Service

Repair Manual
Touareg 2010 ➤
Touareg 2015 ➤
Heating, Ventilation and Air Conditioning
Engine ID
CAT CNR CGF CGR
A B A A
Edition 06.2017 ag e n
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Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
00 - General, Technical Data
80 - Heating, Ventilation
87 - Air Conditioning

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Technical information should always be available to the foremen and mechanics, because their
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careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
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safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
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matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2017 Volkswagen AG, Wolfsburg D3E802DF870

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

Contents

00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety Precautions g e nAGwhen Working
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1.2 Safety Precautions
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1.3 Start/Stop
rise System Safety Precautions . . . . n.te. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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1.4 ut
aHigh Voltage System Safety Precautions . . . . o.r a.c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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1.5 Safety Precautions near High Voltage Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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1.6 Cooling System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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1.7 Safety Precautions when Working with Parking/Auxiliary Heater . . . . . . . . . . . . . . . . . . . . 4
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2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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2.1 Odors in Vehicles with A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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2.2 Information for Vehicles with Start/Stop System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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3 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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3.1 Working on Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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3.3 Refrigerant Circuit Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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4.1 Refrigerant R134a Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.2 Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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4.3 Oil Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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80 - Heating, Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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1 Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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87 - Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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1 tComponent Location Overview - A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.1 Component Location Overview - Components Outside of Passenger Compartment . . . . 11
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2 Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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2.1 System Overview - Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2 Evacuating and Charging Valve, Removing and Installing, Low and High Pressure Side . . 18
2.3 Dryer Bag/Dryer Cartridge, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.4 A/C Compressor, Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.5 High Pressure Sensor G65 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.6 Expansion Valve, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.7 Condenser, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3 A/C Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.1 A/C Compressor, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.2 Pressure Relieve Valve on A/C Compressor, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.3 Drive Plate with Overload Protection, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 55
3.4 Drive Plate with Overload Protection, Checking Run-Out and Adjusting . . . . . . . . . . . . . . 56
3.5 A/C Compressor Drive Plate, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.6 Hardy Discs, Changing to Gate Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.7 Mount with Free-Running Hub on A/C Compressor, Removing and Installing . . . . . . . . . . 58
4 Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.1 Heater and A/C Unit Actuators, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.2 Overview - Heater and A/C Unit Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.3 Defroster Door Motor V107 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.4 Left Side Vent Motor V299 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.5 Left Center Vent Motor V110 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.6 Left Footwell Door Motor V108 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.7 Left Temperature Door Motor V158 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 64
4.8 Right Temperature Door Motor V159 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 64

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 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

4.9 Fresh Air/Recirculating Air/Back Pressure Door Motor V425 , Removing and Installing . . 65
4.10 Indirect Ventilation Door Motor V213 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 65
4.11 Right Indirect Ventilation Door Control Motor V453 , Removing and Installing . . . . . . . . . . 66
4.12 Left Rear Temperature Door Motor V313 , Removing and Installing . . . . . . . . . . . . . . . . . . 67
4.13 Right Rear Temperature Door Motor V314 , Removing and Installing . . . . . . . . . . . . . . . . 68
5 Front Heater and A/C Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.1 Overview - Heater and A/C Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.2 Auxiliary Heater Heating Element Z35 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 71
5.3 Heater and A/C Unit, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.4 Heater and A/C Unit, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.5 Dust and Pollen Filter, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.6 Fresh Air Blower V2 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.7 Evaporator Temperature Sensor G308 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 80
5.8 Heater Core, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.9 Condensation Water Drain, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.10 Evaporator Housing, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.11 Evaporator, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.12 Rear Evaporator, Removing and Installing, with Heater and A/C Unit Installed . . . . . . . . . . 88
6 Rear Heater and A/C Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
6.1 Overview - Heater and A/C Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
6.2 Rear Heater and A/C unit, Service Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6.3 Heater and A/C Unit, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6.4 Second Rear Heating and A/C Unit, Disassembling and Assembling . . . . . . . . . . . . . . . . 97
6.5 Left Rear Vent Temperature Sensor G405 , Removing and Installing . . . . . . . . . . . . . . . . 99
6.6 Right Rear Vent Temperature Sensor G406 , Removing and Installing . . . . . . . . . . . . . . . . 100
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6.7 Rear Fresh Air Blower V80 , Removing swag e nand InstallingAG. d.o.e s. . . . . . . . . . . . . . . . . . . . . . . . . 100
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6.8 Heater Core, Removing and d bInstalling . . . . . . . . . . . . . . . . . . .u a.ra. . . . . . . . . . . . . . . . . . . . 100
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6.9 Condensation Drain Hose, u th o Checking . . . . . . . . . . . . . . . . . . . . . . . e.e.or. . . . . . . . . . . . . . . . . 102
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7 Air Guide . . . . . . . s.s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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7.1 Driver Vents in the Instrument Panel, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 103
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7.2 Front Passenger Vents in the Instrument Panel, Removing and Installing . . . . . . . . . . . . 104
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7.3 B-Pillar Side Vents, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

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7.4 Driver Side Footwell Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

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7.5 Front Passenger Side Footwell Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 105
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7.6 Rear Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

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7.7 Fresh Air Intake, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

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7.8 Passenger Compartment Forced Air Extraction, Checking . . . . . . . . . . . . . . . . . . . . . . . . 107

8 Coolant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
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8.1 Coolant Shut-Off Valve N82 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

8.2 Recirculation Pump V55 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
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9 Display and Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

9.1 Overview - Display and Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
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9.2 Display and Control Head, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

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9.3 Function of the Climatronic via the Infotainment System . . . . . . . . . . . . . . . . . . . . . . . . . . 122

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10 Additional Components for Control and Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

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10.1 Sunlight Photo Sensor G107 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 125

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10.2 Air Quality Sensor G238 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

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10.3 Function of Air Quality Sensor G238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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10.4 Outside Air Temperature Sensor G17 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 127
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10.5 A/C Humidity Sensor G260 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
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10.6 Left Footwell Vent Temperature Sensor G261 , Removing and Installing . . . . . . . . . . . . . . 128
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10.7 Right Footwell Vent Temperature Sensor G262 , Removing and Installing . . . . . . . . . . . . 128
10.8 Right Front Upper Body Vent Temperature Sensor G386 and Left Front Upper Body Vent
Temperature Sensor G385 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
11 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

ii Contents
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

12 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

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Contents iii
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

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iv Contents
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

00 – General, Technical Data

1 Safety Precautions
(Edition 06.2017)
⇒ “1.1 Safety Precautions when Working on Air Conditioning Sys‐
tems Safety Precautions”, page 1
⇒ “1.2 Safety Precautions when Handling Refrigerant”,
page 1
⇒ “1.3 Start/Stop System Safety Precautions”, page 2
⇒ “1.4 High Voltage System Safety Precautions”, page 2
⇒ “1.5 Safety Precautions near High Voltage Components”, page
3
⇒ “1.6 Cooling System Safety Precautions”, page 3

1.1 Safety Precautions when Working on Air

Conditioning Systems Safety Precau‐
tions
WARNING
Ignition Sources Are Extremely Dangerous and Pose a Risk of
Explosion
Ignition sources near the A/C system and refrigerant containers
are extremely dangerous and pose a risk of explosion. Leaking
refrigerant can ignite and lead to an explosion. Death or serious
bodily injury by explosion.

– Never bring ignition sources near A/C systems and refrigerant

containers.
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Risk of Destroying the Refrigerant Lines.

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The refrigerant lines can be destroyed by ripping through the

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WARNING
Risk of Asphyxiation and Poisoning from the Refrigerant
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– Never breathe in refrigerant fumes.

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– Only perform procedures on the refrigerant circuit in well ven‐

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1. Safety Precautions
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Heating, Ventilation and Air Conditioning - Edition 06.2017ho
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– Never perform procedures in and near basement staircases

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or other below ground areas.

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– Switch on the exhaust extracting system.

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There Is a Risk of Getting Frostbite from the Refrigerant.

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Refrigerant can come out under pressure when working on the
A/C system. Frostbite on the skin and other parts of the body is

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possible.

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– Wear safety gloves.
– Wear protective eyewear.

e rcia

form
– Extract refrigerant and open the refrigerant circuit immediate‐

a
ly.

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tionin
or c
– If more than 10 minutes elapse after extracting the refrigerant

th i
te
and the refrigerant circuit was not opened, extract the refrig‐
iva

d s
o
erant again. Pressure can develop in the refrigerant circuit due
pr

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to evaporation.

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1.3 Start/Stop System Safety Precautions t. Co py

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WARNING cte d ag e n
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There Is A Risk of Injury from the Engine Starting Unexpectedly.

The engine can start unexpectedly on vehicles with an activated
Start/Stop System. A visible message appears in the instrument
cluster indicating whether the Start/Stop System is activated.

– Deactivate the Start/Stop System: Turn off the ignition.

1.4 High Voltage System Safety Precau‐

tions
DANGER
Extremely Dangerous Due to High Voltage.
The high voltage system is under high voltage. Death or serious
bodily injury by electric shock.

– Individuals with electronic/medical life- and health sustaining

machines in or on their person cannot perform any work on
high voltage systems. Life- and health sustaining machines
are for example pain killer pumps, implanted defibrillators,
pacemakers, insulin pumps, and hearing aids.
– Have the high voltage system de-energized by a qualified per‐
son.

WARNING
There Is A Risk of Injury from the Engine Starting Unexpectedly.
On electric - hybrid vehicles an active ready mode is difficult to
identify. Parts of the body can be clamped or pulled.

– Turn off the ignition.

– Place the ignition key outside of the vehicle interior.

2 Rep. Gr.00 - General, Technical Data

 AG. Volkswag e nAG d
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Heating,u tVentilation
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CAUTION

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Risk of Damaging the High Voltage Cables.

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Misuse can damage the insulation of high voltage cables or high

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voltage connectors.

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u rpose s, inpart or inwh
– Never support objects on the high voltage cables and the high

t toth e co tne ss of inform

voltage connectors.
– Never support tools on the high voltage cables and the high

rre c
voltage connectors.
– Never sharply bend or kink the high voltage cables.
– When connecting pay attention to the coding of the high volt‐

cial p
age connectors.
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WARNING

ion
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There Is a Risk of Injury When the Auxiliary Climate Control Is

h is
ate
Activated.

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When the auxiliary climate control is activated on electric and

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ng
t.
hybrid vehicles, the auxiliary climate control can turn on unin‐
i
py Co
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tentionally. Parts of the body may be pinched or pulled by
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automated radiator fans.
g h
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– Deactivate the auxiliary climate control.

1.5 Safety Precautions near High Voltage

Components
DANGER
Extremely Dangerous Due to High Voltage
The high voltage system is under high voltage. Electrocution
can cause death or very serious personal injury from damages
high voltage components and high voltage cables.

– Perform a visual inspection of the high voltage components

and the high voltage cables.
– Never use tools that are for cutting, deformed, or sharp edged.
– Never use welding, soldering, thermal adhesive or hot air.

1.6 Cooling System Safety Precautions

WARNING
There Is A Risk of Burning from Hot Coolant
The cooling system is under pressure when the engine is warm.
There is a risk of scalding from hot steam and coolant.

– Wear protective gloves.

– Wear protective eyewear.
– Reduce the pressure: cover the coolant reservoir cap with a
cloth and carefully open.

1. Safety Precautions 3
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

1.7 Safety Precautions when Working with

Parking/Auxiliary Heater
There Is a Risk of Fire and Explosion by the Parking/Auxiliary
Heater
In areas that are subject to fire and explosion, a spark or the high
temperature of the parking/auxiliary heater can ignite a fire or
cause an explosion. It is possible to be burned.
– In areas that are subject to fire and explosion, switch off the
parking/auxiliary heater.
Risk of Poisoning from the Exhaust Fumes
The parking/auxiliary heater produces poisonous exhaust fumes.
Respiratory system injury and poisoning are possible.
– Only switch on the parking/auxiliary heater in closed areas
with an exhaust extracting system.
– Switch off the parking/auxiliary heater in closed areas with no
exhaust extracting system. ag e n
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Risk of Damage by Engine Start e d by gu
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It is possible to damage the parking/auxiliary heater when
au
th fuel or
ac
system components and parking/auxiliary heater coolant ss circuit
components are removed or opened.

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– Never start the engine when these system components are

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removed or opened.

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Malfunctions Due to Air in the Fuel Supply

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After working on the fuel tank or the fuel delivery unit, the metering

spe
pump draws in air and sends the air to the parking/auxiliary heat‐
u rpose s, inpart or inwh

ct toth e
er. Parking/auxiliary heater malfunctions due to air in the parking/
auxiliary heater fuel supply are possible.

corre ctne ss of in
– Fill the fuel extraction tube with fuel.
Risk of Accident and Injury by the Activated Parking/Auxiliary
Heater Timer
cial p

For vehicles with an activated timer for the parking/auxiliary heat‐

form
er, the parking/auxiliary heater can turn on unintentionally. Poi‐
me r

soning by exhaust fumes and burns from hot parking/auxiliary

a
m

ti
heater components are possible, as well as the risk of fire and
r co

onin
explosion due to high temperatures.
o

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– Deactivate the timer for the parking/auxiliary heater.

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4 Rep. Gr.00 - General, Technical Data

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

AG. Volkswag e nAG d

ag e n
2 General Information Volksw
oe s
not
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e
⇒ “2.1 Odors in Vehicles with A/C System”, page ht o
ri 5
s nte
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au ra
⇒ “2.2 Information for Vehicles with Start/Stop
ss System”, c
page 5

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2.1 Odors in Vehicles with A/C System

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♦ If there are unpleasant odors coming from the evaporator,

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clean the evaporator.

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♦ For cleaning the evaporator, Volkswagen has tested and ap‐

u rpose s, inpart or inwh

proved the -VAS6189B- as well as the -VAG1538- with a

t toth e co tne ss of inform

suitable spray nozzle.
♦ Instructions for cleaning the evaporator are provided with the

rre c
tools.
♦ Refer to ⇒ Refrigerant R1234yf Servicing; Rep. Gr. 87 ; Re‐
frigerant Circuit; Possible Complaints or ⇒ Refrigerant R134a
cial p

Servicing; Rep. Gr. 00 ; Concerns; Odor from the Heater and

A/C Unit .
me r

a
2.2 Information for Vehicles with Start/Stop
m

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System
o

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Pay Attention to the Safety Precautions for Vehicles with a Start/
p

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m
Stop System. Refer to

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t.
⇒ “1.3 Start/Stop System Safety Precautions”, page 2 .
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If the vehicle has a start-stop system, perform the following ter‐
h g h
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mination conditions to deactivate the start-stop function: y cop Vo
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Prote AG.
♦ Use the Start/Stop button to switch off the Start/Stop System.
♦ The battery charge level does not make it possible to start the
engine again (start voltage prediction).
♦ The defrost function is active.
♦ The windshield defogger is active.
♦ The selected temperature deviates more than 8 °C (46.4 °F)
from the actual temperature inside the vehicle.
♦ The engine speed exceeds 1,200 RPM.
♦ The Generator - C- is faulty, for example, the ribbed belt is torn.
♦ The coolant temperature is not in the specified range of 25 °C
to 100 °C (77 to 212 °F).
♦ Increasing the blower speed by more than four increments.
Further Information:
♦ Refer to Self Study Program No. 426; Start/Stop System 2009
for more information.

2. General Information 5
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

3 Repair Information
⇒ “3.1 Working on Refrigerant Circuit”, page 6
⇒ “3.2 General Repair Information”, page 6 nAG. Volkswag e nAG d o
wag e es n
Volks ot g
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⇒ “3.3 Refrigerant Circuit Seals”, page 6 e db ran
ris te e
th o
or
3.1 Working on Refrigerant Circuit
ss
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In some countries, other qualifications are required when opening

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the refrigerant circuit.

