VW Lupo Heating Air Conditioning Eng

Service
Workshop Manual
Lupo 1999 ➤
Lupo 3L 1999 ➤
Heating, air conditioning
Edition 04.2007
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
80 - Heating
87 - Air conditioning system
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.
Lupo 1999 ➤ , Lupo 3L 1999 ➤
Heating, air conditioning - Edition 04.2007
Contents
80 - Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Repairing heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Passenger compartment heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Removing and installing fresh air blower V2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Removing and installing activated charcoal filter or dust and pollen filter . . . . . . . . . . . . . . 3
1.4 Removing leaf screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Removing centre vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.6 Removing and installing vent on front passenger side . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.7 Removing and installing vent on driver side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.8 Removing footwell vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.9 Removing and installing controls for fresh and heated air . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.10 Notes on mapped cooling, engine code ARR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.11 Mapped cooling layout, engine code ARR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.12 Mapped cooling components in engine compartment, engine code ARR . . . . . . . . . . . . . . 13
1.13 Connection diagram for mapped cooling vacuum hoses, engine code ARR . . . . . . . . . . . . 14
1.14 Checking ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.15 Checking auxiliary air heater element Z35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.16 Removing auxiliary heating heater element contact switch F268 . . . . . . . . . . . . . . . . . . . . 19
2 Heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.1 Removing and installing heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3 Dismantling and assembling heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.1 Dismantling heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4 Dismantling and assembling heated air and fresh air controls . . . . . . . . . . . . . . . . . . . . . . 28
5 Installing and adjusting cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.1 Adjusting cable at temperature flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.2 Adjusting cable at footwell/defroster flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.3 Adjusting cable at centre flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
87 - Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1 Notes on repair work to vehicles with air conditioning and on handling refrigerant . . . . . . 32
2 Air conditioning system with manual controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.1 Air conditioning and heating - passenger compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.3 Removing and installing heating and air conditioning controls . . . . . . . . . . . . . . . . . . . . . . 35
2.4 Dismantling and assembling heating and air conditioning controls . . . . . . . . . . . . . . . . . . 37
2.5 Installing and adjusting heating and air conditioning cables . . . . . . . . . . . . . . . . . . . . . . . . 38
2.6 Adjusting cable at temperature flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.7 Adjusting cable at footwell/defroster flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.8 Adjusting cable at centre flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.9 Air conditioning system and heating - engine compartment, vehicles ▸ 02.00 . . . . . . . . . . 41
2.10 Checking water drain valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.11 Removing high-pressure sender G65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.12 Removing ambient temperature switch F38 or temperature sender for compressor switch-off
G346 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.13 Air conditioning system and heating - engine compartment, vehicles ▸ 03.00 . . . . . . . . . . 44
2.14 Air conditioning system and heating - engine compartment, engine codes ANY and AYZ
........................................................................ 47
2.17 Checking coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.18 Repairing Sanden magnetic clutch for air conditioning system N25 . . . . . . . . . . . . . . . . . . 51
3 Climatronic air conditioning with automatic regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Contents i
Lupo 1999 ➤ , Lupo 3L 1999 ➤
3.1 Procedure for checking and adjusting components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

3.2 Function of operating and display unit for Climatronic air conditioning system E87 . . . . . . 56
3.3 Connectors on Climatronic control unit J255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.4 Climatronic - passenger compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.5 Removing and installing footwell vent temperature sender G192 . . . . . . . . . . . . . . . . . . . . 64
3.6 Removing and installing sunlight penetration photosensor G107 . . . . . . . . . . . . . . . . . . . . 65
3.7 Removing and installing fresh air blower control unit J126 . . . . . . . . . . . . . . . . . . . . . . . . 65
3.9 Removing and installing operating and display unit for Climatronic air conditioning system
E87 and Climatronic control unit J255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.10 Removing and installing air flow flap control motor V71 . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.11 Removing and installing temperature flap control motor V68 . . . . . . . . . . . . . . . . . . . . . . 68
3.12 Removing and installing centre flap control motor V70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.13 Removing and installing footwell and defroster flap control motor V85 . . . . . . . . . . . . . . . . 70
3.14 Climatronic - engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.17 Removing ambient temperature sensor G17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4 Bracket for air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.1 Removing and installing air conditioner compressor bracket, engine code AHT . . . . . . . . 74
4.2 Removing and installing air conditioner compressor bracket, engine code ALL . . . . . . . . 76
4.3 Removing and installing air conditioner compressor, engine codes AER, AFK, AHW, AKQ
ALD, ANV, APE, AQQ, AUA, AUB, AUC, AUD, BBY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.4 Removing and installing air conditioner compressor bracket, engine code AMF . . . . . . . . 80
4.5 Removing and installing air conditioner compressor bracket, engine codes ANY, AYZ . . 82
4.6 Removing and installing air conditioner compressor bracket, engine code ARR . . . . . . . . 84
4.7 Removing and installing air conditioner compressor bracket, engine code AVY . . . . . . . . 86
5 Repair work on refrigerant circuit which may be performed only in appropriate workshops by
specially trained mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.1 Renewing refrigerant circuit components, vehicles ▸ 02.00 . . . . . . . . . . . . . . . . . . . . . . . . 89
5.2 Renewing refrigerant circuit components, vehicles 03.00 ▸ . . . . . . . . . . . . . . . . . . . . . . . . 94
5.3 Renewing components of refrigerant system, engine codes ANY and AYZ . . . . . . . . . . . . 98
5.4 Removing receiver with dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.5 Evacuating and charging valve, low-pressure side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.6 Evacuating and charging valve, high-pressure side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.7 Quick release coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.8 Removing and installing air conditioner compressor, engine codes AER, AFK, AHT, AHW,
AKQ, ALD, ALL, AMF, ANV, APE, AQQ, AUA, AUB, AUC, AVY and BBY . . . . . . . . . . . . 109
5.9 Removing and installing air conditioner compressor, engine codes ANY and AYZ . . . . . . 112
5.10 Removing and installing air conditioner compressor, engine codes ARR . . . . . . . . . . . . . . 114
5.11 Notes on installing air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.12 Removing and installing heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.13 Dismantling and assembling evaporator housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
5.14 Expansion valve, function and removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
5.15 Expansion valve - function and removing, engine codes ANY, ARR, AVY and AYZ . . . . . . 125
5.16 Removing and installing condenser, vehicles ▸ 02.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.17 Removing and installing condenser, vehicles 03.00 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.18 Removing and installing condenser engine codes ANY, ARR, AVY and AYZ . . . . . . . . . . 132
6 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
6.1 Refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
6.2 Refrigerant oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
ii Contents
Lupo 1999 ➤ , Lupo 3L 1999 ➤
80 – Heating
1 Repairing heating system
1.1 Passenger compartment heating
1 - Air duct
2 - Activated charcoal filter or
dust and pollen filter
❑ In plenum chamber.
❑ Removing and installing
⇒ page 3
3 - Leaf screen
❑ Removing ⇒ page 4
4 - Dash panel
⇒ Rep. Gr. 70
5 - Controls for fresh and heat‐
ed air
❑ With fresh air blower
switch -E9-
❑ With fresh air and air re‐
circulation flap switch -
E159-
⇒ page 8
❑ Dismantling and assem‐
bling ⇒ page 28
❑ Installing and adjusting
cables ⇒ page 29
6 - Vent on front passenger
side
7 - Fresh air and air recircula‐
tion flap control motor -V154-
⇒ page 26
8 - Fresh air blower -V2-
Volkswagen Technical Site: http://vwts.ru http://vwts.info
❑ Removing and installing ⇒ page 2
9 - Fresh air blower series resistor with overheating fuse -N24-
❑ Removing ⇒ page 2 , fresh air blower -V2- .
10 - Centre vents
11 - Heater unit
12 - Footwell vent
1. Repairing heating system 1

Lupo 1999 ➤ , Lupo 3L 1999 ➤
13 - Cables
❑ Installing and adjusting ⇒ page 29 .
14 - Cover
15 - Footwell system
16 - Intermediate piece, defrost
❑ To renew, remove dash panel ⇒ Rep. Gr. 70 .
17 - Vent on driver side
18 - Heat exchanger
❑ To renew, remove dash panel ⇒ Rep. Gr. 70 .
19 - Seal between heat exchanger and bulkhead
❑ Note installation position ⇒ page 25 .
20 - Auxiliary air heater element -Z35-
❑ Only vehicles with a diesel engine.
❑ Checking ⇒ page 15
1.2 Removing and installing fresh air blower

-V2-
1- Heater unit
2- Fresh air blower -V2-
3- Fresh air blower series resistor with overheating fuse -N24-
1.2.1 Removing
– Remove compartment on passenger side ⇒ Rep. Gr. 68 .
– Pull connector off series resistor.
WARNING
Danger of burn injuries.

The fresh air blower series resistor with overheating fuse -N24-
can be hot.
Before removing fresh air blower series resistor with overheat‐
ing fuse -N24- , let it cool off.
– Remove
fresh air blower series resistor with overheating fuse -N24-
-3-.
– Pull fresh air blower -V2- -2- out downwards.
2 Rep. Gr.80 - Heating

Lupo 1999 ➤ , Lupo 3L 1999 ➤
1.2.2 Installing
Install in reverse order.
1.3 Removing and installing activated char‐

coal filter or dust and pollen filter
1- Plenum chamber cover
2- Cover for activated charcoal filter or dust and pollen filter
3- Activated charcoal filter or dust and pollen filter
4- Plastic nut, 2.5 Nm
5- Filter housing
1.3.1 Removing
– Remove end seal -1-.
– Pull off rubber seal -2- on plenum chamber cover (right) up‐
wards to centre of vehicle.
– Remove three bolts -3- and remove plenum chamber cover
-4-.
– Press tabs -A- of filter housing in -direction of arrow- and lift

out filter insert with frame.
– Remove filter element from frame.
1.3.2 Installing
– Insert left and right edges of frame into first rib -arrows- of new
filter element.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
– Insert frame into housing with lug -1- in corresponding recess‐

es and press frame and filter element downwards.
– Fit plenum chamber cover -4- and secure it with three bolts
-3-.
– Press on rubber seal -2-.
– Insert end seal -1-.
1.4 Removing leaf screen
1.4.1 Removing
-4-.
Plenum chamber cover -1-
– Unscrew plastic nuts -2- (2.5 Nm).

– Remove leaf screen -3-.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
1.5 Removing centre vents
1.5.1 Removing
– Remove radio -1- ⇒ Rep. Gr. 91 .
– Remove stowage compartment -2-.
– Unscrew bolts -arrows-.
– Pull centre vents out at the bottom and remove at the same
time.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
1.6 Removing and installing vent on front

passenger side
1.6.1 Removing
– Unclip vent near -arrows- using a screwdriver and pad.
– Pull out vent.
1.6.2 Installing
– Press vent in lightly until it locates.
1.7 Removing and installing vent on driver

side
1.7.1 Removing
– Remove light switch -1- ⇒ Rep. Gr. 96 .

Lupo 1999 ➤ , Lupo 3L 1999 ➤
– Remove bolt -arrow-.
– Unclip vent near -arrows- using a screwdriver and pad.

– Pull off connector for headlight range control.
– Pull out vent.
1.7.2 Installing
– Press vent in lightly until it engages.
1.8 Removing footwell vent

1- Bolt
2- Footwell vent
3- Cover
4- Footwell system
5- Spreader rivet
6- Heater unit
7- Bolt
8- Intermediate piece, defrost
1.8.1 Removing

Lupo 1999 ➤ , Lupo 3L 1999 ➤
– Remove bolt -1-.

– Pull connecting piece out towards driver side footwell
-arrow A-.
1.9 Removing and installing controls for

fresh and heated air
1.9.1 Removing
– Using a screwdriver, unclip and remove storage compart‐
ments -1- and -2-.
– Using a screwdriver, unclip trim from controls -arrows-.

Lupo 1999 ➤ , Lupo 3L 1999 ➤

– Remove driver side compartment ⇒ Rep. Gr. 68 .
– Remove centre console ⇒ Rep. Gr. 68 .
– Release cables on controls -arrows-.

