diagnosis, testing and information system VAS 5051A or vehicle
diagnosis and service information system VAS 5052 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Technical data of self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Test prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Diagnosis functions with vehicle diagnosis, testing and information system VAS 5051A or
vehicle diagnosis and service information system VAS 5052 . . . . . . . . . . . . . . . . . . . . . . 3
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1.6 Fault table . . . . . . . . . . . . . . . . . .ks.w.a.ge. n. A.G. . . . . . . . n. A. G. d. o.e.s .n . . . . . . . . . . . . . . . . . . . . . . . 10
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80 - Heating . . . . . . . . . . . . s.au. . . .
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1 Repairing heater, vehicles ▸ 09.99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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1.1 Passenger compartment heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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1.2 Removing and installing fresh air blower series resistor with overheating fuse N24 . . . . . . 24
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1.3 Removing fresh air blower V2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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1.4 Removing and installing controls for fresh and heated air . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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1.5 Removing and installing right plenum chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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1.6 Removing dust and pollen filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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1.7 Removing right vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.8 Removing left vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.9 Removing centre vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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1.10 Removing and installing footwell vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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1.11 Removing and installing heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.12 Dismantling and assembling heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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1.13 Installing and adjusting cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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1.14 Dismantling and assembling heated air and fresh air controls . . . . . . . . . . . . . . . . . . . . . . 34
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2 Repairing heater, vehicles 10.99 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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2.1 Passenger compartment heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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2.3 Removing and installing dust and pollen filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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2.4 Removing centre vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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2.5 Removing and installing vent on front passenger side . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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2.6 Removing and installing vent on driver side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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2.7 Removing footwell vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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2.8 Removing and installing controls for fresh and heated air . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.9 Checking ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.10 Removing and installing heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.11 Dismantling and assembling heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.12 Installing and adjusting lever for central flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.13 Installation position of seal for heat exchanger and bulkhead . . . . . . . . . . . . . . . . . . . . . . 47
2.14 Removing and installing fresh air and air recirculation flap control motor V154 . . . . . . . . 47
2.15 Dismantling and assembling heated air and fresh air controls . . . . . . . . . . . . . . . . . . . . . . 48
87 - Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

1 Notes on repair work to vehicles with air conditioning and on handling refrigerant . . . . . . 51
2 Air conditioning system with manual controls, vehicles ▸ 09.99 . . . . . . . . . . . . . . . . . . . . 52
2.1 Repairing air conditioning and heating - passenger compartment . . . . . . . . . . . . . . . . . . . . 52
2.2 Removing air conditioning system switch E30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.3 Renewing fresh air blower series resistor with overheating fuse N24 . . . . . . . . . . . . . . . . 55
2.4 Removing and installing fresh air blower V2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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2.5 Renewing temperature switch for evaporator E33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

2.6 Removing and installing vacuum unit for fresh air and air recirculation flap . . . . . . . . . . . . 55
2.7 Installing support for vacuum line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.8 Repairing air conditioning and heating - engine compartment . . . . . . . . . . . . . . . . . . . . . . 56
2.9 Removing and installing air conditioning shut-off thermal switch F163 . . . . . . . . . . . . . . . . 58
2.10 Removing and installing two-way valve for fresh and recirculating air flap N63 . . . . . . . . 58
2.11 Removing and installing vacuum unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.12 Removing and installing water drain valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.13 Checking high-pressure safety valve on air conditioner compressor . . . . . . . . . . . . . . . . . . 59
2.14 Checking air conditioning system pressure switch F129 . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.16 Vacuum hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3 Air conditioning system with manual controls, vehicles 10.99 ▸ . . . . . . . . . . . . . . . . . . . . 65
3.1 Air conditioning and heating system - passenger compartment . . . . . . . . . . . . . . . . . . . . . . 65
3.3 Removing and installing heating and air conditioning controls . . . . . . . . . . . . . . . . . . . . . . 67
3.4 Dismantling and assembling heating and air conditioning controls . . . . . . . . . . . . . . . . . . 68
3.5 Installing and adjusting heating and air conditioning cables . . . . . . . . . . . . . . . . . . . . . . . . 70
3.6 Air conditioning - engine room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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3.7 Checking water drain valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.8 Removing high pressure sender G65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.9 Removing ambient temperature switch F38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.10 Checking high-pressure safety valve on air conditioner compressor . . . . . . . . . . . . . . . . . . 75
4 Climatronic air conditioning system with automatic regulation, vehicles 10.99 ▸ . . . . . . . . 76
4.1 Function of operating and display unit for Climatronic air conditioning system E87 . . . . . . 76
4.2 Connectors on Climatronic control unit J255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.3 Climatronic - passenger compartment . . . . k.s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
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4.4 Removing and installing footwelllksvent wage temperature sender esG192
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4.5 Removing sunlight penetration ed by photosensor G107 . . . . . . . g.u.ar. . . . . . . . . . . . . . . . . . . . .
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4.6 Removing fresh air blower ris control unit J126 . . . . . . . . . . . . . . . .nt.ee. . . . . . . . . . . . . . . . . . . 84
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4.7 Removing fresh airssblower a V2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a.c . . . . . . . . . . . . . . . . 84
4.8 Removing and installing operating and display unit for Climatronic air conditioning system
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E87 with Climatronic control unit J255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

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4.9 Removing and installing air flow flap control motor V71 . . . . . . . . . . . . . . . . . . . . . . . . . . 86
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4.10 Removing and installing temperature flap control motor V68 . . . . . . . . . . . . . . . . . . . . . . 88

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4.11 Removing and installing central flap control motor V70 . . . . . . . . . . . . . . . . . . . . . . . . . . 89

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4.12 Removing and installing footwell and defroster flap control motor V85 . . . . . . . . . . . . . . . . 89
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4.13 Climatronic - engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

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4.14 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 92

4.15 Removing high pressure sender G65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.16 Checking water drain valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
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4.17 Removing ambient temperature sensor G17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

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5 Removing and installing air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

5.1 Removing and installing air conditioner compressor: engine code ADX, AEA, AEE, AEV,
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AEX, AFH, AHS, AJV, AKV, ANX, APQ, ARC and AVY . . . . . . . . . . . . . . . . . . . . . . . . . . 95
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5.2 Removing and installing air conditioner compressor: engine code AER, AFK, AHW, AKK,
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AKP, ALD, ALL, APE, AUA, AUB, AUC und AUD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

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5.3 Removing and installing air conditioner compressor with bracket: engine code AMF and
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5.4 Removing and installing air conditioner compressor: engine codes AEF, AGD, AHG, AKU
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5.5 Repairing Sanden SD6 V12 air conditioning system magnetic coupling N25 . . . . . . . . . . 104
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5.6 Removing and installing Sanden SD6 V12 air conditioning system magnetic coupling N25
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5.7 Repairing Sanden SD7 B10 air conditioning system magnetic coupling N25 with compressor
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5.8 Removing and installing Sanden SD7 B10 air conditioning system magnetic coupling N25
........................................................................ 113
6 Repair work on refrigerant circuit which may be performed only in appropriate workshops by
specially trained mechanics for vehicles ▸ 09.99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
6.2 Repairing components in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
6.3 Removing extraction and charging valve, low pressure side . . . . . . . . . . . . . . . . . . . . . . . . 118
6.4 Removing extraction and charging valve, high pressure side . . . . . . . . . . . . . . . . . . . . . . 118
6.5 Tasks of receiver with dryer bag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
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6.6 Removing lkswexpansion valve . . . .e.s n. o.t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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6.7 Removing
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6.8 thoDismantling and assembling evaporator housing
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7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
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7.2 Renewing refrigerant circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
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7.3 Removing extraction and charging valve, low pressure side . . . . . . . . . . . . . . . . . . . . . . . . 127
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7.4 Removing extraction and charging valve, high pressure side . . . . . . . . . . . . . . . . . . . . . . 128
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7.5 Tasks of receiver with dryer bag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
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7.6 Quick release coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
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7.7 Checking high pressure sensor G65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
7.8 Removing and installing heater and air conditioner unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
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7.9 Dismantling and assembling evaporator housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
7.10 Expansion valve, function and removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
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7.11 Removing and installing condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

8 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
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8.1 Refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

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8.2 Refrigerant oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

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Contents iii
Polo 1995 ➤
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iv Contents
Polo 1995 ➤
01 – Self-diagnosis
1 Self-diagnosis of Climatronic, vehi‐
cles 10.99 ▸
Special tools and workshop equipment required
♦ Vehicle diagnosis, testing and information system -VAS
5051A-
satelettronica
♦ Diagnosis lead -VAS 5051/6A-
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1.1 Connecting vehicle diagnosis, testing

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– Open ash tray cover -2-.

– Pull ashtray -1- out of centre console.
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– Plug connector of diagnosis lead -VAS 5051/5A- or diagnosis

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– Switch on ignition.
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pyri by
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by
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Prote AG.
1. Self-diagnosis of Climatronic, vehicles 10.99 ▸ 1

olkswagen AG
wag en AG. V
Polo 1995 ➤ olks
does
not
yV gu
se
d b - Edition 06.2004 ara
nte
ri
ho eo
ut ra
1.1.1 Selecting diagnostic function
a c
ss
ce
le
un
pt
All diagnostic functions which can be performed are shown on the
an
d
itte
y li
display.
rm
ab
pe
ility
– Press button on display for required function.
ot
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
♦ The display fields in the functions -04- Basic setting and -08-
Read measured value block are displayed from top to bottom.
rrectness of i
♦ The following test procedures are described for the vehicle di‐
agnosis, testing and information system -VAS 5051A- or ve‐
l purpos
hicle diagnosis and service information system -VAS 5052- .

♦ Some components and functions of the Climatronic are not
nform
ercia
tested by self-diagnosis ( temperature sensor blower -V42-

m
and high pressure sender -G65- ).
a
com
tion in
r
te o
thi
Additional information:
s
iva
do
r
♦ Measures to correct current, model-specific faults ⇒ Technical

rp
cum
satelettronica
fo
Service Handbook
en
ng
t.
yi Co
op
♦ Climatronic air conditioning system with automatic regulation
C py
ht. rig
⇒ page 76 rig ht
py by
co Vo
by lksw
♦ Repair work on refrigerant circuit which may be performed only
cted agen
Prote AG.
in appropriate workshops by specially trained mechanics
⇒ page 115
1.2 Function
The Climatronic control unit -J255- receives information from
electrical and electronic components (information transmitters).
This information is processed in the Climatronic control unit -
J255- in accordance with specifications. The output signals of the
Climatronic control unit -J255- then control the electrical compo‐
nents (final controls).
The Climatronic control unit -J255- is located behind the control
and display unit for Climatronic air conditioning -E87- . The two
components are a single part which cannot be dismantled. So that
the problem source can be quickly found when a component fails
or there is an open circuit, the Climatronic control unit -J255- is
equipped with a fault memory which can be read using the vehicle
diagnosis, testing and information system -VAS 5051A- or the
vehicle diagnosis and service information system -VAS 5052- .
Should a fault be detected in one of the monitored sensors or
components, it is stored in the fault memory.
If a fault having a permanent effect on the operation of the Cli‐
matronic is stored to memory, the display of the operating and
display unit for Climatronic air conditioning -E87- on Climatronic
control unit -J255- flashes for approx. 15 seconds when the igni‐
tion is switched on. In the case of all faults, the Climatronic control
unit -J255- can continue operation at the selected settings in
emergency mode.
Self-diagnosis must be initiated at the beginning of the fault find‐
ing process and the stored information read using the vehicle
diagnosis, testing and information system -VAS 5051A- or vehicle
diagnosis and service information system -VAS 5052- .
The fault information displayed guide one via a fault table with
notes on the possible causes to appropriate repair measures.
2 Rep. Gr.01 - Self-diagnosis

Polo 1995 ➤
AG. Volkswagen AG d
agen oes
lksw not
1.3 Technical data of self-diagnosis Vo gu
d by ara
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or eo
h
Memory: aut Non-volatile ra
ss c
ce
le
Data output: Rapid data transfer
un
pt
an
d
Interrogation of fault memory: yes
itte
y li
erm
ab
Final control diagnosis: yes
ility
ot p
wit
Basic setting: yes
is n
h re
ole,
Coding control unit: yes
spec
Read measured value block: yes
t to the co
rrectne
1.4 Test prerequisites:
♦ All fuses OK according to the circuit diagram.
ss o
cial p
f
♦ The battery voltage must be at least 11.5 V.
inform
mer
♦ Battery negative terminal checked for tight seating.
atio
om
n
c
page
i
or
satelettronica
thi
te
sd
01 - Select ⇒ vehicle diagnosis, testing and in‐ ⇒ page 3
iva
o
r
formation system -VAS 5051A- or vehicle

p
cum
r
fo
diagnosis and service information system -
en
ng
t.
yi
VAS 5052-
Co
Cop py
t. rig
02 - Read fault memory. ⇒ page 4
gh ht
pyri by
Vo
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by c
03 - Final control diagnosis ⇒ page 5
lksw
cted agen
Prote AG.
04 - Basic setting. ⇒ page 6
05 - Erase fault memory ⇒ page 7
06 - End output ⇒ page 8
07 - Code control unit ⇒ page 9
08 - Read measured value block ⇒ page 10
1.5 Diagnosis functions with vehicle diagno‐

sis, testing and information system -
VAS 5051A- or vehicle diagnosis and
service information system -VAS 5052-
– Connect vehicle diagnosis, testing and information system -
VAS 5051A- or vehicle diagnosis and service information
system -VAS 5052- ⇒ page 1 .
1.5.1 Selecting operating mode

– Press button on the display for “vehicle self-diagnosis”
-arrow-.

Polo 1995 ➤
1.5.2 Selecting vehicle system agen

AG. Volkswagen AG d
oes
olksw not
– Press 08 A/C-/heater electronics -arrow-
ed by on the display.
V gu
ara
ris nte
Indicated on display aut
ho eo
ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
The control unit identification and code appear on the display
-arrow-, e.g.:
s
Part number for Climatronic control unit -J255-
s o
cial p
f in
♦ Left-hand drive with blue display 3B1 907 044 C.
form
mer
♦ Right-hand drive with blue display 3B2 907 044 C.
atio
satelettronica
om
n
c
Climatronic = System designation
i
or
n thi
te
sd
a
SXX = Software version

iv
o
pr
cum
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fo
Code: no code 00000 - display flashes
en
ng
t.
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Cop py
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gh ht
pyri by
Vo
o
Code number For vehicles
by c lksw
cted agen
Prote AG.
04000 All countries except Japan
04100 Japan
04001 All countries except Japan without ambient temperature display
04101 Japan without ambient temperature display
Note
♦ If code differs from vehicle version:

♦ Check control unit code ⇒ page 9 .
– Press arrow key -1- on display.
1.5.3 Reading fault memory 02

– Select vehicle system ⇒ page 4 .

Polo 1995 ➤
– Press “02 Read fault memory” -arrow- on the display.
Note
The fault information displayed is updated not continuously but

only upon initiating self-diagnosis or activating function 05 “Erase
fault memory”.
. Volkswagen AG
gen AG does
The stored faults areVoshown
lksw
a
on the display. not
y gu
db a
– Press Printris button
e in display and then “Screen” inraprint
nte
ho eo
menu. aut r ac
ss
A list of faults can be found in the fault table ⇒ page 10 .
ce
le
un
pt
an
d
The printer of the vehicle diagnosis, testing and information sys‐

itte
y li
rm
tem -VAS 5051A- prints the faults shown on the screen or “0 faults
ab
pe
ility
detected”. If faults are stored, repair measures are required. The
ot
wit
fault log must be handed over for the repair.
, is n
h re
hole
– End output ⇒ page 8 .
spec
es, in part or in w
t to the co
1.5.4 Final control diagnosis 03
satelettronica
rrectness of i
Note
l purpos
Final control diagnosis must be carried out with engine stationary,

ignition switched on and Climatronic switched off. nform
mercia
a
com
– To do this, switch Climatronic off via push button for reducing

ion in
blower speed.
r
te o
thi
s
iva
do
r
rp
cum
Note
fo
en
ng
t.
yi Co
op
♦ For results to be definitive, final control diagnosis must be car‐
C py
ht. rig
ried out at an ambient temperature of at least 12° as displayed
rig ht
py by
o Vo
on control and display panel.
by c lksw
cted agen
Prote AG.
♦ Climatronic is not regulated during final control diagnosis.
♦ If necessary, final control diagnosis can be repeated several
times.

Polo 1995 ➤
AG. Volkswagen AG d
lksw
agen oes
n
o ot g
yV ua
edb ran
– Press “03 Final control diagnosis” ho
ris-arrow- on the display. tee
aut or
ac
The following tests will be carried
ss out:
ce
e
nl
♦ Indication of display of operating and display unit for Clima‐
pt
du
an
itte
tronic air conditioning system -E87- ⇒ page 6 .
y li
erm
ab
♦ Functional test of the 4 control motors.
ility
ot p
wit
, is n
♦ Circuit to fresh air blower -V2- is tested.
h re
hole
spec
♦ Switch sequence of control unit for air conditioning system
es, in part or in w
magnetic coupling -N25- is tested.
t to the co
♦ All sensors are checked.
The tests will be completed in about 30 seconds.
rrectness of i
l purpos
Note
nform
ercia
After completing final control diagnosis, read fault memory

m
at
⇒ page 4 .
om
ion
c
in t
or
his
ate
1.5.5 Checking indication of display of oper‐
satelettronica
do
priv
cum
or
ating and display unit for Climatronic air

f
en
ng
t.
yi
conditioning system -E87-
Co
Cop py
t. rig
gh ht
yri by
Shows full display. op Vo
by c lksw
cted agen
Prote AG.
Note
All segments appear on the display during the period of the final
control diagnosis 03. If not, the Climatronic control unit -J255-
must be renewed.
1.5.6 Basic setting 04
Note
If the display flashes after “ignition is switched on” although no

faults were shown in function “Read fault memory 02”, perform
function “Code control unit 07” followed by function “Basic setting
04”.

– Interrogate fault memory ⇒ page 4 and rectify all faults shown.
– Erase fault memory ⇒ page 7 .
– Check code ⇒ page 9 and correct if necessary.

Polo 1995 ➤
– Press “04 Basic setting” -arrow- on the display.
Indicated on display
– Press 0 key in number block of display -arrow-.
– Confirm entry with Q key.
Note
satelettronica
When all control motors haveagmoved
en AG. V to the
olkswageend
n AGposition,
does the Cli‐
matronic control unit -J255-
yV
olkswstores all the potentiometernot values,
gu
assuming in this way
ise
d bthe basic settings of all control motors.ara
n r tee
ho
aut or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
Note
ot p
wit
, is n
h re
The movement of the four positioning motors can be followed on

hole
spec
the display. However, the changes in the feedback values do not

es, in part or in w
indicate a faulty motor.

t to the co
– Read fault memory again ⇒ page 4 .

rrectness of i
l purpos
1.5.7 Erasing fault memory 05

nf
ercia
orm
m
atio
om
n in
c
Note
or
thi
te
sd
iva
The contents of the fault memory are automatically output after

o
r
rp
cu
erasing it. If the fault memory cannot be erased, read the fault
o
m
f
en
ng
memory again and rectify the fault.

t.
yi Co
Cop py
t. rig
gh ht
yri
Prerequisite: p by
co Vo
by lksw
cted agen
• Fault memory has been read ⇒ page 4 . Prote AG.
• All faults are rectified.


Polo 1995 ➤
– Press “05 Erase fault memory” -arrow- on the display.

– Confirm the information -arrow-.

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
The fault memory
autho
is thus erased. eo
ra
ss c
– End output ⇒ page 8 .
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
1.5.8 Ending output 06

l purpos
nf
ercia
or
– Press Go to button -arrow- on the display.

m
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 1995 ➤
– Press End button -arrow- on the display.

– Switch off ignition and disconnect the diagnostic connector.
1.5.9 Coding control unit 07

AG. Volkswagen AG d
agen oes
lksw not
Note d byV
o gu
ara
ise nte
or eo
h
♦ Every Climatronic
s aut control unit -J255- replacement part must ra
c
be codeds after installing.
ce
e
nl
pt
du
♦ Perform basic setting 04 after each coding ⇒ page 6 .
satelettronica
an
itte
y li
erm
ab
♦ If the appropriate vehicle code or the appropriate equipment
ility
ot p
level is not displayed, the Climatronic control unit -J255- must
wit
be coded as follows:
, is n
h re
hole
♦ The display of the control and display unit for Climatronic air
spec
conditioning -E87- flashes 15 seconds if the Climatronic con‐
es, in part or in w
trol unit -J255- has not been coded. t to the co

rrectness of i

l purpos

nform
ercia
m
at
om
– Press 07 Coding control unit on display -arrow-.

ion
c
in t
or
– Enter code number and confirm with Q key.

his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Code number For vehicles

04000 All countries except Japan
04100 Japan
04001 All countries except Japan without ambient temperature display
04101 Japan without ambient temperature display
– Confirm entry with Q key.

Polo 1995 ➤
The control unit code and part number will be displayed on the
vehicle diagnosis, testing and information system -VAS 5051A-
or vehicle diagnosis and service information system -VAS 5052- .
1.5.10 Read measured value block 08
Note
♦ There are 4 display group numbers that can display up to 4

measured values.
♦ A 2nd mechanic is require to read measured values during a
test drive.

– Press “08 Read measured value block” -arrow- on the display.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
– Press on numerical keypad of display -arrow- number of y li

erm
ab
measured value block to be read and confirm entry by pressing ility
ot p
Q key.
wit
, is n
h re
Overview of selectable display group numbers ⇒ page 17 .

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
The display zones are read from top to bottom.

rm
m
atio
m
If measured values have been read out, terminate output

o
n in
c
⇒ page 8 .
or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.6 Fault table

♦ The following table lists all possible faults, with the corre‐
sponding 5-digit code numbers, that can be detected by the

Polo 1995 ➤
Climatronic control unit -J255- and printed from the vehicle di‐
agnosis, testing and information system -VAS 5051A- .
♦ Faults which occur only occasionally are displayed as “spora‐
dic faults” (“SP”).
♦ Fault codes appear only in the printout.
♦ The fault table may also include the type of fault.
♦ Following a repair, always erase fault memory using vehicle
diagnosis, testing and information system -VAS 5051A- or ve‐
hicle diagnosis and service information system -VAS 5052-
and read again.
♦ If, despite customer's complaint no fault in Climatronic can be
found, carry out function “Final control diagnosis gen AG 03”
. Volkswagen AG
does
⇒ page 5 or function “Read measured o l swa block 08”
kvalue not
V gu
⇒ page 10 . If display flashes although
e d by no fault was detected, ara
nte
start functions “07 Code control
thoris
unit” and “04 Basic setting” eo
one after the other ( ⇒ pages 6 ).
au ra
c
s
ce
le
Display on VAS 5051A Possible cause of fault Rectifying fault

un
pt
an
d
itte
y li
00000
erm
ab
ility
No fault detected If “No fault detected” appears after repairs have been performed, self-diagnosis
satelettronica
ot p
has been completed. If display still flashes, select the following functions one
wit
is n
h re
after the other: 07 Code control unit ⇒ page 6 and 04 Basic settings
ole,
⇒ page 9 .
spec
t to the co
rrectne
00281
Vehicle speed sender -G68- 1)
ss o
cial p
f
Short circuit or open circuit in Check signal– from speedometer
inform
wiring or connectors for the sender -G22- using “08 Read meas‐
mer
speedometer signal from en‐ ured value block” ⇒ page 10 . atio

m
gine control unit to Climatronic

o
n
c
control unit Check wiring and– connectors to con‐

i
or
n thi
trol unit using current flow diagram.

te
sd
iva
Speedometer sender -G22- Renew speedometer

– sender -G22- .
pr
cum
r
fo
defective (only if speedometer

en
ng
t.
-G21- is also not functioning)
yi Co
Cop py
.
Cannot be checked at present This display appears only if final control diagnosis was carried out before
ht rig
rig ht
py by
reading fault memory. This fault is erased from fault memory after ignition
co Vo
by lksw
cted
is switched off. If speedometer sender -G68- is defective, the fault will
agen
Prote AG.
reappear when driving.
1) A fault is detected in speedometer sender -G22- , not in vehicle speed sender

-G68- . The fault is only detected if, during 5 driving cycles (start, travel over 15
km/h, stop), no speed signal is measured within 4 minutes of engine start.

00532
Voltage supply
Signal too large2) Alternator -C- defective – Check supply voltage (terminal 15) using
“Read measured value bock 08”⇒
⇒ page 10 .
– Check alternator -C- ⇒ Current flow dia‐
grams, Electrical fault finding and Fitting
locations.

Polo 1995 ➤

Signal too small 2)
Wiring or connectors to Clima‐ – Check supply voltage (terminal 15) using
tronic control unit -J255- “Read measured value bock 08”⇒
⇒ page 10 .
– Repair wiring and connectors according

to current flow diagram.
– Check alternator -C- ⇒ Current flow dia‐
grams, Electrical fault finding and Fitting
locations.
2) One of these readouts is displayed in addition to relevant component.