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Further Information

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♦ Additional information on vehicles with A/C and handling re‐

h re
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frigerant. Refer to ⇒ Refrigerant R1234yf Servicing; Rep. Gr.

spe c
00 ; Safety Precautions or ⇒ Refrigerant R134a Servicing;
u rpose s, inpart or inwh

Rep. Gr. 00 ; A/C System General Information; Safety Pre‐

t toth e co tne ss of inform

cautions when Working on Vehicles with A/C and Refrigerant
R134a .

rre c
♦ Information regarding work using the A/C Service Station on
vehicles with A/C. Refer to ⇒ Refrigerant R1234yf Servicing;
Rep. Gr. 87 ; Working with A/C Service Station or ⇒ Refrig‐
erant R134a Servicing; Rep. Gr. 00 ; Working with A/C Service
cial p

Station .
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♦ Condition and procedure for flushing with refrigerant R1234yf.

a
m

ti
Refer to ⇒ Refrigerant R1234yf Servicing; Rep. Gr. 87 ; Re‐
r co

onin
frigerant Circuit; Refrigerant Circuit, Cleaning or ⇒ Refrigerant
o

th i
e

R134a Servicing; Rep. Gr. 00 ; Refrigerant Circuit, Removing

t
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d s
Contamination; Refrigerant Circuit, Flushing (Cleaning) with

o
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cu
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Refrigerant R134a .

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♦ Information for testing equipment and special tools when re‐ Cop py
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pairing vehicles with A/C can be found in ELSA. Refer to ⇒ yri
g t by h
Refrigerant R1234yf Servicing; Rep. Gr. 87 ; Tools and Test‐ cop Vo
by lksw
ing Equipment (7P6 only) or ⇒ Refrigerant R134a Servicing;
cte d ag e n
Prote AG.
Rep. Gr. 00 ; Test Equipment and Tools .
♦ Under certain conditions, the desiccant bag/dryer cartridge no
longer needs to be replaced each time the refrigerant circuit is
opened on A/C systems with refrigerant R1234yf. Refer to ⇒
Refrigerant R1234yf General Information; Rep. Gr. 87 ; Re‐
frigerant Circuit; Components, Replacing .
♦ Under certain conditions, the dryer bag should no longer be
replaced each time the refrigerant circuit is opened on A/C
systems with refrigerant R134a. Refer to ⇒ Refrigerant R134a
Servicing; Rep. Gr. 00 ; Replacing Components .

3.2 General Repair Information

No components of the heating and A/C system can be serviced.
Replace faulty components using original parts.

3.3 Refrigerant Circuit Seals

♦ Replace the seals after removing.
♦ Coat the seals with refrigerant oil before installing.
♦ Make sure the seals are positioned correctly on the pipe or in
the groove.
♦ Ensure cleanliness when working. Even the smallest contam‐
inant, a hair for example, can cause a leak.
♦ Only install seals that are resistant to refrigerant R134a /
R1234yf and the corresponding refrigerant oil. Refer to Parts
Catalog.

6 Rep. Gr.00 - General, Technical Data

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

The dimensions -a and B- are dependent on the component lo‐

cation of the seal. Refer to Parts Catalog.

nAG. Volkswag e nAG d o

wag e es n
Volks ot g
d by ua
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th o
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3. Repair Information 7
 n AG. Volkswag e nAG d
Touareg 2010 ➤ , Touareg 2015 ➤ wag e oe s
olks not
Heating, Ventilation and Air Conditioning - EditionbyV
06.2017 gu
ara
d e
ris nte
tho e or
au ac
ss
4 Technical Data

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an
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⇒ “4.1 Refrigerant R134a Capacities”, page 8

itte

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rm

ab
⇒ “4.2 Refrigerant Oil”, page 8

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wit
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⇒ “4.3 Oil Distribution”, page 9

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spe c
4.1 Refrigerant R134a Capacities

u rpose s, inpart or inwh

t toth e co tne ss of inform

⇒ “4.1.1 Refrigerant R1234yf Capacities”, page 8
⇒ “4.1.2 Refrigerant R134a Capacities”, page 8

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4.1.1 Refrigerant R1234yf Capacities
System Type Total Capacity
cial p

Vehicles with one evaporator Refer to ⇒ Fluid Capacity Ta‐

me r

bles; Rep. Gr. 03 ; Touareg

a
m

tion
o

Vehicles with two evaporators Refer to ⇒ Fluid Capacity Ta‐

c

int
or

bles; Rep. Gr. 03 ; Touareg

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Note
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A filling tolerance of ± 15 grams is permitted due to type label
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differences. by lksw
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Prote AG.

4.1.2 Refrigerant R134a Capacities

System Type Total Capacity
Vehicles with one evaporator Refer to ⇒ Fluid Capacity Ta‐
bles; Rep. Gr. 03 ; Touareg
Vehicles with two evaporators Refer to ⇒ Fluid Capacity Ta‐
bles; Rep. Gr. 03 ; Touareg

4.2 Refrigerant Oil

There are different refrigerant oils depending on the manufactur‐
er. Refer to the Parts Catalog for the part number.
Refrigerant oil attracts moisture. Because of this, refrigerant oil
that was stored for long periods of time in an open container is
unusable.
– Close opened containers immediately after use to prevent
moisture contamination.
Type Total Capacity 1
Touareg with one evapora‐ Refer to ⇒ Fluid Capacity Tables;
tor 6SEU14 Rep. Gr. 03 ; Touareg
Touareg with a second Refer to ⇒ Fluid Capacity Tables;
evaporator 6SEU14 Rep. Gr. 03 ; Touareg
Touareg with an evapora‐ Refer to ⇒ Fluid Capacity Tables;
tor 7SEU17C Rep. Gr. 03 ; Touareg
Touareg with second Refer to ⇒ Fluid Capacity Tables;
evaporator 7SEU17C Rep. Gr. 03 ; Touareg
Touareg with one evapora‐ Refer to ⇒ Fluid Capacity Tables;
tor ES34 Rep. Gr. 03 ; Touareg
1)This quantity of refrigerant oil is included in a replacement A/C
compressor and equates to the total capacity.

8 Rep. Gr.00 - General, Technical Data

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

2)This quantity of refrigerant oil should also be supplied to the

refrigerant circuit on systems with two evaporators.

4.3 Oil Distribution

♦ When the A/C system is being used, the refrigerant oil that was
in the A/C compressor before switching on the A/C system for
the first time is distributed throughout the entire refrigerant cir‐
cuit.
♦ Depending on the previous operating condition of the A/C sys‐
tem before switching it off, the ambient temperatures, etc., the
distribution of the refrigerant oil in the refrigerant circuit varies.
A general statement about the refrigerant oil distribution in the
refrigerant circuit is therefore not possible. Pay attention to the
information about the replacement of refrigerant circuit com‐
ponents. Refer to ⇒ Refrigerant R134a Servicing; Rep. Gr.
00 ; Components, Replacing or ⇒ Refrigerant R1234yf Serv‐
icing; Rep. Gr. 87 ; Refrigerant Circuit; Components, Replac‐
ing .

AG. Volkswag e nAG d

ag e n oe s
olksw not
V gu
d by ara
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th o e or
au ac
ss

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ab
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is n

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ate

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Prote AG.

4. Technical Data 9
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

80 – Heating, Ventilation
1 Heating

Note

♦ At this time only one heater with A/C system is installed in the
Touareg.
♦ For repair information. Refer to
⇒ G r.87 “Air Conditioning”, page 11 .

AG. Volkswag e nAG d

ag e n oe s
olksw not
V gu
d by ara
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th o e or
au ac
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Prote AG.

10 Rep. Gr.80 - Heating, Ventilation

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

87 – Air Conditioning
1 Component Location Overview - A/C
System
⇒ “1.1 Component Location Overview - Components Outside of
Passenger Compartment”, page 11

1.1 Component Location Overview - Com‐

ponents Outside of Passenger Com‐
partment
⇒ “1.1.1 Component Location Overview - Components Outside of
Passenger Compartment, Climatronic”, page 11

1.1.1 Component Location Overview - Com‐

ponents Outside of Passenger Com‐
partment, Climatronic

Note

♦ Under certain conditions, the desiccant bag/dryer cartridge no

kswag e nAG
. Voleach
longer needs to be replaced
swa
g e nAG time the
d oe srefrigerant circuit is
opened on A/C y V systems with refrigerant R1234yf.
olk not
g Refer to ⇒
Refrigerant e d bR1234yf General Information; Rep.u aGr. ran 87 ; Re‐
ris te e
frigerant
u t Circuit; Components, Replacing .
h o
or
sa ac
s
♦ Under certain conditions, the dryer bag no longer needs to be
ce
le
un

replaced each time the refrigerant circuit is opened on A/C

pt
an
d

systems with refrigerant R134a. Refer to ⇒ Refrigerant R134a

itte

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Servicing; Rep. Gr. 00 ; Replacing Components .

rm

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e

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lksw
cte d ag e n
Prote AG.

1. Component Location Overview - A/C System 11

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017
. Volkswag e nAG
wa g e nAG d oe
1 - Air Quality Sensor - G238- olks s no
tgu
byV ara
❑ Removing and instal‐ ris
ed nte
ling. Refer to tho e or
au
⇒ “10.2 Air Quality Sen‐ ac
ss
sor G238 , Removing

ce
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pt
and Installing”,

an
d
itte
page 126

y li
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ab
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2 - High Pressure Sensor -

wit
G65-
is n

h re
ole ,

❑ Removing and instal‐

spe c
ling. Refer to
u rpose s, inpart or inwh

⇒ “2.5 High Pressure

t toth e co tne ss of inform

Sensor G65 , Removing
and Installing”,
page 25 .

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3 - Right Front Upper Body
Vent Temperature Sensor -
G386-
cial p

❑ Removing and instal‐

me r

ling. Refer to

a
m

t
⇒ “10.8 Right Front Up‐

i
r co

onin
per Body Vent Temper‐
o

th i
ature Sensor G386 and
te
ir va

d s
Left Front Upper Body

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Vent Temperature Sen‐
r
fo

m
en
sor G385 , Removing
ng

t.
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and Installing”, Cop py
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page 129 . yri
g t by h
cop by
Vo
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4 - Fresh Air Blower - V2- Prote
cte d ag e n
AG.
❑ Removing and instal‐
ling. Refer to
⇒ “6.7 Rear Fresh Air
Blower V80 , Removing
and Installing”,
page 100 .
5 - Evaporator Temperature
Sensor - G308-
❑ Removing and installing. Refer to
⇒ “5.7 Evaporator Temperature Sensor G308 , Removing and Installing”, page 80 .
6 - Sunlight Photo Sensor - G107-
❑ Removing and installing. Refer to
⇒ “10.1 Sunlight Photo Sensor G107 , Removing and Installing”, page 125 .
7 - A/C Humidity Sensor - G260-
❑ Checking: via the Vehicle Electrical System Control Module - J519- using the Vehicle Diagnostic Tester
in “Guided Fault Finding” function an. Refer to ⇒ Wiring diagrams, Troubleshooting & Component loca‐
tions.
❑ Removing and installing. Refer to
⇒ “10.5 A/C Humidity Sensor G260 , Removing and Installing”, page 128 .
8 - Right Footwell Vent Temperature Sensor - G262-
❑ Removing and installing. Refer to
⇒ “10.1 Sunlight Photo Sensor G107 , Removing and Installing”, page 125 .
9 - Climatronic Control Module - J255-
❑ The Climatronic Control Module - J255- , Front A/C Display Control Head - E87- and the Instrument Panel
Temperature Sensor - G56- with the Interior Temperature Sensor Fan - V42- are one component that
cannot be disassembled.
❑ Removing and installing. Refer to
⇒ “9.2 Display and Control Head, Removing and Installing”, page 120 .

12 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

10 - Left Front Upper Body Vent Temperature Sensor - G385-

❑ Removing and installing. Refer to
⇒ “10.8 Right Front Upper Body Vent Temperature Sensor G386 and Left Front Upper Body Vent Tem‐
perature Sensor G385 , Removing and Installing”, page 129 .
11 - Recirculation Pump - V55-
12 - Left Footwell Vent Temperature Sensor - G261-
❑ Removing and installing. Refer to
⇒ “10.6 Left Footwell Vent Temperature Sensor G261 , Removing and Installing”, page 128 .
13 - A/C Compressor Regulator Valve - N280-
❑ The A/C Compressor Regulator Valve - N280- and A/C compressor cannot be disassembled.
❑ A/C compressor, removing and installing. Refer to
⇒ “3.1 A/C Compressor, Removing and Installing”, page 35 .
14 - Outside Air Temperature Sensor - G17-
❑ Removing and installing. Refer to
⇒ “10.4 Outside Air Temperature Sensor G17 , Removing and Installing”, page 127 .

nAG. Volkswag e nAG d o

wag e es n
Volks ot g
y ua
e db ran
ris te e
th o
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au ac
ss

ce
e
nl

pt
du

an
itte

y li
e rm

ab
ility
ot p

wit
is n

h re
ole ,

spe c
u rpose s, inpart or inwh

t toth e co tne ss of inform

rre c
cial p
me r

a
m

tion
co

int
or

h is
ate

do
iv
pr

cum
or
f

en
ng

t.
yi Co
Cop py
ht. rig
rig t by h
py Vo
d by co lksw
cte ag e n
Prote AG.

1. Component Location Overview - A/C System 13

 Touareg 2010 ➤ , Touareg 2015 ➤ nAG. Volkswag e nAG d o
wag e es n
olks
Heating, Ventilation and Air Conditioning y- VEdition 06.2017 ot g
b ua
ed ran
ris te e
tho or
au
2 Refrigerant Circuit ss
ac

ce
le
un

pt
⇒ “2.1 System Overview - Refrigerant Circuit”, page 14

an
d
itte

y li
rm
⇒ “2.2 Evacuating and Charging Valve, Removing and Installing,

ab
e

ility
ot p
Low and High Pressure Side”, page 18

wit
is n
⇒ “2.3 Dryer Bag/Dryer Cartridge, Removing and Installing”, page

h re
ole ,
20

spe c
u rpose s, inpart or inwh
⇒ “2.4 A/C Compressor, Installation Information”, page 24

t toth e co tne ss of inform

⇒ “2.5 High Pressure Sensor G65 , Removing and Installing”,
page 25

rre c
⇒ “2.6 Expansion Valve, Removing and Installing”, page 26
⇒ “2.7 Condenser, Removing and Installing”, page 31
cial p

2.1 System Overview - Refrigerant Circuit

me r

a
m

t
⇒ “2.1.1 System Overview - Refrigerant Circuit, Evaporator Sys‐

ion
co

tem 1”, page 14

int
or

h is
te
iva

⇒ “2.1.2 System Overview - Refrigerant Circuit, Evaporator Sys‐

do
pr

c
tem 2”, page 16

um
r
fo

en
ng

t.
2.1.1 System Overview - Refrigerant Circuit,
i
py Co
. Co py
rig
Evaporator System 1
h t
g h
yri t by
by cop Vo
lksw
cte d ag e n
Prote AG.

Note

♦ Extract the refrigerant using the A/C Service Station .

♦ Environmentally hazardous draining of refrigerant is an of‐
fense punishable by law.
♦ The previously used service stations can still be used see
equipment catalog.
♦ Safety measures when working on an evacuated refrigerant
circuit (refer to
⇒ “1.1 Safety Precautions when Working on Air Conditioning
Systems Safety Precautions”, page 1 ), notes regarding repair
work on vehicles with air conditioning and the handling of re‐
frigerant.
♦ All open refrigerant circuit components must be sealed with
suitable plugs to prevent any humidity from entering them.
♦ Pay attention to all safety precautions. Refer to
⇒ “1.3 Start/Stop System Safety Precautions”, page 2 .
♦ Under certain conditions, the desiccant bag/dryer cartridge no
longer needs to be replaced each time the refrigerant circuit is
opened on A/C systems with refrigerant R1234yf. Refer to ⇒
Refrigerant R1234yf General Information; Rep. Gr. 87 ; Re‐
frigerant Circuit; Components, Replacing .
♦ Under certain conditions, the dryer bag no longer needs to be
replaced each time the refrigerant circuit is opened on A/C
systems with refrigerant R134a. Refer to ⇒ Refrigerant R134a
Servicing; Rep. Gr. 00 ; Replacing Components .

14 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

1 - Expansion Valve
❑ Removing and instal‐
ling. Refer to
⇒ “2.6 Expansion Valve,
Removing and Instal‐
ling”, page 26 .
2 - High Pressure Sensor -
G65-
❑ Removing and instal‐
ling. Refer to
⇒ “2.5 High Pressure AG. Volkswag e nAG d
ag e n oe s
lksw not
Sensor G65 by
V, Removing
o gu
ara
d
and Installing”,
e
ris nte
page t o
h 25 . eo
u a r ac
ss
3 - Refrigerant Line with Inner

ce
le
un

Heat Exchanger

pt
an
d
itte

y li
e rm

ab
Note

ility
ot p

wit
is n

In this refrigerant line, the liquid

h re
ole ,

warm refrigerant flowing on the high

spe c
pressure side releases energy into
u rpose s, inpart or inwh

the vaporous cold refrigerant flow‐

t toth e co tne ss of inform

ing on the low pressure side. This
increases the efficiency of the Air
Conditioning (A/C) system and min‐

rre c
imizes fuel consumption.

