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Heating, air conditioner - Edition 06.2017
1 - Flap for rear air duct
❑ Equipment version
Electrical/manual air condi‐
tioning system
❑ The air duct is sealed
with a plug
❑ Dependant on manufac‐
ture, not always fitted for
electrically/manually
controlled air condition‐
ing systems (not nee‐
ded as air duct is sealed
off)
Climatronic (depending on ve‐
hicle)
❑ For rear vent in centre
console.
2 - Operating lever
❑ For flap control
❑ Equipment version with
Climatronic
❑ -1- not always fitted on
electric/manual air con‐
ditioning systems.
3 - Left flap for left dash panel
vent
4 - Operating lever
❑ For actuation of vent
flaps
❑ Actuated via actuation
unit
⇒ Item 3 (page 112) .
5 - Left flap for centre dash
panel vent
6 - Right flap for right dash panel vent
7 - Right flap for centre dash panel vent
5.5
Removing and installing heater and air
conditioning unit
Special tools and workshop equipment required
♦ Hose clamps to 25 mm - 3094-
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♦ Torque wrench - V.A.G 1331-
♦ Engine bung set - VAS 6122-
lk
♦ Drip tray for workshop hoist - VAS 6208-
♦ Compressed air gun
Removing
Vehicles with 176 kW TDI bi-turbo engine
– Remove low-pressure turbocharger ⇒ Rep. gr. 21 ; Turbo‐
charger; Removing and installing turbocharger .
All vehicles
– If necessary, remove engine cover panel ⇒ Rep. gr. 10 ; En‐
gine cover panel; Removing and installing engine cover panel .
– If necessary, remove air filter housing ⇒ Rep. gr. 23 ; Air filter;
Assembly overview - air filter housing .
– Disconnect the refrigerant line with internal heat exchanger at
the expansion valve ⇒ page 43 .
– For any further work, immediately seal open lines and con‐
nections with clean plugs from engine bung set - VAS 6122- .
– Place drip tray for workshop hoist - VAS 6208- beneath en‐
gine.
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– Mark coolant hoses -2- and -3- so that they can be reconnec‐
ted to proper sides again later. The heat exchanger is de‐
signed for a certain direction of coolant flow only.
– Clamp off coolant hoses with hose clamps up to 25 mm - 3094-
-1- and -4-.
CAUTION
On a warm engine, the cooling system is under high pressure.
Danger of scalding by steam and hot coolant.
Skin and other parts of the body may be scalded.
– Wear protective gloves.
– Wear protective goggles.
– Reduce excess pressure by covering cap of coolant expan‐
lk
sion tank with cloths and opening it carefully.
– Lift up retaining clips.
– Remove coolant hoses.
– Push a piece of hose onto upper union.
– Insert compressed air gun into end of hose.
– Place a container under the lower union and carefully blow
coolant out of the heat exchanger with a compressed air pistol.
– Seal open lines and connections with clean plugs from engine
bung set - VAS 6122- .
– Remove dash panel central tube ⇒ General body repairs, in‐
terior; Rep. gr. 70 ; Dash panel central tube; Removing and
installing dash panel central tube .
– If necessary, remove the air duct to the rear vent
⇒ page 174 .
– Lift rear footwell vents under front seats and pull them towards
rear to ease removal of footwell vents from heater and air con‐
ditioning unit.
– Remove rear footwell vents from heater and air conditioning
unit.
– Remove baffle plate ⇒ page 165 .
Note
Disregard items -1- and -2-.
– Disconnect electrical connector -3-.
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lk
Note
Disregard items -1, 2, 3- and -4-.
– Disconnect electrical connector -5-.
– Cover floor covering and airbag control unit - J234- in interior
of vehicle with a waterproof sheet and absorbent paper.
– If fitted, detach cable ties around condensation drain -2-.
– Carefully pull condensation drain hose -2- off heater and air
conditioning unit -1-.