00538
Reference voltage
Signal too large3) Short circuit or open circuit in wir‐ – Check wiring and connectors to control
ing or connectors. Note wiring of unit using current flow diagram.
connector housing T16b8 on Cli‐
matronic control unit -J255- to
satelettronica
control motors.
Signal too small3) – Check function of control motors for reg‐
ulating air conditioning system via final
control diagnosis 03 ⇒ page 5 .
Temperature flap control motor – Pull off connectors to these components
potentiometer -G92- or central one at a time, erase fault memory
flap control motor potentiometer - ⇒ page 7 and read fault memory again
G112- or air flow flap control mo‐ ⇒ page 4 . If the “reference voltage” fault
tor potentiometer -G113- or foot‐ is no longer detected, renew the motor
well/defroster flap control motor which leads to a fault when reconnected.
potentiometer -G114- defective olkswagen AG
en AG. V
Climatronic control unit -J255-olksw–ag Replace control unit does
ifnonecessary
t gu
and
defective ed byV then select the following functions
ara one
oris after another: Code control unit
nte 07
e
th
au ⇒ page 9 , Adjust basic setting o04 ra
c
ss ⇒ page 6 .
ce
e
nl
pt
du
an
itte
y li
erm
ab

ility
ot p
wit
, is n

h re
hole
spec
00603
es, in part or in w
Footwell and defroster flap

t to the co
control motor -V85-

Short circuit or open circuit in wir‐ – Perform final control diagnosis 03
rrectness of i
ing or connectors to footwell and ⇒ page 5 .

defroster flap control motor -
l purpos
V85- . – Check footwell and defroster flap control

motor -V85- using “read measured value
block 08” ⇒ page 10 .
nform
mercia

at
om
io

n
c
in t
or
Footwell and defroster flap con‐ – Perform final control diagnosis -03
his
ate
trol motor -V85- blocked ⇒ page 5 .

do
priv
cum
or
Footwell and defroster flap con‐ – Renew footwell and defroster flap control
f
en
ng
trol motor -V85- defective 4) motor -V85- . Then select function Initiate
t.
yi Co
op
basic setting 04, ⇒ page 6 . C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Polo 1995 ➤
4) This fault is detected in Basic setting 04, Final control diagnosis 03 and in
normal operation. Both end stops must be reached.

00779
Ambient temperature sensor
-G17-
Open circuit/short to positive Short to positive or open circuit in – Check ambient temperature sensor -
5)
wiring or connectors to ambient G17- using “Read measured value block
temperature sensor -G17- 08” ⇒ page 10 .

Short to earth5) Short to earth in wiring or con‐ – Check ambient temperature sensor -
nectors to ambient temperature G17- using “Read measured value block
sensor -G17- 08” ⇒ page 10 .
AG. Volkswagen AG d
lksw
agen oes
not – Repair wiring and connectors according
d byV
o gu
ara to current flow diagram.
ise nte
hor Ambient temperature sensor
eo - – Renew ambient temperature sensor -
satelettronica
aut G17- defective ra G17- .
ss c
ce
le
un
pt
an
d
itte
y li

rm
ab
pe
ility
ot

wit
, is n
h re
00787
hole
spec
Fresh air intake duct temper‐

es, in part or in w
t to the co
ature sensor -G89-

Open circuit/short to positive Short to positive or open circuit in – Check fresh air intake duct temperature
6)
wiring or connectors to fresh air sensor -G89- using “Read measured val‐
rrectness of i
intake duct temperature sensor - ue block 08” ⇒ page 10 .

G89-
l purpos

nform
ercia
Short to earth6) Short to earth in wiring or con‐ – Check fresh air intake duct temperature
nectors to fresh air intake duct sensor -G89- using “Read measured val‐
m
a
com
temperature sensor -G89- ue block 08” ⇒ page 10 .

ion in
r
te o
thi

s
iva
do

r
rp
cum
fo
Fresh air intake duct temperature – Renew fresh air intake duct temperature
en
ng
t.
sensor -G89- defective sensor -G89- .
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Display on VAS 5051A Possible cause of Rectifying fault

fault
00792
Air conditioning system pressure switch -F129- 7) 8)

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
Polo 1995 ➤ orise nte
h eo
Heating, air conditioning - Edition 06.2004 aut ra
c
ss
ce
le
un
pt
Display on VAS 5051A Possible cause of Rectifying fault
an
d
itte
fault
y li
rm
ab
pe
Short circuit or open – Check air conditioning
ility
ot
circuit in wiring or con‐ system pressure switch -
wit
, is n
nectors to air condi‐ F129- using “Read meas‐
h re
hole
tioning system pres‐ ured value block 08”
spec
sure switch -F129- . ⇒ page 10 .
es, in part or in w
t to the co
Improper filling of re‐
frigerant circuit. En‐ – Repair wiring and con‐
gine cooling insuffi‐ nectors according to cur‐
rrectness of i
cient rent flow diagram.
l purpos
– Take vehicle to specialist
workshop.
nform
ercia
– Check engine cooling ⇒
m
Rep. Gr. 19. .
a
com
tion in
Air conditioning sys‐ – Renew air conditioning
r
te o
tem pressure switch - system pressure switch -
thi
s
iva
F129- defective F129- .
do
r
rp
cum
Cannot be checked at present This display appears only if the final control diagno‐
fo
en
ng
sis 03 was performed and the air conditioning sys‐

t.
yi Co
satelettronica
op
tem pressure switch -F129- could not be checked
C py
t. rig
(e.g. ambient temperature below 12°) before the
gh ht
pyri by
fault memory was read. This fault is erased from fault
o Vo
by c lksw
cted agen
memory after ignition is switched off.
Prote AG.
7) This fault cannot be detected if the ambient temperature is below 12° C or if

the ambient temperature sensor -G17- and the fresh air intake duct temperature
sensor -G89- are defective. The switch is a triple switch. The 2 bar/32 bar switch‐
ing part is tested, but not the 16-bar switching part.
8) The high pressure sender -G65- may be installed in place of the air conditioning
system pressure switch -F129- , and the same fault message will be the same.
Check high pressure sender -G65- ⇒ page 132 .

00797
Sunlight penetration photo‐
sensor -G107-
Open circuit/short to positive Open circuit or short to positive in – Check sunlight penetration photosensor
9)
wiring or connectors to sunlight -G107- using “Read measured value
penetration photo sensor - block 08” ⇒ page 10 .
G107- .
Short to earth9) Short to earth in wiring or con‐ – Check sunlight penetration photosensor
nectors to sunlight penetration -G107- using “Read measured value
photo sensor -G107- defective block 08” ⇒ page 10 .

– Renew sunlight penetration photosensor

-G107- .

01206
Signal for duration of -Igni‐
tion OFF- 10).

Polo 1995 ➤

Short circuit or open circuit in wir‐ – Check time parked signal using “Read
ing or connectors. measured value block 08” ⇒ page 10 .

Climatronic control unit -J255- Renew Climatronic control unit -J255- . Then
defective select following functions one after another:
Code control unit 07, ⇒ page 9 and Initiate
basic setting 04, ⇒ page 6 .
10) Signal for duration of -Ignition OFF- . When the vehicle is parked (ignition
switched off) and then restarted within 2 hours, the Climatronic control unit -J255-
evaluates the signal "duration of -Ignition OFF-" to replace the values of the
ambient air temperature sensor -G17- and the fresh air intake duct temperature
sensor -G89- with the values at the point when the engine was switched off. The
measured values will otherwise be falsified by the heat radiated from the stationary en AG. Volkswagen AG
engine. The signal "duration - Ignition OFF-" comes only following a start. lkswag does
not
o
byV gu
ara
d
Display on VAS 5051A Possible cause of fault orise Rectifying fault nte
eo
h
ut ra
01271 ss a c
satelettronica
ce
Temperature flap control
e
nl
pt
du
motor -V68- 11)
an
itte
y li
erm
Short circuit or open circuit in wir‐ – Check temperature flap control motor -
ab
ility
ing or connectors to temperature V68- using “Read measured value block
ot p
wit
flap control motor -V68- 08” ⇒ page 10 .
, is n
h re
hole
spec
es, in part or in w
t to the co
Temperature flap control motor - – Check end position of temperature flap
V68- installed without the use of control motor -V68- while installed: per‐
function “Initiate basic setting 04” form final control diagnosis 03
rrectness of i
⇒ page 5 .
l purpos
Temperature flap control motor - – Perform final control diagnosis 03

V68- blocked ⇒ page 5 .
nf
ercia
Temperature flap control motor - – Renew temperature flap control motor -
or
V68- defective V68- and initiate function Basic setting 04
m
m
atio
⇒ page 6 .
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o

f
en
ng
t.
yi Co
op
C py
ht. rig
rig ht
by
01272 copy Vo
by lksw
cted agen
Central flap control motor - Prote AG.
V70- 12)
Short circuit or open circuit in wir‐ – Check central flap control motor -V70-
ing or connectors to central flap using “Read measured value block 08”
control motor -V70- ⇒ page 10 .

Central flap control motor -V70- – Perform final control diagnosis 03
blocked ⇒ page 5 .
Central flap control motor -V70- – Renew central flap control motor -V70-
defective and initiate function Basic setting 04
⇒ page 6 .

Polo 1995 ➤

01273
Fresh air blower -V2- or con‐ en AG. V
olkswagen AG
trol unit for fresh air blowero-lkswag does
not
J126- ed byV gu
ara
ris nte
utho Short circuit or open circuit in wir‐ –e or Check fresh air blower -V2- using “Read
ss
a ing or connectors to fresh air ameasured
c value block 08” ⇒ page 10 .
blower -V2-
ce
le
un
pt
an
d
itte
y li
rm
ab
Fresh air blower control unit - – Perform final control diagnosis -03
pe
ility
ot
J126- or fresh air blower -V2- de‐ ⇒ page 5 .
wit
, is n
fective
h re
hole
– Renew fresh air blower control unit -
spec
J126- or fresh air blower -V2- .
es, in part or in w
t to the co
rrectness of i
01274
l purpos
Air flow flap control motor -
satelettronica
V71- 13)
nform
ercia
Short circuit or open circuit in wir‐ – Check air flow flap control motor -V71-
m
a
ing or connectors to air flow flap using “Read measured value block 08”
com
tion in
control motor -V71- ⇒ page 10 .
r
te o
thi
s
iva

do
r
rp

um
fo
en
g
Air flow flap control motor -V71- – Perform final control diagnosis -03
n
t.
yi Co
op
blocked ⇒ page 5 .
C py
t. rig
gh ht
Air flow flap control motor -V71- – Renew air flow flap control motor -V71-
pyri by
Vo
co
defective and initiate function Basic setting 04
by lksw
cted agen
Prote
⇒ page 6 .
AG.

01296
Centre vent temperature
sender -G191-
Centre vent temperature sender
-G191- is not installed.
Open circuit/short to positive Climatronic control unit -J255- in‐ – Select the following functions one after
14)
correctly coded. another: Code control unit 07 ⇒ page 9 ,
Initiate basic setting 04 ⇒ page 6 .
Short to earth 14)
Climatronic control unit -J255- in‐ – Select the following functions one after
correctly coded. another: Code control unit 07 ⇒ page 9 ,
Initiate basic setting 04 ⇒ page 6 .

01297
Footwell vent temperature
sender -G192-

Polo 1995 ➤

Open circuit/short to positive Short to positive or open circuit in – Check footwell vent temperature sender
15)
wiring or connectors to footwell -G192- using “Read measured value
vent temperature sender -G192- block 08” ⇒ page 10 .

Short to earth15) Short to earth in wiring or con‐ – Check footwell vent temperature sender
nectors to footwell vent tempera‐ -G192- using “Read measured value
ture sender -G192- defective block 08” ⇒ page 10 .

– Renew footwell vent temperature sender

-G192-
satelettronica
65535
Climatronic control unit -
J255-
Wiring or connectors to Clima‐ – Check wiring and connectors using cur‐
tronic control unit -J255- defec‐ rent flow diagram.
tive
– Check Climatronic control unit -J255- us‐
ing “Read measured value block 08”
⇒ page 10 .
Renew Climatronic control unit -J255- . Then

select following functions one after another:
AG. Volkswagen AG d
Code control unit 07 ⇒ page 9 , Initiate basic
lksw
agen oes
not setting 04, ⇒ page 6 .
Vo gu
by ara
d
rise nte
tho eo
au ra
1.7 Overview of selectable display group numbers in measured value block 08
ss c
ce
le
un
pt
an
d
Display group num‐ Display zone Designation

itte
y li
ber
erm
ab
ility
ot p
001 1 Air conditioner compressor, air conditioning system magnetic

wit
is n
coupling -N25-
h re
ole,
spec
Code 0: air conditioning system magnetic coupling -N25- is not

switched off. (Code numbers 1 through 12 state reason for being

t to the co
switched off.)
Code 1: is not displayed.
rrectne
Code 2: air conditioning system magnetic coupling -N25- is

switched off because fresh air blower -V2- or fresh air blower
control unit -J126- is defective.
ss o
cial p

inform

mer
atio
m
Code 5: air conditioning system magnetic coupling -N25- switch‐

o
n
c
ed off for 4 seconds (no defect). Code 5 appears for only 5

i
or
n thi
seconds. If it remains, check engine speed signal.

te
sd
iva

pr
cum
r
fo
switched off. ECON mode (no defect).

en
ng
t.
yi Co
Cop py
t. rig
yri
gh switched off because blower output was switched off via blower
by
ht
button (no defect).
cop Vo
by lksw
cted agen
Prote AG.

Polo 1995 ➤

ber
switched off because ambient air temperature is below 3° C (to
prevent icing, no defect). Check ambient air temperature sensor
-G17- and fresh air intact duct temperature sensor -G89- as ap‐
propriate.
switched off because voltage in vehicle power supply is below
9.5 V.
switched off by HOT warning lamp switch (instrument cluster) via
Climatronic control unit -J255- .
switched off by automatic gearbox control unit or engine control
unit via Climatronic control unit -J255- .
2 Engine speed detected
Code 0: no
Code 1: yes
satelettronica
3 Vehicle speed
Display: 0 to 255 km/h
4 Parked time
Code 0 to 240: time in minutes for “ignition OFF”
Code 250: battery nwas disconnected.
AG. Volkswagen AG
kswage does
Code 255:by faulty data transmission
Vol not
gu
a
ed ran
ris tee
tho or
au ac
ss
ce
le
un
pt
an
Note
d
itte
y li
erm
ab
ility
After completing “Read measured value block” function, read fault
ot p
memory ⇒ page 4 . wit

is n
h re
ole,
spec

t to the co
ber
002 1 Temperature flap control motor -V68-
rrectne
Code for measured value: 0 to 255

Permissible deviation from specification ±2
ss
2 Temperature flap control motor -V68-

o
cial p
f in
Specification 0 to 255
form
mer
3 Temperature flap control motor -V68- flap stop: cold

atio
om
Code 0 to 149: temperature flap control motor -V68- defective

n
c
i
or
n thi
e
Code 150 to 250: temperature flap control motor -V68- is OK under

t
sd
va
condition that basic setting 04 was carried out.

i
o
pr
cum
r
fo

en
ng
t.
yi Co
op
4 Temperature flap control motor -V68- flap stop: warm
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
Code 5 to 100: temperature flap control motor -V68- is OK under
cted agen
Prote AG.

Polo 1995 ➤
Note

memory ⇒ page 4 .
Display group number Display zone Designation

003 1 Central flap control motor -V70-
2 Central flap control motor -V70-
3 Central flap control motor -V70- flap stop: air to dash panel
vents
Code 0 to 149: central flap control motor -V70- defective
Code 150 to 250: central flap control motor -V70- is OK under
satelettronica
4 Central flap control motor -V70- flap stop: air to footwell and
defroster vents
Code 5 to 100:lkscentral
wage flap control motor es-V70-
not is OK under
condition dthat
by basic setting 04 was carried out.
Vo gu
ara
e nte
ris to 255: central flap control motor -V70-
Codetho101 defective
eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
h re
hole
memory ⇒ page 4 .
spec
es, in part or in w
t to the co
004 1 Footwell and defroster flap control motor -V85-
rrectness of i
l purpos

2 Footwell and defroster flap control motor -V85-
nf
ercia
rm
m
atio
3 Footwell and defroster flap control motor -V85- flap stop: air to
om
n in
footwell
or c
thi
e
Code 0 to 149: footwell and defroster flap control motor -V85-

t
sd
iva
defective
o
r
rp
cu
o
m
f
Code 150 to 250: footwell and defroster flap control motor -

en
ng
t.
yi Co
V85- is OK under condition that basic setting 04 was carried
Cop py
out.
t. rig
gh ht
pyri by
o Vo
by c lksw
cted agen
V85- defective
Prote AG.
4 Footwell and defroster flap control motor -V85- flap stop: air to
windscreen
defective
is OK under condition that basic setting 04 was carried out.

Polo 1995 ➤

V85- defective
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
Note tho r eo
au ra
ss c
ce
le
un
pt
memory ⇒ page 4 .
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
005 1 Air flow flap control motor -V71-
h re
ole,
spec
t to the co
2 Air flow flap control motor -V71-
rrectne
3 Air flow flap control motor -V71- flap stop: fresh air to passen‐
satelettronica
ger compartment
ss o
Code 0 to 149: air flow flap control motor -V71- defective
cial p
f inform
Code 150 to 250: air flow flap control motor -V71- is OK under
mer

atio
om
c
i
or
n thi
e
4 Air flow flap control motor -V71- flap stop: air recirculation in
t
sd
iva
passenger compartment
o
pr
cum
r
fo

en
ng
t.
yi Co
op
Code 5 to 100: air flow flap control motor -V71- is OK under
C py
t. rig
gh
ht
pyri by
Vo
o
by c lksw
Prote
cted AG. Code 101 to 255: air flow flap control motor -V71- defective
agen
Note

memory ⇒ page 4 .

ber
006 1 Value in °C calculated by Climatronic control unit -J255- and
displayed on control and display unit for Climatronic air condi‐
tioning system -E87-
Value is calculated from temperature measurements of fresh
air intake duct temperature sensor -G89- and ambient air tem‐
perature sensor -G17- . The values is less than indicated by the
measurements from the ambient air temperature sensor -G17-
and the fresh air intake duct temperature sensor -G89- if the
vehicle is parked.
If the measurements of the ambient air temperature sensor -
G17- and the fresh air intake duct temperature sensor -G89-
indicate the current value, there is no defect. The values
approach each other during longer trips. The ambient air tem‐
perature sensor -G17- or the fresh air intake duct temperature
sensor -G89- is defective if the value is extremely unusual.
2 Fresh air intake duct temperature sensor -G89- , current meas‐
urement in °C

Polo 1995 ➤

ber
3 Ambient air temperature sensor -G17- , current measurement
in °C
4 Sunlight penetration photo sensor -G107- , measurement in %,
from 0 to 120
Note

memory ⇒ page 4 .

agen
AG. Volkswagen AG d
o
ksw es n
007 1 Vol vent temperature sender o-G191-
Centre ara display -53.0° C Dis‐
t gu
d by
ri regard value because centre vent temperature
se nte sender -G191-
utho is not installed.
eo
ra
a c
ss
2 Footwell vent temperature sensor -G192- , current measure‐
ce
e
nl
satelettronica
pt
ment in °C
du
an
itte
y li
3 Dash panel temperature sensor -G56- , current measurement
erm
ab
in °C
ility
ot p
wit
4 No display
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos
memory ⇒ page 4 .
nform
ercia

m
at
008 1 Fresh air blower -V2- , specification in Volts
om
ion
c
Off: 0 V
in t
or
his
te
One blower bar: 3.6 V

a
do
priv
Seven blower bars: 12 V

um
for
en
ng
t.
2 Fresh air blower -V2-
yi Co
Cop py
t.
Actual value measured in Volts
rig
gh ht
pyri by
Vo
o
Permissible deviation from specification ±0.8 V
c by lksw
cted agen
Prote AG.
3 Terminal 15
Measurement: voltage in Volts
4 Voltage at air conditioning system magnetic coupling -N25-
Measurement: voltage in Volts
Not measured
Note

memory ⇒ page 4 .

Polo 1995 ➤
80 – Heating
1 Repairing heater, vehicles ▸ 09.99
AG. Volkswagen AG d
agen
1.1 Passenger compartment heating yV
olksw
oes
not
gu
d b ara
ise nte
or eo
h
ut ra
1.1.1 Before beginning repair work, perform s a c
s
ce
le
the following steps:
un
pt
an
d
itte
y li
erm
– Switch off all electrical consumers.
ab
ility
ot p
– Switch off ignition.
wit
is n
h re
ole,
– Pull out ignition key.
spec
t to the co
1 - Left plenum chamber cover
2 - Right plenum chamber cov‐
satelettronica
rrectne
er
❑ Removing and installing
s
⇒ page 25 .
s o
cial p
f in
3 - Dust and pollen filter
form
mer
❑ Removing ⇒ page 26 .
atio
om
n
4 - Dash panel
c
i
or
n thi
e

t
sd
va
⇒ Rep. Gr. 70 .
i
o
pr
cum
r
fo
en
ng
5 - Right vent yi
t.
Co
op
C py
ht. rig
rig ht
❑ Do not dismantle further py by
co Vo
lksw
(vent and adjustable
by
cted agen
Prote
louver are one spare
AG.
part).
6 - Air distribution duct, upper
part
❑ Renewing: remove cen‐
tre vent
⇒ Item 28 (page 23)
and remove air distribu‐
tion duct
⇒ Item 22 (page 23) .
7 - Right air duct
❑ Removing and instal‐
ling: first remove glove
box or front passenger
side airbag unit ⇒ Rep.
Gr. 69 .
8 - Hexagon nut M6
❑ 5 Nm.
9 - Heater unit
❑ Removing and installing ⇒ page 29 .
10 - Fresh air blower -V2-
22 Rep. Gr.80 - Heating

Polo 1995 ➤
11 - Fresh air blower series resistor with overheating fuse -N24-

12 - Trim panel for controls
❑ Carefully unclip using screwdriver.
13 - Central flap lever
❑ Removing and installing: first remove footwell vents ⇒ Item 20 (page 23) and ⇒ Item 18 (page 23) .
14 - Temperature flap lever
Volkswagen AG
en AG.⇒
❑ Removing and installing: first remove footwell
ksw
agvents Item 20 (page
does 23) and ⇒ Item 18 (page 23) .
n ol ot g
yV ua
15 - Controls for fresh and heated air ed
b ran
oris tee
❑ Removing and installing ⇒ page au 25 .
th or
ac
ss
❑ Dismantling and assembling ⇒ page 34 .
ce
e
nl
pt
❑ Installing and adjusting cables ⇒ page 32 .
du
an
itte
y li
erm
16 - Rear duct
ab
ility
ot p
❑ Renewing: first remove centre console, footwell vents ⇒ Item 20 (page 23) and
wit
, is n
⇒ Item 18 (page 23) , seats and carpet.
h re
hole
spec
17 - Seal for rear duct
es, in part or in w
satelettronica
❑ Renewing: first remove footwell vent ⇒ Item 20 (page 23) .
t to the co
18 - Footwell vent, lower part
rrectness of i
19 - Air duct grille
l purpos
nform
ercia

m
at
21 - Cables
om
ion
c
❑ Renewing: first remove centre vent ⇒ Item 28 (page 23) , footwell vents ⇒ Item 20 (page 23) and front
in t
or
his
e
passenger side compartment

at
do
riv
❑ Installing and adjusting ⇒ page 32 .

p
cum
for
en
g
22 - Air distribution duct, lower part

n
t.
yi Co
op py
❑ Renewing: remove centre vent ⇒ Item 28 (page 23) .
t. C rig
gh ht
pyri by
Vo
23 - Seal
co lksw
by
cted agen
Prote
❑ Renew.
AG.
24 - Intermediate piece
❑ With seal.
❑ Renewing: first remove dash panel ⇒ Rep. Gr. 70 .
25 - Heat exchanger
❑ Renewing: remove heater unit ⇒ page 29 .
❑ Removing and installing: ⇒ page 30 .
❑ After removal, completely renew coolant.
26 - Left air duct
❑ Removing and installing: first remove left vent ⇒ Item 27 (page 23) and dash panel insert.
27 - Left vent
❑ Do not dismantle further (vent and adjustable louver are one spare part).
28 - Central vents
29 - Adjustable louver
❑ For centre vent.
1. Repairing heater, vehicles ▸ 09.99 23

Polo 1995 ➤
– Carefully pull out using long nose pliers.
1.2 Removing and installing fresh air blower

series resistor with overheating fuse -
N24-
1.2.1 Removing
– Open air duct cover to side.
– Pull off connectors.
– Press tabs on sides together and pull out series resistor.
AG. Volkswagen AG d
agen oes
ksw
Note byV
ol not
gu
ara
ed
ris nte
o eo
If tabs on sides do not aut engage during installation, the series re‐
h
ra
sistor can be installed
s with a self-tapping screw -arrow-.
s c
ce
e
nl
pt
du
satelettronica
an
itte
y li
erm
ab
ility
ot p
1.2.2 Installing
wit
, is n
h re
hole
– Seal area between series resistor and air duct with AMV 176
spec
000 05 before fitting.
es, in part or in w
t to the co
1.3 Removing fresh air blower -V2- rrectness of i
1.3.1 Removing
l purpos
– Open air duct cover to side.

nf
ercia
or
– Pull connector -1- off series resistor.

m
m
atio
m
– Release retainer -3- then turn fresh air blower -2- in

o
n in
or c
-direction of arrow- and remove.

thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Polo 1995 ➤
1.4 Removing and installing controls for

fresh and heated air
1.4.1 Removing
– Remove centre vent -2- ⇒ page 28 .
– Pull controls -1- with cables attached out of dash panel.
1.4.2 Installing
satelettronica
– Attach cables to removed controls.
1.5 Removing and installing right plenum

chamber
1.5.1 Removing
– Pull off rubber seal -1- upwards to centre of vehicle.
– Unclip plenum chamber cover -2- -arrows- and pull out.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
1.5.2 Installing
hole
spec
es, in part or in w
Install in reverse order.

t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Polo 1995 ➤
1.6 Removing dust and pollen filter

1- Frame
2- Filter element
AG. Volkswagen AG d
3- Plastic nuts ksw
agen oes
not
Vol
y gu
4- Filter housing with seal ise
d b ara
nte
or eo
th
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
1.6.1 Removing
satelettronica
ss
– Press tabs of filter housing in -direction of arrow B- and remove
o
cial p
f
filter element with frame.
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 1995 ➤
1.6.2 Installing
– Frame must engage in first fin of filter element -arrow A-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
satelettronica
1.7 Removing right vent
nform
mercia
a
com
ti
1.7.1 Removing
on in
r
te o
thi
– Unclip vent housing -arrows-.
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
Note
Co
Cop py
t. rig
gh ht
yri
Do not dismantle housing and adjustable louver further (vent and
p by
o Vo
by c lksw
adjustable louver are one spare part). cted agen
Prote AG.