4 - Evacuating and Charging

cial p

Valve
me r

❑ High pressure side

a
m

❑ Environmentally haz‐
i
r co

onin

ardous draining of re‐

o

th i

frigerant is an offense
te
ir va

d s

punishable by law.
o
p

cu
r
fo

❑ Removing and instal‐

en
ng

i t.
ling. Refer to py Co
Co py
⇒ “2.2 Evacuating and Charging Valve, Removing and Installing, Low and High Pressure Side”,
h t. rig
g h
page 18 . yri t by
by cop Vo
lksw
❑ Capacities. Refer to ⇒ “4.1 Refrigerant R134a Capacities”, page 8 .
cte d ag e n
Prote AG.

5 - Evacuating and Charging Valve

❑ Low pressure side
❑ Environmentally hazardous draining of refrigerant is an offense punishable by law.
❑ Removing and installing. Refer to
⇒ “2.2 Evacuating and Charging Valve, Removing and Installing, Low and High Pressure Side”,
page 18 .
❑ Capacities. Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03 .
6 - A/C Compressor
❑ Pay attention to notes for installing A/C compressor. Refer to
⇒ “2.4 A/C Compressor, Installation Information”, page 24 .
❑ Removing and installing. Refer to ⇒ “3.1 A/C Compressor, Removing and Installing”, page 35 .
7 - Condenser
❑ Removing and installing. Refer to ⇒ “2.7 Condenser, Removing and Installing”, page 31 .

2. Refrigerant Circuit 15
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

8 - Receiver/Dryer with Dryer Bag

Note

♦ Under certain conditions, the

desiccant bag/dryer cartridge no
longer needs to be replaced
each time the refrigerant circuit is
opened on A/C systems with re‐
frigerant R1234yf. Refer to ⇒
Refrigerant R1234yf General In‐
formation; Rep. Gr. 87 ; Refrig‐
erant Circuit; Components, Re‐
placing .
♦ Under certain conditions, the
dryer bag no longer needs to be
replaced each time the refriger‐
ant circuit is opened on A/C sys‐
tems with refrigerant R134a. Re‐
fer to ⇒ Refrigerant R134a
Servicing; Rep. Gr. 00 ; Replac‐
ing Components .
❑ Desiccant bag, Removing. Refer to
⇒ “2.3 Dryer Bag/Dryer Cartridge, Removing and Installing”, page 20 .

2.1.2 System Overview - Refrigerant Circuit,

Evaporator System 2

Note
AG. Volkswag e nAG d
ag e n oe s
lksw
♦ Under certain conditions, the desiccant bag/dryerVocartridge no not
by gu
longer needs to be replaced each time the refrigerant
ed circuit is ara
nte
opened on A/C systems with refrigerant R1234yf.
o ris Refer to ⇒ e
th or
Refrigerant R1234yf General Information;au Rep. Gr. 87 ; Re‐ ac
ss
frigerant Circuit; Components, Replacing .
ce
le
un

pt

♦ Under certain conditions, the dryer bag no longer needs to be

an
d
itte

y li

replaced each time the refrigerant circuit is opened on A/C

rm

ab

systems with refrigerant R134a. Refer to ⇒ Refrigerant R134a

e

ility
ot p

Servicing; Rep. Gr. 00 ; Replacing Components .

wit
is n

h re
ole ,

spe c
u rpose s, inpart or inwh

t toth e co tne ss of inform

rre c
cial p
me r

a
m

tion
co

int
or

h is
te
iva

d o
pr

cu
r
fo

m
en
ng

t.
yi Co
Cop py
ht. rig
g h
yri t by
cop by
Vo
lksw
cte d ag e n
Prote AG.

16 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

1 - Refrigerant Line
❑ High pressure side
❑ Below rear left wheel
housing liner
2 - O-ring
❑ Always replace
❑ 9.5 mm; 2.5 mm
3 - O-ring
❑ Always replace
❑ 13.7 mm; 2.5 mm
4 - Cylindrical Combi-Screw
M8x28
❑ 12 Nm ± 1 Nm
❑ Quantity: 2
5 - Refrigerant Line
❑ Low pressure side
❑ Below rear left wheel
housing liner AG. Volkswag e nAG d
ag e n oe s
olksw not
6 - Cylindrical Combi-Screw d byV gu
ara
M6x35 rise nte
ht o eo
❑ 3.5 Nm ± 0.5a Nm
u ra
c
ss

ce
le

7 - Cylindrical Combi-Screw
un

pt
M6x35
an
d
itte

y li
e rm

❑ 3.5 Nm ± 0.5 Nm
ab
ility
ot p

8 - Cylindrical Combi-Screw wit

is n

M6x70 h re
ole ,

spe c
❑ 3.5 Nm ± 0.5 Nm
u rpose s, inpart or inwh

t toth e co tne ss of inform

9 - Cylindrical Combi-Screw
M6x70
❑ 3.5 Nm ± 0.5 Nm
rre c

10 - O-ring
❑ Always replace
cial p

❑ 13.7 mm; 2.5 mm

me r

11 - O-ring
a
m

tion
r co

❑ Always replace
int
o

❑ 9.5 mm; 2.5 mm

h is
ate

do
ir v
p

12 - Refrigerant Line
cum
r
fo

en

❑ Low pressure side

ng

i t.
py Co
❑ On the underbody t. Co py
rig
h g h
yri t by
13 - Refrigerant Line y cop Vo
lksw
b
cte d ag e n
❑ High pressure side Prote AG.

❑ On the underbody
14 - Screw M6x16
❑ 8 Nm ± 1.2 Nm
15 - Auxiliary Component Bracket
16 - Screw M6x16
❑ 8 Nm ± 1.2 Nm

2. Refrigerant Circuit 17
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

17 - Spacer
18 - Cylindrical Combi-Screw M6x35
❑ 3.5 Nm ± 0.5 Nm
19 - Cylindrical Combi-Screw M6x35
❑ 3.5 Nm ± 0.5 Nm
20 - Damper
21 - O-ring
❑ Always replace
❑ 9.5 mm; 2.5 mm
22 - Cylindrical Combi-Screw M8x28
❑ 12 Nm ± 1 Nm
23 - Refrigerant Line
❑ High pressure side
❑ Under front left wheel housing liner
24 - O-ring
❑ Always replace
❑ 13.7 mm; 2.5 mm
25 - Cylindrical Combi-Screw M8x28
❑ 12 Nm ± 1 Nm
26 - Refrigerant Line
❑ Low pressure side
❑ Under front left wheel housing liner
nAG. Volkswag e nAG d o
wag e es n
Volks ot g
by ua
d ran
2.2 Evacuating
th
and Charging Valve, Re‐
orise te e
or
moving au and Installing, Low and High ac
ss
Pressure Side
ce
le
un

pt
an
d
itte

y li

Special tools and workshop equipment required

rm

ab
pe

ility

♦ Refrigerant Sockets - T10364-

ot

wit
, is n

h re

♦ Torque Wrench 1783 - 2-10Nm - VAG1783-

h ole

spe c

♦ Engine Bung Set - VAS6122-

e s, inpart or inw

t toth e co tne ss of inform

Removing
– Observe safety precautions when working on the high voltage
rre c

system. Refer to
⇒ “1.4 High Voltage System Safety Precautions”, page 2 .
l pu rpos

– Pay attention to safety precautions for working near high volt‐

age components. Refer to
e rcia

⇒ “1.5 Safety Precautions near High Voltage Components”,

m

page 3 .
at
com

ion

– Note the high voltage system danger classification. Refer to

int
r
te o

h is

⇒ Electrical System Hybrid; Rep. Gr. 93 ; High Voltage Sys‐

iva

tem General Warnings .

o
r
rp

cu
fo

– See notes. Refer to

en
ng

t.
yi Co
⇒ “3.1 Working on Refrigerant Circuit”, page 6 . . Cop py
rig
ht h
rig t by
py Vo
d by co lksw
cte ag e n
Prote AG.

18 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

DANGER
Danger to life due to high voltage.
Death or serious bodily injury by electric shock.
– Have the high voltage system de-energized by a qualified
person.

– Switch off the high voltage system. Refer to ⇒ Electrical Sys‐

tem Hybrid; Rep. Gr. 93 ; Disabling the High Voltage System .
Vehicles with Refrigerant R134a
– Drain the refrigerant circuit. Refer to ⇒ Refrigerant R134a
Servicing; Rep. Gr. 00 ; Working with A/C Service Station .
Vehicles with Refrigerant R1234yf
nAG. Volkswag e nA
ge G do
k swa not es
Vol
– Drain thebyrefrigerant circuit. Refer to ⇒ Refrigerant
gu R1234yf
d ara
Servicing;
rise Rep. Gr. 87 ; Working with A/C Service nte Station;
ho
Refrigerant Circuit, Discharging . eo
ut a r ac
ss
Continuation for All Vehicles

ce
le
un

pt
an
d
itte

CAUTION

y li
rm

ab
e

ility
ot p

Danger or frostbite due to refrigerant coming out under pres‐

wit
is n

sure.

h re
ole ,

Frostbite on the skin and other parts of the body is possible.

spe c
u rpose s, inpart or inwh

– Wear safety gloves.

t toth e co tne ss of inform
– Wear protective eyewear.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately.
rre c

– If more than 10 minutes elapse after extracting the refriger‐

ant and the refrigerant circuit was not opened, extract the
refrigerant again. Evaporation can cause pressure to devel‐
cial p

op in the refrigerant circuit.

me r

a
m

tion

– For all the following work, close the open lines and connec‐
co

int

tions with clean plugs from the -VAS6122- .

or

h is
te
iva

do
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig t by h
py Vo
d by co lksw
cte ag e n
Prote AG.

2. Refrigerant Circuit 19
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

Note

Ignore items -1 and 3-

– Remove the valve insert -2- using the -T10364- .

AG. Volkswag e nAG d
Installing ag e n oe s
olksw not
V gu
by ara
Install in reverse order of removal and note the following: rise d
nte
th o e or
au ac
NOTICE ss

ce
le
un

pt
There is a risk of damaging the A/C compressor if the refrigerant

an
d
itte
circuit is empty.

y li
rm

ab
– Never start the engine with the refrigerant circuit empty.

ility
ot p

wit
is n

h re
Vehicles with Refrigerant R134a ole ,

spe c
u rpose s, inpart or inwh

– Fill the refrigerant circuit. Refer to ⇒ Refrigerant R134a Serv‐

t toth e co tne ss of inform

icing; Rep. Gr. 00 ; Working with A/C Service Station .
– Perform the leak test on the closed line connections of the
refrigerant circuit. Refer to ⇒ Refrigerant R134a Servicing;

rre c
Rep. Gr. 00 ; Refrigerant Circuit, Detecting Leaks .
Vehicles with Refrigerant R1234yf
cial p

– Fill the refrigerant circuit. Refer to ⇒ Refrigerant R1234yf

Servicing; Rep. Gr. 87 ; Working with A/C Service Station;
me r

Refrigerant Circuit, Filling .

a
m

tion
co

int
– Perform the leak test on the closed line connections of the
or

h is
te

refrigerant circuit. Refer to ⇒ Refrigerant R1234yf Servicing;

iva

do
Rep. Gr. 87 ; Refrigerant Circuit; Determining Leaks .
pr

cum
r
fo

en
Tightening Specifications
ng

i t.
py Co
t. Co py
rig
h g h
Component Tightening Specification
yri t by
y cop Vo
lksw
b
cte d
Valve insert -2- 2 Nm
ag e n
Prote AG.

2.3 Dryer Bag/Dryer Cartridge, Removing

and Installing
Special tools and workshop equipment required
♦ Torque Wrench 1410 - VAG1410-
♦ Engine Bung Set - VAS6122-

Caution

This procedure contains mandatory replaceable parts. Refer

to component overview prior to starting procedure.

Mandatory Replacement Parts

♦ Cap
♦ O-rings - Cap
♦ Dryer Bag

20 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

Removing
– Observe safety precautions when working on the high voltage
system. Refer to
⇒ “1.4 High Voltage System Safety Precautions”, page 2 .
– Pay attention to safety precautions for working near high volt‐
age components. Refer to
⇒ “1.5 Safety Precautions near High Voltage Components”,
page 3 .
– Note the high voltage system danger classification. Refer to
⇒ Electrical System Hybrid; Rep. Gr. 93 ; High Voltage Sys‐
tem General Warnings .
– See notes. Refer to
⇒ “3.1 Working on Refrigerant Circuit”, page 6 .
– Extract the refrigerant using the A/C Service Station , only then
open the refrigerant circuit.
Additional Work for Vehicles with a TDI Engine
– Loosen the right upper charge air hose. Refer to ⇒ Rep. Gr.
21 .
Additional Work for Hybrid Vehicles

DANGER
Danger to life due to high voltage.
AG. Volkswag e nAG d
Death or serious bodily injury by electric ag e n oe s
olksw shock. not
V gu
by ara
– Have the high voltage system ir se de-energized by a qualified
d
nte
person. u th o eo
r
a ac
ss

ce
le

– Switch off the high voltage system. Refer to ⇒ Electrical Sys‐

un

pt
an
d

tem Hybrid; Rep. Gr. 93 ; Disabling the High Voltage System .

itte

y li
e rm

– Remove the coolant reservoir and move it to the side. Refer ab

ility
ot p

to ⇒ Rep. Gr. 19 . wit

is n

h re
Continued for All Engines
ole ,

spe c
u rpose s, inpart or inwh

– Remove the center air grille -3- and, if equipped, the license
t toth e co tne ss of inform

plate holder -2-. Refer to ⇒ Body Exterior; Rep. Gr. 63 ; Front

Bumper Cover; Center Vent Grille, Removing and Installing .
rre c
cial p
me r

a
m

tion
r co

int
o

h is
ate

do
riv
p

cum
r
fo

en
ng

t.
yi Co
Cop py
h t. g
rig
h
yri t by
by cop Vo
lksw
cte d ag e n
Prote AG.

2. Refrigerant Circuit 21
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Fold up the air guide on the left and right -arrow- and remove nAG. Volkswag e nAG d o
wag e es n
the bolts -A- (25 Nm). Volks ot g
y b ua
ed ran
ris te e
u th o or
a ac
ss

ce
le
un

pt
an
d
itte

y li
rm

ab
e

ility
ot p

wit
is n

h re
ole ,

spe c
u rpose s, inpart or inwh

t toth e co tne ss of inform

– Push the radiator toward the engine and remove the clips
-arrows- on top of the radiator.

rre c
cial p
me r

a
m

tion
co

int
or

h is
te
iva

do
pr

cum
r
fo

en
ng

t.
yi Co
op py
– Push the locking pins -B- in both radiator mount -A- in direction
. C rig
ht h
rig
of -arrow- and remove them.
t by
py Vo
d by co lksw
cte ag e n
– Push the radiator carefully toward the engine compartment Prote AG.
and secure it.
Vehicles with Refrigerant R134a
– Drain the refrigerant circuit. Refer to ⇒ Refrigerant R134a
Servicing; Rep. Gr. 00 ; Working with A/C Service Station .
Vehicles with Refrigerant R1234yf
– Drain the refrigerant circuit. Refer to ⇒ Refrigerant R1234yf
Servicing; Rep. Gr. 87 ; Working with A/C Service Station;
Refrigerant Circuit, Discharging .
Continuation for All Vehicles

CAUTION
Danger or frostbite due to refrigerant coming out under pres‐
sure.
Frostbite on the skin and other parts of the body is possible.
– Wear safety gloves.
– Wear protective eyewear.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately.
– If more than 10 minutes elapse after extracting the refriger‐
ant and the refrigerant circuit was not opened, extract the
refrigerant again. Evaporation can cause pressure to devel‐
op in the refrigerant circuit.