– Pull heater and air conditioning unit -1- off retainers on plenum
chamber bulkhead.
– Unhook electrical wiring harness -1- -arrows-.
– Remove wiring duct -2- from mountings -arrows-.
– Disconnect connectors on heater and air conditioner unit.
Note
The following work steps must be performed by a second me‐
chanic.
– Remove heater and air conditioning unit to the side.
Installing
Install in reverse order of removal, observing the following:
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– Ensure that the condensation drain hose -3- is properly seat‐
ed.
lk
– Coding -2- and -arrow- must align with heater and air condi‐
tioning unit -1-.
– If a commercially available cable tie was installed to retain the
condensation drain -3-, then renew it.
– The condensation drain hose must be routed below the wiring
harness of the airbag control unit - J234- -4- in the figure.
– Moisten new seals with refrigerant oil before installing refrig‐
erant line.
NOTICE
Risk of damage to air conditioner compressor if refrigerant cir‐
cuit is empty.
– Never start the engine if the refrigerant circuit is empty.
Vehicles with R134a refrigerant
– Charge refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00 ; Working with air conditioner
service station .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00 ; Detecting leaks in refrigerant circuit .
Vehicles with R1234yf refrigerant
– Charge refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Charging refrigerant cir‐
cuit .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning systems with refrigerant
R1234yf - general information; Rep. gr. 87 ; Refrigerant circuit;
Detecting leaks .
Continued for all vehicles
– Fill up with coolant ⇒ Rep. gr. 19 ; Cooling system/coolant;
Draining and filling coolant .
– Check operation of heater and air conditioning system.
Specified torques
♦ ⇒ “2.1 System overview - refrigerant circuit”, page 17
♦ ⇒ “5.1 Assembly overview - heater and air conditioning unit”,
page 111
♦ Air filter; Assembly overview - air filter housing ⇒ Rep. gr. 23 ;
Air filter;Assembly overview - air filter housing
♦ Dash panel central tube; Assembly overview - dash panel
central tube ⇒ General body repairs, interior; Rep. gr. 70 ;
Dash panel central tube; Assembly overview - dash panel
central tube .
5.6
Dismantling and assembling heater and
air conditioning unit
The following information applies to left-hand drive vehicles. A
right-hand drive vehicle is similar.
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Note
♦ There are different designs and makes of heater and air con‐
ditioning unit. The individual components of the various heat‐
ers and air conditioning units are similar but not identical. The
combined fitting of different makes of component is therefore
not permissible ⇒ Electronic parts catalogue (ETKA) .
♦ The following illustrations show a “Valeo” heater/air condition‐
ing unit, distinguishing features with respect to other makes
⇒ page 4 .
1 - Air distribution housing
❑ Different versions ⇒
Electronic parts cata‐
logue (ETKA)
❑ Depending on vehicle
equipment with or with‐
out auxiliary air heater
element - Z35- with aux‐
iliary air heater control
unit - J604- .
2 - Electrical wiring harness
❑ Different versions ⇒
Electronic parts cata‐
logue (ETKA)
3 - Evaporator housing
4 - Bolt
❑ Qty. 3
❑ 1 Nm
5 - Left bracket
❑ For heater and air con‐
ditioning unit
❑ Removing and installing
⇒ page 128
6 - Nut
❑ 4.5 Nm
7 - Nut
❑ 4.5 Nm
8 - Right bracket
❑ For heater and air con‐
ditioning unit
❑ Removing and installing
⇒ page 128
9 - Air intake box
❑ Different versions ⇒ Electronic parts catalogue (ETKA)
10 - Bolt
❑ Qty. 2
❑ 1 Nm
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5.7
Removing and installing air distribution
housing
The following information applies to left-hand drive vehicles. A
right-hand drive vehicle is similar.
Removing
– Remove heater and air conditioning unit ⇒ page 122 .