Polo 1995 ➤
1.8 Removing left vent
1.8.1 Removing
– Remove light switch ⇒ Rep. Gr. 96 .
– Unclip vent housing -arrows-.
Note
Do not dismantle housing and adjustable louver further (vent and

adjustable louver are one spare part).
satelettronica
1.9 Removing centre vents n AG. Volkswagen AG do
lkswage es n
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1.9.1 Removing autho
or
ac
ss
– Remove radio ⇒ Rep. Gr. 91 .
ce
e
nl
pt
du
an
– Remove switch.
itte
y li
erm
ab
– Unclip trim panel for controls.
ility
ot p
wit
, is n
– Unbolt controls -2-.

h re
hole
– Remove centre console -4- ⇒ Rep. Gr. 68 . spec

es, in part or in w
t to the co
– Remove 3 bolts -arrows A-.
– Pull adjustable louver -3- out carefully with pointed pliers.
rrectness of i
– Remove 2 bolts -arrows B- and remove centre vent -1-.

l purpos
nf
ercia
orm
m
atio
om
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or c
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t.
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Cop py
t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.
1.10 Removing and installing footwell vents
1.10.1 Removing
– Remove driver side footwell cover ⇒ Rep. Gr. 68 .

Polo 1995 ➤
– Unclip trim panel for controls -1-.

– Remove trim or compartment -2-.
Note
For clarity, the following figure shows centre vent removed.
– Remove 3 bolts -arrows A-.

– Footwell vent, upper part -1- push into lower part of footwell
vent -2- -arrow B-.
– Pull out footwell vent to left.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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1.11 Removing and installing heater unit
ce
e
nl
pt
du
an
itte
y li

erm
ab
ility
ot p
♦ Hose clamps up to 40 mm Ø -3093-

wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
c
♦ Drip tray for workshop hoist -VAS 6208-

or
thi
te
sd
iva
o
r
rp
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o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Polo 1995 ➤
Note
AG. Volkswagen AG d
agen oes
lksw not
To prevent coolant from entering byinterior of vehicle, seal heat ex‐ guar
Vo
d
changer connections beforeoremoving
ris
e
heater unit. an
tee
th or
au ac
ss
1.11.1 Removing
ce
e
nl
pt
du
an
itte
– Remove dash panel ⇒ Rep. Gr. 70 .
y li
erm
ab
ility
– Unbolt earth connection -arrow- on right A-pillar.
ot p
wit
, is n
– Remove dust and pollen filter together with filter housing
h re
hole
⇒ page 26 .
spec
es, in part or in w
– Open expansion tank cap.
t to the co
WARNING
rrectness of i
Danger of scalding injuries.
l purpos
The cooling system is pressurised. When the engine is warm,

the coolant temperature may be above 100° C.
nf
ercia
satelettronica
orm
If necessary, release pressure before carrying out repairs.
m
atio
om
n in
or c
thi
te
– Place drip tray -VAS 6208- beneath engine.
sd
iva
o
r
rp
cu
– Clamp off coolant hoses near heat exchanger using hose
o
m
f
en
ng
clamps to 40 mm Ø -3093- so that no coolant can escape.

t.
yi Co
Cop py
t.
– Remove coolant hoses from heat exchanger.
rig
gh ht
pyri by
Vo
o
by c
– Place a compressed air pistol in heat exchanger connection
lksw
cted agen
Prote
and carefully blow out remaining coolant.
AG.
– Unscrew hexagon nuts from bulkhead in engine compartment.
1.11.2 Installing
– Filling and bleeding cooling system ⇒ Rep. Gr. 19 .
1.12 Dismantling and assembling heater unit

Polo 1995 ➤
agen
AG. Volkswagen AG d
oes
olksw not
y V gu
1 - Clip rise
db ara
nte
tho eo
2 - Air duct with main
s au flap ra
c
s
❑ Do not dismantle fur‐
ce
e
nl
pt
ther. du
an
itte
y li
erm
3 - Wiring clip
ab
ility
ot p
4 - Seal
wit
, is n
h re
5 - Fresh air blower series re‐
hole
spec
sistor with overheating fuse -
es, in part or in w
N24-
t to the co
rrectness of i
7 - Seal
l purpos
8 - Seal
❑ Renew.
nf
ercia
9 - Air distribution duct, lower
orm
part
m
atio
om
n in
10 - Hexagon nut
or c
thi
e
satelettronica
t
sd
11 - Controls for fresh and
iva
o
r
heated air
rp
cu
o
m
f
en
ng
❑ Dismantling and assem‐

t.
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bling ⇒ page 34 . Cop py
ht. rig
rig ht
12 - Air duct cover py by
co Vo
by lksw
cted agen
13 - Plug Prote AG.
14 - Clip
15 - Cables
❑ Renewing: first remove
cover
⇒ Item 12 (page 31) .
❑ Installing and adjusting
⇒ page 32 .
18 - Footwell/defroster flap lever
19 - Air distribution housing
❑ With temperature flap.
❑ With central flap.
❑ With footwell/defroster flap.
❑ Do not dismantle further.
20 - Wiring clip
22 - Self-tapping fillister head screw
23 - Seal
❑ Renew.
24 - Heat exchanger
❑ Seals must be bonded free of gaps all around.
❑ If retaining tabs do not engage when inserted, then bolt on heat exchanger.
25 - Seal
❑ Renew.

Polo 1995 ➤
26 - Wiring clip
1.13 Installing and adjusting cables
Note
♦ First connect the cables to the removed controls then adjust

and secure the cables to the levers on the heater.
♦ Place Bowden cable sheath against stops on controls and se‐
cure.
♦ Adjust cables at flap levers with controls installed.
♦ When control knobs are turned, all flaps must audibly contact
stop. AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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1 - Temperature flap cable ut
hor eo
a ra
❑ From temperature con‐ ss c
satelettronica
ce
trol rotary knob to tem‐
e
nl
pt
du
perature flap.
an
itte
y li
❑ Blue sheath.
erm
ab
ility
ot p
❑ Adjusting cable at tem‐
wit
, is n
perature flap
h re
⇒ page 33 .
hole
spec
es, in part or in w
2 - Footwell/defroster flap ca‐
t to the co
ble
❑ From air distribution
control rotary knob to
rrectness of i
footwell/defroster flap.
l purpos
❑ Black sheath.
❑ Adjust cable at footwell/
nform
ercia
defroster flap
⇒ page 33 .
m
at
om
io
3 - Central flap cable

n
c
in t
or
❑ From air distribution ro‐

his
ate
tary control to central

do
priv
flap.
um
for
en
ng
❑ Yellow sheath.
t.
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Cop py
❑ Adjusting cable at cen‐
t. rig
gh ht
yri
tral flap ⇒ page 33 . p by
o Vo
by c lksw
cted agen
Prote AG.

Polo 1995 ➤
1.13.1 Adjusting cable at temperature flap
Note
To adjust cable at lever of temperature flap, footwell vent must be

removed ⇒ page 28 .
– Install controls for heated air and fresh air blower ⇒ page 25 .
– Turn temperature rotary knob to stop of “cold” position.
– Press temperature flap lever to stop -arrow- and secure blue
cable sheath.
satelettronica
1.13.2 Adjusting cable at central flap
AG. Volkswagen AG d
agen Note oes
olksw not
y V gu
d b ara
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To adjust cable
thor at lever of central flap, footwell vent must be
e o re‐
moved ⇒ spage
sa
u
28 . ra
c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Turn air distribution rotary knob to stop of Defrost position.

ility
ot p
– Press central flap lever to stop -arrow- and secure yellow cable
wit
, is n
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sheath.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
1.13.3 Adjusting cable at footwell/defroster flap

om
ion
c
in t
or
his
ate
do
riv
Note
p
cum
for
en
ng
t.
To adjust cable at lever of footwell/defroster flap, driver side com‐
yi Co
op py
partment must be removed. t. C rig
gh ht
pyri by
Vo
co lksw
by
– Remove driver side compartment ⇒ Rep. Gr. 68 . cted agen
Prote AG.

Polo 1995 ➤

– Press footwell/defroster flap lever to stop -arrow- and secure
black cable sheath.
1.14 Dismantling and assembling heated air and fresh air controls
1 - Controls
❑ With fresh air blower
switch -E9- .
2 - Light conductor
satelettronica
3 - Coloured filter
4 - Fresh air regulation light
bulb -L16- AG. Volkswagen AG d
agen oes
5 - Cap olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
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o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Polo 1995 ➤
2 Repairing heater, vehicles 10.99 ▸
2.1 Passenger compartment heating
2.1.1 Before beginning repair work, perform

1 - Air duct
❑ In plenum chamber.
❑ With active charcoal fil‐
satelettronica
ter.
⇒ page 37 .
3 - Controls for fresh and heat‐
ed air AG. Volkswagen AG d
agen oes
o lksw not
❑ With fresh air blower ed byV gu
ara
switch -E9- .ho ris nte
eo
ut
❑ With fresh ss aair and air re‐ ra
c
circulation flap switch -
ce
le
un
E159- .
pt
an
d
itte
y li

erm
ab
⇒ page 42 .
ility
ot p
wit

is n
h re
bling ⇒ page 48 .
ole,
spec

cables ⇒ page 49 .
t to the co
4 - Dash panel
rrectne
⇒ Rep. Gr. 70 .
s
5 - Vent on front passenger

s o
side
cial p
f inform
❑ Remove vent
mer
⇒ page 39 .
atio
om
6 - Fresh air and air recircula‐

c
i
or
tion flap control motor -V154-

thi
te
sd
va

i
o
pr
cum
r
⇒ page 47 .
fo
en
ng
t.
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7 - Fresh air blower -V2- ht. Cop py
rig
❑ Removing ⇒ page 36 . rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
9 - Central vents
❑ Remove vent ⇒ page 38 .
10 - Heater unit
2. Repairing heater, vehicles 10.99 ▸ 35

Polo 1995 ➤
11 - Cables
12 - Connecting piece
13 - Cover
14 - Footwell vent
15 - Footwell system
16 - Intermediate piece, defrost wage
es n
olks ot g
❑ To renew, remove and install dash panel
d by V ⇒ Rep. Gr. 70 . ua
r e an
ris tee
17 - Heat exchanger ut
ho or
a ac
❑ To renew, remove dash panelss⇒ Rep. Gr. 70 .
ce
e
nl
❑ Installing ⇒ page 46 .
pt
du
an
itte
y li
❑ After renewal, completely renew coolant.
erm
ab
ility
ot p
18 - Heat exchanger/bulkhead seal
wit
, is n
❑ Note installation position ⇒ page 47 .
h re
hole
spec
19 - Vent on driver side
satelettronica
es, in part or in w
t to the co
rrectness of i
2.2 Removing fresh air blower -V2-
l purpos
1- Heating
nform
ercia
2- Fresh air blower -V2-

m
3- Fresh air blower series resistor with overheating fuse -N24-
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
2.2.1 Removing
cted agen
Prote AG.

– Remove centre console ⇒ Rep. Gr. 68 .
– Remove glove box ⇒ Rep. Gr. 68 .
– Separate foam cover beneath heater unit.
– Pull connectors off fresh air blower -V2- -2-.
– Remove fresh air blower series resistor with overheating fuse
-N24- -3-.
– Pull fresh air blower -V2- out downwards.

Polo 1995 ➤
2.3 Removing and installing dust and pollen

filter
1- Plenum chamber cover
2- Cover
3- Dust and pollen filter cover
4- Dust and pollen filter
5- Plastic nut, 2.5 Nm
6- Filter housing
2.3.1 Removing
– Pull off rubber seal -1- on plenum chamber cover (right) up‐
wards to centre of vehicle.
– Unclip two clips -arrows- beneath water deflector (rubber) and
remove plenum chamber cover -2-.
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
– Press out cover -1- in -direction of arrow- and press filter hous‐
an
itte
y li
ing tabs -A- in -direction of arrow- and remove filter element

erm
ab
with frame upwards.

ility
ot p
wit
, is n
– Remove filter element from frame.

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
2.3.2 Installing
orm
m
atio
m
– Insert left and right edges of frame into first rib -arrows- of new
o
n in
c
filter element.
or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 1995 ➤
– Insert frame into housing with lug -1- in corresponding recess‐

es and press frame and filter element downwards.
– Install plenum chamber cover -2- and secure beneath water

deflector with two clips -arrows-.
– Press on rubber seal -1-.
satelettronica
AG. Volkswagen AG d
agen oes
ksw
2.4 Removing centre vents ol not
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
2.4.1 Removing
s
ce
le
un
pt
an
d
itte
– Remove radio -1- ⇒ Rep. Gr. 91 . y li

erm
ab
– Remove compartment -2-. ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Polo 1995 ➤
– Remove bolts -arrows A-.

– Lever retaining tabs -arrows B- upwards.
– Pull centre vents out at the bottom and remove at the same
time.
– Separate connectors to hazard warning light switch -E3- .
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
2.5 Removing and installing vent on front

pt
du
an
itte
passenger side y li
erm
ab
ility
ot p
wit
, is n
h re
2.5.1 Removing
hole
spec
es, in part or in w
– Unclip vents with a screwdriver and pad -arrows-.

t to the co
– Pull out vent.

rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.5.2 Installing
– Press vent in lightly until it locates.

Polo 1995 ➤
AG. Volkswagen AG d
agen oes
olksw not
2.6 Removing and installing vent on driver y V gu
d b ara
ise nte
side or eo
th
au ra
ss c
ce
le
un
pt
an
d
2.6.1 Removing
itte
y li
rm
ab
pe
ility
– Remove light switch -E1- -1- ⇒ Rep. Gr. 96 .
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tio
– Remove bolt -arrow-.
n in
r
te o
satelettronica
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Unclip vents with a screwdriver and pad -arrows-.

– Pull off connector for headlight range control.
– Pull out vent.
2.6.2 Installing
– Press in until vent engages.

Polo 1995 ➤
2.7 Removing footwell vent

1- Bolt
2- Footwell vent
3- Connecting piece
4- Cover
5- Footwell system
6- Spreader rivet
7- Heater unit
8- Bolt
Volkswagen AG
9- Intermediate piece,
swa
gendefrost
AG. does
k not
Vol gu
by ara
ed nte
oris eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
2.7.1 Removing
y li
rm
satelettronica
ab
pe
ility
ot
wit
, is n
h re
hole
– Remove glove box ⇒ Rep. Gr. 68 . spec

es, in part or in w
t to the co
– Remove screw -1-.
– Pull out footwell vent -2- towards driver side footwell
rrectness of i
-arrow A-.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 1995 ➤
2.8 Removing and installing controls for

AG. Volkswagen AG d
agen
fresh andbyheated
Vol
ksw
air oes
not
gu
ara
ed nte
oris e
th or
au ac
2.8.1 Removingss
ce
le
un
pt
– Press downwards with finger tips in compartment -1-.
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
– Pull trim off controls -arrows-.
mer
satelettronica
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove bolts -arrows-.

– Release cables on controls -arrows-.

– Pull off connectors -1- and -2-.
As soon as controls have been removed, check function of cables
for heated air and fresh air.

Polo 1995 ➤
– To do this, move wire ends of cables back and forth in direction

of arrow.
– Replace damaged or stiff cables.
2.8.2 Installing
Note
♦ The cable sheaths are colour coded.

. Volkswagen AG
gen AG does
♦ Check cables before installing; replace stiff or damaged ca‐
Vol
ksw
a
not
bles.
satelettronica
y gu
db ara
rise nte
♦ When control knobs are turned, all flaps must tho contact
audibly
eo
au ra
stop. ss c
ce
e
nl
pt
du
an
– Bend wire ends of cables -1- and press onto lever of control
itte
y li
erm
-2- -arrow-.
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
o
– Press cable for footwell/defroster flap, cable for temperature
rm
m
flap and cable for central flap -1- into locking device -2- until it
atio
m
engages.
o
n in
or c
thi
e
Identification of footwell/defroster flap cable: left-hand drive:

t
sd
iva
green; right-hand drive: black.

o
r
rp
cu
o
m
f
en
Identification of central flap cable: left-hand drive: yellow; right-

ng
t.
yi Co
hand drive: grey. t. Cop py
rig
gh ht
Identification of temperature flap cable: red left-hand drive: beige; pyri by
Vo
co
right-hand drive: white.
by lksw
cted agen
Prote AG.

Polo 1995 ➤
2.9 Checking ventilation

AG. Volkswagen AG d
agen oes
olksw not
Note byV gu
ara
ed
ris nte
ho eo
ut
♦ The stale air escapes via ventilationss openings in the luggage
a ra
c
compartment trim.
ce
le
un
pt
an
d
♦ If the ventilation is to function properly, the ventilation open‐
itte
y li
ings must not be covered. rm
ab
pe
ility
♦ The ventilation vents are located in the side panel under the
ot
wit
, is n
bumper.
h re
hole
spec
es, in part or in w
2.9.1 Checking
t to the co
– The sealing lips -1- in the ventilation frame -2- must move
freely and close by themselves.
rrectness of i
l purpos
nform
ercia
satelettronica
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op py
2.10 Removing and installing heater unit
. C rig
ht ht
rig by
copy Vo
by lksw
Special tools and workshop equipment required Prote
cted AG.
agen
♦ Drip tray for workshop hoist -VAS 6208-
♦ Hose clamps up to 40 mm Ø -3093-

AG. Volkswagen AG d
lksw
agen oes
not Polo 1995 ➤
o
ara Heating, air conditioning - Edition 06.2004
V gu
d by
ise nte
or eo
h
1- Hexagon autnut ra
ss c
❑ In engine compartment.
ce
le
un
pt
an
❑ Qty. 3
d
itte
y li
erm
ab
❑ 4 Nm.
ility
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2 - Bulkhead
wit
is n
h re
ole,
3 - Heater unit
spec
Removing
t to the co
– Remove dash panel ⇒
Rep. Gr. 70 .
rrectne
– Place drip tray -VAS
s
6208- beneath engine.
s o
cial p
f inform
mer
WARNING
atio
m
Danger of scalding inju‐

o
n
c
i
ries.
or
n thi
te
sd
va
The cooling system is

i
o
pr
satelettronica
um
r
pressurised. When the

fo
en
ng
engine is warm, the cool‐

t.
yi Co
op
ant temperature may be
C py
t. rig
gh
above 100° C.
ht
pyri by
Vo
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by c lksw
cted agen
If necessary, release Prote AG.
pressure before carrying
out repairs.
– Clamp off coolant hoses

in engine compartment
using hose clamps up to
40 mm Ø -3093- and re‐
move from heat ex‐
changer.
– Place a compressed air

pistol in heat exchanger connection and carefully blow out remaining coolant.
– Remove hexagon nut ⇒ Item 1 (page 45) .
Installing
– Guide heater unit to bulkhead and push studs through intended holes.
– At the same time, make sure that heater unit sits on guide pin ⇒ Item 4 (page 45) against stop.
– Screw hexagon nuts ⇒ Item 1 (page 45) onto bulkhead in engine compartment and tighten them.
– Check coolant level and top up ⇒ Rep. Gr. 19 .

❑ Dismantling and assembling heater unit ⇒ page 46 .
4 - Guide pin

Polo 1995 ➤
2.11 Dismantling and assembling heater unit
1 - Heat exchanger
❑ To renew: remove heat‐
er unit ⇒ page 44 .
❑ After removal, com‐
pletely renew coolant.
2 - Self-tapping fillister head
screw
❑ Do not dismantle fur‐
ther.
❑ Installing ⇒ page 47 . AG. Volkswagen AG d
agen oes
lksw not
5 - Self-tapping fillister head byV
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ara
screw rised
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satelettronica
6 - Fresh air blower -V2- ss a ra
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nl
pt
du
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itte
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ility
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N24-
wit
, is n
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hole
spec
8 - Self-tapping fillister head
es, in part or in w
screw
t to the co
rrectness of i
⇒ page 46 .
l purpos

❑ Observe correct spare
nf
ercia
part number.
orm
m
11 - Base plate atio

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n in
or c
12 - Heat exchanger/bulkhead
thi
te
seal
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ng
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Cop py
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2.12 Installing and adjusting lever for central py by
co Vo
by lksw
flap
cted agen
Prote AG.
– The central flap pinion has an adjustment mark. Fit lever so

that adjustment markings on lever and pinion align -arrows-.

Polo 1995 ➤
2.13 Installation position of seal for heat ex‐

changer and bulkhead
The seal between the heat exchanger and the bulkhead has an
adjustment mark.
– Fit seal -1- so that adjustment mark on seal and mark on base
plate -2- align -3-.
2.14 Removing and installing fresh air and air

recirculation flap control motor -V154-
satelettronica
2.14.1 Removing lksw
agen
AG. Volkswagen AG d
oes
not
Vo gu
by
– Remove dash panel ⇒ rRep.
ised Gr. 70 . ara
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aut ra
ss c
Note
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un
pt
an
d
itte
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♦ A new control motor is supplied in the “Air recirculation” end

erm
ab
position.
ility
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wit
is n
♦ The control motor is easier to install in the centre position.

h re
ole,
spec
To move the control motor to the centre position, proceed as fol‐

t to the co
lows:
– Attach voltage supply connector -1- to control motor.
rrectne
– Press fresh air and air recirculation button.
ss o
cial p
When centre position has been reached

inform
mer
– Pull voltage supply connector off control motor.

atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Polo 1995 ➤
2.14.2 Installing
– Place control motor -2- on fresh air and air recirculation flap
lever -arrow B-.
The fresh air and air recirculation flap lever must be moved by
hand depending on the position of the control motor. To do so,
remove fresh air blower -V2- ⇒ page 36 .
– Turn control motor -2- in direction of -arrow D-.
– Fit securing bolt -3-.
– Connect voltage supply connector.
2.15 Dismantling and assembling heated air and fresh air controls
1 - Controls
switch -E9- and fresh air
satelettronica
and air recirculation flap
switch -E159- .
2 - Light conductor
AG. Volkswagen AG d
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3 - Coloured filter olksw not
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d b ara
4 - Trim rise nte
tho eo
au ra
ss c
bulb -L16-
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e
nl
pt
du
an
itte
6 - Rotary knob
y li
erm
ab
❑ For blower speed.

ility
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wit
❑ To remove: use pliers

, is n
h re
with suitable plastic or

hole
spec
rubber protection on
es, in part or in w
jaws.
t to the co
7 - Rotary knob
❑ For air distribution.
rrectness of i

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jaws.
nf
ercia
or
8 - Trim
m
m
atio
m
9 - Rotary knob
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n in
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thi
❑ For inside temperature.

te
sd
iva

o
r
rp
cu

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m
f
en
ng
t.
yi Co
op
jaws.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 1995 ➤
Note
♦ Attach cables to removed controls first and then attach cables

to heater levers.
bles.
stop.

flap.
❑ Identification of cable
sleeve: left-hand drive:
satelettronica
yellow; right-hand drive:
grey. agen
AG. Volkswagen AG d
oes
lksw not
❑ Adjusting cable at cen‐ d by
Vo gu
ara
tral flap ⇒ page 50 . orise nte
h eo
ut ra
2 - Footwell/defroster flap ca‐ ss a c
ble
ce
le
un
pt
❑ From air distribution
an
d
itte
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control rotary knob to
erm
ab
footwell/defroster flap.
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is n
h re
ole,
spec
green; right-hand drive:
black.
t to the co
defroster flap
⇒ page 50 .
rrectne
3 - Controls for fresh and heat‐
s
ed air
s o
cial p
❑ Removing and installing f inform

⇒ page 42 .
mer
atio
4 - Temperature flap cable

om
n
c
❑ From temperature con‐

or
n thi
e
trol rotary knob to tem‐

t
sd
va
perature flap.
i
o
pr
cum
r
fo
en
ng
t.
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Co
op py
beige; right-hand drive:
t. C rig
gh ht
yri
white. p by
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by c lksw
cted agen
Prote AG.
perature flap ⇒ page 49 .