– Pull off connectors -1-, -2- and -3- (connector -1-, only vehicles
with mapped cooling). Observe notes on vehicles with map‐
ped cooling ⇒ page 10 .
As soon as controls have been removed, check function of heated
air and fresh air cables.
– To do this, move wire ends of cables back and forth in direction

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

♦ Check cables before installing; replace stiff or damaged ca‐
bles.
♦ When rotary knobs are turned, all flaps must audibly contact
stop.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
– Bend wire ends of cables -1- and press onto lever of control
-2- -arrow-.
– Press cable for footwell/defroster flap, cable for temperature

flap and cable for centre flap -1- into locking device -2- until it
engages.
Identification of footwell/defroster flap cable: left-hand drive vehi‐
cle: green; right-hand drive vehicle: black.
Identification of centre flap cable: left-hand drive vehicle: yellow;
right-hand drive vehicle: grey.
Identification of temperature flap cable: left-hand drive: beige;
right-hand drive: white.
1.10 Notes on mapped cooling, engine code

ARR

Lupo 1999 ➤ , Lupo 3L 1999 ➤
Note
♦ Vehicles with mapped cooling are equipped with a heating

control having an additional electric component -A-. The tem‐
perature flap position switch -F269- and potentiometer for
temperature selection rotary knob -G267- are integrated in this
component.
♦ The 2-way valve for coolant shut-off valve -N147- is actuated
via temperature flap position switch -F269- (contacts 1 and 2)
when temperature rotary knob -A- is in the “cold” end position.
This directs vacuum to the coolant shut-off valve, which blocks
the coolant flow through the heat exchanger in the heater unit.
♦ The potentiometer for temperature selection rotary knob -
G267- has a resistance of approx. 1000 ohms between con‐
tacts 3 and 5 and between 100 and 900 ohms between
contacts 4 and 3 or 5 (depending on the position of the control
knob).
♦ The position of the temperature selection rotary knob is trans‐
mitted to the engine control unit via the potentiometer for
temperature selection rotary knob -G267- (contacts 3, 4 and
5). This influences the characteristic curve for actuation of the
map-controlled engine cooling thermostat -F265- . This con‐
trols the temperature of the coolant when, for example, the
engine is running at partial load, in such a way that the tem‐
perature of the air that is blown out of the vents during heating
(temperature control knob in heating position) is not higher
than that of vehicles that do not have mapped cooling.
♦ Vehicles with mapped cooling are equipped with a thermostat
in which an additional electric control element is integrated.
This control element ( thermostat for map-controlled engine
cooling -F265- ) is controlled by the engine control unit based
on the momentary engine load and the position of the tem‐
perature control knob ⇒ Rep. Gr. 19 .
♦ The temperature of the coolant is influenced by actuating the
thermostat for map-controlled engine cooling -F265- (when
the engine is running at partial load, the thermostat opens at
a higher temperature than when running at full load).
1.11 Mapped cooling layout, engine code ARR
Note
-Part l- specifies the components for vehicles without air conditioning and -part II- for vehicles with Climatronic.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
1 - Potentiometer for tempera‐

ture selection rotary knob -
G267-
❑ In the heating control.
2 - Heat exchanger
3 - Temperature flap position
switch -F269-
❑ In the heating control.
4 - Engine control unit
5 - Centre vent temperature
sender -G191-
❑ Only with Climatronic.
6 - Climatronic control unit -
J255-
7 - Relay for 2-way valve for
coolant shut-off valve -J585-
8 - 2-way valve for coolant
shut-off valve -N147-
9 - Non-return valve
10 - Brake servo unit
11 - Coolant shut-off valve
❑ Closed when tempera‐
ture selection rotary
knob is in the “Cold” end
position; there is no flow
through the heat ex‐
changer.
12 - Coolant connection
13 - Intake manifold

Lupo 1999 ➤ , Lupo 3L 1999 ➤
1.12 Mapped cooling components in engine compartment, engine code ARR

❑ Fitted in coolant hose
between engine and
heat exchanger.
❑ Fitted on left side of
bulkhead (in direction of
travel).
❑ Uses vacuum to actuate
coolant shut-off valve.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
1.13 Connection diagram for mapped cooling vacuum hoses, engine code ARR

❑ Observe direction of
coolant flow -arrow-.
❑ The coolant shut-off
valve is installed in the
coolant hose between
the engine and heat ex‐
changer (coolant sup‐
ply).
❑ The heating control is fit‐
ted with an additional
temperature flap posi‐
tion switch -F269- which
controls the 2-way valve
for coolant shut-off
valve -N147- .
❑ The 2-way valve for
coolant shut-off valve -
N147- is fitted on the left
side of the bulkhead in
the engine compart‐
ment (in the direction of
travel).
3 - Vacuum hose
❑ To vacuum connection
on engine.
4 - Non-return valve
❑ White connection points
to engine.

1.14 Checking ventilation
Note
♦ The stale air escapes via ventilation openings in the luggage

compartment trim.
♦ If the ventilation is to function properly, the ventilation open‐
ings must not be covered.
♦ The ventilation frames can be found on the lower rear cross
panel, under the bumper.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
1.14.1 Checking
– The sealing lips -1- in the ventilation frame -2- must move
freely and close by themselves.
1.15 Checking auxiliary air heater element -

Z35-
1.15.1 Checking auxiliary air heater element -

Z35- with peripherals
Auxiliary air heater element -Z35- peripherals (load signal for al‐
ternator terminal DF, low heat output relay -J359- , high heat
output relay -J360- , intake manifold temperature sender -G72- ,
coolant temperature sender -G62- ) can be read via the engine
control unit self-diagnosis.
1.15.2 Checking auxiliary air heater element -Z35-

Lupo 1999 ➤ , Lupo 3L 1999 ➤
Special tools and workshop

equipment required
♦ Hand multimeter -V.A.G
1526B-
♦ Multimeter -V.A.G 1715-
♦ Auxiliary measuring set -
V.A.G 1594C-
♦ Digital potentiometer -
V.A.G 1630-
♦ Vehicle diagnosis, testing
and information system -
VAS 5051A-
1.15.3 Test conditions

• Intake temperature less than 19° C
• Coolant temperature less than 80° C
• Passenger compartment temperature about 20° C
• Battery voltage greater than 11 V
• Alternator load not greater than 50% (terminal DF)
• Engine speed greater than 450 rpm
• Blower speed 4 for fresh air blower -V2-
• Turn rotary knob for interior temperature to end position for
maximum temperature.
1.15.4 Test procedure

If the specifications for intake and coolant temperature are not
attained, create the following test conditions.
The intake manifold temperature sender -G72- is located together
with the intake manifold pressure sender in a common housing
on the intake manifold.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
– Connect digital potentiometer -V.A.G 1630- to connector for

intake manifold temperature sender -G72- between contacts
-1- and -2-. Specification: see diagram.
Area -A- shows the resistance values for the temperature range
0...50° C and area -B-, the values for the temperature range
50...100° C.
Examples:
♦ 10° C corresponds to a resistance of 3500...4000 Ω
– Pull connector off coolant temperature sensor -G62- ⇒ Rep.
Gr. 19 .
– Connect digital potentiometer -V.A.G 1630- to connector for

coolant temperature sender -G62- between contacts -1- and
-3-. Specification: see diagram.
Area -A- shows the resistance values for the temperature range
0...50° C and area -B-, the values for the temperature range
50...100° C.
Examples:

Lupo 1999 ➤ , Lupo 3L 1999 ➤
– Connect multimeter -V.A.G 1715- to feeder for supplementary

heater element -Z35- using pick-up clamp.
– Set multimeter -V.A.G 1715- to amp test.
Ten seconds after the engine has been started, the auxiliary air
heater element -Z35- is enabled for heating by the diesel direct
injection system control unit -J248- . The three heating elements
are switched on and off by the engine control unit in stages via
relays.
– Start engine and leave running at idling speed.
If air conditioning is fitted, switch it off.
The starting current for auxiliary air heater element -Z35- is ap‐
prox. 38.9 A and more at the set test conditions. After a heating
phase of about 10 minutes for the auxiliary air heater element -
Z35- , the current consumption drops to about 31.6 A. Should the
figure drop by a further 10 A or more, check voltage supply cables
according to the current flow diagram.
If no fault is found in the wiring
– Renew auxiliary air heater element -Z35- ⇒ page 25 .
– Clear fault memory using vehicle diagnosis, testing and infor‐
mation system -VAS 5051A- .

Lupo 1999 ➤ , Lupo 3L 1999 ➤
1.16 Removing auxiliary heating heater ele‐

ment contact switch -F268-
The auxiliary heating heater element contact switch -F268- is lo‐
cated on the housing for the heating or air conditioning unit. The
rotary knob for interior temperature adjusts the temperature flap
lever by means of a Bowden cable. From a heating setting of 80%,
a cam on the lever actuates the auxiliary heating heater element
contact switch -F268- .

equipment required
♦ Hand multimeter -V.A.G
1526B-
♦ Multimeter -V.A.G 1715-
♦ Auxiliary measuring set -
V.A.G 1594C-
1.16.1 Removing

Lupo 1999 ➤ , Lupo 3L 1999 ➤
– Pull off connector -3-.

– Remove securing bolts -1-.
– Remove auxiliary heating heater element contact switch -
F268- -2- from heater unit.
1.16.2 Installing and adjusting

– Check auxiliary heating heater element contact switch -F268-
using hand multimeter -V.A.G 1526B- or multimeter -V.A.G
1715- to see whether auxiliary heating heater element contact
switch -F268- opens at a rotary knob position of 80% (warm).
– If switch does not open, adjust Bowden cable for temperature
flap ⇒ page 30 .

Lupo 1999 ➤ , Lupo 3L 1999 ➤
2 Heater unit
2.1 Removing and installing heater unit
Note
If the vehicle is equipped with an auxiliary air heater element -

Z35- (vehicle with diesel engine), the battery must be disconnec‐
ted beforehand ⇒ Rep. Gr. 27 .
Special tools and workshop equipment required

♦ Hose clamps up to 40 mm Ø -3093-
♦ Drip tray for workshop hoist -VAS 6208-
2. Heater unit 21
Lupo 1999 ➤ , Lupo 3L 1999 ➤
1 - Hexagon nut
❑ In engine compartment
❑ Qty. 3
❑ 4 Nm
2 - Bulkhead
3 - Heater unit
bling heater unit
⇒ page 24
4 - Guide pin
2.1.1 Removing
– Remove dash panel ⇒ Rep. Gr. 70
WARNING
Danger of scalding injuries.

The cooling system is pressurised. When the engine is warm,
the coolant temperature may be above 1000 C.
If necessary, release pressure and reduce temperature before
carrying out repairs.
– Clamp off coolant hoses in engine compartment using hose

clamps up to 40 mm Ø -3093- and remove from heat exchang‐
er.
– Remove hexagon nuts -1- on bulkhead -2- in engine compart‐
ment.
– Carefully blow remaining coolant out of heat exchanger using
a compressed air gun at heat exchanger connection.
– If the vehicle is equipped with an auxiliary air heater element
-Z35- , disconnect battery ⇒ Rep. Gr. 27 .

Lupo 1999 ➤ , Lupo 3L 1999 ➤
– Disconnect earth wire from auxiliary air heater element -Z35-

⇒ page 25 .
– Cover carpet in area under heat exchanger with waterproof foil
and absorbent paper.
2.1.2 Installing
– Guide heater unit to bulkhead -2- and push studs through in‐
tended holes.
– At the same time, make sure that heater unit sits on guide pin
-4- against stop.
– Screw on hexagon nuts (4 ± 1 Nm) -1- to bulkhead -2- in en‐
gine compartment and tighten.
– Check coolant level and top up ⇒ Rep. Gr. 19 .
2. Heater unit 23
Lupo 1999 ➤ , Lupo 3L 1999 ➤
3 Dismantling and assembling heater unit
1 - Heat exchanger
❑ To renew, remove dash
panel ⇒ Rep. Gr. 70 .
❑ After repair work, com‐
pletely renew coolant ⇒
Rep. Gr. 19 .
2 - Fillister head self-tapping
screw
3 - Auxiliary air heater element
-Z35-
❑ Only vehicles with a die‐
sel engine.
4 - Air distribution housing
❑ Do not dismantle further
⇒ page 26
6 - Fillister head self-tapping
screw
8 - Auxiliary heating heater el‐
ement contact switch -F268-
sel engine.
9 - Fresh air blower series re‐
sistor with overheating fuse -
N24-
❑ Removing ⇒ page 2 , remove fresh air blower -V2- and install.
10 - Fillister head self-tapping screw
11 - Centre flap lever
12 - Temperature flap lever
❑ Observe correct part number.
13 - Base plate
14 - Seal between heat exchanger and bulkhead

Lupo 1999 ➤ , Lupo 3L 1999 ➤
3.1 Dismantling heater unit
3.1.1 Installing and adjusting lever for centre

flap
– The centre flap pinion has an adjustment mark. Fit lever so
that adjustment markings on lever and pinion align -arrows-.
3.1.2 Installation position of seal between

heat exchanger 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-.
3.1.3 Removing auxiliary air heater element -

Z35-
– Disconnect battery ⇒ Rep. Gr. 27 .
– Remove driver side footwell cover ⇒ Rep. Gr. 70 and tunnel
trim.
– Pull connector -1- off connector housing -2- and remove con‐
nector housing from heater unit.
3. Dismantling and assembling heater unit 25

Lupo 1999 ➤ , Lupo 3L 1999 ➤
– Disconnect earth wire -3- from auxiliary air heater element -

Z35- .
– Remove heater unit ⇒ page 21 .
WARNING

Residue of coolant may remain in the heat exchanger. When
the engine is warm, the coolant temperature may be above
100 °C.
If necessary, reduce temperature before carrying out repairs.
– Remove both fillister head self-tapping screws -2- from heat

exchanger -1- and pull out heat exchanger in direction of ar‐
row.
WARNING

The auxiliary air heater element -Z35- may be hot.
Before removing auxiliary air heater element -Z35- , allow it to
cool off.
– Press auxiliary air heater element -Z35- -3- in direction of

-arrow- out of mounting and remove upwards together with
supply wire.
Note
♦ When installing, ensure proper seating of boot in heater unit.