– Remove coolant pipes on heat exchanger ⇒ page 156 .
– Separate electrical connector on fresh air and air recirculation
flap control motor and lay wiring harness aside.
– Unscrew bolts -2-.
– Release retaining tabs -1- and -3-.
– Swivel air distribution housing -4- to rear -arrow- and disen‐
gage.
Installing
Install in reverse order of removal. Observe the following:
Note
The smallest leakage at the tongue-and-groove joint between the
air distribution housing and the evaporator housing can lead to
whistling noise from escaping air. Therefore lightly coat joints e.g.
with silicone grease to fully seal the joints. Silicone grease ⇒
Electronic parts catalogue (ETKA) .
Specified torques
♦ ⇒ “5.6 Dismantling and assembling heater and air conditioning
unit”, page 126
5.8
Removing and installing holder for heat‐
er and air conditioning unit
The following information applies to left-hand drive vehicles. A
right-hand drive vehicle is similar.
Note
Leave the holders in the vehicle on removing the heater and air
conditioning unit.
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Removing
– Remove heater and air conditioning unit ⇒ page 122 .
– Separate electrical connector -1-.
– Fold aside heat shield -2- behind ABS unit.
– Unscrew nuts -3- and -5-.
lk
– Detach holder -4- in interior.
Note
The refrigerant pipe with the internal heat exchanger must be re‐
moved if the nut above the ABS unit is not accessible as described
⇒ page 43 .
Installing
Install in reverse order of removal. Observe the following:
– Insert holders -1- and -3- into mounting on heater and air con‐
ditioning unit -2- and place heater and air conditioning unit in
installation position.
– Install heater and air conditioning unit ⇒ page 122 .
– Tighten nuts -3- and -5- on holders.
– Install remaining components.
– Read event memory and clear any entries displayed using
⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode.
– Check operation of heater and air conditioning system.
Specified torques
Component
Nut
Specified torque
4.5 Nm
5.9
Removing and installing evaporator
The following information applies to left-hand drive vehicles. A
right-hand drive vehicle is similar.
Removing
– Remove heater and air conditioning unit ⇒ page 122 .
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– Unscrew bolts -1-.
– Release retaining tabs -4- and -5- -arrows-.
– Detach the top part of the evaporator housing -3- from the
bottom part -2-.
– Pull evaporator -1- out of lower part of evaporator housing.
– Remove seal/insulation -2-.
– Remove expansion valve ⇒ page 23 .
– Remove retaining plate for refrigerant lines.
Installing
Install in reverse order of removal, observing the following:
– If the new evaporator is not equipped with an expansion valve,
the expansion valve from the old evaporator must be installed
⇒ page 23 .
Note
♦ Even minute leakage at the tongue-and-groove joint between
the top and bottom part of the evaporator housing can lead to
whistling noise as a result of escaping air. Therefore lightly
coat joints e.g. with silicone grease to fully seal the joints. Sil‐
icone grease ⇒ Electronic parts catalogue (ETKA) .
♦ Before inserting evaporator, check condensate drain and
clean if necessary.
♦ Before inserting, clean evaporator housing and, if necessary,
evaporator.
Specified torques
♦ ⇒ “5.3 Assembly overview - evaporator housing”, page 118
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5.10
Removing and installing fresh air blower
control unit - J126-
5.10.1
Removing and installing fresh air blower
control unit - J126- , left-hand drive ve‐
hicles
lk
Removing
– Remove baffle plate ⇒ General body repairs, interior; Rep. gr.
68 ; Compartments/covers; Removing and installing footwell
cover on front passenger side .
– Disconnect electrical connectors -3- and -2-.
– Unscrew bolts -1-.
CAUTION
Risk of burns when touching hot cooling surface of control unit.
Risk of burns to the hands.
– Wear protective gloves.
– Remove fresh air blower control unit - J126- -4- from fresh air
blower - V2- .