Prerequisite:
• Heated air and fresh air blower controls are installed.

Polo 1995 ➤ AG. Volkswagen AG d
Heating, air conditioning - Edition agen
06.2004 oes
olksw not
V gu
by ara
ed nte
Adjusting oris eo
th
au ra
c
– Turn temperature rotary knob
ss to left to stop.
ce
e
nl
pt
du
– Attach wire end of cable -1- to temperature flap lever -2-.
an
itte
y li
erm
ab
– Push on temperature flap lever -2- to stop -arrow A- and se‐
ility
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cure cable sheath -1- with clip -3-.
wit
, is n
h re
– Turn temperature rotary knob left and right to stops.
hole
spec
When turning the control knob, both end stops must be reached.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
o
Prerequisite:
rm
m
atio
m

o
n in
or c
Adjusting:
thi
te
sd
iva
satelettronica
o
r
– Turn air distribution rotary knob to left to stop.

rp
cu
o
m
f
en
ng
– Attach wire end of cable -1- to footwell/defroster flap lever

t.
yi Co
op
-3-, -arrow A-. C py
ht. rig
rig ht
by
– Push footwell/defroster flap lever to stop -arrow C- and attach copy Vo
by lksw
cable sheath -1- with clip -2-, -arrow B-. cted agen
Prote AG.
– Turn air distribution rotary knob left and right to stops.


Prerequisites:
• The central flap lever is correctly adjusted ⇒ page 46 .
Adjusting
– Attach wire end of cable -2- to central flap lever -1-.
– Push central flap lever to stop -arrow A- and attach cable
sheath -2- with clip -3-.

lkswage es n
o ot g
byV ua Polo 1995 ➤
d ran
ir se
tho Heating, air conditioning
tee
or - Edition 06.2004
au ac
ss
ce
e
nl
87 – Air conditioning system
pt
du
an
itte
y li
erm
ab
ility
ot p
1 Notes on repair work to vehicles with
wit
, is n
h re
air conditioning and on handling re‐ hole
spec
frigerant
es, in part or in w
t to the co
Notes on repair work to vehicles with air conditioning and on han‐
dling refrigerant can be found in ELSA under repair group ⇒ Rep.
rrectness of i
Gr. 00 Technical information “Air conditioning system - with re‐
frigerant R134a VW”.
l purpos
The version in ELSA under the Internet button is no longer valid.
nform
ercia
Additional information:
m
at
♦ ⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
om
io
cations
n
c
in t
or
his
e
♦ Repairs to evacuated refrigerant circuit that can only be car‐

at
do
riv
ried out by specially trained mechanics at specialist service

p
cum
or
stations ⇒ Service Organisation Handbook (SOH) Volume 1a;

f
en
ng
Chapter 6.4 Workshop Equipment; Tools .

t.
satelettronica
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Notes on repair work to vehicles with air conditioning and on handling refrigerant 51
Polo 1995 ➤
olkswagen AG
en AG. V
2 Air conditioning
yV
olks
wag system with manual
does
not
gu
controls,is vehicles ▸ 09.99
d b ara
e nte
or e
h t or
au ac
ss
ce
e
nl
2.1 Repairing air conditioning and heating -
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
Parts marked “*” can be repaired only in workshops with suitable
t to the co
equipment and specially trained mechanics because the refrig‐
erant must be evacuated beforehand using, for example, the air
conditioning service station -VAS 6007A- .
rrectness of i
l purpos
1 - Dash panel
nform
ercia

⇒ Rep. Gr. 70 .
m
at
satelettronica
om
io
2 - Right vent
n
c
in t
or
his
e
at
do
riv
❑ Do not dismantle further

p
cum
or
(vent and adjustable

f
en
ng
t.
yi
louver are one spare
Co
op py
part).
. C rig
ht ht
rig by
py
3 - Air distribution duct, upper
co Vo
by lksw
cted
part
agen
Prote AG.
❑ To renew: remove cen‐

tre vent
and remove lower part
of air distribution duct
⇒ Item 24 (page 53) .
4 - Right air duct
❑ Removing and instal‐
ling: first remove glove
box ⇒ Rep. Gr. 68 or
front passenger side air‐
bag unit ⇒ Rep. Gr. 96 .
N24-
❑ Renewing ⇒ page 55 .
6 - Air intake duct*
❑ With fresh air and air re‐
circulation flap.
7 - Vacuum unit for fresh air
❑ Ventilated: fresh air op‐
eration.
8 - Vacuum line
❑ Vacuum hose connection diagram ⇒ page 63 .
9 - Temperature switch for evaporator -E33-
❑ Only on “Fix” air conditioner compressor (non-regulating).
52 Rep. Gr.87 - Air conditioning system

Polo 1995 ➤
❑ Behind cover ⇒ Item 19 (page 53) .
❑ Insertion depth of sensor tube: 330 mm.
❑ Renewing ⇒ page 55 .
❑ Task: prevents icing up.
❑ Switching temperature: opens at or below -2° C.
10 - Seal
❑ Renew.
11 - Tensioning strap
❑ Removing and installing: first remove glove box ⇒ Rep. Gr. 68 or front passenger side airbag unit ⇒
Rep. Gr. 96 .
13 - Seal
❑ Renew.
14 - Air distribution duct, lower part
❑ Renewing: remove centre vent ⇒ Item 35 (page 54) .
❑ Renewing upper part of air distribution duct: remove centre vent ⇒ Item 35 (page 54) and lower part of
satelettronica
air distribution duct. en AG. V
olkswagen AG
ag does
ol ksw not
15 - Controls for fresh and heated air yV gu
edb ara
❑ Installing and adjusting cables ⇒ page h70
or .
is nte
eo
ut ra
❑ Removing and installing ⇒ page 25ss. a c
ce
le
❑ Dismantling and assembling ⇒ page 34 .

un
pt
an
d
itte
16 - Air conditioning system switch -E30-
y li
erm
ab
❑ With fresh air and air recirculation flap switch -E159- .
ility
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❑ With air conditioning system switch illumination bulb -L43- .
is n
h re
ole,
spec
17 - Trim panel for controls
t to the co
18 - Cables
❑ Renewing: first remove centre vent ⇒ Item 35 (page 54) , footwell vents ⇒ Item 24 (page 53) and
rrectne
front passenger side compartment
ss o
cial p
19 - Evaporator housing cover

f inform
❑ Removing and installing: first remove glove box ⇒ Rep. Gr. 68 or front passenger side airbag unit ⇒
mer
Rep. Gr. 96 .
atio
om
n
c

i
or
n thi
te
sd
iva
o
pr
cum
r

fo
en
ng
t.
yi
Co
Cop py
t. rig
gh
22 - Rear duct
ht
pyri by
Vo
o
by c lksw
❑ Renewing: first remove centre console, footwell vents ⇒ Item 24 (page 53) and Prote
cted agen
⇒ Item 26 (page 53) , seats and carpet.
AG.
23 - Seal
❑ Renew.
25 - Air duct grille
2. Air conditioning system with manual controls, vehicles ▸ 09.99 53

Polo 1995 ➤
27 - Distribution box*
❑ With temperature flap.
❑ With central flap.
❑ With footwell/defroster flap.
AG. Volkswagen AG d
❑ Do not dismantle further. agen oes
olksw not
y V gu
d b ara
28 - Heat exchanger* orise nte
th eo
❑ Seals must be bonded free of gaps all around.
s au ra
c
s
❑ If tabs do not engage when inserted or if they have broken off, bolt on heat exchanger.
ce
e
nl
pt
du
an
itte
y li
erm
ab
❑ Install support for vacuum line ⇒ page 56 .
ility
ot p
29 - Seal*
wit
, is n
h re
❑ Renew.
hole
spec
es, in part or in w
30 - Support for vacuum line
t to the co
❑ Installing ⇒ page 56 .
31 - Evaporator housing*
rrectness of i
❑ With evaporator.
l purpos
satelettronica
32 - Left air duct
❑ Removing and installing: remove left vent ⇒ Item 34 (page 54) and dash panel insert ⇒ Rep. Gr. 90 .
nf
ercia
or
m
m
atio
m
❑ With seal.
o
n in
or c
❑ To renew, remove dash panel ⇒ Rep. Gr. 70 .
thi
te
sd
iva
34 - Left vent
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
❑ Do not dismantle further (vent and adjustable louver are one spare part). C py
t. rig
gh ht
yri
35 - Central vents
p by
co Vo
by lksw
cted
agen
Prote AG.
2.2 Removing air conditioning system

switch -E30-
2.2.1 Removing
– Remove centre vent ⇒ page 28 .
– Press switch at the four locking points -arrows- simultaneously
against controls and in direction of buttons.

Polo 1995 ➤
2.3 Renewing fresh air blower series resis‐

tor with overheating fuse -N24-
– Remove glove box ⇒ Rep. Gr. 68 or passenger side airbag
unit ⇒ Rep. Gr. 69 .
– Pull out connector -2- and remove bolt -3-.
– Before installation, seal area between series resistor -1- and
air duct with silicone adhesive sealant -D 176 001
gen AA3-
G. Vo. lkswagen AG d
a oes
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y Vol gu
b ara
ed nte
oris eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
2.4 Removing and installing fresh air blower
t to the co
-V2-
satelettronica
rrectne
2.4.1 Removing
ss
– Remove glove box ⇒ Rep. Gr. 68 or passenger side airbag
o
cial p
f
unit ⇒ Rep. Gr. 69 .
inform
mer
– Pull off connector -1-.
atio
m
– Remove the 5 bolts -arrows- and pull fresh air blower -2- out
o
n
c
i
or
n
downwards.
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.4.2 Installing
2.5 Renewing temperature switch for evap‐

orator -E33-
1- Temperature switch with housing
2- Rubber grommet
3- Sensor tube with marking for insertion depth
4- Self-tapping fillister head screw
5- Connector
2.6 Removing and installing vacuum unit for

fresh air and air recirculation flap
– Remove right vent ⇒ page 27 .

Polo 1995 ➤
– Remove glove box ⇒ Rep. Gr. 68 or passengerolkside
swa airbag
ge es n
ot g
unit ⇒ Rep. Gr. 69 . db
y V ua
ran
e
ris tee
– Pull off vacuum hose. tho or
au ac
ss
– Release vacuum unit from lever for fresh air and air recircula‐
ce
le
un
tion flap in -direction of arrow A-.
pt
an
d
itte
y li
– Unclip vacuum unit from evaporator housing and pull in
rm
ab
pe
-direction of arrow B-.
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tio
satelettronica
n in
r
te o
thi
s
iva
do
r
rp
cum
2.7 Installing support for vacuum line
fo
en
ng
t.
yi Co
op py
♦ When installing new heat exchanger -1- in vehicles with fresh . C rig
ht ht
air and air recirculation flap or with air conditioning system,
rig by
opy Vo
install support for vacuum line -2-. by c lksw
cted agen
Prote AG.
♦ Renew seal -3-.
2.8 Repairing air conditioning and heating -

engine compartment
Note
Parts marked “*” can be repaired only in workshops with suitable

equipment and specially trained mechanics because the refrig‐
erant must be evacuated beforehand using, for example, the air

Polo 1995 ➤
1 - Evacuating and charging

valve*
❑ Low pressure side.
valve*
❑ High pressure side.
3 - Vacuum reservoir
❑ Behind right wheel
housing lining.
❑ Insertion depth for vac‐
uum hose: 30 mm.
⇒ page 59 .
❑ Below plenum chamber
cover
⇒ Item 5 (page 57) .
satelettronica
5 - Plenum chamber cover
⇒ page 25 .
6 - Ambient temperature
switch -F38-
❑ Below plenum chamber
cover
❑ Only for internally regu‐
lated air conditioner
compressor. n AG. Volkswagen AG do
lkswage es n
o ot g
yV ua
7 - Expansion valve* ised b ran
or tee
❑ Aperture mustaube th or
ac
sealed against
ss splashed
water.
ce
e
nl
pt
du
an
itte
8 - Vacuum hose
y li
erm
ab
❑ In plenum chamber.
ility
ot p
wit

, is n
h re
hole
9 - Non-return valve
spec
es, in part or in w
Arrow points in direction of suction.

t to the co
10 - Two-way valve for fresh and recirculating air flap -N63-

rrectness of i
❑ Open when current is supplied.

l purpos

nform
ercia
11 - Aperture for heat exchanger and vacuum hose

m
at
12 - Water drain valve

om
ion
c

in t
or
his
e
❑ Lip valve must not become glued with underbody protection.

at
do
priv
cum
13 - Radiator fan control unit -J293-

for
en
ng
t.
yi Co
14 - Air conditioning system shut-off thermal switch -F163- t. Cop py
rig
❑ Air conditioning system shut-off thermal switch -F163- switches off air conditioning system magnetic
gh ht
pyri by
coupling -N25- when the coolant temperature is too high (off at 119°, on at 112°).
co Vo
by lksw
cted agen
Prote
AG.

Polo 1995 ➤
15 - Condenser*
16 - High-pressure safety valve*
❑ Checking ⇒ page 59 .
17 - Air conditioner compressor*
❑ Manufacturer: Sanden, designation: SD7-B10
18 - Air conditioning system magnetic coupling -N25-
19 - Air conditioning system pressure switch -F129-
❑ Checking air conditioning system pressure switch -F129- ⇒ page 60 .
❑ Removing and installing:
❑ Tightening torque 8 Nm.
AG. Volkswagen AG d
agen
❑ Renew O-ring (note partolnumber). oes
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V
by ara
20 - Receiver with dryerribag*
se
d
nte
ho eo
❑ Functions ⇒ pagesa
ut 119 . ra
c
s
ce
le
un
pt
an
d
itte
y li
2.9 Removing and installing air conditioning
erm
ab
ility
shut-off thermal switch -F163-
satelettronica
ot p
wit
is n
h re
ole,
spec
WARNING
t to the co
the coolant temperature may be above 100° C. rrectne

ss o
cial p
f inform
mer
atio
m
Note
o
n
c
i
or
n thi
e
Refill with coolant after installing thermal switch.

t
sd
iva
o
pr
cum
r
fo
1- Thermostat housing
en
ng
t.
yi Co
op
2- Clip
C py
t. rig
gh ht
yri by
3- Air conditioning system shut-off thermal switch -F163-
op Vo
by c lksw
cted agen
Prote AG.
4- Connector housing
5- Coolant temperature display sender -G2- / coolant temper‐
ature sender -G62- , black with yellow ring
2.10 Removing and installing two-way valve

for fresh and recirculating air flap -N63-
1- Cap
2- Observe air-permeable slit.
3- Two-way valve (other designs possible)
4- Vacuum hose to vacuum unit for fresh air and air recircula‐
tion flap
5- Vacuum hose to vacuum unit and engine
– Release two-way valve for fresh and recirculating air flap -
N63- -arrow- and pull downwards.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara Polo 1995 ➤
ise nte
r
ut
ho Heating, air conditioning - Editioneo
r a 06.2004
s a c
s
ce
2.11 Removing and installing vacuum unit
le
un
pt
an
d
itte
y li
– Removing and installing right wheel housing liner ⇒ Rep. Gr.
rm
ab
pe
66 .
ility
ot
wit
, is n
1- Plastic tube, insertion depth 30 mm
h re
hole
spec
2- Rubber seal
es, in part or in w
t to the co
3- Vacuum reservoir
4- Nut
rrectness of i
5- Right wheel housing liner
l purpos
nform
ercia
2.12 Removing and installing water drain

m
a
com
tion in
valve
r
te o
thi
s
iva
1- Water drain valve
do
r
rp
cum
fo
2- Bulkhead
en
ng
t.
yi
satelettronica
Co
op
3- Water drain pipe on evaporator housing
C py
t. rig
gh ht
yri by
4- Assembly plate
op Vo
by c lksw
cted agen
Prote
– Install water drain valve with opening of lip seal downwards.
AG.
• Lip valve must not become glued with underbody protection.
2.13 Checking high-pressure safety valve on

air conditioner compressor
WARNING
Danger of freezing injuries.

The pressure relief valve releases refrigerant when the engine
is running and the pressure in the refrigerant circuit is too high.
Switch off engine.
♦ Task: protects the refrigerant circuit against excessive pres‐

sure.
♦ The high-pressure safety valve indicates whether the valve
has been opened. An attached adhesive plate -arrow- is push‐
ed out.
♦ In this case, the vehicle should be sent to a workshop with
appropriate equipment and specially trained mechanics.

Polo 1995 ➤
2.14 Checking air conditioning system pres‐

sure switch -F129-
Note
♦ The pressure switch can be removed without extracting the

refrigerant from the refrigerant circuit.
♦ Visual check: ensure that O-ring 10.8 mm x 1.8 mm is seated
in groove.
Switch part between chamber 1 and chamber 2 of connector

housing switches air conditioning system magnetic coupling -
N25- off when refrigerant circuit is insufficiently filled or pressure
is too high: AG. Volkswagen AG d
agen oes
lksw not
– Opens below 1.2 bar and closes again above 2.4 bar (switch‐ by Vo gu
ara
ing threshold). rise
d
nte
tho eo
u
– Opens above 32 bar and closes again below 24 bar
ss a(switching ra
c
threshold).
ce
le
un
pt
an
satelettronica
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
2.14.1 Checking switch part:
spec
es, in part or in w
t to the co
– Briefly bridge connections between chambers -1- and -2- while
engine is running. If the air conditioning system magnetic cou‐
pling -N25- switches on, the refrigerant circuit is empty.
rrectness of i
The switch part between chamber -3- and chamber -4- of the
l purpos
connector housing switches the radiator fan -V7- to the second

speed via radiator fan control unit -J293- when the pressure in the
refrigerant circuit rises.
nform
ercia
– Closes above 16 bar and opens below 12.5 bar (switching

m
a
threshold).
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
2.14.2 Evaluating checks of air conditioning
yi Co
Cop py
system pressure switch -F129-

t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
The following checks are performed when installed.
To assess the air conditioner's performance, perform and evalu‐

ate the following checks:
• Check the air conditioner's fill level; the air conditioner is
switched off if the pressure is too low (for example, loss of
refrigerant).
• Check blower switch-on; radiator fan -V7- is switched to the
next higher speed when the pressure in the refrigerant circuit
rises (excessive pressure).
• Check air conditioner switch-off; the air conditioner is switched
off when pressure is excessive (for example when engine
cooling is insufficient).

Polo 1995 ➤
Note
♦ First connect cables to removed controls, then adjust cables at air conditioner levers and secure them.
♦ Place Bowden cable sheath against stops on controls and secure.
♦ Adjust cables at flap levers with controls installed.
♦ When control knobs are turned, all flaps must audibly contact stop.

ble
tary knob to footwell/de‐
froster flap.
❑ Black sheath.
defroster flap
satelettronica
⇒ page 61 .
flap.
❑ Yellow sheath.
tral flap ⇒ page 62 .
3 - Temperature flap cable wage
es n
lks
❑ From temperature rota‐ d byV
o ot g
ua
ry knob to temperature o
ir se
ran
tee
flap. auth or
ac
ss
❑ Blue sheath.
ce
e
nl
pt

du
an
itte
perature flap
y li
erm
ab
⇒ page 62 .
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio

om
n in
or c
thi
te
sd
iva
Note
r
rp
cu
o
m
f
en
ng
t.
yi
To adjust cable at lever of footwell/defroster flap, driver side com‐
Co
op py
partment must be removed.
t. C rig
gh ht
pyri by
Vo
co lksw
by
– Remove driver side compartment ⇒ Rep. Gr. 68 .
cted agen
Prote AG.

Polo 1995 ➤
– Set air distribution rotary knob to stop of Defrost position.

– Press footwell/defroster flap lever to stop -arrow- and secure
black cable sheath.
Note agen
AG. Volkswagen AG d
oes
olksw not
y V gu
b ara
To adjust cable at lever of central flap, footwell
orise vent must be re‐
d
nte
moved ⇒ page 28 .
satelettronica
th eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Press central flap lever to stop -arrow- and secure black cable
wit
, is n
sheath.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion

c
in t
or
his
ate
do
priv
cum
or
Note
f
en
ng
t.
yi Co
op py
To adjust cable at lever of temperature flap, footwell vent must be
t. C rig
gh ht
yri
removed ⇒ page 28 . p by
co Vo
by lksw
cted agen
Prote AG.
– Turn temperature rotary knob to stop of “cold” position.

AG. Volkswagen AG d
agen oes
olksw not
yV gu
ed b ara
nte
Polo 1995 ➤
ris
tho Heating, air conditioning - Edition
eo 06.2004
au ra
c
ss
– Press temperature flap lever to stop -arrow- and secure blue
ce
e
nl
pt
du
cable sheath.
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
2.16 Vacuum hose connection diagram
nf
ercia
orm
m
atio
om
Note
n in
or c
thi
te
sd
a
♦ Insertion depth for vacuum hose in vacuum reservoir: 30 mm, push-on depth for vacuum hose on plastic
iv
o
r
rp
cu
pipe: to stop (approx.15 mm).
o
m
f
en
ng
t.
♦ In a petrol engine, vacuum is created by the intake manifold.
yi
satelettronica
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted
agen
Prote AG.
tion flap vacuum unit
❑ In passenger compart‐
ment.
2 - Hose
• 6.3 x 2.5 x 1100 mm
❑ In passenger compart‐
ment.
3 - Grommet
4 - Two-way valve for fresh and
recirculating air flap -N63-
5 - Reduction hose
6 - Distribution piece
7 - Hose
• 3.5 x 2 x 40 mm
8 - Non-return valve
• Arrow points in direction of
suction.
9 - Hose
• 3.5 x 2 x 80 mm
10 - Hose
• 3.5 x 2 x 40 mm
11 - Plastic pipe
• 4 x 1 x 320 mm
12 - Hose
• 3.5 x 2 x 40 mm

Polo 1995 ➤
13 - Plastic pipe
• 4 x 1 x 490 mm
14 - Vacuum reservoir
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
satelettronica
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Polo 1995 ➤
3 Air conditioning system with manual n AG. Volkswagen AG

controls, vehicles 10.99 ▸ age does
ksw not
y Vol gu
b ara
ed nte
oris e
th or
au ac
3.1 Air conditioning and heating system - ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Switch off all electrical consumers. urposes, in part or in wh
t to the co
rrectne
ss
Note
o
cial p
f inform
satelettronica
mer
Parts marked “*” can be repaired only in workshops with suitable equipment and specially trained mechanics
atio
because the refrigerant must be evacuated beforehand using, for example, the air conditioning service station
om
n
-VAS 6007A- .
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
1 - Air duct
en
ng
t.
yi Co
op
2 - Dust and pollen filter C py
t. rig
gh ht
❑ In plenum chamber. yri
p by
o Vo
by c lksw
❑ With active charcoal fil‐ cted agen
Prote AG.
ter.
⇒ page 37 .
3 - Heating and air conditioning
controls
❑ With built-in air condi‐
tioning system switch -
E30- .
switch -E9- .
E159- .
⇒ page 67 .
bling ⇒ page 68 .
4 - Dash panel
⇒ Rep. Gr. 70 .
5 - Vent on front passenger
side
❑ Removing vent
⇒ page 39 .
⇒ page 47 .
3. Air conditioning system with manual controls, vehicles 10.99 ▸ 65

Polo 1995 ➤

9 - Central vents
❑ Removing vent ⇒ page 38 .
10 - Heater and air conditioner*
❑ Dismantling and assembling evaporator housing ⇒ page 138 .
11 - Cables
13 - Cover
14 - Footwell vent
satelettronica
16 - Intermediate piece, defrost
❑ To renew, remove and install dash panel ⇒ Rep. Gr. 70 .
17 - Heat exchanger* n AG. Volkswagen AG do
swage es n
❑ Removing ⇒ page by
138
Vo .
lk ot g
ua d ran
se
tho
ri seal* tee
or
au ac
❑ Removing ss ⇒ page 138 .
ce
le

un
pt
an
d
itte
y li

rm
ab
pe
ility

ot
wit
, is n
h re
hole
spec

es, in part or in w
t to the co
3.2.1 Removing
rrectness of i
1- Heating and air conditioning

l purpos
2- Fresh air blower -V2-

3- Fresh air blower series resistor with overheating fuse -N24-
nform
ercia

m
a
com
ti

on in
r
te o
thi
– Remove compartment on passenger side ⇒ Rep. Gr. 68 .

s
iva
do
r
rp
– Pull connector off fresh air blower series resistor with over‐
um
fo
heating fuse -N24- .

en
ng
t.
yi Co
op
– Renew fresh air blower series resistor with overheating fuse -
C py
t. rig
gh
N24- .
ht
pyri by
Vo
co lksw
by
cted
– Pull fresh air blower -V2- out downwards.
agen
Prote AG.