♦ Tighten earth wire to 8 ± 1 Nm.
3.1.4 Removing and installing fresh air and air

recirculation flap control motor -V154-
– Partially remove heater unit and pull it sideways to rear.
Note
♦ A new control motor is supplied in the “Air recirculation” end

position.
♦ The control motor is easier to install in the centre position.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
To move the control motor to the centre position, proceed as fol‐

lows:
– Attach voltage supply connector -1- to control motor.
– Switch on ignition.
– Press fresh air and air recirculation button.
When centre position has been reached
– Pull voltage supply connector -1- off control motor.
3.1.5 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 2 .
– Turn control motor -2- in direction of -arrow D-.
– Fit securing bolt -3-.
– Connect voltage supply connector.
3. Dismantling and assembling heater unit 27

Lupo 1999 ➤ , Lupo 3L 1999 ➤
4 Dismantling and assembling heated air and fresh air controls
1 - Controls
switch -E9- and fresh air
and air recirculation flap
switch -E159- .
2 - Light conductor
3 - Coloured filter
4 - Trim
5 - Fresh air control illumina‐
tion bulb -L16-
❑ 12V, 1.2W
❑ To remove, unclip trim
-8- and remove rotary
knob -9-.
❑ Pull out bulb with aid of
fuel hose.
6 - Rotary knob
❑ For blower speed
❑ To remove: use pliers
with suitable plastic or
rubber protection on
jaws.
7 - Rotary knob
❑ For air distribution
jaws.
8 - Trim
9 - Rotary knob
❑ For interior temperature
with suitable plastic or rubber protection on jaws.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
5 Installing and adjusting cables
Note
♦ First connect cables to removed controls and then attach cables to heater levers.
♦ Check cables before installing; replace stiff or damaged cables.
♦ When rotary knobs are turned, all flaps must audibly contact stop.
1 - Centre flap cable

❑ From air distribution ro‐
tary knob to centre flap
❑ Identification of cable
sleeve fastener: left-
hand drive: yellow; right-
hand drive: grey.
❑ Adjusting cable at cen‐
tre flap ⇒ page 30 .
2 - Footwell/defroster flap ca‐
ble
tary knob to footwell/de‐
froster flap.
hand drive: green; right-
hand drive: black.
Renewing:
– Removing and installing

controls for fresh and
heated air ⇒ page 8 .
– Remove driver side
compartment ⇒ Rep.
Gr. 68 .
– Unclip cable on heater

and air conditioning unit.
– Adjust cable at footwell/

defroster flap
⇒ page 30 .
3 - Controls for fresh and heat‐

ed air
❑ Removing and installing Volkswagen Technical Site: http://vwts.ru http://vwts.info
⇒ page 8
4 - Temperature flap cable
❑ From rotary temperature knob to temperature flap
❑ Identification of cable sleeve fastener: left-hand drive: beige; right-hand drive: white.
❑ Adjusting cable at temperature flap ⇒ page 30 .
5. Installing and adjusting cables 29

Lupo 1999 ➤ , Lupo 3L 1999 ➤
5.1 Adjusting cable at temperature flap
5.1.1 Prerequisite:
• Heating and air conditioning controls are installed.
5.1.2 Adjusting
– Turn temperature rotary knob right to stop.
– Attach wire end of cable -1- to temperature flap lever -2-.
– Push temperature flap lever -2- to stop -arrow A- and secure
cable sheath -4- with clip -3-.
– Turn temperature rotary knob left and right to stops.
When rotary knob is turned, flap must reach end stops.
5.2 Adjusting cable at footwell/defroster flap
5.2.1 Prerequisite:
• Heated air and fresh air blower controls are installed.
5.2.2 Adjusting
– Turn air distribution rotary knob to left to stop.
– Attach wire end of cable -1- to temperature flap lever -3-, arrow
-A-.
– Push footwell/defroster flap lever to stop -arrow C- and attach
cable sheath -1- with clip -2-, -arrow B-.
– Turn air distribution rotary knob left and right to stops.
When rotary knob is turned, both end stops must be reached.
5.3 Adjusting cable at centre flap
5.3.1 Prerequisites:
• The centre flap lever is correctly adjusted ⇒ page 25 .
• Heated air and fresh air blower controls are installed.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
5.3.2 Adjusting
– Attach wire end of cable -2- to centre flap lever -1-.
– Press footwell/defroster flap lever to stop -arrow A- and secure
5. Installing and adjusting cables 31

Lupo 1999 ➤ , Lupo 3L 1999 ➤
87 – Air conditioning system

1 Notes on repair work to vehicles with
air conditioning and on handling re‐
frigerant
Note
♦ Notes on repair work to vehicles with air conditioning and on

handling refrigerant can be found in ELSA under “Air condi‐
tioning system with refrigerant R134a VW” ⇒ Rep. Gr. 00
Technical data.
♦ Notes on tools for repair work to vehicles with air conditioning
can be found in ELSA under “Air conditioning system with re‐
frigerant R134a VW” ⇒ Rep. Gr. 00 Technical data.
♦ Under certain conditions, it is not necessary to renew the re‐
ceiver with dryer every time that the refrigerant circuit is
opened. Information can be found in ELSA under “Air condi‐
tioning system with refrigerant R134a” ⇒ Rep. Gr. 00 “Re‐
newing components”.
Additional information:
♦ ⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations
♦ Repairs to evacuated refrigerant circuit that can only be car‐
ried out by specially trained mechanics at specialist service
stations ⇒ Service Organisation Handbook (SOH) Volume 1a;
Chapter 6.4 Workshop Equipment; Tools .
32 Rep. Gr.87 - Air conditioning system

Lupo 1999 ➤ , Lupo 3L 1999 ➤
2 Air conditioning system with manual

controls
2.1 Air conditioning and heating - passenger compartment
Note
Parts marked with an “*” can be repaired only in workshops with suitable equipment and specially trained
mechanics because the refrigerant must be evacuated beforehand using, for example, the air conditioner serv‐
ice station -VAS 6007A- ⇒ page 32 .
1 - Air duct
⇒ page 3
3 - Leaf screen
⇒ page 4
4 - Dash panel
⇒ Rep. Gr. 70
5 - Heating and air conditioning
controls
❑ With built-in air condi‐
tioning system switch -
E35-
switch -E9-
E159-
⇒ page 35
bling ⇒ page 37
6 - Vent on front passenger
side
❑ Removing vent
⇒ page 6 .
9 - Fresh air blower series resistor with overheating fuse -N24-
❑ Removing ⇒ page 35 , remove fresh air blower -V2- and install.
2. Air conditioning system with manual controls 33

Lupo 1999 ➤ , Lupo 3L 1999 ➤
10 - Centre vents
❑ Removing vent ⇒ page 5 .
11 - Heater and air conditioning unit*
❑ Dismantling and assembling evaporator housing ⇒ page 122 .
12 - Footwell vent
13 - Cables
14 - Cover
❑ To renew, remove and install dash panel ⇒ Rep. Gr. 70 .
18 - Heat exchanger*
❑ Removal ⇒ page 122 , Dismantling and assembling the evaporator housing.
❑ After renewal, completely renew coolant.
19 - Seal between heat exchanger and bulkhead*
20 - Auxiliary air heater element -Z35- *
❑ Only vehicles with a diesel engine.

-V2-
1- Heater unit and air conditioning system
3- Fresh air blower series resistor with overheating fuse -N24-
2.2.1 Removing

Lupo 1999 ➤ , Lupo 3L 1999 ➤
– Pull connector off fresh air blower series resistor with over‐
heating fuse -N24- .
WARNING

The fresh air blower series resistor with overheating fuse -N24-
can be hot.
Before removing fresh air blower series resistor with overheat‐
ing fuse -N24- , let it cool off.
– Remove
fresh air blower series resistor with overheating fuse -N24-
-3-.
2.2.2 Installing
2.3 Removing and installing heating and air

conditioning controls
2.3.1 Removing
– Using a screwdriver, unclip and remove storage compart‐
ments -1- and -2-.
– Using a screwdriver, unclip trim from controls -arrows-.

Lupo 1999 ➤ , Lupo 3L 1999 ➤

– Remove compartment on driver side ⇒ Rep. Gr. 68 .
– 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.
– To do so, move wire ends of cables back and forth in

-direction of arrow-.
– Replace damaged or stiff cables.
2.3.2 Installing
Note

bles.
stop.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
– Bend wire ends of cables -1- and press onto lever of control
-2- -arrow-.
– Press cable for footwell/defroster flap, cable for temperature

flap and cable for centre 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 centre flap cable: left-hand drive vehicle: yellow;
right-hand drive vehicle: grey.
Identification of temperature flap cable: left-hand drive: beige;
right-hand drive: white.
2.4 Dismantling and assembling heating and air conditioning controls

Lupo 1999 ➤ , Lupo 3L 1999 ➤

controls
❑ With built-in air condi‐
tioning system switch -
E35-
switch -E9-
E159-
⇒ page 35 .
2 - Light conductor
3 - Coloured filter
4 - Trim
5 - Fresh air control illumina‐
tion bulb -L16-
❑ 12V, 1.2W
❑ To remove, unclip trim
-8- and pull out rotary
knob -6- using pliers
jaws.
❑ Pull out bulb with aid of
fuel hose.
6 - Rotary knob
❑ For blower speed
jaws.
7 - Rotary knob
❑ For air distribution
❑ To remove: use pliers with suitable plastic or rubber protection on jaws.
8 - Trim
9 - Rotary knob
❑ For interior temperature
❑ To remove: use pliers with suitable plastic or rubber protection on jaws.
2.5 Installing and adjusting heating and air

conditioning cables
Note

bles.
♦ First connect cables to removed controls, then adjust cables
at air conditioner levers and secure them.
stop.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
1 - Centre flap cable

tary knob to centre flap
hand drive: yellow; right-
hand drive: grey.
❑ Adjusting cable at cen‐
tre flap ⇒ page 40 .
2 - Footwell/defroster flap ca‐
ble
tary knob to footwell/de‐
froster flap.
hand drive: green; right-
hand drive: black.
Renewing:
– Remove heating and air

conditioning controls
⇒ page 35 .
– Remove driver side

compartment ⇒ Rep.
Gr. 68 .
– Unclip cable on heater

and air conditioning unit.
– Adjust cable at footwell/

defroster flap
⇒ page 40 .

controls
4 - Temperature flap cable
❑ From rotary temperature knob to temperature flap
❑ Identification of cable sleeve fastener: left-hand drive: beige; right-hand drive: white.
❑ Adjusting cable at temperature flap ⇒ page 39 .
2.6 Adjusting cable at temperature flap
2.6.1 Prerequisite:

Lupo 1999 ➤ , Lupo 3L 1999 ➤
2.6.2 Adjusting
– Turn temperature rotary knob right to stop.
– Attach wire end of cable -1- to temperature flap lever -2-.
– Push temperature flap lever -2- to stop -arrow A- and secure
– Turn temperature rotary knob left and right to stops.
2.7 Adjusting cable at footwell/defroster flap
2.7.1 Prerequisite:
2.7.2 Adjusting
– Attach wire end of cable -1- to the footwell/defroster flap lever
-3-, arrow -A-.
– Push footwell/defroster flap lever to stop -arrow C- and attach
cable sheath -1- with clip -2-, -arrow B-.
2.8 Adjusting cable at centre flap
2.8.1 Prerequisite:
• The centre flap lever is correctly adjusted ⇒ page 25 .
2.8.2 Adjusting
– Attach wire end of cable -2- to centre flap lever -1-.
– Press centre flap lever to stop arrow -A- and secure cable
sheath -2- with clip -3-.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
2.9 Air conditioning system and heating - engine compartment, vehicles ▸ 02.00
Note
1 - Leaf screen
⇒ page 4
2 - Ambient temperature
switch -F38- or temperature
sensor for compressor switch-
off -G346-
❑ Vehicles ▸ 04.99 are
equipped with an ambi‐
ent temperature switch -
F38- which switches off
the air conditioning sys‐
tem magnetic clutch -
N25- if the ambient tem‐
perature is too low (off at
-1° C, on at 7° C).
equipped with a temper‐
ature sender for com‐
pressor switch-off -
G346- which switches
off the compressor if the
ambient temperature is
too low (off at 3° C, on at
5° C).
Note
The removal of the temperature

sender for compressor switch-off -
G346- is the same as the removal of
the ambient temperature switch -
F38.-
3 - Water drain valve

4 - Evaporator*
❑ In passenger compartment
❑ Removal ⇒ page 122 , Dismantling and assembling the evaporator housing.
5 - Radiator fan thermal switch -F18-
❑ Removing ⇒ Rep. Gr. 19
6 - Damper*
Engine codes AHT, AHW and AKQ
❑ In refrigerant hose from compressor to condenser.
7 - Radiator fan control unit -J293-
8 - Condenser*

Lupo 1999 ➤ , Lupo 3L 1999 ➤
9 - High-pressure safety valve*

10 - Air conditioner compressor*
❑ Manufacturer: Sanden, designation: SD6V12.
Note
♦ If the air conditioner compressor

has been exchanged because of
internal damage, it is also nec‐
essary to purge the refrigerant
circuit with refrigerant R134a.
♦ The procedure for purging can
be found in the workshop manual
“Air conditioning system with re‐
frigerant R134a VW” ⇒ Rep. Gr.
00 , Technical data, Clearing re‐
frigerant circuit of contaminants.
♦ Observe running-in procedures
for new air conditioner compres‐
sors ⇒ page 117 .
11 - Air conditioning system magnetic clutch -N25-

❑ Repairing ⇒ page 51 .
12 - Refrigerant hose*
❑ From receiver with dryer to condenser.
13 - Damper*
Engine code ANV
❑ In refrigerant hose from expansion valve to compressor.
14 - Receiver with dryer*
❑ Functions ⇒ page 94 .
Note
Under certain conditions, it is not

necessary to renew the receiver
with dryer every time that the refrig‐
erant circuit is opened. Information
can be found in ELSA under “Air
conditioning system with refrigerant
R134a” ⇒ Rep. Gr. 00 “Renewing
components”.
15 - High-pressure sender -G65-

❑ The high-pressure sender -G65- can be removed without extracting the refrigerant from the refrigerant
circuit.
❑ Specified torque: 8 ± 1 Nm
❑ Renew O-ring seal.
Functions:
♦ The high-pressure sender -G65- supplies information to the engine control unit for idling stabilisation and
switching off the air conditioner.
❑ Check with vehicle diagnosis, testing and information system -VAS 5051A- in “guided fault finding” func‐
tion.
16 - Evacuating and charging valve*
❑ Low-pressure side
Engine codes AHT, AHW and AKQ

Lupo 1999 ➤ , Lupo 3L 1999 ➤
❑ Releasing refrigerant into the environment is a punishable offence.
❑ Capacities ⇒ page 135 .
17 - Refrigerant line*
❑ From receiver with dryer to expansion valve.
❑ From expansion valve to air conditioner compressor.
❑ High-pressure side
Engine code ANV
21 - Expansion valve*
❑ In engine compartment on front passenger side.
❑ Function and removal ⇒ page 123 .
2.10 Checking water drain valve

1- Water drain valve
2- Bulkhead
3- Water drain pipe on evaporator housing
4- Assembly plate
Check water drain valve as follows to ensure that it functions cor‐
rectly:
♦ The water drain valve must not be bonded.
♦ The opening of the water drain valve flap must point down‐
ward.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
2.11 Removing high-pressure sender -G65-

– Remove front bumper cover ⇒ Rep. Gr. 63 .
– Counterhold refrigerant line -3- and remove high-pressure
sender -G65- -2- (8 ± 1 Nm).
– Renew O-ring seal.
2.12 Removing ambient temperature switch -

F38- or temperature sender for com‐
pressor switch-off -G346-
-4-.