Installing
Install in reverse order of removal. Observe the following:
– Check operation of fresh air blower - V2- .
Specified torques
♦ ⇒ “5.2 Assembly overview - add-on parts of heater and air
conditioning unit and of air intake box”, page 116
5.10.2
Removing and installing fresh air blower
control unit - J126- , right-hand drive ve‐
hicles
Removing
– Remove baffle plate ⇒ General body repairs, interior; Rep. gr.
68 ; Compartments/covers; Removing and installing footwell
cover on front passenger side .
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– Separate connectors -1- and -4-.
– Unscrew bolts -2-.
CAUTION
Risk of burns when touching hot cooling surface of control unit.
Risk of burns to the hands.
– Wear protective gloves.
– Remove control unit -3- from fresh air blower - V2- .
Installing
Install in reverse order of removal. Observe the following:
– Check operation of fresh air blower - V2- .
Specified torques
♦ ⇒ “5.2 Assembly overview - add-on parts of heater and air
conditioning unit and of air intake box”, page 116
5.11
Removing and installing dust and pollen
filter
The following information applies to left-hand drive vehicles. A
right-hand drive vehicle is similar.
Special tools and workshop equipment required
♦ Commercially available vacuum cleaner
♦ Cover plate - T10532-
♦ Removal wedge - 3409-
Removing
– Move glove compartment lid to service position ⇒ General
body repairs, interior; Rep. gr. 68 ; Compartments and covers;
Glove compartment lid, service position .
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lk
– If necessary, remove insulation.
– Release cover -1- -arrows-.
– Take off cover -1-.
– Push cover plate - T10532- -2- under pollen filter -1-.
– Use cover -1- as a tool and hook the hooks on the side of the
cover -arrow- into the dust and pollen filter -2-.
NOTICE
Risk of damage to fresh air blower caused by dirt dropping out
of the dust and pollen filter when the cover plate is not seated
properly.
– Carefully pull out dust and pollen filter.
– Keep dust and pollen filter covered by cover plate.
– Pull out dust and pollen filter -2- with cover -1-. Do not pull out
cover plate - T10532- -3-.
– Remove dirt and foliage from cover plate - T10532- with a
commercially available vacuum cleaner.
– Remove cover plate - T10532- -2-.
Installing
Install in reverse order of removal, observing the following:
– Insert dust and pollen filter noting installation position.
– Attach and engage cover -1- -arrows-.
– Install insulation, if there is one.
– Move glove compartment lid back from service position ⇒
General body repairs, interior; Rep. gr. 68 ; Compartments
and covers; Glove compartment lid, service position .
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5.12
Removing and installing fresh air blower
- V2-
lk
5.12.1
Removing and installing fresh air blower
- V2- , left-hand drive vehicles
Note
If only the fresh air blower - V2- is defective, remove and install
fresh air blower control unit - J126- ⇒ page 131 .
Removing
The fresh air blower - V2- is accessible from the footwell on the
front passenger side.
– Remove baffle plate ⇒ General body repairs, interior; Rep. gr.
68 ; Compartments/covers; Removing and installing footwell
cover on front passenger side .
– Separate connector -3-.
– If fitted, unscrew bolt -2- from footwell vent.
– Lift the locking lug -4- and turn the fresh air blower -1- clock‐
wise -arrow-.
– Pull the fresh air blower out of the bottom part of the evaporator
housing.
CAUTION
Risk of burns when touching hot cooling surface of control unit.
Risk of burns to the hands.
– Wear protective gloves.
Installing
Install in reverse order of removal.
– Read event memory and clear any entries displayed using
⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode.
– Check operation of fresh air blower - V2- .
Specified torques
♦ ⇒ “5.2 Assembly overview - add-on parts of heater and air
conditioning unit and of air intake box”, page 116
5.12.2
Removing and installing fresh air blower
- V2- , right-hand drive vehicles
Note
If only the fresh air blower - V2- is defective, remove and install
fresh air blower control unit - J126- ⇒ page 131 .