Polo 1995 ➤
3.3 Removing and installing heating and air

conditioning controls
3.3.1 Removing
– Press downwards with finger tips in compartment -1-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Pull trim off controls -arrows-.
es, in part or in w
satelettronica
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
– Remove bolts -arrows-.

p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
– Remove centre console ⇒ Rep. Gr. 68 . gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Release cables on controls -arrows-.

– Pull off connectors -1- and -2-.
As soon as controls have been removed, check function of cables
for heated air and fresh air.

Polo 1995 ➤
Heating, air conditioning - Edition 06.2004 AG. Volkswagen AG d
agen oes
olksw not
V
– To do so, move wire ends of cables back andedforth
by in gu
ara
-direction of arrow-. horis nte
eo
aut ra
– Replace damaged or stiff cables. ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
3.3.2 Installing
l purpos
Note
nform
ercia

m
at
om
ion
c
in t
or
bles.
satelettronica
his
ate
do
riv
p
cum
or
stop.
f
en
ng
t.
yi Co
Cop py
. rig
– Bend wire ends of cables -1- and press onto lever of control
ht ht
rig by
py
-2- -arrow-. co Vo
by lksw
cted agen
Prote AG.
– Press cable for footwell/defroster flap, cable for temperature

flap and cable for central flap -1- into locking device -2- until it
engages.
Identification of footwell/defroster flap cable: left-hand drive:
green; right-hand drive: black.
Identification of central flap cable: left-hand drive: yellow; right-
hand drive: grey.
Identification of temperature flap cable: red left-hand drive: beige;
right-hand drive: white.
3.4 Dismantling and assembling heating and air conditioning controls

Polo 1995 ➤

controls
❑ With built-in air condi‐
tioning system switch -
E30- .
switch -E9- .
E159- .
⇒ page 67 .
2 - Light conductor
3 - Coloured filter
4 - Trim
bulb -L16-
❑ 12V, 1.2W
❑ Removal: unclip trim
satelettronica
AG. Volkswagen AG d
⇒ Item 8 (page 69) agen oes
olksw not
and rotary knob byV gu
ara
ed
⇒ Item 6 (page 69) . horis nte
eo
ut ra
❑ Pull out bulb with aid of ss a c
fuel hose.
ce
e
nl
pt
du
an
6 - Rotary knob
itte
y li
erm
ab
❑ For blower speed.
ility
ot p
wit
, is n
h re
hole
spec
jaws.
es, in part or in w
t to the co
7 - Rotary knob
❑ For air distribution.
rrectness of i
with suitable plastic or rubber protection on jaws.
l purpos
8 - Trim
nf
ercia
9 - Rotary knob orm

m
atio
❑ For inside temperature.
om
n in
c
❑ To remove: use pliers with suitable plastic or rubber protection on jaws.

or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Polo 1995 ➤
3.5 Installing and adjusting heating and air conditioning cables
Note

♦ Check cables before installing; replace stiff or damaged cables.
♦ First connect cables to removed controls, then adjustagcables
en AG. V at airagconditioner
olksw en AG
d levers and secure them.
w oes
olks not
♦ When control knobs are turned, all flaps must
d b audibly contact stop.
yV gu
ara
e nte
ris
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
flap.
ility
ot p
wit
, is n
h re
hole
spec
yellow; right-hand drive:
es, in part or in w
grey.
t to the co
satelettronica
tral flap ⇒ page 71 .
rrectness of i
ble
l purpos

tary knob to footwell/de‐
nform
ercia
froster flap.
m
at
om
io
n
c
in t
r
green; right-hand drive:

o
his
te
black.
a
do
priv
cum
or
Renewing:
f
en
ng
t.
yi Co
op
– Remove heating and air C py
ht. rig
conditioning controls rig ht
py by
⇒ page 67 .
co Vo
by lksw
cted agen
Prote AG.
– Remove driver side
footwell cover ⇒ Rep.
Gr. 68 .
– Unclip cable on heater

and air conditioner unit.
– Adjust cable at footwell/

defroster flap
⇒ page 71 .

controls
4 - Temperature flap cable
❑ From temperature rotary knob to temperature flap.
❑ Identification of cable sleeve: left-hand drive: beige; right-hand drive: white.
❑ Adjusting cable at temperature flap ⇒ page 71 .

Polo 1995 ➤

Prerequisite:
• The heating and air conditioning controls are installed.
Adjusting
– Turn temperature rotary knob to left to stop.
– Attach wire end of cable -1- to temperature flap lever -2-.
– Push on temperature flap lever -2- to stop -arrow A- and se‐
cure cable sheath -1- with clip -3-.
– Turn temperature rotary knob left and right to stops.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
ut
satelettronica
a ra
ss c
ce
le
un
pt
an
Prerequisite:
d
itte
y li
erm
ab

ility
ot p
wit
Adjusting
is n
h re
ole,

spec
– Attach wire end of cable -1- to temperature flap lever -3-, arrow
t to the co
-A-.
– Push footwell/defroster flap lever to stop -arrow C- and attach
rrectne
cable sheath -1- with clip -2-, -arrow B-.

ss o
cial p
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng

t.
yi Co
Cop py
ht. rig
Prerequisite: rig ht
py by
co Vo
by lksw
• The central flap lever is correctly adjusted ⇒ page 46 .
cted agen
Prote AG.

Adjusting

Polo 1995 ➤
– Attach wire end of cable -2- to central flap lever -1-.

– Press footwell/defroster flap lever to stop -arrow A- and secure
AG. Volkswagen AG d
cable sheath -2- with clip -3-. ksw
agen oes
n ol ot g
yV ua
– Turn air distribution rotary knob left and right
ise
d b to stops. ran
r tee
ho
When turning the control knob, both end
sa
ustops
t
must be reached. or
ac
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
3.6 Air conditioning - engine room
t to the co
rrectne
ss o
cial p
f in
satelettronica
form
mer
atio
m

o
n
c
i
or
n thi
te
sd
va
Note
i
o
pr
cum
r
fo
en
ng
t.
yi Co
op
C py
t. rig
gh
-VAS 6007A- .
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 1995 ➤
1 - Refrigerant hose*
❑ From expansion valve
to air conditioner com‐
pressor.
❑ With damper.
2 - Refrigerant line*
to receiver with dryer
bag.
valve*
❑ Releasing refrigerant in‐
to the environment is a
punishable offence.
5 - Expansion valve*
6 - Dust and pollen filter AG. Volkswagen AG d
agen oes
ksw
❑ With active charcoal fil‐ by Vol not
gu
satelettronica
ara
ter. rise
d
nte
ho eo
❑ Removing and installing aut ra
c
⇒ page 37 . ss
ce
e
nl
pt
du
7 - Ambient temperature
an
itte
y li
switch -F38-
erm
ab
❑ From 10.99 replaced by
ility
ot p
temperature sender for
wit
, is n
h re
compressor switch-off -
hole
G346- .
spec
es, in part or in w
❑ Switches off air condi‐
t to the co
tioning system magnetic
coupling -N25- if the am‐
bient temperature is too
rrectness of i
low (off at -1° C, on at
7° C).
l purpos
nf
ercia
orm
m
atio
om
n in
c
9 - Quick release coupling

or
thi
e

t
sd
iva
o
r
rp
cu
❑ Not present with all types of engines.

o
m
f
en
ng
t.
yi
10 - Coolant temperature sender -G62-
Co
Cop py
t.
❑ Coolant temperature sender -G62- switches off air conditioning system magnetic coupling -N25- when
rig
gh ht
yri by
the coolant temperature is too high (off at 119°, on at 112°). cop Vo
by lksw
cted agen
Prote
AG.
12 - Ambient temperature sensor -G17-

❑ from 10.99
❑ Function: temperature sensor controls temperature flap and fresh air blower, depending on temperature.
❑ Emergency operation during failure: fresh air intake duct temperature sensor -G89- takes over the func‐
tion. If both sensors are defective, operation continues with an assumed value of +10° C. Air recirculation
is not possible. The control and display unit for Climatronic air conditioning system -E87- displays “--”.
13 - Receiver with dryer bag*
❑ Functions ⇒ page 129 .

Polo 1995 ➤

❑ From air conditioner compressor to condenser.
❑ Manufacturer: Sanden, designation: SD6-V12
17 - High pressure sender -G65-
❑ Torque setting: 8 Nm
❑ Renew O-ring (note part number).
❑ The high pressure sender -G65- can be removed without extracting the refrigerant from the refrigerant
circuit.
Function:
❑ The high pressure sensor -G65- supplies information to radiator fan control unit -J293- and engine control
unit.
❑ Switches radiator fan -V7- to next higher speed when pressure increases in refrigerant circuit.
❑ The high pressure sender -G65- cannot be checked via the Climatronic self-diagnosis, but only via the
satelettronica
engine control unit self-diagnosis. AG. Volkswagen AG d
agen
❑ Check high pressure sender -G65- o⇒
l page
ksw 132 . oes
not
byV gu
ara
❑ Switches off the air conditioner
ris when the pressure is high (for example,
ed
nte insufficient engine cooling).
tho eo
❑ Switches off the air conditioner
au when the pressure is too low (for example, r a loss of refrigerant).
css
ce
e
nl
pt
du
an
❑ Repairing ⇒ page 104 .
itte
y li
erm
19 - Condenser* ab
ility
ot p
❑ Removing ⇒ page 142 . wit

, is n
h re
hole
20 - Damper*
spec
es, in part or in w
❑ In refrigerant hose from expansion valve to air conditioner compressor.

t to the co
rrectness of i
3.7 Checking water drain valve

l purpos
– Fold cover flap -1- in heat insulation mat -3- on the bulkhead
-4- upwards.
nform
ercia
– Remove water drain valve -2- from bulkhead -4-.

m
at
Check water drain valve as follows to ensure that it functions cor‐

om
ion
rectly:
c
in t
or
his
te
♦ The water drain valve must not be stuck together.

a
do
priv
cum
or
♦ The heat insulation mat must not be deformed or damaged in

f
en
g
the area around the water drain valve.

n
t.
yi Co
Cop py
.
♦ The opening of the water drain valve flap must point down‐
ht rig
rig ht
by
ward. copy Vo
by lksw
cted agen
Prote AG.
Note
When closing, the cover flap -1- must be flush with the heat in‐
sulation mat. If the cover flap -1- is pushed in too far, the water
drain valve shutter flap -2- can get stuck.

Polo 1995 ➤
3.8 Removing high pressure sender -G65-

– Pull off connector -1-. AG. Volkswagen AG d
agen oes
ksw
– Unbolt high pressure by V sender -G65- -2-.
ol not
gu
ara
ed
is nte
– Renew seal. hor eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
3.9 Removing ambient temperature switch -
F38-
rrectness of i
l purpos
– Unclip ambient temperature switch -3- from retainer -2-.
satelettronica
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3.10 Checking high-pressure safety valve on
air conditioner compressor
WARNING

The pressure relief valve releases refrigerant when the engine
is running and the pressure in the refrigerant circuit is too high.
Switch off engine.
♦ Task: protects refrigerant circuit against excessive pressure.

♦ The high-pressure safety valve indicates whether the valve
has been opened. An attached adhesive plate -arrow- is push‐
ed out.
♦ In this case, the vehicle should be sent to a workshop with
appropriate equipment and specially trained mechanics.

Polo 1995 ➤
4 Climatronic air conditioning system

with automatic regulation, vehicles
10.99 ▸
Note
♦ Pressing the “AUTO” button will cancel all settings which de‐
viate from automatic operation.
♦ In ECON mode, only the air conditioner compressor is switch‐ en AG. V
olkswagen AG
ed off; heating and ventilation continue to be controlled elec‐ ksw
ag does
not
Vol
tronically. ed
by gu
ara
ris nte
♦ Modifications made to automatic operation before the engine
au
tho eo
ra
is switched off will be saved. Only the “Air recirculation”
ss func‐ c
tion is erased 20 minutes after the ignition has been switched
ce
le
un
pt
off.
an
d
itte
y li
erm
♦ Deviations from automatic operation ⇒ appropriate operating
ab
ility
instructions .
ot p
wit
is n
satelettronica
♦ If all of the symbols displayed in the operating and display unit
h re
ole,
for Climatronic conditioning -E87- are flashing after the ignition
spec
has been switched on, there is a defect in the system. In this
t to the co
case, first read fault memory ⇒ page 4 .
4.1 Function of operating and display unit
rrectne
for Climatronic air conditioning system -
s
E87-
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
va

i
o
pr
cum
r
fo
en
ng

t.
yi Co
op py
t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Polo 1995 ➤
n AG. VolksHeating,
wagen AG
dair
oes conditioning - Edition 06.2004
lkswage not
o
byV gu
ara
d
1 - Windscreen defroster but‐ oris
e nte
ton auth eo
ra
ss c
2 - Display for blower speed
ce
e
nl
pt
du
❑ In automatic operation
an
itte
y li
⇒ Item 8 (page 77) a
erm
ab
medium blower speed is
ility
ot p
displayed regardless of
wit
the actual blower speed. , is n
h re
hole
spec
3 - Display for ambient temper‐
es, in part or in w
ature
t to the co
❑ If the road speed falls
below 15 km/h and the
rrectness of i
coolant temperature is
above 70° C, the value
l purpos
displayed will not

change. The actual am‐
bient temperature
nf
ercia
o
measured is not dis‐
rm
m
played because it is in‐
atio
m
fluenced by the heat

o
n in
c
build-up in the engine at

or
thi
e
lower speeds.
t
sd
satelettronica
iva
o
r
rp
cu
4 - Display for defrosting wind‐
o
m
f
en
ng
screen
t.
yi Co
Cop py
5 - Display for air recirculation
t. rig
gh ht
pyri by
Vo
o
6 - Display for air flow direction
c by lksw
cted agen
Prote AG.
❑ Pressing button
switches the footwell
air-flow display on or off.
❑ Pressing button
switches the upper-
body air-flow display on
or off.
7 - Display for selected interior
temperature
❑ Switching between Celsius and Fahrenheit:
❑ Press and hold button ⇒ Item 11 (page 78) and then press button ⇒ Item 9 (page 77) .
❑ The corresponding temperature unit appears in the display.
8 - Operating mode display
“AUTO”: Automatic mode
❑ In automatic mode, the Climatronic maintains the selected interior temperature automatically. With this
setting, the vent air temperature, the blower speed and the air distribution are controlled automatically.
“ECON”: conditioning system off
❑ In ECON mode, only the air conditioner compressor is switched off; heating and ventilation continue to
be controlled automatically.
“OFF”: complete system is switched off.
❑ To switch off, press ⇒ Item 17 (page 78) .
❑ Because the flaps remain in the last position set, this means of selection should only be used in special
circumstances e.g. when there is a malfunction.
9 - Button for automatic mode
10 - Dash panel temperature sensor -G56- and temperature sensor blower -V42-
❑ Installation location for right-hand drive vehicles.
4. Climatronic air conditioning system with automatic regulation, vehicles 10.99 ▸ 77

Polo 1995 ➤
11 - “ECON” button
❑ In ECON mode, only the air conditioner compressor is switched off; heating and ventilation continue to
be controlled automatically.
12 - Button for “Warmer”
13 - Button for “Colder”
14 - Button for “Air flow to footwell”
15 - Button for “Air flow to upper body”
16 - Button to increase blower speed
17 - Button
❑ To reduce blower speed.
❑ To switch off air conditioning system: press and hold button down until “OFF” appears in display.
❑ Because the flaps remain in the last position set, this means of selection should only be used in special
circumstances e.g. when there is a malfunction.
18 - Button for fresh air and air recirculation
19 - Dash panel temperature sensor -G56- and temperature sensor blower -V42-
❑ Installation position for left-hand drive vehicles.
satelettronica
4.2 Connectors on Climatronic control unit -
J255-
4.2.1 Pin assignment for multi-pin connectors

A, B, C and D on back of Climatronic
lksw
agen
AG. Volkswagen AG d
oes
not
control unit
o
byV gu
ara
ed
s n i tee
or
12-pin connector, connector housing -A-auth or
ac
ss
1 - K line, diagnosis
ce
e
nl
pt
du
an
5 - Dim voltage 58 d
itte
y li
erm
ab
7 - Fresh air intake duct temperature sensor -G89-

ility
ot p
wit
, is n

h re
hole
spec
9 - Sunlight penetration photosensor -G107-

es, in part or in w
t to the co
12 - Signal earth, control motors

rrectness of i
l purpos
20-pin connector, connector housing -B-

1 - Ambient temperature for estate
nf
ercia
5 - Footwell vent temperature sender -G192-

rm
m
atio
m
6 - Centre vent temperature sender -G191-

o
n in
or c
thi
7 - Evaporator output temperature sender -G263-

te
sd
iva
o
r
8 - Temperature flap control motor potentiometer -G92-

rp
cu
o
m
f
en
ng
9 - Central flap control motor potentiometer -G112-

t.
yi Co
Cop py
. rig
10 - Footwell/defroster flap control motor potentiometer -G114-
ht ht
rig by
copy Vo
lksw
14 - Temperature increase off/ PTC off
by
cted agen
Prote AG.
17 - Air flow flap control motor potentiometer -G113-

Polo 1995 ➤
16-pin connector, connector housing -C-

2 - Diagnosis 2/32 bar (high-pressure side)
4 - Speed signal
6 - Engine speed agen
AG. Volkswagen AG d
oes
olksw not
8 - + 5V 10 mA for control motors byV gu
ara
ed
ris nte
o
11 - Fresh air blower -V2- (-) aut
h eo
ra
ss c
12 - Engine electronics, bidirectional
ce
le
un
pt
an
d
14 - Fresh air blower -V2- (+)
itte
y li
erm
ab
15 - Wiring harness control for VW (internal)
ility
ot p
wit
is n
16 - Fresh air blower control unit -J126- , activation
h re
ole,
spec
16-pin connector, connector housing -D-
t to the co
1- Auxiliary heating
2- Temperature flap control motor -V68-
rrectne
3- Footwell and defroster flap control motor -V85-
satelettronica
ss
4- Central flap control motor -V70-
o
cial p
f in
5- Air flow flap control motor -V71-
form
mer
6- Air conditioning system compressor regulating valve -
atio
m
N280- , externally regulated air conditioner compressor

o
n
c
i
or
n thi
e
7- Terminal 30 (optional)
t
sd
iva
o
pr
c
8- Magnetic coupling/ fan speed 2
um
r
fo
en
ng
t.
yi
9- Terminal 15 for 2-way valve relay for coolant shut-off valve
Co
op py
-J585-
. C rig
ht ht
rig by
py Vo
10 - Temperature flap control motor -V68-
co lksw
by
cted agen
Prote AG.
11 - Footwell and defroster flap control motor -V85-
12 - Central flap control motor -V70-
13 - Air flow flap control motor -V71-
14 - Terminal 31
4.3 Climatronic - passenger compartment


Polo 1995 ➤
♦ Air conditioning service station -VAS 6007A-
Note
Parts marked * can be repaired only in workshops with suitable equipment and specially trained mechanics
-VAS 6007A- .
satelettronica
1 - Air duct
2 - Sunlight penetration photo‐ AG. Volkswagen AG d
sensor -G107- agen oes
olksw not
yV gu
❑ Function: controls tem‐ ised b ara
nte
perature flap and fresh hor eo
ut
air blower depending on ss a ra
c
light intensity
ce
e
nl
pt
du
❑ In event of failure: con‐
an
itte
y li
trol unit -J255- assumes
erm
ab
fixed value.
ility
ot p
❑ Checking: with diagno‐
wit
, is n
h re
sis functions of vehicle
hole
diagnosis, testing and
spec
information system -
es, in part or in w
t to the co
VAS 5051A- or vehicle
diagnosis and service
rrectness of i
VAS 5052- .
l purpos
3 - Dash panel temperature

sensor -G56- with temperature
nform
ercia
sensor blower -V42-

m
at
om
❑ The Climatronic control

ion
c
unit -J255- , the operat‐

in t
or
ing and display unit for

his
ate
Climatronic air condi‐

do
priv
tioning system -E87-

um
for
en
g
and the dash panel tem‐

n
t.
yi Co
perature sensor -G56- Cop py
. rig
with temperature sensor
ht ht
rig by
py
blower -V42- are com‐ co Vo
by lksw
bined in one unit which cted agen
Prote AG.
cannot be dismantled.
❑ Checking: with diagno‐
sis functions of vehicle
diagnosis, testing and
VAS 5051A- or vehicle
diagnosis and service information system -VAS 5052- .

Polo 1995 ➤
❑ In event of dash panel temperature sensor -G56- failure: continued operation assuming value of +24°.
❑ Renewing and adjusting:“code control unit 07” with vehicle diagnosis, testing and information system -
VAS 5051A- or vehicle diagnosis and service information system -VAS 5052- ⇒ page 9 and then initiate
“basic setting 04” ⇒ page 6 .
4 - Defrosting vent
5 - Operating and display unit for Climatronic air conditioning system -E87-
❑ The Climatronic control unit -J255- , the operating and display unit for Climatronic air conditioning system
-E87- and the dash panel temperature sensor -G56- with temperature sensor blower -V42- are combined
in one unit which cannot be dismantled.
❑ Checking: with diagnosis functions of vehicle diagnosis, testing and information system -VAS 5051A- or
❑ Operation and function ⇒ page 76 .
❑ With active charcoal filter.
satelettronica
7 - Dash panel
❑ Removing and installing ⇒ Rep. Gr. 70 .
8 - Vent on front passenger side
9 - Fresh air intake duct temperature sensor -G89-wagen AG. Volkswagen AG doe
ks s no
❑ With seal. Vol t gu
d by ara
e nte
❑ Function: temperature sensor controls
thoris
temperature flap and fresh air blower, depending
eo on temperature.
u ra
❑ In event of failure: ambient temperature
ss a
sensor -G17- takes over the function. c
ce
le
un
pt
vehicle diagnosis and service information system -VAS 5052- . an
d
itte
y li
erm
❑ To renew, remove dash panel ⇒ Rep. Gr. 70 . ab

ility
ot p
❑ Turn temperature sensor 90° and pull out.

wit
is n
h re
❑ Moisten rubber seal with oil when installing.

ole,
spec
10 - Evaporator output temperature sender -G263-

t to the co
❑ Only in vehicles with externally regulated air conditioner compressor.

rrectne
❑ With seal.
s
❑ To renew: remove glove box ⇒ Rep. Gr. 68 .

s o
cial p
❑ Turn temperature sensor 90° and pull out.

inform
❑ Moisten rubber seal with oil when installing.

mer
atio
m
11 - Air flow flap control motor -V71-

o
n
c
i
or
❑ Operates simultaneously fresh air and air recirculation flap.

thi
te
sd
va
i
o
pr
cum

r
fo
en
ng
t.
yi
Co
Cop py
t.
rig
gh ht
yri by
cop Vo
by lksw
“basic setting 04” ⇒ page 6 . cted agen
Prote AG.


Polo 1995 ➤
. Volkswagen AG
n AG06.2004
Heating, air conditioninglk-sEdition
wage does
n
o ot g
yV ua
edb ran
13 - Fresh air blower control
ho
ris unit -J126- tee
ut or
❑ Task: continuously
ss
a variable control
of fresh air blower on voltage. speed depending ac
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
14 - Central vents
wit
, is n
h re
hole
spec
15 - Climatronic control unit -J255-
es, in part or in w
t to the co
❑ The Climatronic control unit -J255- , the operating and display unit for Climatronic air conditioning system
-E87- and the dash panel temperature sensor -G56- with temperature sensor blower -V42- are combined
in one unit which cannot be dismantled.
rrectness of i
l purpos

nf
ercia
or
m
m
atio
om
n in
or c
16 - Heater and air conditioner*
thi
te
sd
a
satelettronica
iv
❑ With heat exchanger.
o
r
rp
cu
o
m
❑ With evaporator.
f
en
ng
t.
yi Co
❑ Removing ⇒ page 135 . t. Cop py
rig
gh ht
17 - Central flap control motor -V70- yri
p by
o Vo
by c lksw
cted agen
Prote AG.
18 - Temperature flap control motor -V68-
19 - Footwell vent temperature sender -G192-
❑ Function: controls air distribution between defroster and footwell and the fresh air blower speed depend‐
ent upon the vent temperature.
❑ Emergency running in event of failure: continued operation assuming water temperature of +80° C.
21 - Cover
22 - Footwell vent
24 - Intermediate piece, defrost
❑ To renew, remove dash panel ⇒ Rep. Gr. 70 .