– Unclip ambient temperature switch -F38- or temperature send‐
er for compressor switch-off -G346- -1- from holder -3-.
2.13 Air conditioning system and heating - engine compartment, vehicles ▸ 03.00
Note

Lupo 1999 ➤ , Lupo 3L 1999 ➤
❑ From expansion valve
to air conditioner com‐
pressor.
❑ With damper
to receiver with dryer.
4 - Evacuating and charging
valve*
❑ Releasing refrigerant in‐
to the environment is a
punishable offence.
⇒ page 3
8 - Radiator fan control unit -
J293-
9 - Temperature sender for
compressor switch-off -G346-
❑ Switches off air condi‐
tioning system magnetic
clutch -N25- if the ambi‐
ent temperature is too
low (off at 3 °C, on at 5 °
C).
❑ Functions ⇒ page 102
Note

components”.
11 - Condenser*
❑ From air conditioner compressor to condenser.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
Note

sors ⇒ page 117 .

circuit.
❑ Renew O-ring seal.
Functions:
tion.
16 - Damper*
❑ In refrigerant hose from expansion valve to air conditioner compressor.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
2.14 Air conditioning system and heating - engine compartment, engine codes
ANY and AYZ
Note

⇒ page 3
2 - Quick release coupling*
⇒ page 106
3 - Ambient temperature
switch -F38- or temperature
sensor for compressor switch-
off -G346-
equipped with an ambi‐
ent temperature switch -
F38- which switches off
the air conditioning sys‐
tem magnetic clutch -
N25- if the ambient tem‐
perature is too low (off at
-1° C, on at 7° C).
❑ Vehicles 05.99 ▸ are
equipped with a temper‐
ature sender for com‐
pressor switch-off -
G346- which switches
off the compressor if the
ambient temperature is
too low (off at 3° C, on at
5° C).
Note
The removal of the temperature

sender for compressor switch-off -
G346- is the same as the removal of
the ambient temperature switch -
F38.-

5 - Damper*
Engine code ANY
7 - Condenser*

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Note

components”.
❑ From expansion valve to air conditioner compressor.
❑ With damper
❑ Testing ⇒ page 101
❑ Lupo 3L, manufacturer: Calsonic, designation: CSV613.
Note

sors ⇒ page 117 .

circuit.
Functions:
tion.
❑ From receiver with dryer to expansion valve.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
17 - Coolant temperature sender -G62-

❑ Coolant temperature sender -G62- switches air conditioning system magnetic clutch -N25- off when the
refrigerant temperature is too high (off at 119 °C, on at 112 °C).
❑ In engine compartment on front passenger side.

1- Water drain valve
2- Bulkhead
3- Water drain pipe on evaporator housing
4- Assembly plate
rectly:
ward.

– Counterhold threaded connection with suitable tool and re‐
move high-pressure sender -G65- -2- (8 ± 1 Nm).

Lupo 1999 ➤ , Lupo 3L 1999 ➤
2.17 Checking coolant temperature sender -

G62-
2.17.1 Function of coolant temperature sender
-G62-
1- Clip
2- Thermostat housing
3- Coolant temperature sender -G62-
In accordance with the signal from the coolant temperature send‐
er -G62- , the engine control unit does the following via the
radiator fan control unit -J293- :
♦ It switches on the air conditioning system magnetic clutch -
N25- .
or
♦ It switches off the air conditioning system magnetic clutch -
N25- .
Note
♦ Cooling system is pressurized when engine is warm. If nec‐

essary, release pressure before carrying out repairs.
♦ Refill coolant after installing coolant temperature sender -G62-
⇒ Rep. Gr. 19 .
♦ The coolant temperature sender -G62- supplies information to
the engine control unit.
WARNING

the coolant temperature may be above 100 °C.
– Removing coolant temperature sender -G62- ⇒ Rep. Gr. 19 .
2.17.2 Checking coolant temperature sender -

G62-
♦ Vehicle diagnosis, testing and information system -VAS
5051A-
Procedure
Select “guided fault finding” function in the vehicle diagnosis, test‐
ing and information system -VAS 5051A- .
After all control units have been read:
– Press Go to button.
– Select “Function/component selection”.
– “Select drive”

Lupo 1999 ➤ , Lupo 3L 1999 ➤
– Select “Engine code”.

– Select “On Board Diagnostic (OBD) capable systems”.
– Select “Engine control”.
– Select “Electrical components”.
– Select “Function/component”.
2.18 Repairing Sanden magnetic clutch for air conditioning system -N25-

equipment required
♦ Torque wrench -V.A.G
1331- (5…50 Nm)
♦ Drift -2051-
♦ Pin wrench -3212-
♦ Three-arm puller -KUKKO
45-2-
Not illustrated
♦ Two-arm puller, e.g. KUKKO 20-10 with 100 mm hooks.
♦ Open jaw flexible spanner
♦ Circlip pliers
♦ Depth gauge

Lupo 1999 ➤ , Lupo 3L 1999 ➤
2.18.1 Repairing air conditioning system magnetic clutch -N25-
Note
♦ The air conditioning system magnetic clutch -N25- can also be repaired without extracting the refrigerant.
In this case, the air conditioner compressor must be removed from the bracket ⇒ page 109 and secured to
the body ( ⇒ page 76 , Securing air conditioner compressor to body).
♦ If the air conditioner compressor has to be removed, observe the notes ⇒ page 32 , because the refrigerant
must be evacuated using, for example, air conditioner service station -VAS 6007A- ⇒ page 89 .
– Move lock carrier to service position ⇒ Rep. Gr. 50 .

– Unbolt air conditioner compressor from bracket.
1 - Circlip
❑ Renew
❑ Install correctly: flat side
faces air conditioner
compressor
❑ Ensure that it is seated
correctly in groove
2 - Solenoid
❑ Remove ⇒ page 55 .
❑ Locking with dowel pin
❑ Secured with circlip -1-.
Note
An overheating fuse is installed in

the solenoid. The overheating fuse
interrupts the solenoid as soon as
the magnetic clutch overheats (for
example due to a binding compres‐
sor).
3-
Spacers
❑ To adjust clearance be‐
tween clutch disc and
poly V-belt pulley
❑ Checking clearance
⇒ page 55
4 - Woodruff key
5 - Air conditioner compressor
❑ Carefully secure re‐
moved air conditioner
compressor in a vice
⇒ page 53 .
6-
Poly V-belt pulley
❑ Pulling off ⇒ page 54
❑ Fitting ⇒ page 55 .
7-
Circlip
❑ Renew
❑ Install correctly: flat side faces air conditioner compressor

Lupo 1999 ➤ , Lupo 3L 1999 ➤
❑ Ensure that it is seated correctly in groove
8-
Clutch disc
❑ Pulling off ⇒ page 53
❑ Checking clearance ⇒ page 55
9 - Hexagon nut
❑ 20 ± 2 Nm
❑ Self-locking
❑ Always renew
2.18.2 Removing air conditioning system mag‐

netic clutch -N25- from air conditioner
compressor
Note
♦ Use protective jaw covers when clamping the air conditioner

compressor in the vice.
♦ Make sure cable to magnetic clutch is not pinched between
vice and air conditioner compressor housing.
– Carefully secure air conditioner compressor in a vice.
– Using a pin wrench -3212- and flexible socket wrench, un‐

screw hexagon nuts.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
– Insert a screwdriver into gap between coupling disc and poly

V-belt pulley.
– Turn screwdriver slightly -arrow-.
– Repeat procedure at two other points along circumference
-arrows-.
– Remove clutch disc ⇒ page 53 -8-.
– Remove spacers ⇒ page 52 -3-.

– Remove circlip for poly V-belt pulley ⇒ page 52 -7-.
– Pull off poly V-belt pulley ⇒ page 52 -6- using three-arm puller
-KUKKO 45-2- .
– Place hooks -arrow- 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 clutch -
N25- .

Lupo 1999 ➤ , Lupo 3L 1999 ➤
– Remove solenoid by removing circlip holding it.

– Remove solenoid from compressor.
2.18.3 Fitting magnetic clutch and poly V-belt

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

driven in.
– Mount poly V-belt pulley using drift -2051- and a rubber ham‐
mer.
Checking and adjusting clearance
– Check clearance with a depth gauge by repeatedly switching

magnetic clutch on and off (apply a voltage of 12 V).
♦ Specification: 0.4 to 0.8 mm
– If necessary, use spacers to adjust clearance. Pull off clutch
disc to do this.
Note
♦ The clearance must lie within permitted tolerances over the

complete circumference.
♦ The clearance can also be measured when the air conditioner
compressor is installed.
♦ If the clearance is outside of the specifications, remove the
clutch disc and adjust the clearance by removing or adding
spacers.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
3 Climatronic air conditioning with au‐

tomatic regulation
Note
♦ Pressing the AUTO button will cancel all settings which deviate
from automatic operation.
♦ In “ECON” operation, the air conditioner compressor and,
where fitted, the auxiliary air heater element -Z35- is switched
off; heating and ventilation continue to be controlled electron‐
ically.
♦ Modifications made to automatic operation before the engine
is switched off will be saved. Only the “Air recirculation” func‐
tion is erased 20 minutes after the ignition has been switched
off.
♦ Deviations from automatic operation ⇒ appropriate operating
instructions .
♦ If all of the symbols displayed in the operating and display unit
for Climatronic air conditioning system -E87- flash after the
ignition has been switched on, there is a fault in the system.
In this case, first read the fault memory using vehicle diagno‐
sis, testing and information system -VAS 5051A- .
3.1 Procedure for checking and adjusting

components
3.1.1 Procedure
Select “guided fault finding” function of vehicle diagnosis testing
and information system -VAS 5051A- .
Once all control units have been read:
– Press Go to button.
– Select “Function/component selection”.
– Select “Body”.
– “Heating, ventilation, air conditioning (Repair group 01; 80 to
87).”
– Select “On Board Diagnostic (OBD) capable systems”.
– Select “Climatronic”.
– Select “Functions”:
– “Basic setting”
– “Coding Climatronic control unit”
– “Check function of auxiliary heater element.”
3.2 Function of operating and display unit for Climatronic air conditioning sys‐
tem -E87-

Lupo 1999 ➤ , Lupo 3L 1999 ➤
1 - Windscreen defroster but‐

ton
2 - Display for blower speed
❑ In automatic operation
-8- a medium blower
rpm is displayed regard‐
less of the actual blower
speed.
3 - Ambient temperature dis‐
play
❑ If road speed drops be‐
low 15 km/h and the
coolant temperature is
above 70° C, the value
displayed will not
change. The actual am‐
bient temperature
measured is not dis‐
played because it is in‐
fluenced by the heat
build-up in the engine at
lower speeds.
4 - Display for windscreen de‐
frosting
5 - Display for air recirculation
6 - Display for air flow direction
❑ Pressing button -14-
switches the footwell
air-flow display on or off.
❑ Pressing button -15-
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 -11- and then press button -9-.
❑ 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 button -18-.
❑ Because the flaps remain in the last position set, this manner 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.
3. Climatronic air conditioning with automatic regulation 57

Lupo 1999 ➤ , Lupo 3L 1999 ➤
11 - “ECON” button
❑ In ECON mode, the air conditioner compressor is switched off; heating and ventilation continue to be
controlled automatically.
Note
If the vehicle is equipped with the

auxiliary air heater element -Z35- ,
this element will be switched off as
well.
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.
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.
3.3 Connectors on Climatronic control unit -

J255-
3.3.1 Pin assignment for multi-pin connectors

A, B, C and D on back of Climatronic
control unit
12-pin connector, connector housing -A-
1- K line, diagnosis
2- Engine speed increase
3- AC standby
4- Vacant
5- Dim voltage 58 d
6- Vacant
7- Fresh air intake duct temperature sensor -G89-
8- Ambient temperature sensor -G17-
9- Signal earth, control motors
10 - Vacant
11 - Hot lamp 118° C
12 - Signal earth, control motors

Lupo 1999 ➤ , Lupo 3L 1999 ➤
20-pin connector, connector housing -B-

1- Ambient temperature for dash panel insert
2- Vacant
3- Vacant
4- Vacant
5- Footwell vent temperature sender -G192-
6- Centre vent temperature sender -G191-
7- Evaporator out-flow temperature sender -G263-
8- Temperature flap control motor potentiometer -G92-
9- Potentiometer for centre flap control motor -G112-
10 - Potentiometer for footwell/defroster flap control motor -
G114-
11 - Vacant
12 - Vacant
13 - Downtime - dash panel insert (optional)
14 - Temperature increase off/ PTC off
15 - Relay for 2-way valve for coolant shut-off valve -J585-
16 - Vacant
17 - Air flow flap control motor potentiometer -G113-
18 - Sunlight penetration photosensor -G107-
16-pin connector, connector housing -C- T16b