22 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning
e nAG. V
olkswag e- n
Edition
AG 06.2017
ag d oe s
ksw not
Vol gu
– Remove the cap -1-. d by ara
e nte
ris
– Remove the desiccant bag -2- in direction of -arrow- th o e
au using
or
ac
needle nose pliers. ss

ce
le
un

pt
– Immediately seal the open receiver/dryer with clean plugs

an
d
itte
from the -VAS6122- .

y li
rm

ab
e

ility
ot p
Installing

wit
is n
Install in reverse order of removal and note the following:

h re
ole ,

spe c
u rpose s, inpart or inwh

t toth e co tne ss of inform

Note

Replace the cap, seal and desiccant bag after every opening of

rre c
the receiver/dryer. Refer to Parts Catalog.

– Coat the new seals with refrigerant oil before installing the re‐
cial p
frigerant line.
me r
– Using the opening, inspect the receiver/dryer on the condens‐

a
m

tion
o

er for dirt and damage on the threaded- and sealing surfaces

c

int
or

-B-.

h is
te
iva

do
– Replace the cap -A- and O-rings -C-. Refer to the Parts Cat‐
pr

cum
r
fo

alog.

en
ng

i t.
py Co
– Coat the O-rings -C- on the new cap -A- lightly with refrigerant . Co py
oil before installing.
h t rig
g h
yri t by
cop Vo
– Install the new desiccant bag -D-. Refer to the Parts Catalog.
by lksw
cte d ag e n
Prote AG.

Note

The high-voltage system must be turned off when charging the

refrigerant circuit.

– A second technician will be needed to install the radiator bolts.

NOTICE
There is a risk of damaging the A/C compressor if the refrigerant
circuit is empty.
– Never start the engine with the refrigerant circuit empty.

Vehicles with Refrigerant R134a

– Fill the refrigerant circuit. Refer to ⇒ Refrigerant R134a Serv‐
icing; Rep. Gr. 00 ; Working with A/C Service Station .
– Perform the leak test on the closed line connections of the
refrigerant circuit. Refer to ⇒ Refrigerant R134a Servicing;
Rep. Gr. 00 ; Refrigerant Circuit, Detecting Leaks .
Vehicles with Refrigerant R1234yf
– Fill the refrigerant circuit. Refer to ⇒ Refrigerant R1234yf
Servicing; Rep. Gr. 87 ; Working with A/C Service Station;
Refrigerant Circuit, Filling .
– Perform the leak test on the closed line connections of the
refrigerant circuit. Refer to ⇒ Refrigerant R1234yf Servicing;
Rep. Gr. 87 ; Refrigerant Circuit; Determining Leaks .
Tightening Specifications

2. Refrigerant Circuit 23
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

Component Tightening Specification

Cap -1- 12 Nm

2.4 A/C Compressor, Installation Informa‐

tion
Installing
– After installing a new A/C compressor or adding fresh refrig‐
erant oil (for example, after blowing through the refrigerant
circuit), turn the A/C compressor ribbed belt pulley 10 rotations
by hand before starting the engine. This prevents damage to
the A/C compressor. nAG. Volkswag e nAG d o
wag e e ks s no
Vol tgu
d by ara
e nte
ris
Note ho e
aut or
ac
ss

ce
♦ Start the engine only after assembling the refrigerant circuit.
e
nl

pt
du

an
itte

♦ Only start the engine when the refrigerant circuit is filled.

y li
e rm

ab
ility
ot p

♦ The A/C compressor is always driven by the ribbed belt pulley/

wit
is n

torsion elastic clutch. It does not have a magnetic clutch.

h re
ole ,

♦ If an A/C compressor locks-up the overload protection for the

spe c
A/C compressor shaft is triggered. An indication that the A/C
u rpose s, inpart or inwh

t toth e co tne ss of inform

compressor has locked-up is deformations/bumps on the rib‐
bed belt pulley/overload protection in front of A/C compressor,
but these are not always easy to detect. Another indicator is
abraded rubber material in the area of the ribbed belt pulley /

rre c
overload protection.
♦ The A/C compressor is equipped with a protected oil supply,
cial p

this prevents A/C compressor damage in the event that the

system is empty. This means that approximately 40 to 50
me r

cm3 of refrigerant oil remains in the A/C compressor.

a
m

tion
o

♦ The engine may only be started when the refrigerant circuit is

c

int
r
te o

installed correctly. For example; if the refrigerant lines are not

h is
a

connected to A/C compressor, when the engine is running the

do
riv
p

A/C compressor may heat up (via internal heat generation) so

um
or
f

much that the A/C compressor will be damaged.

en
ng

t.
yi Co
op py
♦ A/C Compressor Regulator Valve - N280- is not activated
. C rig
ht g h
when the refrigerant circuit is empty and the A/C compressor
yri t by
cop Vo
idles with the engine.
by lksw
cte d ag e n
Prote AG.
♦ If it is necessary to start the engine with a discharged refrig‐
erant circuit:
♦ Refrigerant circuit must be fully assembled.
♦ At least a quarter of the prescribed refrigerant oil must be in
the A/C compressor.
♦ Do not let the engine RPM go above 2,000.
♦ The engine should run less than 10 minutes and the A/C sys‐
tem should be switched off.
♦ Note safety precautions. Refer to
⇒ “1.3 Start/Stop System Safety Precautions”, page 2 .

– Pay attention to the following when starting the engine for the
first time after filling the refrigerant circuit:
– Start engine with A/C compressor switched off ( AC “off”) and
wait until the idling speed stabilizes.

24 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Open the instrument panel vents. nAG. Volkswag e nAG d o

lkswag e es n
Vo ot g
– Select the “Lo” temperature setting on the Front d bA/C Display
y ua
ran
Control Head - E87- . rise te e
ho t or
au ac
– Now switch the A/C compressor on (“Auto” ss mode or AC “on”)

ce
le
and let it run for at least five minutes at less than 1,500 RPM

un

pt
with the engine running.

an
d
itte

y li
e rm

ab
2.5 High Pressure Sensor - G65- , Remov‐

ility
ot p
ing and Installing

wit
is n

h re
ole ,

spe c
Special tools and workshop equipment required

u rpose s, inpart or inwh

t toth e co tne ss of inform

♦ Socket - 24mm - T40284-
♦ Torque Wrench 1410 - VAG1410-

rre c
♦ Engine Bung Set - VAS6122-

Caution
cial p

This procedure contains mandatory replaceable parts. Refer

me r

a
to component overview prior to starting procedure.
m

tion
r co

int
o

h is
ate

Mandatory Replacement Parts

do
ir v
p

cum
r
fo

♦ O-ring - High pressure sensor

en
ng

i t.
py Co
Removing t. Co py
rig
h g h
yri t by
– Observe safety precautions when working on the high voltage y cop Vo
lksw
b
system. Refer to cte d ag e n
Prote AG.
⇒ “1.4 High Voltage System Safety Precautions”, page 2 .
– Pay attention to safety precautions for working near high volt‐
age components. Refer to
⇒ “1.5 Safety Precautions near High Voltage Components”,
page 3 .
– Note the high voltage system danger classification. Refer to
⇒ Electrical System Hybrid; Rep. Gr. 93 ; High Voltage Sys‐
tem General Warnings .
– See notes. Refer to
⇒ “3.1 Working on Refrigerant Circuit”, page 6 .
– Remove the plenum chamber cover. Refer to ⇒ Body Exterior;
Rep. Gr. 50 ; Plenum Chamber Cover .

CAUTION
Danger or frostbite due to refrigerant coming out under pres‐
sure.
Frostbite on the skin and other parts of the body is possible.
– Wear safety gloves.
– Wear protective eyewear.
– If refrigerant flows out of the refrigerant line longer than 1
second when loosening the pressure sensor, tighten the
pressure sensor and replace the faulty check valve.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately.
– If more than 10 minutes elapse after extracting the refriger‐
ant and the refrigerant circuit was not opened, extract the
refrigerant again. Pressure can develop in the refrigerant
circuit due to evaporation.

2. Refrigerant Circuit 25
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Disconnect the connector -1-.

– Counterhold the refrigerant line with a suitable tool. At the
same time loosen the High Pressure Sensor - G65- -2- with
the -T40284- .

CAUTION
Danger or frostbite due to refrigerant coming out under pres‐
sure. If work is performed improperly the connection can tear
and refrigerant can flow out.
Frostbite on the skin and other parts of the body isspossible. AG. Volkswag e nAG d
ag e n oe s
olk w not
– Wear protective gloves. V gu
d by ara
ise nte
r
– Wear protective eyewear. tho eo
au ra
– Counterhold the refrigerant line with
ss a suitable tool. c

ce
le
un

pt
an
d
itte

– For all the following work, close the open lines and connec‐

y li
rm

ab
tions with clean plugs from the -VAS6122- .
e

ility
ot p

– Remove the High Pressure Sensor - G65- -2-.

wit
is n

h re
ole ,

Installing

spe c
u rpose s, inpart or inwh

Install in reverse order of removal and note the following:

t toth e co tne ss of inform

– Replace the seal from the High Pressure Sensor - G65- -2-.
Tightening Specifications

rre c
Component Tightening Specification
cial p

High Pressure Sensor - G65- -2- 8 Nm

me r

a
m

tion
co

int
or

2.6 Expansion Valve, Removing and Instal‐

h is
te
iva

ling
d o
pr

cu
r
fo

m
en
ng

⇒ “2.6.1 Expansion Valve, Removing and Installing, Front”, page

i t.
py Co
26 Co py
h t. rig
g h
yri t by
⇒ “2.6.2 Expansion Valve, Removing and Installing, Rear”, y cop Vo
lksw
page 29
b
cte d ag e n
Prote AG.

2.6.1 Expansion Valve, Removing and Instal‐

ling, Front
Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Engine Bung Set - VAS6122-

Caution

This procedure contains mandatory replaceable parts. Refer

to component overview prior to starting procedure.

Mandatory Replacement Parts

♦ O-rings - Expansion valve
Removing
– Observe the safety precautions when working on the high-
voltage system. Refer to
⇒ “1.4 High Voltage System Safety Precautions”, page 2 .

26 Rep. Gr.87 - Air Conditioning

 nAG. Volkswag e nAG d o
wag e es n
Volks ot g
y ua
e db ran
ir s te e
th o Touareg or 2010 ➤ , Touareg 2015 ➤
au ac
ss Heating, Ventilation and Air Conditioning - Edition 06.2017

ce
le
un

pt
– Pay attention to safety precautions when working near high-

an
d
itte

y li
voltage components. Refer to

rm

ab
⇒ “1.5 Safety Precautions near High Voltage Components”,

pe

ility
page 3 .

ot

wit
, is n

h re
– Note the high-voltage system danger classification. Refer to
h ole

spe c
⇒ Rep. Gr. 93 ; General Warnings when Working on High-
e s, inpart or inw
Voltage System .

t toth e co tne ss of infor

– See notes. Refer to
⇒ “3.1 Working on Refrigerant Circuit”, page 6 .

rre c
– Remove the plenum chamber cover. Refer to ⇒ Rep. Gr. 64 .
l pu rpos

Hybrid Vehicles
e rcia

– Note the high-voltage system danger classification. Refer to

⇒ Rep. Gr. 93 ; General Warnings when Working on High-

m
m

a
Voltage System .
com

tion
int
Vehicles with Refrigerant R134a
r
te o

h is
iva

d
– Drain the refrigerant circuit. Refer to ⇒ Refrigerant R134a

o
r
rp

cu
Servicing; Rep. Gr. 00 ; Working with A/C Service Station .
fo

m
en
ng

t.
yi
Vehicles with Refrigerant R1234yf
Co
Cop py
ht. rig
– Drain the refrigerant circuit. Refer to ⇒ Refrigerant R1234yf
g h
yri t by
cop Vo
Servicing; Rep. Gr. 87 ; Working with A/C Service Station; by lksw
cte d ag e n
Refrigerant Circuit, Discharging . Prote AG.

Continuation for All Vehicles

CAUTION
Danger or frostbite due to refrigerant coming out under pres‐
sure.
Frostbite on the skin and other parts of the body is possible.
– Wear safety gloves.
– Wear protective eyewear.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately.
– If more than 10 minutes elapse after extracting the refriger‐
ant and the refrigerant circuit was not opened, extract the
refrigerant again. Evaporation can cause pressure to devel‐
op in the refrigerant circuit.

– For all the following work, close the open lines and connec‐
tions with clean plugs from the -VAS6122- .
– Remove the bolts -1-.
– Pull the refrigerant lines from the expansion valve.

2. Refrigerant Circuit 27
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Remove the bolts -1 and 3-.

– Remove the expansion valve -4- from the heat shield insula‐
tion -2-.

Installing
Install in reverse order of removal and note the following:
– Coat the new seals -1- with refrigerant oil before installing.
– Push the new seal -1- on the connecting tubes -2-.
– Check the refrigerant line for contamination and damage. If
necessary, clean or replace.

nAG. Volkswag e nAG d o

wag e es n
Volks ot g
by ua
d ran
rise te e
o
Note au
th or
ac
ss

ce
le

♦ Ignore items -1, 3, and 4-.

un

pt
an
d
itte

y li
♦ A missing or incorrectly installed heat shield insulation -2- can
e rm

ab
reduce the output of the A/C system (change of the adjusted

ility
ot p

control characteristic due to radiant heat).

wit
is n

h re
ole ,

spe c
NOTICE
u rpose s, inpart or inwh

t toth e co tne ss of inform

There is a risk of damaging the A/C compressor if the refrigerant
circuit is empty.
– Never start the engine with the refrigerant circuit empty.

rre c
Vehicles with Refrigerant R134a
cial p

– Fill the refrigerant circuit. Refer to ⇒ Refrigerant R134a Serv‐

icing; Rep. Gr. 00 ; Working with A/C Service Station .
me r

a
m

– Perform the leak test on the closed line connections of the

ion
r co

refrigerant circuit. Refer to ⇒ Refrigerant R134a Servicing;

int
o

h is

Rep. Gr. 00 ; Refrigerant Circuit, Detecting Leaks .

ate

do
riv
p

Vehicles with Refrigerant R1234yf

um
r
fo

en
ng

t.
– Fill the refrigerant circuit. Refer to ⇒ Refrigerant R1234yf
i
py Co
Co py
Servicing; Rep. Gr. 87 ; Working with A/C Service Station; h t. rig
h
Refrigerant Circuit, Filling .
g
yri t by
op Vo
d by c lksw
– Perform the leak test on the closed line connections of the
cte ag e n
Prote AG.
refrigerant circuit. Refer to ⇒ Refrigerant R1234yf Servicing;
Rep. Gr. 87 ; Refrigerant Circuit; Determining Leaks .
Tightening Specifications

Component Tightening Specification

Bolts -1- 10 Nm

28 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

2.6.2 Expansion Valve, Removing and Instal‐

ling, Rear
Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Engine Bung Set - VAS6122-

AG. Volkswag e nAG d

Cautionlkswag e n oe s
not
o
yV gu
e db ara
ris nte
This procedure
th o
contains mandatory replaceable parts. e o Refer
to component
sa
u overview prior to starting procedure. ra
c
s

ce
le
un

pt
an
d

Mandatory Replacement Parts

itte

y li
rm

ab
e

♦ O-rings - Expansion valve

ility
ot p

wit
is n

Removing

h re
ole ,

spe c
– Remove the side trim panel on the left side of the luggage
u rpose s, inpart or inwh

compartment. Refer to ⇒ Rep. Gr. 70 .

t toth e co tne ss of infor

Vehicles with Refrigerant R134a
– Drain the refrigerant circuit. Refer to ⇒ Refrigerant R134a

rre c
Servicing; Rep. Gr. 00 ; Working with A/C Service Station .
Vehicles with Refrigerant R1234yf
cial p

– Drain the refrigerant circuit. Refer to ⇒ Refrigerant R1234yf

Servicing; Rep. Gr. 87 ; Working with A/C Service Station;
me r

ma

Refrigerant Circuit, Discharging .

m

tion
o
or c

int

Continuation for All Vehicles

h is
te
iva

d o
pr

CAUTION
cu
r
fo

m
en
ng

Danger or frostbite due to refrigerant coming out under pres‐

i t.
py Co
sure. Co py
h t. rig
g h
yri
Frostbite on the skin and other parts of the body is possible.
t by
by cop Vo
lksw
– Wear safety gloves.
cte d ag e n
Prote AG.

– Wear protective eyewear.