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Heating, air conditioner - Edition 06.2017
Removing
– Remove baffle plate ⇒ General body repairs, interior; Rep. gr.
68 ; Compartments/covers; Removing and installing footwell
cover on front passenger side .
– Remove glove compartment ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments/covers; Removing and installing
glove compartment .
– Remove footwell vent on front passenger side ⇒ page 172 .
– Separate electrical connectors.
– Unscrew bolts -2-.
– Unclip retaining tabs -arrows-.
– Remove fresh air blower - V2- -1-downwards
-in direction of arrow-.
CAUTION
Risk of burns when touching hot cooling surface of control unit.
Risk of burns to the hands.
– Wear protective gloves.
Installing
Install in reverse order of removal. Observe the following:
– Push fresh air blower - V2- onto centring pins -3-.
– Read event memory and clear any entries displayed using
⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode.
– Check operation of fresh air blower - V2- .
Specified torques
♦ ⇒ “5.2 Assembly overview - add-on parts of heater and air
conditioning unit and of air intake box”, page 116
5.13
Checking auxiliary air heater element -
Z35- with auxiliary air heater control unit
- J604-
⇒ “5.13.2 Checking auxiliary air heater element Z35 with auxiliary
air heater control unit J604 , right-hand drive vehicles”,
page 136
5.13.1
Checking auxiliary air heater element -
Z35- with auxiliary air heater control unit
- J604- , left-hand drive vehicles
Special tools and workshop equipment required
♦ Vehicle diagnostic tester with 100 A pick-up clamp - VAS
5051B/7-
Check
Test conditions:
•
•
Ambient temperature lower than 5°C
Coolant temperature less than 80°C
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•
•
•
•
•
Passenger compartment temperature approx. 20°C
Battery voltage greater than 11 V
Alternator load not greater than 50% (terminal DF)
Engine speed greater than 450 rpm and stable
Turn rotary knob for interior temperature to highest tempera‐
ture (> 90%; on vehicles with Climatronic select highest level).
– Remove centre console trim in left footwell ⇒ General body
repairs, interior; Rep. gr. 68 ; Centre console; Assembly over‐
view - centre console .
– Use ⇒ Vehicle diagnostic tester and 100 A pick-up clamp -
lk
VAS 5051B/7- to measure current draw on earth wire -1- of
auxiliary air heater element - Z35- -2- -arrow-.
3-level -Z35- 1000 W
Low heat output: ≈ 30 amps
Medium heat output: ≈ 60 amps
High heat output: ≈ 80 amps
Stepless -Z35- 1400 W
– Run -Z35- at maximum output without steps.
Maximum current value ≈ 100 A
5.13.2
Checking auxiliary air heater element -
Z35- with auxiliary air heater control unit
- J604- , right-hand drive vehicles
Special tools and workshop equipment required
♦ Vehicle diagnostic tester with 100 A pick-up clamp - VAS
5051B/7-
Check
Test conditions:
•
•
•
•
•
•
•
Ambient temperature lower than 5°C
Coolant temperature less than 80°C
Passenger compartment temperature approx. 20°C
Battery voltage greater than 11 V
Alternator load not greater than 50% (terminal DF)
Engine speed greater than 450 rpm and stable
Turn rotary knob for interior temperature to highest tempera‐
ture (> 90%; on vehicles with Climatronic select highest level).
– Remove centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console; Assembly overview - centre console .
– Remove glove compartment ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments/covers; Removing and installing
glove compartment .
– Detach dash board in vicinity of glove compartment far enough
that dash board can be pulled away sufficiently to pull out aux‐
iliary air heater element - Z35- .
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– Use ⇒ Vehicle diagnostic tester and 100 A pick-up clamp -
VAS 5051B/7- to measure current draw on earth wire -1- of
auxiliary air heater element - Z35- -2- -arrow-.