Polo 1995 ➤
25 - Footwell and defroster flap control motor -V85-

26 - Heat exchanger*
27 - Heat exchanger/bulkhead seal*
❑ Removal ⇒ page 138 , Dismantling and assembling evaporator housing.
4.4 Removing and installing footwell vent

temperature sender -G192-
satelettronica
4.4.1 Removing
– Pull connector off footwell vent temperature sender -G192- .
– Turn footwell vent temperature sensor -G192- -1- 90° and re‐
move it from housing -2-. wage
e ks s no
Vol t gu
d by ara
e nte
ris
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
4.4.2 Installing
t to the co

– When installing, moisten rubber seal on footwell vent temper‐
rrectne
ature sender -G192- with oil.

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Polo 1995 ➤
4.5 Removing sunlight penetration photo‐

sensor -G107-
4.5.1 Removing
– Use a screwdriver to unclip trim -2- above sunlight penetration
photosensor -G107- along side -1-.
– Use a screwdriver to unclip sunlight penetration photosensor
-G107- -1- along side.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
4.6 Removing fresh air blower control unit -
s
ce
e
nl
satelettronica
pt
du
J126-
an
itte
y li
erm
ab
ility
ot p
wit
, is n
4.6.1 Removing
h re
hole
spec
es, in part or in w
t to the co
– Pull out connector -2- and remove bolt -3-.
– Remove fresh air blower control unit -J126- -1-.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
Co
Cop py
ht. rig
rig ht
1- Heating py by
co Vo
by lksw
cted agen
2- Fresh air blower -V2- Prote AG.
3- Cover
4.7.1 Removing

Polo 1995 ➤
olkswagen AG
wHeating,
AG. Vair conditioning
does - Edition 06.2004
s agen
olk not
byV gu
ara
d
– Remove plastic foam cover -3- below the air oconditioning
ris
e unit. nte
th eo
u ra
– Remove bolts -1-. ss
a c
ce
e
nl
– Remove cover -item 2-.
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Pull connector -1- off fresh air blower.
l purpos
– Pull fresh air blower -2- out downwards.
nform
mercia
at
om
ion
c
in t
or
his
te
satelettronica
a
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
4.8 Removing and installing operating and
cted agen
Prote AG.
display unit for Climatronic air condition‐

ing system -E87- with Climatronic con‐
trol unit -J255-

Note
The Climatronic control unit -J255- and the operating and display
unit for Climatronic air conditioning system -E87- are a single
component which cannot be dismantled.

Polo 1995 ➤
4.8.2 yV
olkswage Removing es n
ot g
b ua
ed ran
– Unclip trim for operating
horis and display unit for Climatronic air tee
conditioning system au -E87- with a screwdriver and a pad
t or
ac
-arrows-. ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Remove bolts -arrows- from instrument panel trim.
s
– Pull out operating and display unit for Climatronic air condi‐
s o
tioning system -E87- with Climatronic control unit -J255- .
cial p
f inform
– Release connectors and pull off.
mer
atio
m
– Pull out and remove operating and display unit for Climatronic
o
satelettronica
n
c
i
air conditioning system -E87- with Climatronic control unit -
or
n thi
e
J255- .
t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
4.8.3 Installing and adjusting
agen
Prote AG.
– “Code control unit 07” with vehicle diagnosis, testing and in‐
formation system -VAS 5051A- or vehicle diagnosis and serv‐
ice information system -VAS 5052- ⇒ page 9 and then initiate
4.9 Removing and installing air flow flap

control motor -V71-

Note
♦ The air flow flap control motor also operates the fresh air and
air recirculation flap.
♦ When installing control motor, ensure that wires are correctly
routed. They should be routed so that they do not come into
contact with moving parts (for example the levers on the con‐
trol motors).
♦ After installing a new control motor, perform function “Basic
settings 04” ⇒ page 6 .

Polo 1995 ➤
AG. Volkswagen AG d
agen oes
ksw
4.9.2 Removing
ol not
y V gu
d b ara
rise nte
– Remove
autho
dash panel ⇒ Rep. Gr. 70 . eo
ra
ss c
– Remove heater unit with evaporator.
ce
le
un
pt
an
d
– Carefully unclip air flow flap operating rod -1- from lever -2-
itte
y li
using a screwdriver.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia

m
a
com
t
– Remove securing bolts -3-.
ion in
satelettronica
r
te o
The control motor is to be guided into the distribution box and

thi
s
iva
evaporator housing. To prevent damage: do

r
rp
cum
fo
– Lower control motor and simultaneously pull from shaft for

en
ng
t.
fresh air and air recirculation flap -2-, -arrow A-.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4.9.3 Installing
– Insert control motor in shaft of fresh air and air recirculation
flap -1-.
– Turn control motor in direction of -arrow A- and tighten bolts.
– Clip in operating rod for air flow flap.
– Push connector -1- onto control motor-2-.

– “Code control unit 07” with vehicle diagnosis, testing and in‐
formation system -VAS 5051A- or vehicle diagnosis and serv‐
ice information system -VAS 5052- ⇒ page 9 and then initiate

Polo 1995 ➤
4.10 Removing and installing temperature

flap control motor -V68-

Note

trol motors).
satelettronica
AG. Volkswagen AG d
4.10.2 Removing Volksw
agen oes
not
gu
d by ara
e
– Remove glove box ⇒ Rep. Gr.ho68 ris . nte
eo
aut ra
– Remove driver side footwells cover ⇒ Rep. Gr. 68 .
s c
ce
e
nl
pt
du
an
itte
– Remove support bracket. y li

erm
ab
ility
ot p
– Remove connecting piece. wit

, is n
h re
hole
spec
es, in part or in w
– Carefully unclip operating rod -2- from lever -arrow A- using a

t to the co
screwdriver.
rrectness of i
– Remove control motor -3-.

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate

do
priv
cum
for
en
g
– Initiate “basic setting 04” using vehicle diagnosis, testing and

n
t.
yi Co
information system -VAS 5051A- or vehicle diagnosis and t. Cop py
service information system -VAS 5052- ⇒ page 6 .
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Polo 1995 ➤
4.11 Removing and installing central flap

control motor -V70-
Note

trol motors).
AG. Volkswagen AG d
agen
4.11.1 Removing Volksw
oes
not
gu
d by ara
e
– Remove centre console ⇒ Rep. Gr. 68th.oris nte
eo
au ra
– Remove glove box ⇒ Rep. Gr. 68 . ss c
ce
le
un
pt
an
d
itte
y li
– Remove support bracket.
erm
ab
satelettronica
ility
ot p
– Remove connecting piece.
wit
is n
h re
ole,
spec
– Carefully unclip operating rod -2- from lever -arrow A- using a
t to the co
screwdriver.
rrectne
– Turn operating rod -2- and remove control motor -4-.
s
– Remove control motor.
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
a

iv
o
pr
cum
r
fo
en
ng
– Initiate “basic setting 04” using vehicle diagnosis, testing and

t.
yi Co
information system -VAS 5051A- or vehicle diagnosis and Cop py
t. rig
service information system -VAS 5052- ⇒ page 6 . opyri
gh by
Vo
ht
by c lksw
4.12 Removing and installing footwell and cted agen
Prote AG.
defroster flap control motor -V85-
4.12.1 Removing

Polo 1995 ➤

– Turn control motor -4- and remove from operating rod -2-.
– Remove control motor -4- from housing.
satelettronica
AG. Volkswagen AG d
agen oes
lksw not
– Initiate “basic setting 04” using vehicle by Vdiagnosis, testing and
o gu
ara
information system -VAS 5051A-orior s vehicle diagnosis and
ed
nte
service information system -VAS aut 5052- ⇒ page 6 .
h eo
ra
ss c
4.13 Climatronic - engine compartment
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
Note
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
-VAS 6007A- . t to the co

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Polo 1995 ➤
pressor.
❑ With damper.
2 - Refrigerant line*
wage es n
3 - Refrigerant hose* yV
olks ot g
ua
d b
❑ From expansion o
ir sevalve
ran
tee
to receiver with
au dryer
th or
ac
bag. ss
ce
e
nl
pt
du
an
itte
valve*
y li
erm
ab
ility
ot p
wit
, is n
punishable offence.
h re
hole
spec
5 - Expansion valve*
es, in part or in w
t to the co
❑ With active charcoal fil‐
satelettronica
ter.
rrectness of i
l purpos
⇒ page 37 .
nform
ercia
m
at
om
i
on
c
in t
or

his
te
⇒ page 129 .
a
do
priv
❑ Not present with all

um
for
en
g
types of engines.
n
t.
yi Co
Cop py
9 - Coolant temperature send‐
t. rig
gh ht
yri
er -G62- p by
co Vo
by lksw
cted
❑ Coolant temperature
agen
Prote AG.
sender -G62- switches
off air conditioning system magnetic coupling -N25- when the coolant temperature is too high (off at 119°,
on at 112°).
❑ Emergency operation during failure: fresh air intake duct temperature sensor -G89- takes over the func‐
tion. If both sensors are defective, operation continues with an assumed value of +10° C. Air recirculation
is not possible. The control and display unit for Climatronic air conditioning system -E87- displays “--”.
12 - Receiver with dryer bag*
❑ From air conditioner compressor to condenser.
❑ Manufacturer: Sanden, designation: SD6-V12

Polo 1995 ➤
16 - High pressure sender -G65-

❑ The high pressure sender -G65- can be removed without extracting the refrigerant from the refrigerant
circuit.
❑ The high pressure sensor -G65- supplies information to radiator fan control unit -J293- and engine control
unit.
Function:
❑ The high pressure sender -G65- cannot be checked via the Climatronic self-diagnosis, but only via the
engine control unit self-diagnosis.
❑ Check high pressure sender -G65- ⇒ page 132 .
❑ Switches off the air conditioner when the pressure is high (for example, insufficient engine cooling).
❑ Switches off the air conditioner when the pressure is too low (for example, loss of refrigerant).
❑ Repairing ⇒ page 104 .
satelettronica
18 - Condenser* AG. Volkswagen AG d
agen oes
lksw not
19 - Damper* d by Vo gu
ara
se nte
❑ In refrigerant hose from texpansion
ho
ri valve to air conditioner compressor. eo
au ra
ss c
ce
le
un
4.14 Removing and installing coolant temper‐ pt

an
d
itte
y li
rm
ature sender -G62- ab

pe
ility
ot
wit
, is n
1- Clip h re
hole
2- Thermostat housing
spec
es, in part or in w
t to the co
3- Coolant temperature sender -G62-

rrectness of i
l purpos
nform
ercia
4.14.1 Function of coolant temperature sender

m
-G62-
a
com
tion in
r
te o
Depending on the signal from the coolant temperature sender -

thi
s
iva
G62- , the engine control unit does the following via radiator fan
do
r
rp
control unit -J293- :

cum
fo
en
ng
t.
♦ It switches on the air conditioning system magnetic coupling -
yi Co
op
N25- .
C py
t. rig
gh ht
yri by
♦ It switches off the air conditioning system magnetic coupling - cop Vo
by lksw
cted
N25- .
agen
Prote AG.
4.14.2 Removing
– Pull connector off coolant temperature sender -G62- .

Polo 1995 ➤
WARNING

AG. Volkswagen AG d
agen oes
olksw not
– Remove eclip by V-1- from thermostat housing -2-. gu
ara
d
ris nte
o eo
– Pull aout
ut coolant temperature sender -G62- -3-.
h
ra
ss c
ce
le
un
pt
an
Note
d
itte
y li
rm
ab
pe
ility
♦ The coolant temperature sender -G62- supplies information to
ot
wit
the engine control unit.
, is n
h re
hole
♦ The coolant temperature sender -G62- can only be checked
spec
via engine control unit self-diagnosis.
es, in part or in w
t to the co
♦ The coolant temperature sender -G62- is checked via self-di‐
satelettronica
agnosis using the vehicle diagnosis, testing and information
system -VAS 5051A- or the vehicle diagnosis and service in‐
rrectness of i
formation system -VAS 5052- ⇒ Rep. Gr. 01 .
l purpos
4.14.3 Installing
nform
ercia

m
a
com
tion in
r
te o
thi
Note
s
iva
do
r
rp
cum
fo
Refill with coolant after installing thermal switch ⇒ Rep. Gr. 19 .

en
ng
t.
yi Co
Cop py
ht. rig
4.15 Removing high pressure sender -G65-
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
The high pressure sender -G65- can be removed without extract‐

ing the refrigerant from the refrigerant circuit.

– Unbolt high pressure sender -2-.
– Renew seal.

Polo 1995 ➤
4.16 Checking water drain valve
4.16.1 Checking
– Fold cover flap -1- in heat insulation mat -3- on the bulkhead
-4- upwards.
– Remove water drain valve -2- from bulkhead -4-.
Check water drain valve as follows to ensure that it functions cor‐
rectly:
♦ The water drain valve must not be stuck together.
♦ The heat insulation mat must not be deformed or damaged in
the area around the water drain valve.
♦ The opening of the water drain valve flap must point down‐
ward.
Note
satelettronica
When closing, the cover flap -1- must be flush with the heat in‐
sulation mat. If the cover flap -1- is pushed in too far, the water
drain valve shutter flap -2- can get stuck.
4.17 Removing ambient temperature sensor

-G17- Volkswag AG. en AG
agen does
olksw not
yV gu
db ara
4.17.1 Removing
tho
rise nte
eo
s au ra
c
– Unclip grille
s -1- from cover.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness

o
cial p
f in
– Unclip temperature sensor -1- from retainer -3-.

form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 1995 ➤
5 Removing and installing air condi‐

tioner compressor
5.1 Removing and installing air conditioner

compressor: engine code ADX, AEA,
AEE, AEV, AEX, AFH, AHS, AJV, swage
nAKV,
AG. Volkswagen AG d
oes
ANX, APQ, ARC and AVY olk not
byV gu
ara
ed
ris nte
au
tho eo
ra
ss c
♦ Torque wrench -V.A.G 1331-
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nform
ercia
Note
m
a
com
tion in
♦ Air conditioner compressor bracket and related parts can be removed and installed without opening refrig‐
r
te o
erant circuit.
thi
s
iva
do
♦ To remove poly V-belt ⇒ Rep. Gr. 13 .
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5. Removing and installing air conditioner compressor 95

Polo 1995 ➤
1 - Bracket for alternator, air

conditioner compressor and
power steering vane pump
♦ Part No. 032 145 169 G
♦ Part No. 032 145 169 M
Removing
– Move lock carrier to
service position ⇒ Rep.
Gr. 50 .
– Remove alternator ⇒
Rep. Gr. 27 .
– Remove power steering
vane pump ⇒ Rep. Gr.
48 .
– Remove air conditioner
compressor from brack‐
et and secure to body
with suitable material
(e.g. welding wire)
⇒ page 97 .
– Unbolt bracket from cyl‐
inder block.
satelettronica
Installing
When installing, always note:
• Renew securing bolts.
• Observe securing bolts
tightening sequence.
♦ Tightening sequence: first
tighten hexagon bolt
⇒ Item 3 (page 96) , then
hexagon bolt
⇒ Item 5 (page 96) and fi‐
nally hexagon bolts
AG. Volkswagen AG d
⇒ Item 2 (page 96) and ksw
agen oes
not
l
⇒ Item 4 (page 96) . by
Vo gu
ara
ed
is nte
2 - Hexagon bolt M10×50 ut
hor eo
a ra
❑ 45 Nm. ss c
ce
e
nl
pt
3 - Hexagon bolt M10×50

du
an
itte
y li
❑ 45 Nm.
erm
ab
ility
ot p

wit
, is n
❑ 45 Nm.
h re
hole
spec

es, in part or in w
t to the co
❑ 45 Nm.
6 - Refrigerant hoses
rrectness of i
7 - Air conditioner compressor

l purpos
♦ Part number: SD6 V12

♦ Part number: SD7 B10
nf
ercia
or
Removing
m
m
atio
om
n in
– Remove power steering vane pump ⇒ Rep. Gr. 48 .

or c
thi
te
sd
a
– Unscrew hexagon bolts ⇒ Item 9 (page 97) by a few turns and drive back threaded bush on air condi‐
iv
o
r
rp
cu
tioner compressor. Continue unscrewing hexagon bolts.

o
m
f
en
ng
t.
yi Co
– Remove air conditioner compressor from bracket and secure to body with suitable material (e.g. welding t. Cop py
wire) ⇒ page 97 .
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Polo 1995 ➤
8 - Bush
❑ Always observe during installation: lightly coat sleeve with polycarbamide grease -G 052 142 A2- before
installation and then press in.
❑ 45 Nm.
10 - Poly V-belt
❑ Poly V-belt routing ⇒ page 97 .
11 - Tensioner
12 - Tensioning element for tensioning roller
5.1.1 Securing air conditioner compressor to

body
If compressor is removed without opening refrigerant circuit, it
should be secured to body using suitable material, for example,
welding wire.
satelettronica
When doing this, ensure that refrigerant hoses on air conditioner
compressor are not stressed.
5.1.2 Poly V-belt routing olkswage es n
ot g
byV ua
d ran
ir se tee
tho
or
Note ss
au ac
ce
e
nl
pt
When installing poly V-belt, ensure that it is correctly seated on
du
an
itte
poly V-belt pulley.

y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co

rrectness of i
compressor: engine code AER, AFK,

AHW, AKK, AKP, ALD, ALL, APE, AUA,
l purpos
AUB, AUC und AUD

nf
ercia

rm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 1995 ➤
Note
AG. Volkswagen AG d
agen o
♦ Air conditioner compressor bracket and related
Vol parts can be removed andotinstalled
ksw es n
g
without opening refrig‐
erant circuit. ise
db
y ua
ran
r tee
♦ To remove poly V-belt ⇒ Rep. tho .
Gr. au13 or
s ac
s
satelettronica
ce
le
un
pt
an
d
itte
1 - Bracket for alternator, air
y li
erm
ab
conditioner compressor and
ility
ot p
power steering vane pump
wit
is n
h re
♦ Part No. 032 145 169 G
ole,
spec
♦ Part No. 032 145 169 M
t to the co
Removing
rrectne
Gr. 50 .
s
Rep. Gr. 27 .
s o
cial p
– Remove power steering f in

vane pump ⇒ Rep. Gr.
form
mer
48 .
atio
m

o
n
c

i
or
n thi

te
sd
a

iv
o
pr
(e.g. welding wire)

um
r
fo
en
ng
⇒ page 99 .
t.
yi Co
– Unbolt bracket from cyl‐ Cop py
t. rig
inder block. yri
gh by
ht
Installing
op Vo
by c lksw
When installing, always note: cted agen
Prote AG.
• Observe securing bolts
tightening sequence.
♦ Tightening sequence: first
tighten hexagon bolt
⇒ Item 3 (page 99) , then
hexagon bolt
⇒ Item 5 (page 99) and fi‐
nally hexagon bolts
⇒ Item 2 (page 98) and
❑ 50 Nm.

Polo 1995 ➤

❑ 50 Nm.
❑ 50 Nm.
❑ 50 Nm.
AG. Volkswagen AG d
6 - Refrigerant hoses ksw
agen oes
not
Vol
by gu
7 - Air conditioner compressor ised ara
nte
or eo
h
♦ Part number: SD6 V12 s aut ra
c
s
♦ Part number: SD7 B10
ce
le
un
pt
an
d
itte
Removing
y li
erm
ab
ility
ot p
– Remove power steering vane pump ⇒ Rep. Gr. 48 .
wit
is n
h re
– Unscrew hexagon bolts ⇒ Item 9 (page 99) by a few turns and drive back threaded bush on air condi‐
ole,
spec
tioner compressor. Continue unscrewing hexagon bolts.
t to the co
– Remove air conditioner compressor from bracket and secure to body with suitable item (e.g. uncoated
satelettronica
wire) ⇒ page 99 .
rrectne
8 - Bush
ss
o
cial p
f in
form
mer
❑ 45 Nm.
atio
om
n
c
10 - Poly V-belt
i
or
n thi
e

t
sd
iva
o
pr
c
um
r
fo
en
ng
t.
yi
11 - Tensioner
Co
Cop py
t. rig
12 - Tensioning element for tensioning roller
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

body
welding wire.
When doing this, ensure refrigerant hoses on air conditioner com‐
pressor are not stressed.

Polo 1995 ➤
5.2.2 Poly V-belt routing
Note

poly V-belt pulley.

compressor with bracket: engine code
AMF and ATL
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
Note rise
d b ara
nte
tho eo
au ra
♦ The air conditioner compressor
ss bracket and related components can bec removed and installed without the
refrigerant circuit being opened.
ce
e
nl
pt
du
an
itte
♦ To remove poly V-belt ⇒ Rep. Gr. 13 .

y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 1995 ➤
1 - Bracket for air conditioner

compressor
♦ Part No. 045 903 143 E
Removing

Gr. 50 .
Rep. Gr. 27 .
Volkswagen AG
– Remove air conditioner wage
n AG. does
compressor from brack‐ Volks not
gu
by ara
et and secure to body ris
ed nte
with suitable material utho eo
ra
(e.g. welding wire) ss a c
⇒ page 102 .
ce
e
nl
pt
du
an
itte
y li
erm
ab
inder block.
ility
ot p
wit
, is n
Installing
satelettronica
h re
hole
spec
es, in part or in w
t to the co
2 - Hexagonal combi bolt
rrectness of i
M10×45
l purpos
❑ 45 Nm.
❑ Qty. 6
nf
ercia
orm
m
atio
om
n in
or c
Removing:
thi
te
sd
iva
❑ Remove hexagon bolts

o
r
rp
cu
⇒ Item 5 (page 101) .

o
m
f
en
ng
t.
yi
❑ Remove air conditioner compressor from bracket and secure to body with suitable material (e.g. welding
Co
op py
wire) ⇒ page 102 .
t. C rig
gh ht
pyri by
Vo
5 - Hexagon bolt M8x100
co lksw
by
cted agen
Prote
❑ 25 Nm.
AG.
❑ Qty. 3
6 - Poly V-belt
7 - Tensioner
❑ 25 Nm.
❑ Qty. 3

Polo 1995 ➤

body
welding wire.
Note
satelettronica
poly V-belt pulley.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
compressor: engine codes AEF, AGD,
itte
y li
erm
ab
AHG, AKU und ASX
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Polo 1995 ➤
1 - Bracket for air conditioner

compressor
Removing

Gr. 50 .
Rep. Gr. 27 .

(e.g. welding wire)
⇒ page 104 .

inder block.
Installing
satelettronica
. Volkswagen AG
gen AG does
swa
• Renew securing bolts. y Volk not
gu
edb ara
nte
• Note tightening sequencehoris
eo
⇒ page 104 . aut ra
ss c
ce
le

un
pt
an
d
❑ 25 Nm.
itte
y li
rm
ab
❑ Qty. 2
pe
ility
ot
wit
, is n
h re
hole
❑ 25 Nm.
spec
es, in part or in w
❑ Qty. 2
t to the co
rrectness of i
Removing:
l purpos
❑ Remove hexagon bolts ⇒ Item 7 (page 103) .

nform
ercia
❑ Remove air conditioner compressor from bracket and secure to body with suitable material (e.g. welding
wire) ⇒ page 104 .
m
a
com
tio
6 - Bush
n in
r
te o
thi
s
iva

do
r
rp
cum
fo

en
ng
t.
yi Co
❑ 45 Nm. t. Cop py
rig
gh
❑ Qty. 2
ht
pyri by
Vo
o
by c lksw
8 - Poly V-belt
cted agen
Prote AG.

Polo 1995 ➤
5.4.1 Tightening sequence, compact bracket

to cylinder block
– Set compact bracket in locating hole -1-.
wage es n
– Tighten bolts -2-, -3-, -4-, -5- and -6- one after theyother Volks to ot g
ua
25 Nm. ir se
d b ran
o tee
th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
body
rrectne
satelettronica
s o
welding wire.
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1- Crankshaft vibration damper

2- Poly V-belt
3- Tensioner
4- Alternator -C-
5- Power steering vane pump
6- Coolant pump
5.5 Repairing Sanden SD6 V12 air conditioning system magnetic coupling -
N25-

Polo 1995 ➤
Special tools and workshop

equipment required
♦ Torque wrench -V.A.G
1331-
♦ Drift -2051-
♦ Pin wrench -3212-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
satelettronica
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Not illustrated: Cop py
ht. rig
rig ht
♦ Two-arm puller, e.g. KUKKO 20-10 with 100 mm hooks or py by
co Vo
by lksw
three-arm puller, e.g. KUKKO 45-2 with 44-45 hooks Prote
cted AG.
agen
♦ Open jaw flexible spanner

♦ Circlip pliers
Note
♦ The coupling can also be repaired without extracting the refrigerant. In this case, unbolt air conditioner
compressor from bracket and secure to body ⇒ page 102 .
♦ If the air conditioner compressor is to be removed, the refrigerant must be extracted beforehand, e.g. with
the air conditioning service station -VAS 6007A- .
♦ To prevent the ingress of moisture, all components of the refrigerant circuit which have been opened must
be sealed with suitable plugs.
Removing
– Move lock carrier to service position ⇒ Rep. Gr. 50 .
– Unbolt air conditioner compressor from bracket ⇒ page 95 .