– Extract refrigerant and open the refrigerant circuit immedi‐
ately.
– If more than 10 minutes elapse after extracting the refriger‐
ant and the refrigerant circuit was not opened, extract the
refrigerant again. Evaporation can cause pressure to devel‐
op in the refrigerant circuit.

– For all the following work, close the open lines and connec‐
tions with clean plugs from the -VAS6122- .

2. Refrigerant Circuit 29
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Remove the bolts -A-.

– Remove the refrigerant lines -B and C- from the expansion
valve -D-.
nAG. Volkswag e nAG d o
wag e es n
Volks ot g
d by ua
ran
ir se te e
th o
or
au ac
ss

ce
le
un

pt
an
d
itte

y li
rm

ab
e

ility
ot p

wit
is n

– Remove the bolts -A-.

h re
ole ,

spe c
– Remove the expansion valve -B-.
u rpose s, inpart or inwh

t toth e co tne ss of inform

Installing
Install in reverse order of removal and note the following:

rre c
– Replace the seals -C and D-. Refer to the Parts Catalog.
– Make sure that the seals -C and D- are properly seated on
connecting pipes to evaporator.
cial p

– Place the expansion valve -B- on the connections on the evap‐

me r

orator.

a
m

tion
co

– Coat the new seals with refrigerant oil before installing.

int
or

h is
te
iva

do
pr

cum
Note
r
fo

en
ng

t.
yi Co
op
The retaining plate -E- is installed on the connecting pipes. Make
C py
h t. rig
sure they are seated correctly when installing the expansion
g h
yri t by
cop Vo
valve. by lksw
cte d ag e n
Prote AG.

30 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Attach the refrigerant lines -B and C- to the rear expansion

valve.
– Install the bolts -A- (tightening specification 10 ± 1 Nm).
– Replace the O-rings -D and E-. Refer to the Parts Catalog.
– Check the alignment pin -G- (installed in the low pressure line
connection or in the expansion valve -F-, not installed in all
connections) and sleeves -H- on refrigerant lines for damage
and proper seating.

NOTICE
There is a risk of damaging the A/C compressor if the refrigerant
circuit is empty.
– Never start the engine with the refrigerant circuit empty.

Vehicles with Refrigerant R134a

– Fill the refrigerant circuit. Refer to ⇒ Refrigerant R134a Serv‐
icing; Rep. Gr. 00 ; Working with A/C Service Station .
– Perform the leak test on the closed line connections of the
refrigerant circuit. Refer to ⇒ Refrigerant R134a Servicing;
Rep. Gr. 00 ; Refrigerant Circuit, Detecting Leaks .
Vehicles with Refrigerant R1234yf
– Fill the refrigerant circuit. Refer to ⇒ Refrigerant R1234yf
Servicing; Rep. Gr. 87 ; Working with A/C Service Station;
Refrigerant Circuit, Filling .
– Perform the leak test on the closed line connections of the
refrigerant circuit. Refer to ⇒ Refrigerant R1234yf Servicing;
Rep. Gr. 87 ; Refrigerant Circuit; Determining Leaks .
G. Volkswag e nA nAG d
wag e oe s
olks
Tightening Specifications not
yV b gu
ara
ed nte
ris
th o ore
Components au Tightening
ac Specification
s
Bolts -A- 10 Nm
ce
e
nl

pt
du

an
itte

y li
e rm

ab
ility
ot p

2.7 Condenser, Removing and Installing

wit
is n

h re
ole ,

Special tools and workshop equipment required

spe c
u rpose s, inpart or inwh

♦ Torque Wrench 1331 5-50Nm - VAG1331-

t toth e co tne ss of inform

♦ Engine Bung Set - VAS6122-

rre c

Caution

This procedure contains mandatory replaceable parts. Refer

cial p

to component overview prior to starting procedure.

me r

a
m

tion
o

Mandatory Replacement Parts

c

int
or

h is
e

♦ O-rings - Refrigerant lines

t
iva

do
pr

cum

Removing
for

en
ng

i t.
py Co
– Observe safety precautions when working on the high voltage Co py
system. Refer to h t. rig
g h
yri t by
⇒ “1.4 High Voltage System Safety Precautions”, page 2 . by cop Vo
lksw
cte d ag e n
– Pay attention to safety precautions for working near high volt‐
Prote AG.

age components. Refer to

2. Refrigerant Circuit 31
 .V ag e nAG olksw
Touareg 2010 ➤ , Touareg 2015 g e nAG
a➤ d oe s
olksw not
Heating, Ventilation and dAir
by Conditioning - Edition 06.2017 g u a
V
ran
ise te e
or
thnear
⇒ “1.5 Safety Precautions u High Voltage Components”, or
a ac
page 3 . ss

ce
le
un

pt
– Note the high voltage system danger classification. Refer to

an
d
itte

y li
⇒ Electrical System Hybrid; Rep. Gr. 93 ; High Voltage Sys‐

e rm

ab
tem General Warnings .

ility
ot p

wit
is n
Additional work for Hybrid Vehicles

h re
ole ,

– Note the high voltage system danger classification. Refer to

spe c
u rpose s, inpart or inwh

⇒ Electrical System Hybrid; Rep. Gr. 93 ; High Voltage Sys‐

t toth e co tne ss of inform

tem General Warnings .
– Remove the coolant reservoir and move it to the side. Refer
to ⇒ Rep. Gr. 19 .

rre c
Vehicles with Refrigerant R134a
– Drain the refrigerant circuit. Refer to ⇒ Refrigerant R134a
cial p

Servicing; Rep. Gr. 00 ; Working with A/C Service Station .

me r

Vehicles with Refrigerant R1234yf

a
m

tion
r co

– Drain the refrigerant circuit. Refer to ⇒ Refrigerant R1234yf

int
o

Servicing; Rep. Gr. 87 ; Working with A/C Service Station;

h is
ate

Refrigerant Circuit, Discharging .

do
riv
p

cum
r
fo

Continuation for All Vehicles

en
ng

i t.
py Co
. Co py
CAUTION
h t rig
g h
yri t by
cop Vo
Danger or frostbite due to refrigerant coming out under pres‐
by lksw
cte d ag e n
Prote
sure.
AG.

Frostbite on the skin and other parts of the body is possible.

– Wear safety gloves.
– Wear protective eyewear.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately.
– If more than 10 minutes elapse after extracting the refriger‐
ant and the refrigerant circuit was not opened, extract the
refrigerant again. Evaporation can cause pressure to devel‐
op in the refrigerant circuit.

– For all the following work, close the open lines and connec‐
tions with clean plugs from the -VAS6122- .
– Disassemble the radiator module. Refer to ⇒ Rep. Gr. 19 ;
Radiator/Radiator Fan; Radiator Module, Disassembling .

32 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

1 - Clip
2 - O-ring
❑ Always replace
❑ 23.8 mm; 2.4 mm
3 - O-ring
❑ Always replace
❑ 9.5 mm; 2.5 mm
4 - Bolts
❑ 12 ± 1.5 Nm
❑ Refrigerant Line
5 - Condenser

nAG. Volkswag e nAG d o

wag e es n
Volks ot g
d by ua
ran
ir se te e
th o
or
au ac
ss

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
h ole

spe c
e s, inpart or inw

t toth e co tne ss of infor

rre c
l pu rpos
e rcia

Installing

m
m

a
com

tion
Install in reverse order of removal and note the following: int
r
te o

Procedure when installing a new A/C compressor

h is
iva

d o
r
rp

– Determine the refrigerant oil quantity of the removed A/C com‐

cu
fo

pressor by letting drain in a measuring container.

en
ng

t.
yi Co
Cop py
ht. rig
g h
yri t by
Note by cop Vo
lksw
cte d ag e n
Prote AG.
Catch the refrigerant oil from the new A/C compressor for reuse
in a suitable container.

– Drain the refrigerant oil from the new A/C compressor.

– Add the quantity of refrigerant oil determined from the remove
A/C compressor, in equal amounts in the empty new A/C com‐
pressor.
– Coat the new seals with refrigerant oil before installing the re‐
frigerant line.

2. Refrigerant Circuit 33
 nAG. Volkswag e nAG d o
wag e es n
Volks ot g
d by ua
ran
ir se te e
o
Touareg 2010 ➤ , Touareg 2015 ➤ au
th or
ac
ss 06.2017
Heating, Ventilation and Air Conditioning - Edition

ce
le
un

pt
an
d
itte

y li
NOTICE

e rm

ab
ility
ot p
There is a risk of damaging the A/C compressor if the refrigerant

wit
is n
circuit is empty.

h re
ole ,
– Never start the engine with the refrigerant circuit empty.

spe c
u rpose s, inpart or inwh

t toth e co tne ss of inform

Vehicles with Refrigerant R134a
– Fill the refrigerant circuit. Refer to ⇒ Refrigerant R134a Serv‐

rre c
icing; Rep. Gr. 00 ; Working with A/C Service Station .
– Perform the leak test on the closed line connections of the
refrigerant circuit. Refer to ⇒ Refrigerant R134a Servicing;

cial p
Rep. Gr. 00 ; Refrigerant Circuit, Detecting Leaks .

me r
Vehicles with Refrigerant R1234yf

a
m

tion
r co
– Fill the refrigerant circuit. Refer to ⇒ Refrigerant R1234yf

int
o
Servicing; Rep. Gr. 87 ; Working with A/C Service Station;

h is
te
Refrigerant Circuit, Filling .
a

do
riv
p

cum
r
fo
– Perform the leak test on the closed line connections of the

en
ng
refrigerant circuit. Refer to ⇒ Refrigerant R1234yf Servicing;
t.
yi Co
op
Rep. Gr. 87 ; Refrigerant Circuit; Determining Leaks . C py
h t. g
rig
h
yri t by
by cop Vo
lksw
cte d ag e n
Prote AG.

34 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

3 A/C Compressor
⇒ “3.1 A/C Compressor, Removing and Installing”, page 35
⇒ “3.2 Pressure Relieve Valve on A/C Compressor, Checking”,
page 55
⇒ “3.3 Drive Plate with Overload Protection, Removing and In‐
stalling”, page 55
⇒ “3.4 Drive Plate with Overload Protection, Checking Run-Out
and Adjusting”, page 56
⇒ “3.5 A/C Compressor Drive Plate, Removing and Installing”,
page 56
⇒ “3.6 Hardy Discs, Changing to Gate Connection”, page 57
⇒ “3.7 Mount with Free-Running Hub on A/C Compressor, Re‐
moving and Installing”, page 58

3.1 A/C Compressor, Removing and Instal‐

ling
⇒ “3.1.1 A/C Compressor, Removing and Installing, Engine Co‐
des CATA, CNRB”, page 35
⇒ “3.1.2 A/C Compressor, Engine Code CKDA, removing and in‐
stalling”, page 38
⇒ “3.1.3 A/C Compressor, Removing and Installing, Engine Code
CGRA”, page 41
⇒ “3.1.4 Electrical A/C Compressor V470 , Removing and Instal‐
AG. Volkswag e nAG d
ling, Engine Code CGFA (Hybrid)”, page 44 ksw
ag e n oe s
n ol ot g
b yV u
⇒ “3.1.5 A/C Compressor, Removing and Installing, Engineed Code ara
nte
ris
CGNA”, page 49 u
ht o e or
a ac
ss
3.1.1 A/C Compressor, Removing and Instal‐

ce
e
nl

pt
ling, Engine Codes CATA, CNRB
du

an
itte

y li
e rm

ab
Special tools and workshop equipment required

ility
ot p

wit
is n

♦ Torque Wrench 1331 5-50Nm - VAG1331-

h re
ole ,

♦ Engine Bung Set - VAS6122-

spe c
u rpose s, inpart or inwh

t toth e co tne ss of inform

Note
rre c
♦ For A/C systems with refrigerant R1234yf, the dryer bag/dryer
cartridge must be replaced each time the refrigerant circuit is
opened. Refer to ⇒ Refrigerant R1234yf Servicing; Rep. Gr.
cial p

87 ; Refrigerant Circuit; Replacing Components .

♦ Under certain conditions, the dryer bag no longer needs to be
me r

replaced each time the refrigerant circuit is opened on A/C

m

tion
o

systems with refrigerant R134a. Refer to ⇒ Refrigerant R134a

c

int
r
te o

Servicing; Rep. Gr. 00 ; Replacing Components .

h is
a

do
riv
p

cum

– Observe safety precautions when working on the high voltage

or
f

en

system. Refer to
ng

i t.
py Co
⇒ “1.4 High Voltage System Safety Precautions”, page 2 . h t. Co py
rig
g h
yri t by
– Pay attention to safety precautions for working near high volt‐ y cop Vo
lksw
age components. Refer to
b
cte d ag e n
Prote AG.
⇒ “1.5 Safety Precautions near High Voltage Components”,
page 3 .

3. A/C Compressor 35
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– See notes. Refer to

⇒ “3.1 Working on Refrigerant Circuit”, page 6 .

1 - Crankcase
2 - Air Conditioning (A/C) Com‐
pressor Sub-Assembly Brack‐
et
❑ No. on housing 059 145
169 P
3 - O-ring
❑ Always replace O-ring
4 - Bolt
❑ 9 Nm
5 - Coolant Pipe
6 - Bolt
❑ 9 Nm
7 - Bolt
❑ 40 ± 3 Nm
8 - Bolt
❑ 20 ± 3 Nm nAG. Volkswag e nAG d o
wag e es n
olks ot g
9 - A/C Compressor d by
V ua
ran
ir se te e
10 - Refrigerant Line Bracket th o
or
au ac
ss
11 - Bolt

ce
le
un

pt
❑ 25 ± 3 Nm

an
d
itte

y li
❑ Quantity: 3
e rm

ab
ility
ot p

12 - Refrigerant Line Bracket

wit
is n

h re
13 - Ribbed Belt Pulley - A/C
ole ,

spe c
System Compressor
u rpose s, inpart or inwh

t toth e co tne ss of inform

14 - Alignment Sleeves
❑ Ensure a correct fit in
the auxiliary component
rre c

bracket and A/C com‐

pressor during installation.
15 - Bolt
cial p

❑ 25 ± 3 Nm
me r

16 - Bolt
m

tion
r co

❑ 40 ± 3 Nm
int
o

h is
ate

17 - Bolt
do
riv
p

cum
r
fo

❑ 9 Nm
en
ng

t.
yi Co
18 - Cover h t.
Cop py
rig
g h
yri
19 - Bolt
t by
by cop Vo
lksw
❑ 9 Nm
cte d ag e n
Prote AG.

20 - Seal
❑ Always replace the seal.
❑ Make sure it fits correctly inside the auxiliary component bracket.

36 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

Removing
– Remove the charge air hose. Refer to ⇒ Rep. Gr. 21 .
– Remove the ribbed belt. Refer to ⇒ Rep. Gr. 13 .
– Power steering pump, removing and installing. Refer to ⇒
Rep. Gr. 48 .
– Disconnect the connector from the A/C compressor.
Vehicles with Refrigerant R134a
– Drain the refrigerant circuit. Refer to ⇒ Refrigerant R134a
Servicing; Rep. Gr. 00 ; Working with A/C Service Station .
Vehicles with Refrigerant R1234yf
– Drain the refrigerant circuit. Refer to ⇒ Refrigerant R1234yf
Servicing; Rep. Gr. 87 ; Working with A/C Service Station;
Refrigerant Circuit, Discharging .
Continuation for All Vehicles

CAUTION
Danger or frostbite due to refrigerant coming out under pres‐
sure.
Frostbite on the skin and other parts. Vof
olkthe
swagbody
e nAG
is possible.
e nAG
– Wear safety gloves. olkswag d oe s
not
byV gu
ara
– Wear protectiveriseeyewear.
d
nte
h o e
– Extract refrigerant
aut and open the refrigerant circuit immedi‐ or a
s c
ately. s
ce
le
un

– If more than 10 minutes elapse after extracting the refriger‐

pt
an
d

ant and the refrigerant circuit was not opened, extract the
itte

y li
rm

refrigerant again. Evaporation can cause pressure to devel‐

ab
e

ility
ot p

op in the refrigerant circuit.

wit
, is n

h re
h ole

– For all the following work, close the open lines and connec‐
spe

tions with clean plugs from the -VAS6122- .

e s, inpart or inw

ct toth e

– Remove the refrigerant line from the bracket -10 and 12-.
corre ctne ss of in

– Remove the refrigerant lines from the A/C compressor.