1- Vacant
2- High-pressure sender -G65-
3- Compressor voltage
4- Speedometer signal
5- Engine speed
6- Vacant
7- Vacant
8- + 5V 10 mA for control motors
9- Vacant
10 - Vacant
11 - Fan feedback signal V2 (-)
12 - Engine electronics, bidirectional
13 - Vacant
14 - Fan feedback signal V2 (+)
15 - Vacant
16 - Fresh air blower control unit -J126-

Lupo 1999 ➤ , Lupo 3L 1999 ➤
16-pin connector, connector housing -D- T16a

1- Auxiliary heater
2- Temperature flap control motor -V68- (cold)
3- Footwell and defroster flap control motor -V85- (footwell)
4- Centre flap control motor -V70- (chest vent)
5- Air flow flap control motor -V71- (increased flow)
6- Air conditioner compressor regulating valve -N280-
7- Terminal 30 (optional)
8- Radiator fan control unit -J293- (2nd fan speed)
9- Terminal 15 for relay for 2-way valve for coolant shut-off
valve -J585- and 2-way valve for coolant shut-off valve -
N147-
10 - Temperature flap control motor -V68- (warm)
11 - Footwell and defroster flap control motor -V85- (defrost)
12 - Centre flap control motor -V70-
13 - Air flow flap control motor -V71- (air recirculation)
14 - Terminal 31
15 - Terminal 31
3.4 Climatronic - passenger compartment
Note

Lupo 1999 ➤ , Lupo 3L 1999 ➤
1 - Air duct
2 - Sunlight penetration photo‐
sensor -G107-
❑ Function: controls tem‐
perature flap and fresh
air blower -V2- depend‐
ing on light intensity.
❑ In event of failure: Cli‐
matronic control unit -
J255- assumes fixed
value.
❑ Check with vehicle diag‐
nosis, testing and infor‐
mation system -VAS
5051A- in “guided fault
finding” function.
⇒ page 65
3 - Dash panel temperature
sensor -G56- with temperature
sensor blower -V42-
❑ The Climatronic control
unit -J255- , the operat‐
ing and display unit for
Climatronic air condi‐
tioning system -E87-
and the temperature
sensor blower -V42-
with dash panel temper‐
ature sensor -G56- are
combined in one unit
which cannot be dis‐
mantled.
❑ Function: temperature
sensor controls temper‐
ature flap and fresh air
blower, depending on
temperature
❑ In event of failure of dash panel temperature sensor -G56- : continued operation assuming value of
+24° C.
tion.
❑ Renewing and adjusting: “code control unit” and then initiate “basic setting” using vehicle diagnosis,
testing and information system -VAS 5051 A- ⇒ page 56 .
4 - Defroster 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 temperature sensor blower -V42- with dash panel temperature sensor -G56- are combined
in one unit which cannot be dismantled.
tion.
❑ Operation and function ⇒ page 56 .
6 - Activated charcoal filter or dust and pollen filter
7 - Dash panel
❑ Removing and installing ⇒ Rep. Gr. 70

Lupo 1999 ➤ , Lupo 3L 1999 ➤
8 - Vent on front passenger side

9 - Fresh air intake duct temperature sensor -G89-
❑ With seal.
❑ Function: temperature sensor controls temperature flap and fresh air blower, depending on temperature
❑ In event of failure: ambient temperature sensor -G17- takes over the function.
tion.
❑ Turn temperature sensor 90° and pull out.
❑ When installing, moisten rubber seal with oil.
10 - Evaporator out-flow temperature sender -G263-
❑ With seal.
tion.
❑ To renew: remove front passenger side compartment ⇒ Rep. Gr. 68 .
– Grasp sender behind the distribution box with hand from below.
– Turn sender 90° and pull out.
– Moisten rubber seal with oil when installing.
11 - Air flow flap control motor -V71-

❑ Operates simultaneously fresh air and air recirculation flap
tion.
❑ Renewing and adjusting: initiate “basic setting” using vehicle diagnosis, testing and information system
-VAS 5051 A- ⇒ page 56
tion.
13 - Fresh air blower control unit -J126-
❑ Continuously variable control of the speed of fresh air blower -V2- depending on voltage.
tion.
❑ Replacing ⇒ page 65 .
14 - Centre vents
15 - Climatronic control unit -J255-
❑ The Climatronic control unit -J255- , the operating and display unit for Climatronic air conditioning system
-E87- and the temperature sensor blower -V42- with dash panel temperature sensor -G56- are combined
in one unit which cannot be dismantled.
tion.
16 - Distribution box and evaporator housing*
❑ With heat exchanger.
❑ With evaporator
Removing:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

❑ Extract refrigerant, e.g. with air conditioner service station -VAS 6007A- .
Note
♦ An auxiliary air heater element -

Z35- is fitted on vehicles with a
diesel engine.
♦ Checking ⇒ page 15
♦ Removing ⇒ page 25
17 - Centre flap control motor -V70-

tion.
-VAS 5051 A- ⇒ page 56 .
18 - Temperature flap control motor -V68-
tion.
-VAS 5051 A- ⇒ page 56 .
19 - Footwell vent temperature sender -G192-
❑ Function: controls air distribution between defroster and footwell and speed of fresh air blower -V2-
dependent upon vent temperature.
❑ In event of failure: continued operation assuming coolant temperature of +80° C.
tion.
20 - Connecting piece
21 - Cover
22 - Footwell vent
24 - Distribution box and evaporator housing*
❑ With heat exchanger.
❑ With evaporator
Removing:
26 - Footwell flap and defrost flap control motor -V85-
tion.
❑ Removing
-VAS 5051 A- ⇒ page 56 .
27 - Heat exchanger*
❑ After removal, completely renew coolant.
Removing:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

❑ Remove distribution box and evaporator housing ⇒ page 122 .
28 - Seal between heat exchanger and bulkhead*
30 - Relay
❑ On relay carrier
❑ Location: ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.
3.5 Removing and installing footwell vent

temperature sender -G192-
3.5.1 Removing
– Pull connector off footwell vent temperature sender -G192- .
– Turn footwell vent temperature sender -G192- -1- 90° and re‐
move it from housing -2-.
3.5.2 Installing
– When installing, moisten rubber seal on footwell vent temper‐
ature sender -G192- with oil.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
3.6 Removing and installing sunlight pene‐

tration photosensor -G107-
3.6.1 Removing
– Use a screwdriver to unclip trim -2- above sunlight penetration
photosensor -G107- along side -1-.
– Using a screwdriver, unclip sunlight penetration photosensor
-G107- -1- on side.
3.6.2 Installing

control unit -J126-
3.7.1 Removing
– Pull off connector -2- and remove bolt -3-.
WARNING

The heat sink on the fresh air blower control unit -J126- may
be hot.
Let the heat sink cool down before removing the fresh air blow‐
er control unit -J126- .
– Remove fresh air blower control unit -J126- -1-.
3.7.2 Installing

-V2-
1- Heater unit
3- Cover

Lupo 1999 ➤ , Lupo 3L 1999 ➤
3.8.1 Removing
– Remove plastic foam cover -3- below the air conditioning unit.
– Remove bolts -1- (1.5 Nm).
– Remove cover -2-
– Pull connector -1- off fresh air blower -V2- .

3.8.2 Installing
3.9 Removing and installing operating and

display unit for Climatronic air condition‐
ing system -E87- and Climatronic con‐
trol unit -J255-
Note
The operating and display unit for Climatronic air conditioning

system -E87- and the Climatronic control unit -J255- cannot be
dismantled.
3.9.1 Removing
– Unclip trim for operating and display unit for Climatronic air
conditioning system -E87- using a screwdriver and a pad
-arrows-.

Lupo 1999 ➤ , Lupo 3L 1999 ➤

– Pull out operating and display unit for Climatronic air condi‐
tioning system -E87- with Climatronic control unit -J255- .
– Release connectors and pull off.
– Pull out operating and display unit for Climatronic air condi‐
tioning system -E87- with Climatronic control unit -J255- .
3.9.2 Installing and adjusting

– “Code control unit” and then initiate “basic setting” using ve‐
hicle diagnosis, testing and information system -VAS 5051 A-
⇒ page 56 .
3.10 Removing and installing air flow flap

control motor -V71-
Note
♦ When installing the air flow flap control motor -V71- , ensure
the wiring harnesses are correctly laid. They should be routed
so that they do not come into contact with moving parts (for
example the levers on the control motors).
♦ After installing a new control motor, initiate “basic setting” us‐
ing vehicle diagnosis, testing and information system -VAS
5051A- ⇒ page 56 .
♦ The air flow flap control motor also operates the fresh air and
air recirculation flap.
3.10.1 Removing
– Remove heater unit as well as heater and air conditioning unit
⇒ page 118 .
– Carefully unclip air flow flap operating rod -1- from lever -2-
using a screwdriver.

Lupo 1999 ➤ , Lupo 3L 1999 ➤

– Remove securing bolt -3-.
The control motor is to be guided into the distribution box and
evaporator housing. To prevent damage:
– Tip control motor downwards and simultaneously pull it out of
shaft for fresh air and air recirculation flap -2-, arrow -A-.
3.10.2 Installing
– Attach air flow flap control motor -V71- to shaft for fresh air and
air recirculation flap -1-.
– Turn air flow flap control motor -V71- in direction of -arrow A-
and tighten bolts.
– Clip in operating rod for air flow flap.
– Push connector -1- onto air flow flap control motor -V71- -2-.
– After installing a new control motor, initiate “basic setting” us‐
5051 A- ⇒ page 56 .
3.11 Removing and installing temperature

flap control motor -V68-
Note
♦ When installing the temperature flap control motor -V68- , en‐

sure the wiring harnesses are correctly laid. They should be
routed so that they do not come into contact with moving parts
(for example the levers on the control motors).
5051 A- ⇒ page 56 .
3.11.1 Removing
– Remove support bracket.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
– Removing connecting piece

– Carefully unclip operating rod -2- from lever -arrow A- using a
screwdriver.
– Remove temperature flap control motor -V68- -3-.
3.11.2 Installing
After installing a new control motor, initiate “basic setting” using
vehicle diagnosis, testing and information system -VAS 5051 A-
⇒ page 56 .
3.12 Removing and installing centre flap con‐

trol motor -V70-
Note
♦ When installing the centre flap control motor -V70- , ensure

the wiring harnesses are correctly laid. They should be routed
so that they do not come into contact with moving parts (for
example the levers on the control motors).
5051 A- ⇒ page 56 .
3.12.1 Removing
– Remove support bracket.
– Removing connecting piece
– Carefully unclip operating rod -2- from lever -arrow A- using a
screwdriver.
– Turn operating rod -2- and remove it from centre flap control
motor -V70- -4-.
– Remove centre flap control motor -V70- .
3.12.2 Installing
After installing a new control motor, initiate “basic setting” using
vehicle diagnosis, testing and information system -VAS 5051 A-
⇒ page 56 .

Lupo 1999 ➤ , Lupo 3L 1999 ➤
3.13 Removing and installing footwell and

defroster flap control motor -V85-
Note
♦ When installing the footwell flap and defroster flap control mo‐
tor -V85- , ensure the wiring harnesses are correctly laid. They
should be routed so that they do not come into contact with
moving parts (for example the levers on the control motors).
5051 A- ⇒ page 56 .
3.13.1 Removing
– Remove footwell flap and defroster flap control motor -V85-
-4- by turning operating rod -2-.
– Remove footwell flap and defroster flap control motor -V85-
-4- from housing.
3.13.2 Installing
After installing a control motor, initiate “basic setting” using vehicle
diagnosis, testing and information system -VAS 5051 A-
⇒ page 56 .
3.14 Climatronic - engine compartment
Note
Parts marked with an “*” can be repaired only in workshops with

suitable equipment and specially trained mechanics because the
refrigerant must be evacuated beforehand using, for example, the
air conditioner service station -VAS 6007A- (or later model)
⇒ page 32 .

Lupo 1999 ➤ , Lupo 3L 1999 ➤
pressor.
❑ With damper
to receiver with dryer.
valve*
punishable offence.
⇒ page 3
8 - Radiator fan control unit -
J293-
9 - Ambient temperature sen‐
sor -G17-
❑ Function: ambient tem‐
perature sensor -G17-
controls temperature
flap and fresh air blower,
depending on tempera‐
ture.
❑ In event of failure: fresh
air intake duct tempera‐
ture sensor -G89- takes over the function. 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 “--”.
tion.
Note

components”.
11 - Condenser*

Lupo 1999 ➤ , Lupo 3L 1999 ➤

❑ Engine code ARR:
❑ Observe remarks on installation of air conditioner compressor ⇒ page 117 .
Note

sors ⇒ page 117 .

❑ Renew O-ring (note part number)
circuit.
❑ The high pressure sensor -G65- supplies information to radiator fan control unit -J293- and engine control
unit.
Function:
❑ 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
engine control unit self-diagnosis.
tion.
❑ Switches off the air conditioner when the pressure is too high (for example, insufficient engine cooling).
❑ Switches off the air conditioner when the pressure is too low (for example, loss of refrigerant).
16 - Damper*
3.15.1 Removing
– Remove front bumper ⇒ Rep. Gr. 63 .

Lupo 1999 ➤ , Lupo 3L 1999 ➤
Note
Counterhold threaded connection with suitable tool when loos‐

ening and tightening.
– Unscrew high-pressure sender -G65- -2- (8 ± 1 Nm).


– Raise cover flap -1- in heat insulation mat -3- on bulkhead
-4-.
– Remove water drain valve -2- from bulkhead -4-.
rectly:
♦ The heat insulation mat must not be deformed or damaged in
the area around the water drain valve.
ward.
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.
3.17 Removing ambient temperature sensor

-G17-
3.17.1 Removing
– Unclip temperature sensor -2- from retainer -1-.
– Separate connector.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
4 Bracket for air conditioner compres‐

sor
4.1 Removing and installing air conditioner

compressor bracket, engine code AHT
♦ Torque wrench -V.A.G 1331- (5…50 Nm)
Note
♦ The bracket for air conditioner compressor and the related parts can be removed and installed without
opening refrigerant circuit.
♦ To remove poly V-belt ⇒ Rep. Gr. 13 .