3-level -Z35- 1000 W
Low heat output: ≈ 30 amps
Medium heat output: ≈ 60 amps
High heat output: ≈ 80 amps
Stepless -Z35- 1400 W
– Run -Z35- at maximum output without steps.
Maximum current value ≈ 100 A
5.14
Removing and installing auxiliary air
heater element - Z35- with auxiliary air
heater control unit - J604-
⇒ “5.14.2 Removing and installing auxiliary air heater element
Z35 with auxiliary air heater control unit J604 , right-hand drive
vehicles”, page 138
5.14.1
Removing and installing auxiliary air
heater element - Z35- with auxiliary air
heater control unit - J604- , left-hand
drive vehicles
Removing
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and reconnecting battery .
lk
– Remove driver side knee airbag ⇒ General body repairs, in‐
terior; Rep. gr. 69 ; Knee airbags; Assembly overview - knee
airbag .
– Remove centre console trim in left footwell ⇒ General body
repairs, interior; Rep. gr. 68 ; Centre console; Assembly over‐
view - centre console .
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– Loosen nut -3- and remove earth wire -4-.
CAUTION
Risk of burns on metal surfaces of auxiliary air heater element.
The heater elements may become very hot.
Risk of burns to the skin.
– Wear protective gloves.
– Never touch the metal surfaces of the heater element.
– Separate electrical connector -2- by sliding locking element
-5- upwards and pressing catch inwards.
– Unscrew bolts -arrows-.
– Pull auxiliary air heater element - Z35- with auxiliary air heater
control unit - J604- -1- leftwards out of heater and air condi‐
tioning unit -6-.
Installing
lk
Install in reverse order of removal. Observe the following:
Note
Ensure that the earth wire is in proper position and bolted on cor‐
rectly.
Specified torques
♦ ⇒ “5.1 Assembly overview - heater and air conditioning unit”,
page 111
5.14.2
Removing and installing auxiliary air
heater element - Z35- with auxiliary air
heater control unit - J604- , right-hand
drive vehicles
Removing
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and reconnecting battery .
– Loosen central tube for dash panel and pull it forwards until
the auxiliary air heater element - Z35- can be pulled out ⇒
General body repairs, interior; Rep. gr. 70 ; Dash panel central
tube; Removing and installing dash panel central tube .
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– Loosen nut -3- and remove earth wire -4-.
CAUTION
Risk of burns on metal surfaces of auxiliary air heater element.
The heater elements may become very hot.
Risk of burns to the skin.
– Wear protective gloves.
– Never touch the metal surfaces of the heater element.
– Separate electrical connector -2- by sliding locking element
-5- upwards and pressing catch inwards.
– Unscrew bolts -arrows-.
– Pull auxiliary air heater element - Z35- with auxiliary air heater
control unit - J604- -1- leftwards out of heater and air condi‐
tioning unit -6-.
Installing
Install in reverse order of removal. Observe the following:
Note
Ensure that the earth wire is in proper position and bolted on cor‐
rectly.
lk
Specified torques
♦ ⇒ “5.1 Assembly overview - heater and air conditioning unit”,
page 111
♦ Install central tube for dash panel ⇒ General body repairs,
interior; Rep. gr. 70 ; Dash panel central tube; Removing and
installing dash panel central tube
5.15
Removing and installing heat exchanger
⇒ “5.15.2 Removing and installing Valeo heat exchanger, right-
hand drive vehicles”, page 143
⇒ “5.15.3 Removing and installing Denso heat exchanger, left-
hand drive vehicles”, page 147
⇒ “5.15.4 Removing and installing Denso heat exchanger, right-
hand drive vehicles”, page 152
5.15.1
Removing and installing Valeo heat ex‐
changer, left-hand drive vehicles
Special tools and workshop equipment required
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2024 VW Tiguan Owner's Manual