The bolt tightening specification is 20 ± 3 Nm.
l pu rpos

Installing
e rcia

Install in reverse order of removal and note the following:

form
m

– If the A/C compressor is replaced, check the ribbed belt for

a
om

tio

damage and if necessary replace. Refer to ⇒ Rep. Gr. 13 ;

nin
or c

Cylinder Block, Belt Pulley Side; Ribbed Belt, Removing and

th i
te

Installing .
iva

d s
o
pr

cu
r

– Clean the surfaces on the A/C compressor and bracket.

fo

m
en
ng

t.
yi Co
Cop py
ht. rig
rig t by h
py Vo
d by co lksw
cte ag e n
Prote AG.

3. A/C Compressor 37
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Insert the alignment sleeves -1- in the A/C compressor -2-.

Note
AG. Volkswag e nAG d
ag e n oe s
olksw not
♦ Incorrectly installed alignment sleeves and dirty or damaged
d by
V gu
ara
e
contact surfaces can cause alignment irregularities ri between
s nte
ht o eo
the A/C compressor and engine. Alignment irregularities
au dam‐ ra
ss c
age the A/C compressor over time.

ce
le
un

pt
♦ If the A/C compressor is replaced because of complaints (for

an
d
itte
example, internal damage), then the refrigerant circuit must be

y li
rm

ab
cleaned. Refer to ⇒ Refrigerant R1234yf Servicing; Rep. Gr.

ility
ot p
87 ; Refrigerant Circuit; Components, Replacing .

wit
is n

h re
♦ There is an unspecified amount of refrigerant oil in a removed
ole ,

spe c
A/C compressor, therefore observe the information about re‐
u rpose s, inpart or inwh

placing the A/C compressor. Refer to ⇒ Refrigerant R1234yf

t toth e co tne ss of inform

Servicing; Rep. Gr. 87 ; Refrigerant Circuit; Components, Re‐
placing .

rre c
– Coat the new seals with refrigerant oil before installing the re‐
frigerant lines.
cial p

NOTICE
me r

There is a risk of damaging the A/C compressor if the refrigerant

a
m

circuit is empty.

tion
co

int
– Never start the engine with the refrigerant circuit empty.
or

h is
te
iva

do
pr

c
Vehicles with Refrigerant R134a

um
r
fo

en
ng

i t.
– Fill the refrigerant circuit. Refer to ⇒ Refrigerant R134a Serv‐ py Co
Co py
icing; Rep. Gr. 00 ; Working with A/C Service Station . h t. rig
g h
yri t by
op Vo
– Perform the leak test on the closed line connections of the by c lksw
cte d ag e n
refrigerant circuit. Refer to ⇒ Refrigerant R134a Servicing; Prote AG.
Rep. Gr. 00 ; Refrigerant Circuit, Detecting Leaks .
Vehicles with Refrigerant R1234yf
– Fill the refrigerant circuit. Refer to ⇒ Refrigerant R1234yf
Servicing; Rep. Gr. 87 ; Working with A/C Service Station;
Refrigerant Circuit, Filling .
– Perform the leak test on the closed line connections of the
refrigerant circuit. Refer to ⇒ Refrigerant R1234yf Servicing;
Rep. Gr. 87 ; Refrigerant Circuit; Determining Leaks .

3.1.2 A/C Compressor, Engine Code CKDA,

removing and installing
Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm - V.A.G 1331-

38 Rep. Gr.87 - Air Conditioning

 AG. Volkswag e nAG d
ag e n oe s
olksw not
V gu
d by ara
ir se Touareg 2010 ➤ , Touareg 2015 nte ➤
th o eo
Heating,
s au Ventilation and Air Conditioning - Edition 06.2017 ra
c
s

ce
le
un
♦ Engine Bung Set - VAS 6122-

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
h ole

spe c
e s, inpart or inw

t toth e co tne ss of infor

rre c
l pu rpos
e rcia
Removing

m
m

a
– Observe the safety precautions when working on the high-
com

tion
voltage system. Refer to

int
r
⇒ “1.4 High Voltage System Safety Precautions”, page 2 . te o

h is
iva

d o
r
– Pay attention to safety precautions when working near high- rp

cu
fo

m
voltage components. Refer to

en
ng t.
yi
⇒ “1.5 Safety Precautions near High Voltage Components”,
Co
op py
page 3 .
C
h t. g
rig
h
yri t by
cop
– See notes. Refer to
Vo
by lksw
cte d
⇒ “3.1 Working on Refrigerant Circuit”, page 6 .
ag e n
Prote AG.

– Remove the engine cover. Refer to ⇒ Engine; Rep. Gr. 10 .

– Remove the ribbed belt. Refer to ⇒ Rep. Gr. 13 .
Vehicles with refrigerant R134a
– Drain the refrigerant circuit. Refer to ⇒ Refrigerant R134a
Servicing; Rep. Gr. 00 ; Working with A/C Service Station .
Vehicles with refrigerant R1234yf
– Drain the refrigerant circuit. Refer to ⇒ Refrigerant R1234yf
Servicing; Rep. Gr. 87 ; Working with A/C Service Station;
Refrigerant Circuit, Discharging .
Continuation for All Vehicles

CAUTION
Danger or frostbite due to refrigerant coming out under pres‐
sure.
Frostbite on the skin and other parts of the body is possible.
– Wear safety gloves.
– Wear protective eyewear.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately.
– If more than 10 minutes elapse after extracting the refriger‐
ant and the refrigerant circuit was not opened, extract the
refrigerant again. Evaporation can cause pressure to devel‐
op in the refrigerant circuit.

– For all the following work, close the open lines and connec‐
tions with clean plugs from the Engine Bung Set - VAS 6122- .

3. A/C Compressor 39
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Disconnect the connectors -1-.

– Unscrew the screws -arrows A- from the bracket and put the
bracket aside.
– Remove the bolts -2- and -3- (20 ± 3 Nm) for the refrigerant
lines.

– Remove the bolt -1- at the refrigerant pipe clamp.

Note
AG. Volkswag e nAG d
Ignore position -2-. ag e n oe s
olksw not
V gu
d by ara
ise nte
or e
th or
NOTICE au ac
ss
Risk of destroying the refrigerant lines by ripping the inner foil.

ce
le
un

pt
an
d

– Never bend the refrigerant lines to a radius smaller than r =

itte

y li
100 mm.
e rm

ab
ility
ot p

wit
is n

– Remove the bolts -arrows B- (25 ± 3 Nm) and the A/C com‐

h re
ole ,

pressor.

spe
u rpose s, inpart or inwh

ct toth e
Pay attention to both alignment sleeves between the engine and
A/C compressor (belt side).

corre ctne ss of in
Installing
Install in reverse order of removal and note the following:
– If the A/C compressor is replaced, check the ribbed belt for
cial p

damage and if necessary replace. Refer to ⇒ Rep. Gr. 13 ;

form
Cylinder Block, Belt Pulley Side; Ribbed Belt, Removing and
me r

Installing .

a
m

ti
r co

onin
– If the A/C compressor is replaced, check the ribbed belt for
o

th i
e

damage and if necessary replace. Refer to ⇒ Rep. Gr. 13 ;

t
ir va

d s
Cylinder Block, Belt Pulley Side; Ribbed Belt, Removing and o
p

cu
r
fo

Installing .
m
en
ng

i t.
py Co
– Clean the surfaces on the A/C compressor and bracket. h t. Co py
rig
g h
yri t by
y cop Vo
lksw
b
cte d ag e n
Prote AG.

40 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Insert the alignment sleeves -1- in the A/C compressor -2-.

Note

♦ Incorrectly installed alignment sleeves and dirty or damaged

contact surfaces can cause alignment irregularities between
the A/C compressor and engine. Alignment irregularities dam‐
age the A/C compressor over time.
♦ If the A/C compressor is replaced because of complaints (for
example, internal damage), then the refrigerant circuit must be
cleaned. Refer to ⇒ Refrigerant . Volkswag eServicing;
nAGR1234yf nAG d Rep. Gr.
wag e oe
olksComponents, Replacing s. not g
87 ; Refrigerant Circuit;
V
by u ara
ed n
ris
♦ There is an unspecified amount of refrigerant oil in a removed
te e
th o o
A/C compressor,
sa
u therefore observe the information about re‐r ac
placing thes A/C compressor. Refer to ⇒ Refrigerant R1234yf

ce
le
un

Servicing; Rep. Gr. 87 ; Refrigerant Circuit; Components, Re‐

pt
an
d

placing .
itte

y li
rm

ab
e

ility
ot p

– Coat the new seals with refrigerant oil before installing the re‐

wit
is n

frigerant lines.

h re
ole ,

spe c
NOTICE
u rpose s, inpart or inwh

t toth e co tne ss of inform

There is a risk of damaging the A/C compressor if the refrigerant
circuit is empty.
– Never start the engine with the refrigerant circuit empty.

rre c
Vehicles with refrigerant R134a
cial p

– Fill the refrigerant circuit. Refer to ⇒ Refrigerant R134a Serv‐

icing; Rep. Gr. 00 ; Working with A/C Service Station .
me r

a
m

tion

– Perform the leak test on the closed line connections of the

co

int

refrigerant circuit. Refer to ⇒ Refrigerant R134a Servicing;

or

h is
te

Rep. Gr. 00 ; Refrigerant Circuit, Detecting Leaks .

iva

d o
pr

cu

Vehicles with refrigerant R1234yf

r
fo

m
en
ng

t.
yi
– Fill the refrigerant circuit. Refer to ⇒ Refrigerant R1234yf
Co
op py
Servicing; Rep. Gr. 87 ; Working with A/C Service Station;
. C rig
ht g h
yri
Refrigerant Circuit, Filling .
t by
cop by
Vo
lksw
cte d ag e n
– Perform the leak test on the closed line connections of the Prote AG.
refrigerant circuit. Refer to ⇒ Refrigerant R1234yf Servicing;
Rep. Gr. 87 ; Refrigerant Circuit; Determining Leaks .

3.1.3 A/C Compressor, Removing and Instal‐

ling, Engine Code CGRA
Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm - VAG1331- (5 to 50 Nm)
♦ Engine Bung Set - VAS6122-

3. A/C Compressor 41
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

Note

♦ For A/C systems with refrigerant R1234yf, the dryer bag/dryer

cartridge must be replaced each time the refrigerant circuit is
opened. Refer to ⇒ Refrigerant R1234yf Servicing; Rep. Gr.
87 ; Refrigerant Circuit; Replacing Components .
♦ Under certain conditions, the dryer bag no longer needs to be
replaced each time the refrigerant circuit is opened on A/C
systems with refrigerant R134a. Refer to ⇒ Refrigerant R134a
Servicing; Rep. Gr. 00 ; Replacing Components .

– Observe safety precautions when working on the high voltage

system. Refer to
⇒ “1.4 High Voltage System Safety Precautions”, page 2 .
– Pay attention to safety precautions for working near high volt‐
age components. Refer to
⇒ “1.5 Safety Precautions near High Voltage Components”,
page 3 .
– See notes. Refer to
⇒ “3.1 Working on Refrigerant Circuit”, page 6 .

1 - High Pressure Refrigerant

Line
2 - A/C Compressor Regulator
Valve - N280- Connector
3 - Bolt
❑ 20 ± 3 Nm
❑ Quantity: 2 ag e n
AG. Volkswag e nAG d
oe s
olksw not
4 - Low Pressure Refrigerant V gu
d by ara
Line ir se nte
th o eo
au ra
5 - Bolt ss c
ce
le

❑ 45 ± 3 Nm
un

pt
an
d
itte

❑ M10 x 100
y li
rm

ab
e

ility

6 - Bolt
ot p

wit
is n

❑ 25 ± 3 Nm
h re
ole ,

❑ M8 x 95 (quantity: 2)
spe c
u rpose s, inpart or inwh

7 - Air Conditioning (A/C) Com‐

t toth e co tne ss of inform

pressor
rre c
cial p
me r

a
m

tion
co

int
or

h is
te
iva

do
pr

cum
r
fo

en
ng

i t.
py Co
t. Co py
rig
h g h
yri t by
by cop Vo
lksw
cte d ag e n
Prote AG.

42 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

Removing
– Remove the ribbed belt. Refer to ⇒ Rep. Gr. 13 .
– Loosen the power steering pump and hang it on the side. Refer
to ⇒ Rep. Gr. 48 .
– Disconnect the connector -2-.
AG. Volkswag e nAG d
Vehicles with Refrigerant R134a ag e n oe s
olksw not
V gu
d by ara
– Drain the refrigerant circuit. Refer ir se to ⇒ Refrigerant R134a nte
Servicing; Rep. Gr. 00 ; Working th o with A/C Service Station . eo
au ra
ss c
Vehicles with Refrigerant R1234yf

ce
le
un

pt
an
– Drain the refrigerant circuit. Refer to ⇒ Refrigerant R1234yf
d
itte

y li
Servicing; Rep. Gr. 87 ; Working with A/C Service Station;
e rm

ab
Refrigerant Circuit, Discharging .

ility
ot p

wit
is n

Continuation for All Vehicles

h re
ole ,

spe c
u rpose s, inpart or inwh

CAUTION

t toth e co tne ss of inform

Danger or frostbite due to refrigerant coming out under pres‐
sure.

rre c
Frostbite on the skin and other parts of the body is possible.
– Wear safety gloves.
– Wear protective eyewear.
cial p

– Extract refrigerant and open the refrigerant circuit immedi‐

ately.
me r

a
m

t
– If more than 10 minutes elapse after extracting the refriger‐

i
r co

onin
ant and the refrigerant circuit was not opened, extract the
o

th i
refrigerant again. Evaporation can cause pressure to devel‐
te
ir va

s
op in the refrigerant circuit.

d o
p

cu
r
fo

m
en
ng

i t.
– For all the following work, close the open lines and connec‐ py Co
Co py
tions with clean plugs from the -VAS6122- . h t. rig
g h
yri t by
cop Vo
– Remove the bolts -3- and the refrigerant lines from the A/C by lksw
cte d ag e n
compressor and then seal off the openings with plugs. Prote AG.

– Remove the top bolt -6- and the right bolt -5-.
– Remove the lower engine cover.
– Remove the bottom bolt -6- and then remove the A/C com‐
pressor.
Installing
Install in reverse order of removal and note the following:
– If the A/C compressor is replaced, check the ribbed belt for
damage and if necessary replace. Refer to ⇒ Rep. Gr. 13 ;
Cylinder Block, Belt Pulley Side; Ribbed Belt, Removing and
Installing .
– If the A/C compressor is replaced, check the ribbed belt for
damage and if necessary replace. Refer to ⇒ Rep. Gr. 13 ;
Cylinder Block, Belt Pulley Side; Ribbed Belt, Removing and
Installing .
– Clean the surfaces on the A/C compressor and bracket.

3. A/C Compressor 43
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Insert the alignment sleeves -1- in the A/C compressor -2-.

Note

♦ Incorrectly installed alignment sleeves and dirty or damaged

contact surfaces can cause alignment irregularities between
AG. Volkswag e nAG
the A/C compressor and engine. Alignment ag e n d oe s
olksw irregularities dam‐ not
age the A/C compressor over time. byV gu
ara
ed nte
ris
th o because of complaints (for
♦ If the A/C compressor is replaced e or
au ac
example, internal damage), sthen
s the refrigerant circuit must be
cleaned. Refer to ⇒ Refrigerant R1234yf Servicing; Rep. Gr.

ce
le
un

pt
87 ; Refrigerant Circuit; Components, Replacing .

an
d
itte

y li
rm

♦ There is an unspecified amount of refrigerant oil in a removed

ab
e

ility
ot p

A/C compressor, therefore observe the information about re‐

wit
, is n

placing the A/C compressor. Refer to ⇒ Refrigerant R1234yf

h re
Servicing; Rep. Gr. 87 ; Refrigerant Circuit; Components, Re‐
h ole

spe
placing .
e s, inpart or inw

ct toth e
– Coat the new seals with refrigerant oil before installing the re‐
frigerant lines.

corre ctne ss of in
NOTICE
l pu rpos

There is a risk of damaging the A/C compressor if the refrigerant

circuit is empty.
e rcia

form
– Never start the engine with the refrigerant circuit empty.
m

a
om

tionin
or c

Vehicles with Refrigerant R134a

th i
te
iva

s
– Fill the refrigerant circuit. Refer to ⇒ Refrigerant R134a Serv‐

d o
pr

cu
icing; Rep. Gr. 00 ; Working with A/C Service Station .
r
fo

m
en
ng

t.
– Perform the leak test on the closed line connections of the
yi Co
op py
refrigerant circuit. Refer to ⇒ Refrigerant R134a Servicing;
C
h t. rig
h
Rep. Gr. 00 ; Refrigerant Circuit, Detecting Leaks .
g
yri t by
by cop Vo
lksw
cte d
Vehicles with Refrigerant R1234yf
ag e n
Prote AG.