Lupo 1999 ➤ , Lupo 3L 1999 ➤
1 - Cylinder block
2 - Bracket for alternator, air
conditioner compressor and
power steering vane pump
❑ Part No. 047 903 143 E.
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 76 .
– Unbolt bracket from cyl‐

inder block.
3 - Hexagon combi-bolt
❑ 45 ± 2 Nm
4 - Refrigerant hoses
Removing:

48 .
– Unscrew hexagon bolts -6- by a few turns and drive back threaded bush on air conditioner compressor.
Continue unscrewing hexagon bolts.
– Remove air conditioner compressor from bracket and secure to body with suitable material (e.g. welding
wire) ⇒ page 76 .
6 - Hexagon bolt M10×112

❑ 45 ± 2 Nm
7 - Poly V-belt
❑ Removing and installing ⇒ Rep. Gr. 13 .
❑ Poly V-belt routing ⇒ page 76 .
4. Bracket for air conditioner compressor 75

Lupo 1999 ➤ , Lupo 3L 1999 ➤
4.1.1 Securing air conditioner compressor to

body
If the compressor is removed without opening the refrigerant cir‐
cuit, the compressor should be secured to the body with suitable
material, for example, uncoated wire.
– When doing this, ensure that refrigerant hoses on air condi‐
tioner compressor are not stressed.
4.1.2 Poly V-belt routing
Note
When installing poly V-belt, ensure that it is correctly seated on

poly V-belt pulley.
Illustration for vehicles without a power steering vane pump
Illustration for vehicles with a power steering vane pump

compressor bracket, engine code ALL

Lupo 1999 ➤ , Lupo 3L 1999 ➤
Note

❑ Part No. 032 145 169 G.
❑ Part No. 032 145 169 M.
Removing:

Gr. 50 .
Rep. Gr. 27 .

48 .

(e.g. welding wire)
⇒ page 78 .

inder block.

❑ 45 ± 2 Nm
❑ 45 ± 2 Nm
Removing:
– Remove power steering vane pump ⇒ Rep. Gr. 48 .

Lupo 1999 ➤ , Lupo 3L 1999 ➤
wire) ⇒ page 78 .
6 - Poly V-belt
❑ 45 ± 2 Nm
8 - Tensioning roller
9 - Tensioning element for tensioning roller

body
If compressor is removed without opening refrigerant circuit, it
should be secured to body using suitable material, for example,
welding wire.
Note

poly V-belt pulley.

compressor, engine codes AER, AFK,
AHW, AKQ ALD, ANV, APE, AQQ,
AUA, AUB, AUC, AUD, BBY

Lupo 1999 ➤ , Lupo 3L 1999 ➤
Note

❑ Part No. 032 145 169 G.
❑ Part No. 032 145 169 M.
Removing:

Gr. 50 .
Rep. Gr. 27 .
48 .

(e.g. welding wire)
⇒ page 80 .

inder block.

❑ 45 ± 2 Nm
❑ 45 ± 2 Nm
❑ 45 ± 2 Nm
❑ 45 ± 2 Nm
Removing:
wire) ⇒ page 80 .

❑ 45 ± 2 Nm

Lupo 1999 ➤ , Lupo 3L 1999 ➤
9 - Poly V-belt

body
welding wire.
Note

poly V-belt pulley.

compressor bracket, engine code AMF
Note

Lupo 1999 ➤ , Lupo 3L 1999 ➤

❑ Part No. -045 903 143
C-
Removing:
Gr. 50 .
Rep. Gr. 27 .
48 .
(e.g. welding wire)
⇒ page 82 .
inder block.
Installing:
♦ When installing, observe
notes:
Note
♦ Renew securing bolts.

♦ Observe tightening sequence for
securing bolts ⇒ page 82 .
M10×45
❑ 45 ± 2 Nm
❑ Qty. 6
❑ Observe tightening se‐
quence for securing
bolts ⇒ page 82 .
Removing:

wire) ⇒ page 82 .

❑ 45 ± 2 Nm
6 - Poly V-belt
❑ 25 ± 2 Nm

Lupo 1999 ➤ , Lupo 3L 1999 ➤
❑ Qty. 3

body
welding wire.
Note

poly V-belt pulley.
4.4.3 Tightening sequence for bracket to cyl‐

inder block
– Position bracket on cylinder block (note dowel sleeve between
bracket and cylinder block).
– Tighten bracket in sequence as illustrated to 45 ± 2 Nm.
– -A, B, C, D, E and F-

compressor bracket, engine codes
ANY, AYZ

Lupo 1999 ➤ , Lupo 3L 1999 ➤
Note
1 - Bracket for air conditioner

compressor
❑ Part No. -045 903 143
E-
Removing:
Gr. 50 .
Rep. Gr. 27 .
(e.g. welding wire)
⇒ page 84 .
inder block.
Installing:
notes:
Note
Renew securing bolts.
M10×45
❑ 45 ± 2 Nm
❑ Qty. 6
Removing:
– Remove hexagon bolts

-5-.
wire) ⇒ page 84 .

Lupo 1999 ➤ , Lupo 3L 1999 ➤
5 - Hexagon bolts M8x100

❑ 25 ± 2 Nm
❑ Qty. 3
6 - Poly V-belt
8 - Hexagon bolts M8×50
❑ 25 ± 2 Nm
❑ Qty. 3

body
welding wire.
Note

poly V-belt pulley.

compressor bracket, engine code ARR

Lupo 1999 ➤ , Lupo 3L 1999 ➤
Note
♦ The bracket for air conditioner compressor and the related

parts can be removed and installed without opening refrigerant
circuit.
1 - Bracket for air conditioner

compressor
❑ Part No. -036 145 169
A-
Removing:
Gr. 50 .
Rep. Gr. 27 .
(e.g. welding wire)
⇒ page 86 .
inder block.
Installing:
notes:
Note
♦ Renew securing bolts.

♦ Tighten securing bolts in the fol‐
lowing order: first -2-, then -3-,
-4- and -5-.

❑ 45 ± 2 Nm
❑ 45 ± 2 Nm
❑ 45 ± 2 Nm
❑ 45 ± 2 Nm
Removing:
– Remove hexagon bolts -8-.

wire) ⇒ page 86 .
8 - Hexagon bolts M8x100

❑ 25 ± 2 Nm
❑ Qty. 3

Lupo 1999 ➤ , Lupo 3L 1999 ➤
9 - Bush

body
welding wire.
Note

poly V-belt pulley.

compressor bracket, engine code AVY
Note

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Removing:
Gr. 50 .
Rep. Gr. 27 .
48 .
(e.g. welding wire)
⇒ page 88 .
inder block.
Installing:
notes:
Note
♦ Renew securing bolts -2-,

-3-,-4- and -5-.
♦ Tightening sequence: first tight‐
en hexagon bolt -3-, then hexa‐
gon bolt -5- and finally hexagon
bolts -2- and -4-.

❑ 45 ± 2 Nm
❑ 45 ± 2 Nm
❑ 45 ± 2 Nm
❑ 45 ± 2 Nm
Removing:
wire) ⇒ page 88 .

❑ 45 ± 2 Nm
9 - Poly V-belt

Lupo 1999 ➤ , Lupo 3L 1999 ➤

body
welding wire.
Note

poly V-belt pulley.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
5 Repair work on refrigerant circuit

which may be performed only in ap‐
propriate workshops by specially
trained mechanics
Note
♦ Notes on repair work to vehicles with air conditioning and on

handling refrigerant can be found in ELSA under “Air condi‐
tioning system with refrigerant R134a VW” ⇒ Rep. Gr. 00 ,
Technical data.
♦ Notes on tools for repair work to vehicles with air conditioning
can be found in ELSA under “Air conditioning system with re‐
frigerant R134a VW” ⇒ Rep. Gr. 00 , Technical data.
WARNING
Danger of freezing injuries.

If the refrigerant circuit has not been evacuated, refrigerant will
escape.
Extract refrigerant before opening refrigerant circuit. If the re‐
frigerant circuit is not opened within 10 minutes after it has
been evacuated, pressure may develop in refrigerant circuit
due to re-evaporation. Extract refrigerant again.
5.1 Renewing refrigerant circuit components, vehicles ▸ 02.00
WARNING

escape.
5. Repair work on refrigerant circuit which may be performed only in appropriate workshops by specially trained mechanics 89
Lupo 1999 ➤ , Lupo 3L 1999 ➤
Note
♦ The refrigerant circuit must be purged with refrigerant R134a:

♦ If dirt or other contamination is in the circuit.
♦ If during the evacuation of a leak-tight refrigerant circuit the vacuum is not maintained at the gauge (there
is moisture in the refrigerant circuit and this generates vapour pressure).
♦ If the refrigerant circuit has been left open for longer than normally required for repairs (e.g. following an
accident).
♦ When pressure and temperature measurements in the refrigerant circuit indicate that there is moisture in
the refrigerant circuit.
♦ There is doubt about the amount of refrigerant oil in the refrigerant circuit.
♦ The air conditioner compressor has to be exchanged because of internal damage (e.g. noisy or lack of
power).
♦ The procedure for purging can be found in the workshop manual “Air conditioning system with refrigerant
R134a VW” ⇒ Rep. Gr. 00 , Technical data, Clearing refrigerant circuit of contaminants.
♦ The refrigerant must be extracted beforehand, e.g. with air conditioner service station -VAS 6007A- (or later
model).
♦ Releasing refrigerant into the environment is a punishable offence.
♦ The previously used service stations can still be used ⇒ Volkswagen Workshop Equipment catalogue.
♦ Safety measures when working with an extracted refrigerant circuit ⇒ page 32 . Notes on repair work to
vehicles with air conditioning and on handling refrigerant.
♦ To prevent the intrusion of moisture, all components of the refrigerant circuit which have been opened must
be sealed with suitable plugs.
♦ The colour coding of O-rings for R134a refrigerant circuits has been discontinued. Coloured and black O-
rings are used.
♦ Under certain conditions, it is not necessary to renew the receiver with dryer every time that the refrigerant
circuit is opened. Information can be found in ELSA under “Air conditioning system with refrigerant R134a”
⇒ Rep. Gr. 00 “Renewing components”.
♦ Only the components marked with an “*” can be renewed without opening and evacuating the refrigerant
circuit.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
1 - O-ring
❑ 10.8 mm; 1.82 mm
2 - O-ring
❑ 7.6 mm; 1.82 mm
valve
punishable offence.
⇒ page 105
❑ Capacities
⇒ page 135 .
4 - Socket head combi-bolt
❑ 7 ± 1 Nm
5 - Refrigerant hose
❑ From air conditioner
compressor to condens‐
er.
❑ With damper
6 - O-ring
❑ 10.8 mm; 1.82 mm
7 - 3/4" thread - 16 UNF
Note
Counterhold threaded connection

with suitable tool when loosening
and tightening.
❑ 30 ± 2 Nm
8 - Condenser
9 - 5/8" thread - 18 UNF
Note

and tightening.
❑ 16.5 ± 1.6 Nm
10 - O-ring
❑ 7.6 mm; 1.82 mm
11 - 3/4" thread - 16 UNF
Note

and tightening.
❑ 30 ± 2 Nm
Lupo 1999 ➤ , Lupo 3L 1999 ➤
12 - O-ring
❑ 10.8 mm; 1.82 mm
13 - Receiver with dryer
Note

components”.
14 - O-ring
❑ 10.8 mm; 1.82 mm
15 - Refrigerant line
16 - O-ring
❑ 10.8 mm; 1.82 mm
17 - High-pressure sender -G65- *
tion.
18 - 5/8" thread - 18 UNF
Note

and tightening.
❑ 16.5 ± 1.6 Nm
19 - O-ring
❑ 10.8 mm; 1.82 mm
❑ From condenser to receiver with dryer.
22 - O-rings
❑ Low pressure side: 14.3 mm; 2.4 mm.
❑ High pressure side: 10.8 mm; 1.82 mm.
❑ 22 ± 1 Nm
24 - High-pressure safety valve
❑ Manufacturer: Sanden, designation: SD6V12.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
Note

sors ⇒ page 117 .
26 - Evacuating and charging valve

❑ From air conditioner compressor to expansion valve
28 - Bolt
❑ 8 Nm
29 - Bolt
❑ 8 Nm
30 - O-ring
❑ 16.7 mm; 1.82 mm
31 - Expansion valve
❑ In engine compartment on right.
32 - O-ring
❑ 14 mm; 1.82 mm
33 - Threaded plate
34 - Seal
35 - Evaporator
❑ Removing: remove heater and air conditioning unit ⇒ page 118
Lupo 1999 ➤ , Lupo 3L 1999 ➤
Functions of receiver with dryer
Note
Under certain conditions, it is not necessary to renew the receiver

with dryer every time that the refrigerant circuit is opened. Infor‐
mation can be found in ELSA under “Air conditioning system with
refrigerant R134a” ⇒ Rep. Gr. 00 “Renewing components”.
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 in the receiver.
Checking high-pressure safety valve on air conditioner compres‐

sor
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 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.
5.2 Renewing refrigerant circuit components, vehicles 03.00 ▸
WARNING

escape.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
Note
♦ The refrigerant must be extracted beforehand, e.g. with air conditioner service station -VAS 6007A- .
rings are used.
circuit.
1 - O-ring
❑ 10.8 mm; 1.82 mm
2 - O-ring
❑ 8.2 mm; 1.85 mm
valve
punishable offence.
⇒ page 105
❑ Capacities
⇒ page 135 .
❑ 7 Nm
❑ From air conditioner
compressor to condens‐
er.
6 - O-ring
❑ 10.8 mm; 1.82 mm
7 - 3/4" thread - 16 UNF
Note

and tightening.
❑ 30 ± 2 Nm
8 - Condenser
9-
Socket head combi bolt M8×24
❑ 12 ± 1 Nm
10 - O-ring
❑ 10.8 mm; 1.82 mm
Lupo 1999 ➤ , Lupo 3L 1999 ➤

Note

components”.
12 - O-ring
❑ 10.8 mm; 1.82 mm
13 -
Socket head combi bolt M8×18
❑ 12 ± 1 Nm
15 - O-ring
❑ 10.8 mm; 1.82 mm
❑ 12 ± 1 Nm
17 - O-ring
❑ 10.8 mm; 1.82 mm
tion.
20 - Air conditioning system compressor regulating valve -N280-
21 - O-ring
❑ Air conditioner compressor, Sanden: 14,3 mm; 2,4 mm.
❑ Air conditioner compressor, Denso: 23.8 mm; 2,4 mm.
22 - O-ring
❑ 10.8 mm; 1.82 mm
❑ 22 ± 1 Nm
❑ Manufacturer: Sanden, designation: SD6V12 with air conditioning system magnetic clutch -N25- .
❑ Engine code ARR:
❑ Manufacturer: Denso, designation: 6SEU12, observe notes ⇒ page 117 . This air conditioner compressor
has no air conditioning system magnetic clutch -N25- .
❑

Lupo 1999 ➤ , Lupo 3L 1999 ➤
Note

sors ⇒ page 117 .