Polo 1995 ➤
If air conditioning compressor is to be removed, perform the fol‐

lowing work:
– Extract refrigerant, e.g. with air conditioning service station -
VAS 6007A- .
WARNING

If refrigerant circuit has not been evacuated, refrigerant may
escape.
Extract refrigerant before opening refrigerant circuit.
– Separate refrigerant hoses from air conditioner compressor.
1 - Circlip
Renew.
❑ Install correctly: flat side
satelettronica
faces air conditioner
compressor.
❑ Ensure that it is seated
correctly in groove.
2 - Air conditioning system
magnetic coupling -N25-
❑ Remove ⇒ page 107 .
❑ Locking with dowel pin.
❑ Secured with circlip
⇒ Item 1 (page 106) .
Note
An overheating fuse is installed in wage

es n
the solenoid. The overheating y V fuse
o lks ot g
ua
interrupts the solenoid as ir sesoon as
d b ran
tee
the magnetic coupling uthoverheats
o
or
(for example due toss a stiff or tight
a ac
compressor).
ce
e
nl
pt
du
an
itte
y li
3 - Spacers
erm
ab
ility
❑ To adjust clearance be‐

ot p
tween coupling and V-

wit
, is n
h re
poly V-belt pulley.

hole
spec
❑ Checking clearance
es, in part or in w
⇒ page 110 .
t to the co
4 - Dowel pin
rrectness of i

❑ Secure removed air
l purpos
conditioner compressor
in a vice ⇒ page 107 .
nform
ercia
6 - Poly V-belt pulley

m
at
❑ Pulling off ⇒ page 108 .

om
ion
c
❑ Fitting ⇒ page 109 .

in t
or
his
ate
7 - Circlip
do
priv
cum
or
Renew.
f
en
ng
t.
yi Co
op
❑ Install correctly: flat side faces air conditioner compressor. C py
t. rig
gh ht
pyri by
Vo
co
106
by lksw
cted agen
Rep. Gr.87 - Air conditioning system Prote AG.
AG. Volkswagen AG d
agen oes Polo 1995 ➤
olksw not
V
ed by Heating, air conditioning - Edition
gu
ara 06.2004
ris nte
ho e
❑ Ensure that it is seated correctly in groove.
au
t or
ac
ss
8 - Coupling disc
ce
le
un
pt
an
d
itte
y li
erm
ab
❑ Checking clearance ⇒ page 110 .
ility
ot p
wit
9 - Hexagon nut
is n
h re
ole,
❑ 20 Nm.
spec
❑ Self-locking.
t to the co
❑ Always renew.
rrectnes
5.6 Removing and installing
s o
cial p
f
Sanden SD6 V12 air conditioning sys‐
inform
mer
tem magnetic coupling -N25-
atio
om
n
c
5.6.1 Secure air conditioner compressor in a
i
or
n thi
te
vice.
sd
iva
o
pr
cum
satelettronica
r
fo
en
ng
t.
yi Co
Note Cop py
t. rig
gh ht
pyri by
♦ Use protective jaw covers when clamping the air conditioner
co Vo
by lksw
cted agen
compressor in the vice. Prote AG.
♦ Make sure cable to magnetic coupling is not pinched between

vice and air conditioner compressor housing.
5.6.2 Unscrewing hexagon nut


Polo 1995 ➤
– Using a pin wrench -3212- and an open jaw flexible spanner,

unscrew hexagon nuts.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
is nte
5.6.3 Pulling off coupling disc or eo
h
aut ra
ss c
– Insert a screwdriver into gap between coupling disc and poly
ce
le
un
pt
V-belt pulley.
an
d
itte
y li
rm
– Turn screwdriver slightly -arrow-.
ab
pe
ility
ot
– Repeat procedure at two other points along circumference
wit
, is n
-arrows-.
h re
hole
satelettronica
spec
– Remove coupling disc.
es, in part or in w
t to the co
– Remove spacers ⇒ Item 3 (page 106) .
rrectness of i
l purpos
nform
mercia
5.6.4 Pulling off poly V-belt pulley for air con‐
a
com
tion in
ditioning system magnetic coupling -
r
te o
thi
N25-
s
iva
do
r
rp
cum
fo
– Remove retaining ring for poly V-belt pulley.

en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Polo 1995 ➤
– Pull off poly V-belt pulley with a commercially available two-

arm puller, e.g. Kukko 45-2 with 44-45 hooks.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
– Place hooks -arrow- as shown in illustration.
, is n
h re
satelettronica
hole
spec
es, in part or in w
Note
t to the co
If hook is placed on lower edge of poly V-belt pulley, there is a
danger of damaging air conditioning system magnetic coupling -
rrectness of i
N25- .
l purpos
nform
mercia
a
com
tion in
r
5.6.5 Removing solenoid

te o
thi
s
iva
do
r
– Remove retaining ring for solenoid.

rp
cum
fo
en
ng
t.
– Remove solenoid from air conditioner compressor. Cop
yi Co
py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5.6.6 Installing poly V-belt pulley for air con‐

N25-
Note
Set poly V-belt pulley in place flat, or it could be deformed when

driven in.
– Drive in poly V-belt pulley using drift -2051- and a rubber ham‐
mer -direction of arrow-.

Polo 1995 ➤
. Volkswagen AG
gen AG
5.6.7 Checking and adjusting clearancewa does
olks not
yV b gu
ara
ed
– Check clearance with a depth gauge byhorepeatedly switching
ris nte
eo
magnetic coupling on and off (apply as auvoltage
t
of 12 V). ra
c
s
♦ Nominal value: 0.4 to 0.8 mm
ce
le
un
pt
an
d
itte
– If necessary, use spacers to adjust clearance. Pull off the cou‐
y li
rm
ab
pling disc to do this.
pe
ility
ot
wit
, is n
h re
Note
hole
spec
es, in part or in w
t to the co
♦ The clearance must lie within permitted tolerances over the
complete circumference.
♦ The clearance can also be measured when the air conditioner
rrectness of i
compressor is installed.
l purpos
♦ If the clearance is outside of the specifications, remove the

coupling disc and adjust the clearance by removing or adding
spacers.
nform
mercia
a
com
tio
satelettronica
n in
5.7 Repairing Sanden SD7 B10 air condi‐
r
te o
thi
tioning system magnetic coupling -N25-
s
iva
do
r
rp
c
with compressor removed
um
fo
en
ng
t.
yi Co
Special tools and workshop equipment required ht. Cop py
rig
rig ht
♦ Retainer and puller -V.A.G 1616+1616/1- py by
co Vo
by lksw
cted agen
Prote AG.

Polo 1995 ➤
AG. Volkswagen G d
agen Heating, airAconditioning
oes - Edition 06.2004
olksw not
byV gu
a
ed ran
♦ Universal dial gauge bracket -VW 387- ris tee
tho or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
satelettronica
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Not illustrated:
♦ Commercially available two-arm puller e.g. Kukko 20-10 mm
with 100 mm long hooks.
♦ Dial gauge, commercially available
Removing
VAS 6007A- .
Note
Releasing refrigerant into the environment is a punishable offence.
WARNING

escape.
– Unbolt air conditioner compressor from bracket ⇒ page 95 .

Polo 1995 ➤
1 - Hexagon nut
❑ Self-locking.
❑ Renew.
❑ 20 Nm.
2 - Coupling disc
❑ Checking clearance
⇒ page 114 .
3 - Circlip
❑ Renew.
faces air conditioner
compressor.
❑ Ensure that it is seated
correctly in groove.
4 - Poly V-belt pulley
satelettronica
5 - Circlip
❑ Renew.
faces air conditioner AG. Volkswagen AG d
compressor. agen oes
olksw not
yV gu
❑ Ensure that it is seated ed b ara
nte
is
correctly in groove. hor eo
aut ra
c
6 - Solenoid ss
ce
e
nl
❑ Locking with dowel pin.
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
An overheating fuse is installed in
h re
hole
the solenoid. The overheating fuse
spec
interrupts the solenoid as soon as
es, in part or in w
the magnetic coupling overheats
t to the co
(for example due to a stiff or tight
compressor).
7 - Dowel pin rrectness of i

l purpos

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d Polo 1995 ➤
agen oes
olksw not Heating, air conditioning - Edition 06.2004
y V gu
d b ara
rise nte
5.8 Removing and installing
tho eo
au ra
s c
Sanden SD7 B10 air conditioning sys‐
s
ce
e
nl
pt
tem magnetic coupling -N25-
du
an
itte
y li
erm
ab
5.8.1 Unscrewing hexagon nut
ility
ot p
wit
, is n
– Using a pin wrench -3212- and an open jaw flexible spanner,
h re
hole
unscrew hexagon nuts.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
5.8.2 Pulling off coupling disc
ion
c
in t
or
his
ate
do
riv
satelettronica
Note
p
cum
for
en
ng
t.
yi
The three hexagon bolts of retainer and puller -V.A.G 1616
Co
Cop py
+1616/1- have 1/4" threads.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5.8.3 Pulling off poly V-belt pulley for air con‐

N25-
– Remove retaining ring for poly V-belt pulley.
– Place hooks as shown in illustration.
Note
If hook is placed on lower edge of poly V-belt pulley, there is a

danger of damaging air conditioning system magnetic coupling -
N25- .
– Pull off V-belt pulley with a commercially available two-arm

puller, e.g. Kukko 20-10 with 100 mm long hooks.

Polo 1995 ➤
5.8.4 Checking clearance

– Check clearance with a depth gauge and universal dial gauge
bracket -VW 387- by repeatedly switching magnetic coupling
on and off (apply a voltage of 12 V).
♦ Nominal value: 0.4 to 0.8 mm
Note
The clearance must lie within permitted tolerances over the com‐
plete circumference.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 1995 ➤
6 Repair work on refrigerant circuit

which may be performed only in ap‐
propriate workshops by specially
trained mechanics for vehicles ▸
09.99
6.1 Tools
6.1.1 Required special tools, facilities, testing

and measuring instruments and auxili‐
ary items
Gr. 00 Technical information “Air conditioning system - with re‐
frigerant R134a VW”.
satelettronica
Notes on tools for repair work to vehicles with air conditioning can
be found in ELSA under repair group ⇒ Rep. Gr. 00 Technical
information “Air conditioning system - with refrigerant R134a VW”.
6.2 Repairing components in refrigerant circuit
Note
♦ The refrigerant must be extracted beforehand, e.g. with the air conditioning service station -VAS 6007A- .
AG. Volkswagen
gen AG do
swa es
♦ The previously
by
Vol used service stations can still
k not be used ⇒ Volkswagen Workshop Equipment catalogue.
gu
ara
ed
♦ Safety
tho measures when working on an evacuated refrigerant circuit ⇒ page 51 .
ris tee n
o
au ra
ss the components marked with an * can be renewed
♦ Only c
without opening and evacuating the refrigerant
ce
le
circuit.
un
pt
an
d
itte
y li
rm
ab

pe
ility
ot
wit
♦ The colour coding of O-rings for R134a refrigerant circuits has been discontinued. Coloured and black O-
, is n
h re
rings are used.

hole
spec
♦ Moisten threaded connections of refrigerant circuit with polyethylene glycol (PEG) VW part number 294440
es, in part or in w
t to the co
before installation.
♦ Under certain conditions, it is no longer necessary to renew the receiver each time the refrigerant circuit is
opened ⇒ Rep. Gr. 00 Technical information “Air conditioning systems - with refrigerant R134a VW” Re‐
rrectness of i
newing parts.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6. Repair work on refrigerant circuit which may be performed only in appropriate workshops by specially trained mechanics for vehicles ▸
09.99 115
Polo 1995 ➤
1 - O-ring
❑ 10.8 mm; 1.8 mm.
2 - O-ring
❑ 7.6 mm; 1.8 mm.
3 - Extraction and charging
valve
punishable offence.
❑ Removing and installing AG. Volkswagen AG d
⇒ page 118 . agen oes
olksw not
V gu
❑ Capacities d by ara
ise nte
⇒ page 145 . ut
hor eo
a ra
s c
4 - Socket head screw s
ce
le
un
pt
❑ M6×20
an
d
itte
y li
❑ With washer 12 mm;
rm
ab
1.6 mm
pe
ility
ot
satelettronica
wit
❑ 7 Nm.
, is n
h re
hole
5 - Foam hose
spec
es, in part or in w
6 - O-ring
t to the co
❑ 10.8 mm; 1.8 mm.
7 - 3/4" thread -17 UNF
rrectness of i
❑ 35 Nm.
l purpos
8 - Condenser
nform
mercia
9 - 5/8" thread -18 UNF
a
com
tio
❑ 15 Nm.
n in
r
te o
thi
10 - O-ring
s
iva
do
r
rp
❑ 7.6 mm; 1.8 mm. cum

fo
en
ng
t.
yi
11 - Combi bolt
Co
Cop py
t.
❑ M10×32
rig
gh ht
pyri by
Vo
❑ 30 Nm.
o
by c lksw
cted agen
Prote AG.
12 - High-pressure safety valve
13 - O-rings
❑ Qty. 2
❑ 20.5 mm; 1.8 mm.
14 - O-ring
❑ 10.8 mm; 1.8 mm.
15 - Air conditioning system pressure switch -F129- *
Removing and installing:
❑ The high pressure sender -F129- can be removed without extracting the refrigerant from the refrigerant
circuit.
❑ Checking air conditioning system pressure switch -F129- ⇒ page 60 .
Function:

Polo 1995 ➤
❑ Switches off the air conditioner when the pressure is high (for example, insufficient engine cooling).
❑ Switches off the air conditioner when the pressure is too low (for example, loss of refrigerant).
❑ With air conditioning system magnetic coupling -N25- .
17 - Air conditioning system magnetic coupling -N25- for air conditioner compressor
❑ Manufacturer: Sanden
Repairs on the magnetic coupling with the air conditioner compressor installed should only be performed only
as an exception.
olkswagen AG
en AG. V
❑ Repairing magnetic coupling with compressor removed
olks⇒ page 104 .
wag does
not
yV gu
db ara
18 - 3/4" thread -16 UNF rise nte
tho eo
❑ 35 Nm. s au ra
c
s
19 - O-ring
ce
e
nl
pt
du
an
❑ 10.8 mm; 1.8 mm.
itte
y li
erm
ab
20 - Receiver with dryer bag
ility
ot p
wit
, is n
h re
satelettronica
hole
21 - O-ring
spec
es, in part or in w
❑ 7.8 mm; 1.8 mm.
t to the co
22 - 5/8" thread -18 UNF
❑ 15 Nm.
rrectness of i
23 - Extraction and charging valve
l purpos

❑ Releasing refrigerant into the environment is a punishable offence.
nf
ercia
or
m
m
atio
m
❑ Capacities ⇒ page 145 .

o
n in
or c
24 - O-ring
thi
te
sd
iva
❑ 16.7 mm; 1.8 mm.
o
r
rp
cu
o
m
f
en
ng
25 - Expansion valve yi
t.
Co
op
❑ In engine compartment, right.
C py
t. rig
gh ht
yri
❑ Aperture must be sealed against splashed water. p by
co Vo
by lksw
cted
agen
Prote AG.
Functions:
♦ The expansion valve atomises the in streaming refrigerant and regulates the through flow so that the vapour,
depending on heat transport, becomes a gas only upon reaching the outlet of the evaporator.
♦ The expansion valves for R134a refrigerant circuits are marked with a green sticker.
26 - O-ring
❑ 14 mm; 1.8 mm.
27 - Evaporator
❑ In passenger compartment.
❑ With funnel -arrow- to guide of sensor tube from evaporator temperature switch -E33- .
09.99 117
Polo 1995 ➤
6.3 Removing extraction and charging

valve, low pressure side
WARNING

escape.
– Extract refrigerant from refrigerant circuit, e.g. with air condi‐

tioning service station -VAS 6007A- before replacing valve
-3-.
For additional service stations ⇒ V.A.G Workshop Equipment
Catalogue.
Note AG. Volkswagen AG d

agen
satelettronica
oes
olksw not
yV gu
♦ Releasing refrigerant
ised into the environment is a punishable
b ara of‐
nte
fence. ut
hor eo
a ra
s c
♦ All components
s of the refrigerant circuit which have been
ce
e
opened must be sealed with suitable plugs to prevent moisture

nl
pt
du
an
penetration.
itte
y li
erm
ab
ility
ot p
1- Connection with external thread and groove for O-ring

wit
, is n
h re
2- O-ring; 7.6 mm; 1.8 mm

hole
spec
3- Extraction and charging valve

es, in part or in w
t to the co
4- O-ring
5- Cap
rrectness of i
l purpos

valve, high pressure side
nf
ercia
orm
m
atio
WARNING
om
n in
or c
thi

te
sd
iva
o
r

rp
cu
o
escape.
f
en
ng
t.
yi Co
op
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
AG.

-3-.
Catalogue.

Polo 1995 ➤
Note
♦ Releasing refrigerant into the environment is a punishable of‐

fence.
♦ All components of the refrigerant circuit which have been
penetration.
1- Connection with internal thread

2- O-ring; 10.8 mm; 1.8 mm
3- Extraction and filling valve with groove and internal thread
for cap
4- O-ring
5- Cap agen
AG. Volkswagen AG d
oes
olksw not
V gu
6.5 Tasks of receiver with dryer bag
by ara
d
rise nte
tho eo
u
The receiver
ss a collects the liquid droplets and directs them in raac
satelettronica
continuous stream to the expansion valve. Moisture which has
ce
le
un
pt
entered the refrigerant circuit during assembly is collected by the
an
d
itte
dryer bag in the receiver.

y li
rm
ab
pe
ility
ot
wit
, is n
Note h re
hole
spec
Under certain conditions, it is no longer necessary to renew the

es, in part or in w
receiver each time the refrigerant circuit is opened ⇒ Rep. Gr.

t to the co
00 Technical information “Air conditioning systems - with refrig‐

erant R134a VW” Renewing parts.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
6.6 Removing expansion valve

r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
Note opyri
gh by
Vo
ht
c by lksw
cted
agen
Prote AG.
♦ The previously used service stations can still be used ⇒ Volkswagen Workshop Equipment catalogue.
♦ Safety measures when working on an evacuated refrigerant circuit ⇒ page 51 .
♦ Only the components marked with an * can be replaced without opening and evacuating.
rings are used.
09.99 119
Polo 1995 ➤
1 - Threaded plate
2 - O-ring
❑ 10.8 mm; 1.82 mm.
3 - Heat insulation*
4 - Bolts
❑ 8 Nm.
❑ Qty. 2
5 - O-ring
❑ 7.6 mm; 1.8 mm.
6 - Bolt
❑ 7 Nm.
7 - Refrigerant line
❑ From receiver with dryer
bag to expansion valve.
8 - Refrigerant hose
satelettronica
pressor.
❑ With damper.
9 - O-ring
❑ 16.7 mm; 1.8 mm.
10 - Expansion valve
❑ In engine compartment,
right.
❑ Aperture must be
sealed against splashed
water.
Removing
ks wage es
– The refrigerant must be Vol
not
gu
by
extracted beforehand, e.g. with therisair
e conditioning service station -VAS 6007A-
d ara
nt .
ee
tho or
– Remove heat ⇒ Item 3 au
(pagess120) insulation. ac
ce
e
nl
pt
du
an
itte
WARNING
y li
erm
ab
Danger of freezing inju‐

ility
ot p
ries.
wit
, is n
h re
hole
If refrigerant circuit has

spec
not been evacuated, re‐

es, in part or in w
t to the co
frigerant may escape.

Extract refrigerant be‐
rrectness of i
fore opening refrigerant

circuit.
l purpos
– Remove bolt ⇒ Item 6 (page 120) .

nf
ercia
orm
m
– Pull out refrigerant line ⇒ Item 7 (page 120) and refrigerant hose ⇒ Item 8 (page 120) .
atio
om
n in
c
– Renew O-rings ⇒ Item 5 (page 120) and ⇒ Item 9 (page 120) .

or
thi
te
sd
iva
– Remove bolts ⇒ Item 4 (page 120) .

o
r
rp
cu
o
m
f
en
ng
– Remove expansion valve ⇒ Item 10 (page 120) .

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
120
c by lksw
cted agen
Rep. Gr.87 - Air conditioning system Prote AG.
Polo 1995 ➤
– Renew O-rings ⇒ Item 2 (page 120) and ⇒ Item 11 (page 121) .
11 - O-ring
❑ 14 mm; 1.82 mm.
6.7 Removing and installing condenser

Note
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
09.99 121
Polo 1995 ➤
1 - Sealing strip
❑ Qty. 2
2 - Condenser
Removing agen
AG. Volkswagen AG d
oes
olksw not
y V gu
– Extract refrigerant, e.g. sed b ara
nte
with air conditioning tho ri
eo
service station -VAS ss au ra
c
6007A- .
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
Releasing refrigerant into the envi‐
wit
, is n
ronment is a punishable offence.
h re
hole
spec
es, in part or in w
t to the co
WARNING
ries.
rrectness of i
l purpos
satelettronica
nf
ercia
orm
m
atio
m

o
n in
c
circuit.
or
thi
te
sd
iva
o
r
rp
cu
– Remove refrigerant
o
m
f
en
ng
lines on condenser and

t.
yi Co
op
seal. C py
t. rig
gh ht
yri by
– Remove radiator grille
cop Vo
by lksw
cted
⇒ Rep. Gr. 66 .
agen
Prote AG.
– Remove bumper ⇒
Rep. Gr. 63 .
3 - Self-tapping screws
❑ Qty. 4
❑ 10 Nm.
6.8 Dismantling and assembling evaporator

housing

Before dismantling, heater and air conditioner unit must be re‐
moved.
VAS 6007A- .

Polo 1995 ➤
Note
Releasing refrigerant into the environment is a punishable of‐

fence.
WARNING

– Drain the coolant ⇒ Rep. Gr. 19 .

– Remove dash panel ⇒ Rep. Gr. 70 .
– Remove heater and air conditioner unit.
lkswage es n
o ot g
satelettronica
byV ua
d ran
Note o
ir se tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
♦ Underlined components can be renewed only after evaporator with heater has been removed.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
09.99 123
Polo 1995 ➤
1 - Housing, upper part

circulation flap.
❑ Before assembling, coat
fitted surfaces with sili‐
cone adhesive sealant -
D 176 001 A3- .
N24-
3 - Intake housing
❑ With recirculating air
flap. AG. Volkswagen AG d
agen oes
❑ Before assembling, coat olksw not
V gu
fitted surfaces with sili‐ d by ara
ise nte
cone adhesive sealant - ut
hor eo
D 176 001 A3- . ss a ra
c
ce
e
4 - Funnel
nl
pt
du
an
itte
❑ To guide sensor tube of
y li
erm
ab
evaporator temperature
satelettronica
ility
ot p
switch -E33- .
wit
, is n
h re
5 - Intake ring
hole
spec
6 - Vacuum unit for fresh air
es, in part or in w
t to the co
❑ Ventilated: fresh air op‐
eration.
rrectness of i
❑ Vacuum hose connec‐
l purpos
tion diagram
⇒ page 63 .
nform
ercia

m
8 - Housing, lower part
at
om
ion
❑ Before assembling, coat
c
in t
or
fitted surfaces with sili‐
his
ate
cone adhesive sealant -D 176 001 A3- .

do
priv
cum
or
9 - Temperature switch for evaporator -E33-

f
en
ng
t.
yi Co
❑ Insertion depth of sensor tube: 330 mm. t. Cop py
rig
gh
❑ Task: prevents icing up.
ht
pyri by
Vo
o
by c lksw
❑ Switching temperature: opens at or below -2° C. Prote
cted AG.
agen
10 - Sealing cord
❑ Watertight.
11 - Clip
❑ Flaps cannot be renewed.
13 - Heat exchanger
14 - Evaporator
❑ With funnel to guide sensor tube of evaporator temperature switch -E33- .
15 - Seal
❑ Watertight.