– Fill the refrigerant circuit. Refer to ⇒ Refrigerant R1234yf

Servicing; Rep. Gr. 87 ; Working with A/C Service Station;
Refrigerant Circuit, Filling .
– Perform the leak test on the closed line connections of the
refrigerant circuit. Refer to ⇒ Refrigerant R1234yf Servicing;
Rep. Gr. 87 ; Refrigerant Circuit; Determining Leaks .

3.1.4 Electrical A/C Compressor - V470- , Re‐

moving and Installing, Engine Code
CGFA (Hybrid)
Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Engine Bung Set - VAS6122-

44 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

Note

♦ For A/C systems with refrigerant R1234yf, the dryer bag/dryer

cartridge must be replaced each time the refrigerant circuit is
opened. Refer to ⇒ Refrigerant R1234yf Servicing; Rep. Gr.
87 ; Refrigerant Circuit; Replacing Components .
♦ Under certain conditions, the dryer bag no longer needs to be
replaced each time the refrigerant circuit is opened on A/C
systems with refrigerant R134a. Refer to ⇒ Refrigerant R134a
Servicing; Rep. Gr. 00 ; Replacing Components .

Removing
– Observe safety precautions when working on the high voltage
system. Refer to
⇒ “1.4 High Voltage System Safety Precautions”, page 2 .
– Pay attention to safety precautions for working near high volt‐
age components. Refer to
⇒ “1.5 Safety Precautions near High Voltage Components”,
page 3 .
– See notes. Refer to
⇒ “3.1 Working on Refrigerant Circuit”, . Volkswag e
g e nAGpage 6 . nAG d oe
swa s k not
Vol g
– Note the high voltage system by danger classification. Refer to u ar
ed an
oris
⇒ Electrical System tHybrid; Rep. Gr. 93 ; High Voltage Sys‐ te e
h or
tem General Warnings
s au . ac
s

ce
le
un

pt
DANGER

an
d
itte

y li
Danger to life due to high voltage.
e rm

ab
ility
ot p

Death or serious bodily injury by electric shock.

wit
is n

– Have the high voltage system de-energized by a qualified

h re
ole ,

person. spe c
u rpose s, inpart or inwh

t toth e co tne ss of inform

– Switch off the high voltage system. Refer to ⇒ Electrical Sys‐

tem Hybrid; Rep. Gr. 93 ; Disabling the High Voltage System .
rre c

– Remove the left front wheel housing liner. Refer to ⇒ Body

Exterior; Rep. Gr. 66 ; Wheel Housing Liner; Front Wheel
Housing Liner .
cial p

– Push the hose -3- slightly downward and remove the bolts
-2- (25 ± 3 Nm) from the A/C compressor -1-.
me r

a
m

– Remove the engine cover. Refer to ⇒ Rep. Gr. 10 .

i
r co

onin
o

– Remove the electric drive power and control electronics. Refer

th i
te
ir va

to ⇒ Electrical System Hybrid; Rep. Gr. 93 ; Hybrid-Specific

d o
p

cu

Components; Electric Drive Power and Control Electronics -

r
fo

JX1- .
en
ng

t.
yi Co
Cop py
h t. g
rig
h
yri t by
by cop Vo
lksw
cte d ag e n
Prote AG.

3. A/C Compressor 45
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Remove high voltage wire -1- from the A/C compressor in di‐
rection of -arrow-.

Note
nAG. Volkswag e nAG d o
ks wag e es n
Do not turn the connector. Danger of causing damage.
by
Vol ot g
u ara
ed nte
ris
u th o e or
a ac
ss

ce
le
un

pt
an
d
itte

y li
rm

ab
e

ility
ot p
– Remove the connector in direction of -arrow- from the A/C

wit
, is n

compressor.

h re
h ole

spe
Vehicles with Refrigerant R134a
e s, inpart or inw

ct toth e
– Drain the refrigerant circuit. Refer to ⇒ Refrigerant R134a
Servicing; Rep. Gr. 00 ; Working with A/C Service Station .

corre ctne ss of in
Vehicles with Refrigerant R1234yf
l pu rpos

– Drain the refrigerant circuit. Refer to ⇒ Refrigerant R1234yf

Servicing; Rep. Gr. 87 ; Working with A/C Service Station;
Refrigerant Circuit, Discharging .
e rcia

form
Continuation for All Vehicles
m

a
om

tionin
or c

CAUTION

th i
te
iva

s
Danger or frostbite due to refrigerant coming out under pres‐

d o
pr

cu
sure.
r
fo

m
en
ng

Frostbite on the skin and other parts of the body is possible.

i t.
py Co
Co py
– Wear safety gloves. h t. rig
g h
yri t by
– Wear protective eyewear.
op Vo
e d by c lksw
ag e n
ct
– Extract refrigerant and open the refrigerant circuit immedi‐
Prote AG.

ately.
– If more than 10 minutes elapse after extracting the refriger‐
ant and the refrigerant circuit was not opened, extract the
refrigerant again. Evaporation can cause pressure to devel‐
op in the refrigerant circuit.

– For all the following work, close the open lines and connec‐
tions with clean plugs from the -VAS6122- .

– Loosen the nut (8 ± 0.9 Nm) and open the clamp -arrow-. Re‐
move the bolt -1- (12 ± 1.5 Nm). Remove the low pressure line
-2- on top of the engine and seal it with a plug.

46 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Remove the bolt -1- (20 ± 3.0 Nm) and the high pressure line
-2- from the A/C compressor and seal it with a suitable plug.

nAG. Volkswag e nAG d o

wag e es n
Volks ot g
y ua
e db ran
ris te e
th o
or
au ac
ss

ce
e
nl

pt
du

an
itte

y li
e rm

ab
– Remove top bolt -1- (25 ± 3 Nm) from the A/C compressor

ility
ot p

-arrow-.

wit
is n

h re
ole ,

spe c
u rpose s, inpart or inwh

t toth e co tne ss of inform

rre c
cial p
me r

a
m

– Turn the A/C compressor slightly to the right in direction of

tion
co

-arrow 1- and guide in the direction of the radiator in direction int

or

of -arrow 2-.
h is
te
iva

do
pr

Pay attention to both alignment sleeves between the cylinder

cum
or

block and the A/C compressor.

f

en
ng

t.
yi Co
Cop py
ht. rig
g h
yri t by
cop by
Vo
lksw
cte d ag e n
Prote AG.

– Turn the A/C compressor approximately 90° to the right and

remove upward with the front side first in direction of -arrow-.

3. A/C Compressor 47
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Remove the bolt -2- (20 ± 3.0 Nm) and remove the low pres‐
sure line -1- from the A/C compressor.

nAG. Volkswag e nAG d o

wag e es n
olks ot g
Installing by V ua
e d ran
is te e
Install in reverse order
h of removal and note the following: or
ut or
ac
sa
– Install the lows pressure line -1- on the new A/C compressor,

ce
le
un

tighten the bolt -2- (20 ± 3.0 Nm) and then install the A/C com‐

pt
an
d

pressor in reverse order of removal.

itte

y li
e rm

ab
Pay attention to both alignment sleeves between the cylinder

ility
ot p

block and the A/C compressor.

wit
is n

h re
ole ,

spe c
u rpose s, inpart or inwh

Note

t toth e co tne ss of inform

♦ Check the amount of refrigerant oil in the new A/C compressor
if the A/C Compressor Control Module - J842- is faulty. The

rre c
refrigerant circuit must not be flushed with refrigerant.
♦ The procedure for flushing with refrigerant is described in EL‐
SA under ⇒ Refrigerant R1234yf Servicing; Rep. Gr. 87 ;
cial p

Refrigerant Circuit; Refrigerant Circuit, Cleaning or ⇒ Refrig‐

erant R134a Servicing; Rep. Gr. 00 ; Refrigerant Circuit,
me r

Removing Contamination; Refrigerant Circuit, Flushing

a
m

tion

(Cleaning) with Refrigerant R134a .

r co

int
o

h is
ate

– Coat the new seals with refrigerant oil before installing the re‐
do
riv
p

frigerant lines.
cum
r
fo

en
ng

i t.
py Co
NOTICE h t. Co py
rig
g h
yri
There is a risk of damaging the A/C compressor if the refrigerant
t by
cop Vo
circuit is empty.
by lksw
cte d ag e n
Prote AG.
– Never start the engine with the refrigerant circuit empty.

Vehicles with Refrigerant R134a

– Fill the refrigerant circuit. Refer to ⇒ Refrigerant R134a Serv‐
icing; Rep. Gr. 00 ; Working with A/C Service Station .
– Perform the leak test on the closed line connections of the
refrigerant circuit. Refer to ⇒ Refrigerant R134a Servicing;
Rep. Gr. 00 ; Refrigerant Circuit, Detecting Leaks .
Vehicles with Refrigerant R1234yf
– Fill the refrigerant circuit. Refer to ⇒ Refrigerant R1234yf
Servicing; Rep. Gr. 87 ; Working with A/C Service Station;
Refrigerant Circuit, Filling .
– Perform the leak test on the closed line connections of the
refrigerant circuit. Refer to ⇒ Refrigerant R1234yf Servicing;
Rep. Gr. 87 ; Refrigerant Circuit; Determining Leaks .

48 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

3.1.5 A/C Compressor, Removing and Instal‐

ling, Engine Code
swa
g e nCGNA
AG. Volkswag e nAG d
oe s
k not
y Vol gu
Special tools and workshop
se
d b equipment required ara
nte
ri
ho e
♦ Torque ut
Wrench a1331 5-50Nm - V.A.G 1331- or
ac
ss

ce
le
un

pt
an
d
itte

y li
e rm

ab
ility
ot p

wit
is n

h re
ole ,

spe c
u rpose s, inpart or inwh

t toth e co tne ss of inform

rre c
♦ Engine Bung Set - VAS6122-
cial p
me r

a
m

tion
r co

int
o

h is
ate

do
riv
p

cum
r
fo

en
ng

i t.
py Co
t. Co py
rig
h h
rig t by
py Vo
d by co lksw
cte ag e n
Prote AG.

♦ Engine Support Bridge - 10-222 A-

♦ Engine Support Bridge - Sub-frame Adapter - 10-222 A/22-
♦ Engine Support - Basic Set - T40091-
♦ Engine Support - Supplement Kit - T40093A-

3. A/C Compressor 49
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

Note
AG. Volkswag e nAG d
o ag e n
♦ A toothed gear andVo
an
lkswinput shaft -B- drive thee sA/C
not compres‐
g
sor. by ua
ed ran
oris te e
h
♦ On vehiclesau with an 8-cylinder engine, the refrigerant circuit
t or
ac
s
must be sdrained to remove the A/C compressor.

ce
le
un

pt
♦ A/C compressor bracket, removing and installing from engine.

an
d
itte

Refer to ⇒ Rep. Gr. 13 .

y li
e rm

ab
ility
ot p

Removing

wit
is n

h re
ole ,

– Observe the safety precautions when working on the high-

spe c
voltage system. Refer to
u rpose s, inpart or inwh

⇒ “1.4 High Voltage System Safety Precautions”, page 2 .

t toth e co tne ss of inform

– Pay attention to safety precautions when working near high-
voltage components. Refer to

rre c
⇒ “1.5 Safety Precautions near High Voltage Components”,
page 3 .
– Remove the left and right air filter housing. Refer to ⇒ Rep.
cial p

Gr. 24 .
me r

– Remove the front wheel. Refer to ⇒ Rep. Gr. 44 .

a
m

ti
r co

onin
– Remove the noise insulation, if necessary. Refer to “Body Ex‐
o

terior” ⇒ Rep. Gr. 50 . th i

te
ir va

d s
o
p

– Discharge the coolant circuit. Refer to ⇒ Rep. Gr. 19 .

cu
r
fo

m
en
ng

– Remove the front and rear engine cover. Refer to ⇒ Rep. Gr.
t.
yi Co
op
10 . C py
h t. g
rig
h
yri t by
cop Vo
– Remove the refrigerant line clamp nuts and bolts -arrows-.
by lksw
cte d ag e n
Prote AG.

Note

The bolts for refrigerant line clamps are removed, so that the re‐
frigerant lines can be pushed slightly to the side and are not
damaged when inserting the engine support bridge.

Preparatory work to remove left engine support:

Note

This repair manual only outlines the procedure for removing the
left engine support. Always refer to the respective repair manual
when removing the left engine support. Refer to ⇒ Rep. Gr. 10 .

– Position the Engine Support Bridge - 10-222 A- onto the bolted

fender flanges using the Engine Support Bridge - Sub-frame
Adapters - 10-222 A/22- and the Connectors - T40091/3- .

50 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Assemble the other parts of the Engine Support Bridge -

10-222 A- as shown in the illustration by positioning the Engine
Support Bridge - Engine Support 19 - 10-222 A/19- onto the
longitudinal member notch (be careful of the refrigerant lines
on the longitudinal member when doing this).
– Engage the hook of the short Engine Support - Bracket w/
Spindle and hook - 10-222 A/10- into the left rear engine lifting
eye.

AG. Volkswag e nAG d

ag e n oe s
olksw not
V gu
d by ara
ir se nte
h o e
a ut or
ac
– Slide the Support - T40091/2- into the
ss two Connectors -
T40093/4- using the Slider - T40093/5- .

ce
le
un

pt
an
d
– Attach the long spindle from the Engine Support Bridge -
itte

y li
rm

10-222 A- and hang the hook of the spindle into the left front

ab
e

ility
ot p

engine lifting eye.

wit
is n

h re
ole ,

spe c
Note
u rpose s, inpart or inwh

t toth e co tne ss of inform

Fasten the Support - T40091/2- using stud and cotter pins of the
Connectors - T40093/4- .

rre c
– Pretension the engine by pulling evenly on both of the spin‐
dles.
cial p

– Remove the coolant hose -arrows-.

me r

a
m

tion
co

int
or

h is
te
iva

d o
pr

cu
r
fo

m
en
ng

t.
yi Co
Cop py
h t. g
rig
h
yri t by
by cop Vo
lksw
cte d ag e n
Prote AG.

– Remove the nuts and bolts -1- through -5- and then remove
the left engine support. Refer to ⇒ Rep. Gr. 10 .

3. A/C Compressor 51
 AG. V olkswag e nAG
Touareg 2010 ➤ , Touareg 2015 ➤ ag e n d oe s
olksw not
Heating, Ventilation and Air Conditioning - Edition 06.2017
db
yV gu
ara
e nte
ris
– Disconnect the connectors to the Refrigerant th o
Temperature
u
e or
a ac
Sensor - G454- -1-. ss

ce
le
un

pt
Vehicles with refrigerant R134a

an
d
itte

y li
rm

ab
– Drain the refrigerant circuit. Refer to ⇒ Refrigerant R134a

ility
ot p
Servicing; Rep. Gr. 00 ; Working with A/C Service Station .

wit
is n

h re
Vehicles with refrigerant R1234yf

ole ,

spe c
– Drain the refrigerant circuit. Refer to ⇒ Refrigerant R1234yf

u rpose s, inpart or inwh

Servicing; Rep. Gr. 87 ; Working with A/C Service Station;

t toth e co tne ss of inform

Refrigerant Circuit, Discharging .
Continuation for All Vehicles

rre c
CAUTION

cial p
Danger or frostbite due to refrigerant coming out under pres‐
sure. me r
Frostbite on the skin and other parts of the body is possible.

a
m

tion
o

– Wear safety gloves.

c

int
or

– Wear protective eyewear.

h is
te
iva

do
– Extract refrigerant and open the refrigerant circuit immedi‐
pr

cum
r
fo

ately.

en
ng

i t.
py Co
– If more than 10 minutes elapse after extracting the refriger‐ Co py
ant and the refrigerant circuit was not opened, extract the h t. rig
g h
yri t by
refrigerant again. Evaporation can cause pressure to devel‐ y cop Vo
lksw
op in the refrigerant circuit.
b
cte d ag e n
Prote AG.