27 - Damper
29 - Bolt
❑ 8 ± 1 Nm
30 - O-ring
❑ 17 mm; 1.85 mm
32 - O-ring
❑ 14 mm; 1.82 mm
33 - Threaded plate
34 - Evaporator
❑ Removing: remove heater and air conditioning unit ⇒ page 118
Lupo 1999 ➤ , Lupo 3L 1999 ➤
5.3 Renewing components of refrigerant system, engine codes ANY and AYZ
WARNING

escape.
Note
rings are used.
circuit.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
1 - Evaporator
❑ In passenger compart‐
ment
❑ Removing: remove
heater and air condition‐
ing unit ⇒ page 118
bling evaporator hous‐
ing ⇒ page 122 .
2 - O-ring
❑ 10.8 mm; 1.82 mm
3 - O-ring
❑ 8.2 mm; 1.85 mm
valve
punishable offence.
⇒ page 105
❑ Capacities
⇒ page 135 .
❑ With damper
7 - O-ring
❑ 10.8 mm; 1.82 mm
8 - 3/4" thread - 16 UNF
Note

and tightening.
❑ 30 ± 2 Nm
9 - Condenser
❑ 12 ± 1 Nm
11 - O-ring
❑ 10.8 mm; 1.82 mm
Lupo 1999 ➤ , Lupo 3L 1999 ➤
Note

components”.
13 - O-ring
❑ 10.8 mm; 1.82 mm
❑ 12 ± 1 Nm
❑ 12 ± 1 Nm
17 - O-ring
❑ 10.8 mm; 1.82 mm
❑ Manufacturer: Calsonic, designation: CSV613.
Note

sors ⇒ page 117 .

21 - O-ring
❑ 14.3 mm; 2.4 mm
❑ 22 ± 1 Nm
23 - O-ring
❑ 10.8 mm; 1.82 mm
❑ 22 ± 1 Nm
25 - O-ring
❑ 10.8 mm; 1.82 mm

Lupo 1999 ➤ , Lupo 3L 1999 ➤

tion.
28 - Bolt
❑ 8 ± 1 Nm
29 - O-ring
❑ 17 mm; 1.85 mm
31 - Quick release coupling
33 - O-ring
❑ 14 mm; 1.82 mm
34 - Threaded plate
Checking excess pressure relief valve on 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 the refrigerant circuit against excessive pres‐

sure.
♦ The pressure relief valve has operated when refrigerant oil is
found in the immediate vicinity.
♦ In this case, hand over vehicle to a suitable workshop
⇒ page 32 .
5.4 Removing receiver with dryer
Note
Under certain conditions, it is not necessary to renew the receiver

with dryer every time that the refrigerant circuit is opened. Infor‐
mation can be found in ELSA under “Air conditioning system with
refrigerant R134a” ⇒ Rep. Gr. 00 “Renewing components”.
Lupo 1999 ➤ , Lupo 3L 1999 ➤
5.4.1 Removing
– Extract refrigerant, e.g. with air conditioner service station -
VAS 6007A- .
Note
Releasing refrigerant into the environment is a punishable of‐

fence.
WARNING

escape.
– Disconnect refrigerant lines by unscrewing bolts ⇒ page 95

-9- and ⇒ page 96 -13-.
– Unscrew bolts -1- (12 ± 1 Nm) and remove receiver with dryer
from bracket -2-.
Note
Observe the installation position when fitting the receiver with

dryer.
5.4.2 Functions of receiver with dryer

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 in the receiver.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
5.5 Evacuating and charging valve, low-

pressure side
Special tools and work‐
shop equipment re‐
quired
♦ Extract refrigerant,
e.g. with air condition‐
er service station -
VAS 6007A- .
♦ Torque wrench -
V.A.G 1783- (2…
10 Nm)
♦ Ratchet insert tool

1/4" -VAS 6234-
♦ Adapter set for evac‐

uating and charging
valve
Lupo 1999 ➤ , Lupo 3L 1999 ➤
Removing:
WARNING
Danger of freezing in‐

juries.
If the refrigerant circuit
has not been evacu‐
ated, refrigerant will
escape.
Extract refrigerant be‐
fore opening refriger‐
ant circuit. If the refrig‐
erant circuit is not
opened within 10 mi‐
nutes after it has been
evacuated, pressure
may develop in refrig‐
erant circuit due to re-
evaporation. Extract
refrigerant again.
– Evacuate refrigerant
circuit, e.g. with air
conditioner service
station -VAS 6007A-
(or later model) be‐
fore renewing valve
-3-.
– Counterhold threa‐
ded connection with
suitable tool when
loosening and tight‐
ening.
1 - Connection with ex‐
ternal thread and groove
for O-ring
2 - O-ring 7.6 mm; 1.8
mm
3 - Evacuating and
charging valve
(7 ± 1 Nm) with groove
and internal thread for
cap.
4 - O-ring 7.6 mm; 1.8
mm
5 - Cap

Lupo 1999 ➤ , Lupo 3L 1999 ➤
5.6 Evacuating and charging valve, high-

pressure side
Special tools and work‐
shop equipment re‐
quired
♦ Extract refrigerant,
e.g. with air condition‐
er service station -
VAS 6007A- .
♦ Torque wrench -
V.A.G 1783- (2…
10 Nm)
♦ Ratchet insert tool

1/4" -VAS 6234-
♦ Adapter set for evac‐

uating and charging
valve
Lupo 1999 ➤ , Lupo 3L 1999 ➤
Removing:
WARNING
Danger of freezing in‐

juries.
If the refrigerant circuit
has not been evacu‐
ated, refrigerant will
escape.
Extract refrigerant be‐
fore opening refriger‐
ant circuit. If the refrig‐
erant circuit is not
opened within 10 mi‐
nutes after it has been
evacuated, pressure
may develop in refrig‐
erant circuit due to re-
evaporation. Extract
refrigerant again.
– Evacuate refrigerant
circuit, e.g. with air
conditioner service
station -VAS 6007A-
(or later model) be‐
fore renewing valve
-3-.
– Counterhold threa‐
ded connection with
suitable tool when
loosening and tight‐
ening.
1 - Connection with inter‐
nal thread
2 - O-ring 10.8 mm; 1.8
mm
3 - Evacuating and
charging valve
(7 ± 1 Nm) with groove
and internal thread for
cap.
4 - O-ring 10.8 mm; 1.8
mm
5 - Cap
5.7 Quick release coupling
5.7.1 Removing quick release coupling

VAS 6007A- .
– After every removal, the O-ring, retainer and retaining ring
must be renewed.
– Repair kit for quick release coupling -6Q0 298 260 A-

Lupo 1999 ➤ , Lupo 3L 1999 ➤
♦ Air conditioner service station -VAS 6007A- (or later model).
♦ Release tools case -VAS 6127/1- with release tool -VAS

6127/1- , release tool -VAS 6127/2- and release tool -VAS
6127/3-
♦ Protective goggles
♦ Protective gloves
– 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.
WARNING

escape.
– Slide release tool -VAS 6127/3- -2- in -direction of arrow A-

along refrigerant line -1- against stop on coupling housing
-3-.
Lupo 1999 ➤ , Lupo 3L 1999 ➤
– Hold release tool -VAS 6127/3- against stop and pull coupling
housing -1- in direction of arrow.
5.7.2 Dismantling quick release coupling

– Remove release tool -VAS 6127/3- .
– Remove circlip -1- using circlip pliers.
– Remove locking insert -1- and O-ring -2- from coupling hous‐
ing -3-.
5.7.3 Assembling quick release coupling

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

Lupo 1999 ➤ , Lupo 3L 1999 ➤
– 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.
5.7.4 Connecting quick release coupling

– Guide refrigerant line -1- into coupling housing -3- of other re‐
frigerant line until indicators protrude clearly through holes.
– Slide dust seal -2- onto coupling housing -3- so that dust seal
is flush against coupling.

compressor, engine codes AER, AFK,
AHT, AHW, AKQ, ALD, ALL, AMF, ANV,
APE, AQQ, AUA, AUB, AUC, AVY and
BBY
Note
♦ If the air conditioner compressor has been exchanged be‐

cause of internal damage, it is also necessary to purge the
refrigerant circuit with refrigerant R134a.
♦ The procedure for purging can be found in the workshop man‐
ual “Air conditioning system with refrigerant R134a VW” ⇒
Rep. Gr. 00 , Technical data, Clearing refrigerant circuit of
contaminants.
♦ Observe running-in procedures for new air conditioner com‐
pressors ⇒ page 117 .
Lupo 1999 ➤ , Lupo 3L 1999 ➤

Note
The air conditioner compressor can be removed and installed only

after the refrigerant has been extracted with, e.g. air conditioner
service station -VAS 6007A- (or later model).
5.8.1 Removing
Note
The figure shows the engine code AVY. Removing and installing
are identical on engines with other codes.

VAS 6007A- (or later model) before opening refrigerant circuit.
Observe notes ⇒ page 94 .

Lupo 1999 ➤ , Lupo 3L 1999 ➤
– Remove noise insulation under engine ⇒ Rep. Gr. 50 .

– Remove poly V-belt -6- ⇒ Rep. Gr. 13 .
– Separate connector -4- to air conditioner compressor regulat‐
ing valve -N280- .
WARNING

escape.
– Remove socket head combi bolts -1- (22 ± 2 Nm) and separate
refrigerant lines -2- from air conditioner compressor -3-.
– Unscrew hexagon bolts -5- (45 ± 2 Nm) by a few turns and
drive back threaded bushes on air conditioner compressor.
Lupo 1999 ➤ , Lupo 3L 1999 ➤
Continue unscrewing hexagon bolts. Then remove air condi‐

tioner compressor from bracket.
5.8.2 Installing
Installation is carried out in the reverse order. When installing,
note the following:
Note
♦ Always renew O-rings.


compressor, engine codes ANY and
AYZ
Note

contaminants.


Lupo 1999 ➤ , Lupo 3L 1999 ➤
Note

5.9.1 Removing
VAS 6007A- (or later model) before opening refrigerant circuit.
Observe notes ⇒ page 94 .

– Remove poly V-belt ⇒ Rep. Gr. 13 .
Lupo 1999 ➤ , Lupo 3L 1999 ➤
WARNING

escape.
– Remove hexagon bolts -4- (45 ± 2 Nm). Then remove air con‐
ditioner compressor from bracket.
5.9.2 Installing
note the following:
Note

♦ Ensure that dowel sleeves -5- are properly seated when in‐
stalling.

compressor, engine codes ARR
Note

contaminants.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
Note

5.10.1 Removing
– Extract refrigerant, for example, with air conditioner service
station -VAS 6007A- or later models before opening refriger‐
ant circuit. Observe notes ⇒ page 94 .
Lupo 1999 ➤ , Lupo 3L 1999 ➤

– Remove poly V-belt ⇒ Rep. Gr. 13 .
WARNING

escape.
– Remove hexagon bolts -5- (45 ± 2 Nm). Then remove air con‐
ditioner compressor from bracket -6-.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
5.10.2 Installing
note the following:
Note