Polo 1995 ➤
7 Repair work on refrigerant circuit

which may be performed only in ap‐
propriate workshops by specially
trained mechanics for vehicles ▸
10.99
7.1 Tools
7.1.1 Required special tools, facilities, testing

and measuring instruments and auxili‐
ary items
AG. Volkswagen AG d
Gr. 00 Technical informationlksw “Air conditioning system
agen oes - with re‐
not
frigerant R134a VW”.d by V o gu
satelettronica
a ran
e
ris t
Notes on tools for thorepair work to vehicles with air conditioning can
ee
o
be found in ELSA
s au under repair group ⇒ Rep. Gr. 00 Technical r ac
s
information “Air conditioning system - with refrigerant R134a VW”. ce
le
un
pt
an
d

itte
y li
erm
ab
7.2 Renewing refrigerant circuit components
ility
ot p
wit
is n
h re
ole,
spec
Note
t to the co
rrectne

ss
♦ Only the components marked with an * can be renewed without opening and evacuating the refrigerant
o
cial p
circuit.
inform
mer
atio
m

o
n
c
i
or
thi
te
sd
a
rings are used.

iv
o
pr
cum
r
fo
♦ Moisten threaded connections of refrigerant circuit with polyethylene glycol (PEG) VW part number 294440
en
ng
t.
before installation.
yi Co
Cop py
ht. rig
♦ Under certain conditions, it is no longer necessary to renew the receiver each time the refrigerant circuit is
rig ht
py by
opened ⇒ Rep. Gr. 00 Technical information “Air conditioning systems - with refrigerant R134a VW” Re‐
co Vo
by lksw
cted
newing parts.
agen
Prote AG.
10.99 125
Polo 1995 ➤
1 - O-ring
❑ 10.8 mm; 1.82 mm.
2 - O-ring
❑ 8.2 mm; 1.82 mm.
3 - Extraction and charging
valve
punishable offence.
⇒ page 128 .
❑ Capacities
⇒ page 145 .
4 - Socket head combi-bolt
❑ 7 Nm.
satelettronica
⇒ page 129 .
❑ Not present with all
types of engines.
❑ From air conditioner
compressor to condens‐ AG. Volkswagen AG d
agen
er. olksw
oes
not
byV gu
ara
d
7 - O-ring orise nte
eo
h
ut
❑ 10.8 mm; 1.82 mm. ss a ra
c
ce
le
8 - 3/4" thread -17 UNF

un
pt
an
d
itte
y li
9 - Condenser
erm
ab

ility
ot p
wit
is n

h re
ole,
❑ 7 Nm.
spec
t to the co
11 - O-ring
❑ 10.8 mm; 1.82 mm.
rrectne
12 - Receiver with dryer bag

ss
13 - O-ring
o
cial p
f in
❑ 10.8 mm; 1.82 mm.

form
mer

atio
om
❑ 7 Nm.
c
i
or
n thi
te
sd
iva
o
pr
cum
r
16 - O-ring
fo
en
ng
t.
yi
❑ 10.8 mm; 1.82 mm.
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
❑ 7 Nm. Prote
cted AG.
agen
18 - O-ring
❑ 10.8 mm; 1.82 mm.

Polo 1995 ➤
19 - High pressure sender -G65- *

❑ Check high pressure sender -G65- ⇒ page 132 .
22 - O-ring
❑ 20.5 mm; 1.8 mm.
❑ Qty. 2
24 - High-pressure safety valve
❑ Manufacturer: Sanden, designation: SD6-V12.
26 - Damper
27 - Extraction and charging valve
satelettronica
❑ Releasing refrigerant into the environment is a punishable offence.
❑ Capacities ⇒ page 145 .
28 - Bolt
❑ 8 Nm. n AG. Volkswagen AG do
lkswage es n
o ot g
29 - Bolt d byV ua
ran
ir se
❑ 8 Nm. utho tee
or
a ac
30 - O-ring ss
ce
le
un
pt
❑ 17 mm; 1.85 mm.

an
d
itte
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31 - Expansion valve
erm
ab
ility
ot p
❑ In engine compartment, right.

wit
is n
❑ Function and removal ⇒ page 139 .

h re
ole,
spec
32 - O-ring
t to the co
❑ 14 mm; 1.82 mm.

33 - Threaded plate
rrectne
34 - Evaporator
❑ In passenger compartment.
ss o
❑ Removal ⇒ page 138 , Dismantling and assembling evaporator housing.

cial p
f inform
mer
atio
m

o
n
c
i
or
valve, low pressure side

thi
te
sd
iva
o
pr
cum
r
fo
en
WARNING
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
If refrigerant circuit has not been evacuated, refrigerant may cted agen
Prote AG.
escape.
10.99 127
Polo 1995 ➤
– Extract refrigerant from refrigerant circuit, e.g. with air condi‐ gen AG
. Volkswagen AG
does
tioning service station -VAS 6007A- before replacing valve Volkswa not
-3-. ed
by gu
ara
is nte
or
au
th eo
ra
Catalogue. ss c
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
wit
, is n
h re
fence.
hole
spec
es, in part or in w
t to the co
penetration.
rrectness of i
1- Connection with external thread and groove for O-ring
l purpos
2- O-ring; 7.6 mm; 1.8 mm

3- Extraction and charging valve
nform
ercia
4- O-ring
m
at
satelettronica
om
io
5- Cap
n
c
in t
or
his
ate
do
priv
cum
or
valve, high pressure side

f
en
ng
t.
yi Co
Cop py
ht. rig
ht
WARNING
rig by
copy Vo
by lksw
cted agen
Prote
AG.

escape.

-3-.
Catalogue.
Note

fence.
penetration.
1- Connection with internal thread

2- O-ring; 10.8 mm; 1.8 mm
3- Extraction and filling valve with groove and internal thread
for cap
4- O-ring
5- Cap

Polo 1995 ➤
7.5 Tasks of receiver with dryer bag

The receiver collects the liquid droplets and directs them in a
continuous stream to the expansion valve. Moisture which has
entered the refrigerant circuit during assembly is collected by the
dryer bag in the receiver.
swage es n
7.6 Quick release coupling olk ot g
byV ua
d ran
ir se tee
Special tools and workshop equipment required autho
or
ac
ss
ce
le
un
pt
an
d
itte
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satelettronica
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Not illustrated:
nform
ercia
♦ Release tool -VAS 6127/3-

m
a
com
tio
♦ Protective goggles
n in
r
te o
thi
♦ Protective gloves
s
iva
do
r
rp
c
♦ Repair set -6Q0 298 260 A- um
fo
en
ng
t.
yi
– Repair set 6Q0 298 260 A
Co
Cop py
t. rig
gh
7.6.1 Disconnecting quick release coupling
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
After every removal, the O-ring, retainer and retaining ring must
be renewed.

VAS 6007A- .
WARNING

escape.
10.99 129
Polo 1995 ➤
– Slide dust seal -1- away from coupling onto refrigerant line
-2- until assembly area around coupling is free.
– Fit release tool -VAS 6127/3- -2- near coupling. Notches in

release tool -VAS 6127/3- must be in line with indicators.
– Slide release tool -VAS 6127/3- -2- in direction ofwarrow
gen AG-A-
. Volkswagen AG
does
s a
along air conditioner compressor line -1- to stop
yV
olk on coupling not
gu
housing -3-. ris
ed b ara
nt ee
tho or
s au ac
s
ce
le
un
satelettronica
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Hold release tool -VAS 6127/3- against stop and pull coupling
es, in part or in w
housing -1- in -direction of arrow-.
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
7.6.2 Dismantling quick release coupling

um
fo
en
ng
t.
yi Co
op
– Remove release tool -VAS 6127/3- . Then remove circlip -1- C py
ht. rig
using circlip pliers. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
ksw
agen oes
not
Polo 1995 ➤
ol
d byV Heating, airguconditioning
ara - Edition 06.2004
ise nte
or eo
h
– Remove locking insert -1-
s autand O-ring -2- from coupling hous‐ ra
c
ing -3-. s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
7.6.3 Assembling quick release coupling

– Moisten O-ring -1- with refrigerant oil before assembly and
nform
ercia
guide O-ring into coupling housing -2- to stop.

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
satelettronica
um
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Guide locking insert -1- into coupling housing -2-. The indica‐
tors -A- must be positioned so that they are in line with the
holes -B- in the coupling housing.
– Install circlip -1- using circlip pliers.
10.99 131
Polo 1995 ➤
7.6.4 Connecting quick release coupling

– Guide coupling section of air conditioner compressor line -1-
into coupling housing -3- of refrigerant line until indicators
protrude clearly through holes.
– Slide dust seal -2- onto coupling housing -3- so that dust seal
is flush against coupling.
7.7 Checking high pressure sensor -G65-
Special tools and workshop

equipment required
♦ Ignition tester -V.A.G 1767-
satelettronica
♦ Auxiliary measuring set -
V.A.G 1594C-
♦ Text box -V.A.G 1598A-
♦ Air conditioning service sta‐
tion -VAS 6007A-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo 1995 ➤
7.7.1 Testing high pressure sender -G65- via

engine control unit
Depending on the signal from the high pressure sender -G65- ,
the engine control unit does the following via radiator fan control
unit -J293- :
♦ It switches on the air conditioning system magnetic coupling -
N25- .
wage es n
♦ It switches off the air conditioning system magnetic coupling yV
olks - ot g
ua
N25- . ed b ran
oris tee
h
♦ It switches radiator fan -V7- to 2nd stage if pressure
aut
increases. or
ac
ss
♦ The idling speed is raised if air conditioning is switched on.
ce
le
un
pt
an
d
itte
y li
erm
ab
Note
ility
ot p
wit
is n
h re
♦ The high pressure sender -G65- can be removed without ex‐
ole,
tracting the refrigerant from the refrigerant circuit.
spec
t to the co
♦ The high pressure sender -G65- supplies information to the
satelettronica
engine control unit and the radiator fan control unit.
♦ The high pressure sender -G65- can be checked via engine
rrectne
control unit self-diagnosis.
♦ The high pressure sender -G65- can be tested using the ve‐
ss
hicle diagnosis, testing and information system -VAS 5051A-
o
cial p
f i
or vehicle information and service information system -VAS
nform
5052- via engine control unit (engine running, air conditioning
mer
atio
on) ⇒ Rep. Gr 01; Self-diagnosis; Reading measured value
om
block 08; Display group 057 (value 4 in %). Compare value
n
c
i
or
n
with table ⇒ page 134 .
thi
te
sd
iva
o
pr
cum
r
fo
7.7.2 Checking high pressure sender -G65-
en
ng
t.
yi Co
op
with ignition tester -V.A.G 1767-
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
This test is for vehicles on which self-diagnosis via the engine

control unit is not possible.
7.7.3 Assembling tools and equipment

– Connect ignition tester -V.A.G 1767- -1-. Connect tester earth
-2- (black grip) to vehicle earth -3-. Establish connection with
lead from auxiliary measuring set -V.A.G 1594C- from -4- to
connector, 14-pin connector -T14/2- , of radiator fan control
unit -J293- .
Checking:
– Press duty cycle button of ignition tester -V.A.G 1767-
-arrow-.
– Compare value with table ⇒ page 134 .
10.99 133
Polo 1995 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
satelettronica
th or
au ac
ss ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
7.7.4 Evaluating test results

om
n
c
i
or
A workshop temperature of between 20° C to 30° C is assumed

thi
te
sd
a
for the evaluation. The engine is at room temperature.

iv
o
pr
cum
r
fo
Test result Possible cause of fault Rectifying fault

en
ng
t.
yi Co
op
Duty cycle of 20% to 25% High pressure sender -G65- is
C py
t. rig
gh
OK
ht
pyri by
Vo
co lksw
by
Duty cycle 90% Prote
cted High pressure sender -G65- – Renew high pressure sender -G65-
AG.
agen
defective ⇒ page 93 .
Duty cycle 5% ♦ High pressure sender - – Renew high pressure sender -G65-
G65- defective ⇒ page 93 .
or
♦ Refrigerant circuit is empty – Charge with refrigerant.
Duty cycle 0% Short circuit or open circuit in – Check wiring and connections ac‐
wiring or connectors cording to current flow diagram.

Polo 1995 ➤
Note
If the cause of the customer complaint has not been found, check
fault memory of engine electronics control unit.
7.7.5 Measurements for evaluating air condi‐

tioning system
Prerequisite: lkswage es n
o ot g
yV ua
• Radiator fan thermal switch -F18- is OK ⇒ Rep. ir se Gr. 19
d b ran
tee
tho
or
Checking: au ac
ss
ce
le
The following measurements are performed with high pressure
un
pt
sender -G65- installed.
an
d
itte
y li
rm
ab
pe
ility
ot
Note
wit
, is n
h re
satelettronica
hole
spec
If the high pressure sender -G65- is removed or the connector
es, in part or in w
pulled off the high pressure sender -G65- , the air conditioner
t to the co
compressor will not switch on.
To assess the air conditioner's performance, perform and evalu‐
rrectness of i
ate the following checks:
l purpos
– Check the air conditioner's fill level; the air conditioner is

switched off if the pressure is too low (for example, loss of
nform
ercia
refrigerant).
m
– Check blower switch-on; radiator fan -V7- is switched to the
a
com
tio
next higher speed when the pressure in the refrigerant circuit
n in
r
rises (excessive pressure).

te o
thi
s
iva
do
– Check air conditioner switch-off; the air conditioner is switched
r
rp
cum
off when pressure is excessive (for example when engine
fo
en
g
cooling is insufficient).
n
t.
yi Co
Cop py
t. rig
gh ht
7.8 Removing and installing heater and air pyri by
Vo
co lksw
by
conditioner unit
cted agen
Prote AG.

10.99 135
Polo 1995 ➤
Note
AG. Volkswagen AG d
agen oes
lksw not
♦ The refrigerant must be extracted beforehand, e.g. with the air by
Vo gu
ara
conditioning service station -VAS 6007A- . orised
nte
h eo
ut ra
♦ The previously used service stations can still be used s⇒
s Volks‐
a c
wagen Workshop Equipment catalogue.
ce
le
satelettronica
un
pt
an
d
♦ To prevent the ingress of moisture, all components of the re‐

itte
y li
frigerant circuit which have been opened must be sealed with
rm
ab
pe
ility
suitable plugs.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Polo 1995 ➤
1 - Hexagon nut
❑ Qty. 3
❑ 4 Nm.
2 - Bulkhead
bling evaporator hous‐
ing ⇒ page 138 .
Removing
– Remove dash panel ⇒

Rep. Gr. 70 .
WARNING
Danger of scalding inju‐
ries.
The cooling system is
pressurised. When the
satelettronica
engine is warm, the cool‐swagen AG. Volkswagen AG does
ant temperature may by
Vobe
lk not
gu
above 100° C. rised ara
nte
ho eo
ut ra
If necessary,
ss
a release c
pressure before carrying
ce
e
nl
pt
out repairs.
du
an
itte
y li
erm
ab
ility
ot p
– Seal coolant hoses in

wit
, is n
engine compartment
h re
and remove from heat

hole
spec
exchanger.
es, in part or in w
t to the co
– Seal heat exchanger to

prevent coolant from es‐
caping.
rrectness of i
– Extract refrigerant with air conditioning service station -VAS 6007A- .

l purpos
nf
ercia
WARNING
orm
m

atio
m
ries.
o
n in
or c
thi
e

t
sd
iva

o
r
rp
cu
o

m
f
en
ng
t.
yi Co
op
C py
t. rig
gh
ht
pyri by
Vo
circuit.
co lksw
by
cted agen
Prote AG.
– Disconnect refrigerant lines from expansion valve.
– Remove dust and pollen filter with filter housing ⇒ page 37 .
– Remove hexagon nuts ⇒ Item 1 (page 137) .
Installing
– Guide heater and air conditioner unit to bulkhead and push studs through holes provided.
– At the same time, make sure that heater and air conditioner unit sits on guide pin ⇒ Item 4 (page 138)
against stop.
10.99 137
Polo 1995 ➤
– Screw hexagon nuts onto bulkhead in engine compartment and tighten them.
– Check coolant level and top up.
4 - Guide pin
7.9 Dismantling and assembling evaporator

housing
– Remove heater and air conditioner unit ⇒ page 135 .
seal
2 - Heat exchanger
❑ After removal, com‐
pletely renew coolant.
3 - Housing, upper part
circulation flap.
satelettronica
4 - Seal
❑ Installing seal on evap‐
orator ⇒ page 139 .
5 - Evaporator
❑ Installing seal on evap‐
orator connection
⇒ page 139
6 - Housing, lower part
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
138
Prote AG.
Rep. Gr.87 - Air conditioning system
lkswage es n
o ot g
byV Polo
ua 1995 ➤
d ran
ir se
tho Heating, air conditioning - Edition 06.2004
tee
or
au ac
ss
7.9.1 Installing seal on evaporator
ce
le
un
pt
an
d
itte
y li
The evaporator -A- must be sealed against housing along top and
rm
ab
sides with gasket -B-.
pe
ility
ot
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
To ensure that condensed water can drain properly, bottom side
of evaporator must not be fitted with a gasket.
rrectness of i
l purpos
nform
ercia
7.9.2 Installing seal on evaporator connection

m
a
com
tion in
The refrigerant lines -C- must be sealed with gasket -A- along
r
te o
thi
both halves of housing -B-.
s
iva
do
r
rp
cum
fo
en
ng
t.
satelettronica
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
7.10 Expansion valve, function and removal
Note
♦ The refrigerant must be extracted beforehand, e.g. with the air

♦ The previously used service stations can still be used ⇒ Volks‐
♦ Only the components marked with an * can be replaced with‐
out opening and evacuating circuit.
suitable plugs.
10.99 139
Polo 1995 ➤
1 - Threaded plate
2 - O-ring
❑ 10.8 mm; 1.82 mm.
AG . Volkswagen AG
3 - Expansion valve ksw
agen does
not
ol
❑ In engine compartment, yV gu
db ara
right. rise nte
tho eo
❑ Aperture musts au be ra
c
s
sealed against splashed
ce
le
un
pt
water.
an
d
itte
y li
Functions:
erm
ab
ility
♦ The expansion valve atom‐
ot p
wit
ises the in streaming refrig‐
is n
h re
erant and regulates the
ole,
through flow so that the va‐
spec
pour, depending on heat
t to the co
transport, becomes a gas
only upon reaching the out‐
let of the evaporator.
rrectne
4 - Bolts
❑ 8 Nm.
satelettronica
ss o
cial p
❑ Qty. 2
f inform
mer
5 - O-ring
atio
m
❑ 7.6 mm; 1.82 mm.

o
n
c
i
or
n
thi
te
sd
va
❑ 7 Nm.
i
o
pr
cum
r
fo
en
ng
7 - Refrigerant line yi
t.
Co
op
❑ From receiver with dryer
C py
t. rig
gh
bag to expansion valve.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
pressor.
❑ With damper.
9 - O-ring
❑ 17 mm; 1.85 mm.
10 - O-ring
❑ 14 mm; 1.82 mm.
7.10.1 Removing

Polo 1995 ➤

VAS 6007A- .
Note
Releasing refrigerant into the environment is a punishable of‐

fence.
satelettronica
AG. Volkswagen AG d
agen oes
ksw
WARNING by
Vol not
gu
ara
ed
ris nte
o eo
Danger of freezing injuries. aut
h
ra
ss c
ce
le
un
pt
escape.
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
– Remove screw -6-.
hole
spec
es, in part or in w
– Pull out refrigerant line -7- and refrigerant hose -8-.
t to the co
– Remove bolts -4-.
– Remove expansion valve -3-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
10.99 141
Polo 1995 ➤ AG. Volkswagen AG d
agen
V olksw - Edition 06.2004 es not
o
y gu
db ara
rise nte
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
satelettronica
p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
7.11 Removing and installing condenser


Polo 1995 ➤
Note
♦ The refrigerant must be extracted beforehand, e.g. with the air

♦ The previously used service stations can still be used ⇒ Volks‐
satelettronica
suitable plugs.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
10.99 143
Polo 1995 ➤
1 - Lock carrier
❑ Removing ⇒ Rep. Gr.
50 .
2 - Bolts
❑ 8 Nm.
❑ Qty. 4
3 - Condenser
Removing:
– Extract refrigerant, e.g.

with air conditioning
service station -VAS
6007A- .
Note
Releasing refrigerant into the envi‐

ronment is a punishable offence.
– Remove lock carrier ⇒
satelettronica
Rep. Gr. 50 .
WARNING
ries.
not been evacuated, re‐ agen
AG. Volkswagen AG d
oes
olksw not
V gu
d by ara
e nte
Extract refrigerant be‐ horis
eo
fore opening refrigerant aut ra
s c
circuit. s
ce
le
un
pt
an
d
itte
y li
– Remove refrigerant
erm
ab
ility
lines on condenser and seal.

ot p
wit
is n
h re
– Separate receiver with dryer bag from condenser and seal lines.
ole,
spec
– Remove bolts ⇒ Item 2 (page 144) .

t to the co
4 - Radiator
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Polo 1995 ➤
8 Capacities
8.1 Refrigerant R134a

Air conditioner compressor Manufacturer Capacity
SD7 B10 Sanden, ▸ 09.99 700+50 g
SD6 V12 Sanden, 10.99 ▸ 550+25 grammes
8.2 Refrigerant oil

The special refrigerant oil (for use with refrigerant circuits R134a
only) can no longer be obtained on the refrigerant/machine oil
market.
Refrigerant oil can be obtained using following part No. for
SD7 B10 air conditioner compressor; Sanden G 052 100 A2
SD6 V12 air conditioner compressor; Sanden G 052 154 A2
satelettronica
olkswagen AG
en AG. V
Type Production period oCapacity
lksw
ag 16) does
not
yV gu
db ara
6N0 820 803 A ▸ 09.99 ir se 100 ± 15 cm3 nte
tho eo
6N0 820 803 B 10.99 ▸ ss
au
120 ± 15 cm3
ra
c
ce
e
nl
pt
du
an
itte
y li
erm
ab
16) This quantity of refrigerant oil is contained in a replacement compressor and
ility
equals the capacity.
ot p
wit
, is n
Important information:
h re
hole
spec
Because refrigerant oil is very hygroscopic, opened containers
es, in part or in w
must be closed immediately after use to stop ingress of moisture.
t to the co
Because of its chemical properties, refrigerant oil must not be
disposed of together with engine or gear oil.
rrectness of i
8.2.1 Oil distribution
l purpos
The oil, which is located in the sump of the air conditioner com‐
pressor before the air conditioner system is switched on for the
nform
ercia
first time, distributes itself through the refrigerant circuit as follows:

m
at
om
♦ Compressor approx. 50%

ion
c
in t
or
♦ Condenser approx. 10%

his
ate
do
riv
♦ Suction hose approx. 10%

p
cum
for
en
g
♦ Evaporator approx. 20%

n
t.
yi Co
Cop py
♦ Receiver approx. 10%
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
8. Capacities 145

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Service

Service Department. Technical Information

All rights reserved.

Copyright © 2015 Volkswagen AG, Wolfsburg 00050205120

1.1 Passenger compartment heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1.3 Removing fresh air blower V2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1.5 Removing and installing right plenum chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1.11 Removing and installing heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.13 Installing and adjusting cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2 Repairing heater, vehicles 10.99 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.1 Passenger compartment heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.2 Removing fresh air blower V2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2.3 Removing and installing dust and pollen filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

87 - Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

2.5 Renewing temperature switch for evaporator E33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

E87 with Climatronic control unit J255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

4.10 Removing and installing temperature flap control motor V68 . . . . . . . . . . . . . . . . . . . . . . 88

4.11 Removing and installing central flap control motor V70 . . . . . . . . . . . . . . . . . . . . . . . . . . 89

4.13 Climatronic - engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

4.14 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 92

4.17 Removing ambient temperature sensor G17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

5 Removing and installing air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

AKP, ALD, ALL, APE, AUA, AUB, AUC und AUD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

und ASX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

7.2 Renewing refrigerant circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

7.5 Tasks of receiver with dryer bag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

7.6 Quick release coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

7.11 Removing and installing condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

8.1 Refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

8.2 Refrigerant oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

1.1 Connecting vehicle diagnosis, testing

and information system -VAS 5051A- or

vehicle diagnosis and service informa‐

tion system -VAS 5052-

– Open ash tray cover -2-.

– Plug connector of diagnosis lead -VAS 5051/5A- or diagnosis

lead -VAS 5051/6A- into diagnostic connection.

1. Self-diagnosis of Climatronic, vehicles 10.99 ▸ 1

hicle diagnosis and service information system -VAS 5052- .

tested by self-diagnosis ( temperature sensor blower -V42-

and high pressure sender -G65- ).

♦ Measures to correct current, model-specific faults ⇒ Technical

2 Rep. Gr.01 - Self-diagnosis

Coding control unit: yes

Read measured value block: yes

♦ Battery negative terminal checked for tight seating.

formation system -VAS 5051A- or vehicle

diagnosis and service information system -

1.5 Diagnosis functions with vehicle diagno‐

1.5.1 Selecting operating mode

1. Self-diagnosis of Climatronic, vehicles 10.99 ▸ 3

1.5.2 Selecting vehicle system agen

♦ Right-hand drive with blue display 3B2 907 044 C.

Climatronic = System designation

SXX = Software version

Code: no code 00000 - display flashes

♦ If code differs from vehicle version:

– Press arrow key -1- on display.