♦ Ensure that dowel sleeves -5- are properly seated when in‐
stalling.
5.11 Notes on installing air conditioner com‐

pressor
5.11.1 Installing
– Do not start engine until after reassembling refrigerant circuit.
– After installing a new air conditioner compressor or filling with
fresh refrigerant oil (e.g. after blowing out refrigerant circuit),
turn compressor pulley 10 revolutions by hand before starting
engine. On air conditioner compressors with a magnetic
clutch, apply a voltage of 12 V via the fuse 10 A to the con‐
nector contact (green/black wire) for the magnetic clutch. Then
turn the poly V-belt pulley 10 revolutions by hand. This will
prevent damage to the air conditioner compressor.
– If possible, start engine only with refrigerant circuit charged.
Lupo 1999 ➤ , Lupo 3L 1999 ➤
Note
♦ On air conditioner compressors without magnetic clutch, the

poly V-belt pulley is driven permanently.
♦ If an air conditioner compressor (without magnetic clutch)
seizes, the overload protection separates from the air condi‐
tioner compressor shaft. A seized air conditioner compressor
cannot always be identified by visible deformations in the poly
V-belt pulley. Another indication is abraded rubber material in
the area of the poly V-belt pulley.
♦ The air conditioner compressor has an internal oil circuit to
ensure that the air conditioner compressor is not damaged
when the refrigerant circuit is empty. This means that about
40 to 50 cm3 refrigerant oil remain in the compressor.
♦ The engine may be started only when the refrigerant circuit is
properly assembled. If, for example, the refrigerant lines are
not connected to the air conditioner compressor and the en‐
gine is running, the compressor may heat up so much through
internal warming that it will be destroyed.
♦ Air conditioning system compressor regulating valve -N280- is
not activated when the refrigerant circuit is empty and the air
conditioner compressor idles with the engine.
♦ If it is necessary to start engine with an empty refrigerant cir‐
cuit:
♦ The refrigerant circuit must be fully assembled.
♦ At least 1/4 of the quantity of refrigerant oil specified for this
refrigerant circuit must be in the air conditioner compressor.
♦ The engine speed must not exceed 2500 rpm.
♦ Run engine only as long as absolutely necessary.
– Note the following when starting engine for first time after filling
refrigerant circuit:
– Start engine with air conditioner compressor switched off
(“Econ” mode) and wait until the idling speed stabilizes.
– Open dash panel vents.
– Set temperature to “Lo” on the operating and display unit for
Climatronic air conditioning system -E87- .
– Switch air conditioner compressor on (“Auto” mode) and allow
engine to run for at least 5 minutes at idling speed.
5.12 Removing and installing heater and air

conditioning unit

Lupo 1999 ➤ , Lupo 3L 1999 ➤
♦ Hose clamps up to 40 mm Ø -3093-
♦ Drip tray for workshop hoist -VAS 6208-
Lupo 1999 ➤ , Lupo 3L 1999 ➤
1 - Hexagon nut
❑ Qty. 3
❑ 4 ± 1 Nm
2 - Bulkhead
3 - Heater and air conditioning
unit
bling evaporator hous‐
ing ⇒ page 122 .
4-
Guide pin
5.12.1 Removing
WARNING

escape.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
Note
♦ The refrigerant must be extracted beforehand, e.g. with air

conditioner service station -VAS 6007A- .
♦ The previously used service stations can still be used ⇒
Volkswagen Workshop Equipment catalogue.
♦ To prevent the intrusion of moisture, all components of the re‐
frigerant circuit which have been opened must be sealed with
suitable plugs.

VAS 6007A- .
Note

fence.
WARNING

the coolant temperature may be above 100° C.
– Seal coolant hoses to heat exchanger in engine compartment

using hose clamps up to 40 mm Ø -3093- and remove from
heat exchanger.
– Carefully blow remaining coolant out of heat exchanger using
a compressed air gun at heat exchanger connection.
– Cover carpet in area under heat exchanger with waterproof foil
and absorbent paper.
– If the vehicle is equipped with an auxiliary air heater element
-Z35- , disconnect battery ⇒ Rep. Gr. 27 .
– Disconnect earth wire from auxiliary air heater element -Z35-
⇒ page 25 .
– Remove activated charcoal filter or dust and pollen filter with
filter housing ⇒ page 3 .
5.12.2 Installing
– Guide heater and air conditioning unit to bulkhead and push
studs through intended holes.
– At the same time, make sure that heater and air conditioning
unit sits on guide pin ⇒ page 120 -4- against stop.
– Screw on hexagon nuts (4 ± 1 Nm) -1- to bulkhead -2- in en‐
gine compartment and tighten.
– Check coolant level and top up ⇒ Rep. Gr. 19 .
– Refill refrigerant, e.g. with air conditioner service station -VAS
6007A- .
Lupo 1999 ➤ , Lupo 3L 1999 ➤
5.13 Dismantling and assembling evaporator housing
1 - Seal between heat ex‐

changer and bulkhead
❑ Note installation posi‐
tion ⇒ page 122 .
2 - Heat exchanger
❑ After removal, com‐
pletely renew coolant.
3 - Auxiliary air heater element
-Z35-
sel engine.
4-
Housing, upper part
circulation flap
5 - Seal
6 - Evaporator
7-
Housing, lower part
5.13.1 Dismantling
– Remove heater and air conditioning unit ⇒ page 118 .
– Release clips between upper part of housing ⇒ page 122 -4-
and lower part of housing ⇒ page 122 -7- and separate both
housing parts.
5.13.2 Assembling
Assemble in reverse order.
5.13.3 Installation position of seal between

heat exchanger 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-.

Lupo 1999 ➤ , Lupo 3L 1999 ➤
5.14 Expansion valve, function and removal

Note
Only the components marked with an “*” can be renewed without

opening and evacuating the refrigerant circuit.
Lupo 1999 ➤ , Lupo 3L 1999 ➤
1 - Threaded plate
2 - O-ring
❑ 10.8 mm; 1.82 mm
3 - Heat insulation*
4 - Bolts
❑ 8 ± 1 Nm
❑ Qty. 2
5 - O-ring
❑ 7.6 mm; 1.82 mm
❑ 7 ± 1 Nm
❑ From receiver with dryer
to expansion valve
pressor.
❑ With damper
9 - O-ring
❑ 16.7 mm; 1.82 mm
on right.
❑ Aperture must be
sealed against splashed
water.
11 - O-ring
❑ 14 mm; 1.82 mm
5.14.1 Function
♦ The expansion valve atomises incoming refrigerant and reg‐
ulates the flow so that, depending on the heat transport, the
vapour does not become a gas until it reaches the outlet of the
evaporator.
5.14.2 Removing

Lupo 1999 ➤ , Lupo 3L 1999 ➤
Note

suitable plugs.

VAS 6007A- .
Note

fence.
– Remove heat insulation -3-.
WARNING

escape.

– Pull out refrigerant line -7- and refrigerant hose -8-.
Renew O-rings -5- and -9-.
– Remove bolts -4-.
– Remove expansion valve -10-.
5.15 Expansion valve - function and remov‐

ing, engine codes ANY, ARR, AVY and
AYZ
Lupo 1999 ➤ , Lupo 3L 1999 ➤
Note
Only the components marked with an “*” can be renewed without opening and evacuating the refrigerant circuit.
1 - Threaded plate
2 - O-ring
❑ 10.8 mm; 1.82 mm
3 - Expansion valve
on right.
❑ Aperture must be
sealed against splashed
water.
4 - Bolts
❑ 8 ± 1 Nm
❑ Qty. 2
5 - O-ring
❑ 8.2 mm; 1.85 mm
❑ 7 ± 1 Nm
pressor.
❑ With damper
9 - O-ring
❑ 17 mm; 1.85 mm
10 - O-ring
❑ 14 mm; 1.82 mm
5.15.1 Function
♦ The expansion valve atomises incoming refrigerant and reg‐
ulates the flow so that, depending on the heat transport, the

Lupo 1999 ➤ , Lupo 3L 1999 ➤
vapour does not become a gas until it reaches the outlet of the
evaporator.
5.15.2 Removing
Note

suitable plugs.

VAS 6007A- .
Note

fence.
WARNING

escape.

– Pull out refrigerant line -6- and refrigerant hose -8-.
– Remove bolts -4-.
– Remove expansion valve -3-.
Lupo 1999 ➤ , Lupo 3L 1999 ➤
5.16 Removing and installing condenser, ve‐

hicles ▸ 02.00
Note

Lupo 1999 ➤ , Lupo 3L 1999 ➤
1 - Lock carrier
❑ Removing: ⇒ Rep. Gr.
50
2 - 3/4" thread - 16 UNF
❑ 30 ± 2 Nm
❑ Counterhold threaded
connection with suitable
tool when loosening and
tightening.
3 - Sealing strip
❑ Glue on 2 new sealing
strips when exchanging
condenser.
4 - Bolts
❑ 8 ± 1 Nm
❑ Qty. 4
5 - Condenser
6 - 5/8" thread - 18 UNF
❑ 16.5 ± 1.6 Nm
tightening.
7 - Radiator
5.16.1 Removing

VAS 6007A- .
Lupo 1999 ➤ , Lupo 3L 1999 ➤
Note

fence.
WARNING

– Drain coolant ⇒ Rep. Gr. 19 .
WARNING

escape.
– Remove refrigerant lines on condenser and seal.

– Remove lock carrier ⇒ Rep. Gr. 50 .
5.17 Removing and installing condenser, ve‐

hicles 03.00 ▸

Lupo 1999 ➤ , Lupo 3L 1999 ➤
Note
1 - Lock carrier
50
2 - Radiator
3 - 3/4" thread - 16 UNF
❑ 30 ± 2 Nm
tightening.
4 - Sealing strip
condenser.
5 - Socket head combi bolts
❑ 12 ± 1 Nm
❑ Qty. 2
6 - Hexagon nut
❑ 8 ± 1 Nm
❑ Qty. 2
Note

components”.
8 - Condenser
9 - Hexagon nuts
❑ 5 ± 1 Nm
❑ Qty. 2
5.17.1 Removing
Lupo 1999 ➤ , Lupo 3L 1999 ➤

VAS 6007A- .
Note

fence.
WARNING

escape.

5.18 Removing and installing condenser en‐

gine codes ANY, ARR, AVY and AYZ

Lupo 1999 ➤ , Lupo 3L 1999 ➤
Note
1 - Lock carrier
50
2 - 3/4" thread - 16 UNF
❑ 30 ± 2 Nm
tightening.
3 - Sealing strip
condenser.
4 - Socket head combi bolts
❑ 12 ± 1 Nm
❑ Qty. 2
5 - Bolts
❑ 5 ± 1 Nm
❑ Qty. 4
Note

components”.
7 - Condenser
8 - Hexagon nuts
❑ 5 ± 1 Nm
❑ Qty. 2
9 - Radiator
5.18.1 Removing
Lupo 1999 ➤ , Lupo 3L 1999 ➤

VAS 6007A- .
Note

fence.
WARNING

– Drain coolant ⇒ Rep. Gr. 19 .
WARNING

escape.

– Remove lock carrier ⇒ Rep. Gr. 50 .

Lupo 1999 ➤ , Lupo 3L 1999 ➤
6 Capacities
6.1 Refrigerant R134a

Air conditioner compressor Manufacturer Capacity
SD6V12 Sanden 700 + 50 g
CSV613 Calsonic 550 + 50 g
6SEU12 Denso 550 ± 25 g
6SEU14 Denso 550 ± 25 g
6.2 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
SD6V12 air conditioner compressor; Sanden G 052 154 A2
CSV613 air conditioner compressor; Calsonic G 052 154 A2
6SEU12 air conditioner compressor; Denso G 052 300 A2
6SEU14 air conditioner compressor; Denso G 052 300 A2
Air conditioner compressor Production period Total capacity1)

genuine spare part No.
6N0 820 803 B from 10.98 120 ± 15 cm3
6E0 820 803 from 06.99 150 ± 10 cm3
6Q0 820 803 D from 11.00 140 ± 10 cm3
6Q0 820 803 K gradually 80 ± 10 cm3
1) This quantity of refrigerant oil is contained in a genuine replacement air condi‐
tioner compressor and corresponds to the total capacity.
Additional information:
Because refrigerant oil is very hygroscopic, opened containers
must be closed immediately after use to stop intrusion of moisture.
Because of its chemical properties, refrigerant oil must not be
disposed of together with engine or gear oil.
6.2.1 Oil distribution

The oil, which is located in the sump of the air conditioner com‐
pressor before the air conditioner system is switched on for the
first time, distributes itself through the refrigerant circuit as follows:
♦ Compressor approx. 50%
♦ Condenser approx. 10%
♦ Suction hose approx. 10%
♦ Evaporator approx. 20%
♦ Receiver approx. 10%
6. Capacities 135

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Service

Service Department. Technical Information

87 - Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.1 Procedure for checking and adjusting components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

1.1 Passenger compartment heating

1. Repairing heating system 1

1.2 Removing and installing fresh air blower

Danger of burn injuries.

2 Rep. Gr.80 - Heating

1.3 Removing and installing activated char‐

– Press tabs -A- of filter housing in -direction of arrow- and lift

1. Repairing heating system 3

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

1.4 Removing leaf screen

– Unscrew plastic nuts -2- (2.5 Nm).

4 Rep. Gr.80 - Heating

1.5 Removing centre vents

– Unscrew bolts -arrows-.

1. Repairing heating system 5

1.6 Removing and installing vent on front

1.7 Removing and installing vent on driver

6 Rep. Gr.80 - Heating

– Remove bolt -arrow-.

– Unclip vent near -arrows- using a screwdriver and pad.

1.8 Removing footwell vent

1. Repairing heating system 7

– Remove bolt -1-.

1.9 Removing and installing controls for

– Using a screwdriver, unclip trim from controls -arrows-.

8 Rep. Gr.80 - Heating

– Unscrew bolts -arrows-.

– Release cables on controls -arrows-.

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

♦ The cable sheaths are colour coded.

1. Repairing heating system 9

– Press cable for footwell/defroster flap, cable for temperature

1.10 Notes on mapped cooling, engine code

10 Rep. Gr.80 - Heating

♦ Vehicles with mapped cooling are equipped with a heating

1.11 Mapped cooling layout, engine code ARR

1. Repairing heating system 11

1 - Potentiometer for tempera‐

12 Rep. Gr.80 - Heating

1.12 Mapped cooling components in engine compartment, engine code ARR

1 - Coolant shut-off valve

1. Repairing heating system 13

1 - Coolant shut-off valve

Volkswagen Technical Site: http://vwts.ru http://vwts.info

♦ The stale air escapes via ventilation openings in the luggage

14 Rep. Gr.80 - Heating

1.15 Checking auxiliary air heater element -

1.15.1 Checking auxiliary air heater element -

1.15.2 Checking auxiliary air heater element -Z35-

1. Repairing heating system 15

Special tools and workshop

1.15.3 Test conditions

1.15.4 Test procedure

16 Rep. Gr.80 - Heating

– Connect digital potentiometer -V.A.G 1630- to connector for