– For all the following work, close the open lines and connec‐
tions with clean plugs from the Engine Bung Set - VAS6122- .
– Remove the refrigerant lines -2- and -3- from the A/C com‐
pressor.

– Hold the A/C compressor input shaft -A- with a wrench and
turn the A/C compressor power unit -B- in the direction of the
arrow -C-.

Note

♦ Do not turn the input shaft -A-.

♦ The input shaft -A- can be slid into the drive wheel through the
boot -E- after loosening the threaded connection.

– Mark the 2-pin connector -1- to the A/C Compressor Regulator

Valve - N280- (risk of interchanging it with the engine mount
connector).
– Disconnect the 2-pin connector -1- to the A/C Compressor
Regulator Valve - N280- .
– Remove the three bolts -arrows- (tightening specification 25
Nm).
– Remove the A/C compressor forwards.

52 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Remove the bushings -F- from the A/C compressor if neces‐

sary.
Installing
– If the A/C compressor is replaced, check the ribbed belt for
damage and if necessary replace. Refer to ⇒ Rep. Gr. 13 ;
Cylinder Block, Belt Pulley Side; Ribbed Belt, Removing and
Installing .

Note

There is an unspecified quantity of refrigerant oil in the removed

A/C compressor. Therefore, observe the information about re‐
placing an A/C compressor. Refer to ⇒ Refrigerant R1234yf
Replacing; Rep. Gr. 87 ; Refrigerant Circuit; Components, Re‐
placing or ⇒ Refrigerant R134a Servicing; Rep. Gr. 00 ; Com‐
ponents, Replacing .

– Remove the bushings -C- from the A/C compressor bracket if

necessary.
– Clean the contact surfaces -A- and -B- on the bracket (and the
contact surfaces on the A/C compressor) thoroughly.
– Install the bushings -C- in the A/C compressor bracket.

Note

Make sure that the bushings -C- are seated correctly and that the
contact surfaces are clean. Bushings that are installed incorrectly
and dirty or damaged contact surfaces can lead to alignment ir‐
regularities between the compressor and engine. GAlignment
. Volkswag e
ir‐
regularities over time lead to damage to the wa g e nA shaft or nAG d oe
input
ks s no
compressor. Vol tgu
by a
ed ran
ris te e
tho or
au ac
– If necessary, install the input shaft -A- (in the A/C
ss compressor
ce

engine drive wheel) and check the grommet -E- seating.

le
un

pt
an
d
itte

y li
rm

ab

Note
e

ility
ot p

wit
is n

h re

A clamp on the engine toothed drive gear flange -C- prevents the
ole ,

boot -E- from slipping.

spe c
u rpose s, inpart or inwh

t toth e co tne ss of inform

– Check the A/C compressor connections and the refrigerant

lines for damage or dirt.
rre c

– Install the A/C compressor with the bolts -D- and washers
cial p

-E- on the bracket (bolt -D- tightening specification: 25 Nm).

Mind the bushings -F- while doing this.
me r

– Attach the refrigerant lines with a new lightly lubricated o-ring

m

tion
o

on the A/C compressor (tightening specification for bolts -A-

c

int
or

20 ± 3 Nm).
h is
te
iva

d o
pr

cu
r
fo

Note
en
ng

i t.
py Co
t. Co py
rig
O-ring dimensions -B and C-. Refer to the Parts Catalog.
h g h
yri t by
by cop Vo
lksw
cte d ag e n
Prote AG.

3. A/C Compressor 53
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Before installing the input shaft, rotate the A/C compressor by

hand (after installation) 10 turns in the direction of the arrow
-C- via the A/C compressor power unit -B-. This will prevent
the A/C compressor from being damaged the first time it is
switched on.

Note

When turning, the refrigerant oil that has accumulated in the re‐
moved A/C compressor or in the A/C compressor compression
chamber after filling with fresh refrigerant oil (for example, after
blowing through the refrigerant circuit with air) is forced out of the
compression chamber.

– Tighten the input shaft by holding the A/C compressor input

shaft -A- in place with a wrench and turning the A/C compres‐
sor power unit -B- in the direction of the arrow -D- (tightening
specification 60 Nm).

Note
AG. Volkswag e nAG d
ag e n oe s
olksw not
♦ Do not turn the inputd bshaft
yV -A-. gu
ara
se nte
ori
♦ After installing uthe
th input shaft -A-, check the installation posi‐ e or
a ac
tion of the boot
ss -E-.
ce
le
un

pt
an
– Coat the new seals with refrigerant oil before installing the re‐
d
itte

y li
frigerant lines.
rm

ab
pe

ility
ot

wit

NOTICE
, is n

h re
h ole

There is a risk of damaging the A/C compressor if the refrigerant

spe c

circuit is empty.
e s, inpart or inw

t toth e co tne ss of infor

– Never start the engine with the refrigerant circuit empty.

Vehicles with refrigerant R134a

rre c

– Fill the refrigerant circuit. Refer to ⇒ Refrigerant R134a Serv‐

l pu rpos

icing; Rep. Gr. 00 ; Working with A/C Service Station .

e rcia

– Perform the leak test on the closed line connections of the

refrigerant circuit. Refer to ⇒ Refrigerant R134a Servicing;
m
m

Rep. Gr. 00 ; Refrigerant Circuit, Detecting Leaks .

com

tion
int

Vehicles with refrigerant R1234yf

r
te o

h is
iva

– Fill the refrigerant circuit. Refer to ⇒ Refrigerant R1234yf

o
r
rp

cu

Servicing; Rep. Gr. 87 ; Working with A/C Service Station;

fo

m
en

Refrigerant Circuit, Filling .

ng

i t.
py Co
Co py
– Perform the leak test on the closed line connections of the h t. rig
g h
yri t by
refrigerant circuit. Refer to ⇒ Refrigerant R1234yf Servicing; y cop Vo
lksw
Rep. Gr. 87 ; Refrigerant Circuit; Determining Leaks .
b
cte d ag e n
Prote AG.

54 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

3.2 Pressure Relieve Valve on A/C Com‐

pressor, Checking
CAUTION
There is a risk of frostbite through refrigerant. The pressure re‐
lief valve drains refrigerant when the engine is running and the
refrigerant circuit pressure is too high.
Frostbite on the skin and otherwaparts . Volkswag e nAis
g e nAGof the body G possible.
d oe s
olks not
– Wear protective gloves. d by V gu
ara
e nte
ris
– Wear protectiveth oeyewear. eo
au ra
– Turn the enginess off. c

ce
le
un

pt
an
d

♦ Function: Protects the refrigerant circuit against excessive

itte

y li
rm

pressure

ab
e

ility
ot p

♦ The pressure relief valve has operated when refrigerant oil is

wit
is n

found nearby.

h re
ole ,

spe c
Check the pressure relief valve -1- on vehicles with A/C com‐
u rpose s, inpart or inwh

pressors by Denso and 6/10-cylinder engine.

t toth e co tne ss of inform

rre c
cial p
me r

a
m

tion
co

int
or

h is
te
iva

d o
pr

cu

Check pressure relief valve -arrow- on vehicles with A/C com‐

r
fo

m
en

pressor by Denso.
ng

t.
yi Co
Cop py
ht. rig
g h
yri t by
by cop Vo
lksw
cte d ag e n
Prote AG.

3.3 Drive Plate with Overload Protection,

Removing and Installing
– Remove the Air Conditioning (A/C) compressor. Refer to
⇒ “3.1 A/C Compressor, Removing and Installing”, page 35 .

3. A/C Compressor 55
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

Removing
– Remove the bolts -A-.

Note

Use a commercially available band wrench (with webbed band)

to counterhold at drive plate -C-. AG. Volkswag e nA
ag e n G do
es n
ksw
y Vol ot g
Installing e db u ara
nte
ris
– Position drive plate with overload
u th o protection -B- onto drive
e or
a ac
plate -C-. ss

ce
le
un

pt
– Install and tighten the bolts -A- hand-tight.

an
d
itte

y li
e rm

– Check the drive plate run-out -B-. Refer to

ab
ility
ot p

⇒ “3.4 Drive Plate with Overload Protection, Checking Run-

wit
is n

Out and Adjusting”, page 56 .

h re
ole ,

– Tighten the bolts -A- to 10 Nm.

spe c
u rpose s, inpart or inwh

– Check the drive plate run-out -B-. Refer to

t toth e co tne ss of inform

⇒ “3.4 Drive Plate with Overload Protection, Checking Run-
Out and Adjusting”, page 56 .

rre c
3.4 Drive Plate with Overload Protection,
Checking Run-Out and Adjusting
cial p

– Remove the A/C compressor. Refer to

me r

⇒ “3.1 A/C Compressor, Removing and Installing”, page 35 .

a
m

ti
r co

onin
– Clean the drive plate flange -A-.
o

th i
te

– Secure a dial gauge -B- using a dial gauge holder -C- (for ex‐
a

do s
ir v
p

ample, using -VW387- ) onto the A/C compressor. cum

r
fo

en
ng

– Set probe of dial gauge -D- on flange of drive plate -A- with a
i t.
py Co
pre-tension of approximately 1.0 mm. Co py
h t. rig
g h
yri t by
– Turn the A/C compressor power unit -E- a few turns. cop Vo
by lksw
cte d ag e n
Prote
Specified Value
AG.

Run-out deviation is less than 0.21 mm (run-out of dial indicator,

difference between smallest and largest measured value 0.2 mm
maximum).
– If the run-out deviation is greater than 0.2 mm, then loosen the
bolts on the drive plate and readjust the drive plate. Refer to
⇒ “3.3 Drive Plate with Overload Protection, Removing and
Installing”, page 55 .

3.5 A/C Compressor Drive Plate, Removing

and Installing
– Remove the drive plate with overload protection. Refer to
⇒ “3.3 Drive Plate with Overload Protection, Removing and
Installing”, page 55 .

56 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

Removing
– Loosen the drive plate -C- by rotating it in the direction of the
-arrow D- using a commercially available band wrench (with
webbed band). Conterhold the A/C compressor shaft -A- with
a counterhold tool -B-.

Note

Depending on the version of the A/C compressor (the A/C com‐

pressor shafts are different), use a wrench or, for example, a -
T10001/10- from the -T10001- or -3079- to counterhold.

Installing AG. Volkswag e nAG d

ag e n oe s
olksw not
V gu
d by ara
e
– Lightly coat the rubber elements -B- with soapyris water (as a nte
ho eo
lubricant) to install. au t ra
ss c
– Install the rubber element -B- into the drive plate -A-, as illus‐

ce
le
un

pt
trated.

an
d
itte

y li
rm

– Insert the drive plate -A- with the rubber elements -B- into the

ab
e

ility
ot p

drive plate -C- until it makes contact with the compressor shaft.

wit
, is n

h re
h ole

spe
Note
e s, inpart or inw

ct toth e
This illustration shows the rubber element -B- in version “1”. Rub‐
ber elements -B- of version “2” are joined to each other at top.

corre ctne ss of in
l pu rpos

– Screw drive plate -C- onto compressor shaft -A- by rotating in

direction of -arrow E-.
e rcia

– Tighten the drive plate -C- to 30 Nm by rotating it in the direc‐

form
tion of the -arrow E- using a commercially available band
m

a
wrench (with webbed band). Conterhold the A/C compressor
om

tionin
shaft -A- on the A/C compressor shaft -A- with a counterhold
or c

tool -B-.

th i
te
iva

d s
o
pr

cu
r
fo

m
en
Note
ng

i t.
py Co
t. Co py
rig
Depending on the version of the A/C compressor (the A/C com‐
h g h
yri t by
cop
pressor shafts are different), use a wrench or, for example, a -
Vo
by lksw
cte d
T10001/10- from the -T10001- or -3079- to counterhold.
ag e n
Prote AG.

3.6 Hardy Discs, Changing to Gate Connec‐

tion
Special tools and workshop equipment required
♦ Torque Wrench 1332 40-200Nm - VAG1332-
♦ Multi-Tooth Adapter - 3400-
♦ Counterhold - Multiple Use - T10172A- with Counterhold - Kit
- Multiple Use - Adapter - T10172/1-
♦ Adapter - 07Z 260 361-

3. A/C Compressor 57
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

Removing
nAG. Volkswag e nAG d o
wag e es n
Note Volks ot g
by ua
d ran
rise te e
h o
ut
♦ Order the Adapter - 07Z 260a361- before converting from hardy or
ac
discs to a gate connection.ss

ce
le
un

pt
♦ The power steering pump must also be replaced during the

an
d
itte
conversion. Refer to ⇒ Suspension, Wheels, Steering; Rep.

y li
e rm

ab
Gr. 48 .

ility
ot p

wit
is n

♦ See notes. Refer to

h re
⇒ “2.1 System Overview - Refrigerant Circuit”, page 14 .
ole ,

spe c
u rpose s, inpart or inwh

– Remove the engine. Refer to ⇒ Rep. Gr. 10 .

t toth e co tne ss of inform

– Remove the Air Conditioning (A/C) compressor. Refer to
⇒ “2.1 System Overview - Refrigerant Circuit”, page 14 .

rre c
– Secure the A/C compressor in a vise with claw protectors.
– Remove the flange on the overload protection -5-.
cial p

– Screw the Adapter - 07Z 260 361- -3- into the overload pro‐
me r

tection -2- of the A/C compressor -1-.

a
m

tion
r co

– Install the mount with free-running hub -4- onto the adapter

int
o

-3-.

h is
ate

do
riv
p

cum
r
fo

en
ng

i t.
py Co
t. Co py
rig
h h
rig t by
py Vo
d by co lksw
cte ag e n
Prote AG.

– Tighten the mount with free-running hub -4- with the -3400- .
– Lock the A/C compressor using the -T10172A- and the -
T10172/1- and tighten the mount with free-running hub.
Tightening specification: 80 Nm
Installing
Install in reverse order of removal.

Note

Should the mount with free-running hub loosen without the adapt‐
er, clamp adapter upright in an appropriate vise with protective
backings. This ensures loosening with the -T10172A- .

3.7 Mount with Free-Running Hub on A/C

Compressor, Removing and Installing
Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Torque Wrench 1332 40-200Nm - VAG1332-
♦ Multi-Tooth Adapter - 3400-
♦ Torque Wrench 1331 Insert - Open Jaw - 17mm - VAG1331/6-
♦ A/C Service Station

58 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

Removing
– Observe safety precautions when working on the high voltage
system. Refer to
⇒ “1.4 High Voltage System Safety Precautions”, page 2 .
– Pay attention to safety precautions for working near high volt‐
age components. Refer to
⇒ “1.5 Safety Precautions near High Voltage Components”,
page 3 .
– See notes. Refer to
⇒ “3.1 Working on Refrigerant Circuit”, page 6 .
– Extract the refrigerant using the A/C Service Station , only then
open the refrigerant circuit.

Note

The tightening specification for bolts on the refrigerant lines to the

Air Conditioning (A/C) compressor is 20 ± 3 Nm.

– Remove the A/C compressor.

– Secure the A/C compressor in a vise with claw protectors.
– Remove the cap from the free-running hub.
– Insert the -3400- -1- into the A/C compressor free-running hub
using a 17 mm wrench. Insert the M10 socket -2- into the A/C
compressor shaft. AG. Volkswag e nAG d
ag e n oe s
olksw not
– Turn the wrench to the left to loosen the threaded connection. by
V gu
ara
d
Counterhold the reversible ratchet -2- at the same time. ir se nte
th o eo
u ra
Installing ss
a c

ce
le

Install in reverse order of removal. Note the following:

un

pt
an
d
itte

y li
e rm

ab
ility
ot p

wit
is n

h re
ole ,

– First screw the free-running hub onto the A/C compressor in‐

spe c
put shaft by hand until it stops.
u rpose s, inpart or inwh

t toth e co tne ss of inform

– Insert the -3400- -1- into the A/C compressor free-running hub.
– Insert the M10 socket -arrow- into the A/C compressor shaft.

rre c
– Tighten the free-running hub using the -VAG1331/6- -2- and
the -VAG1332- .
cial p

Tightening specification is 80 Nm.

me r

a
m

ti
r co

onin
o

th i
te
ir va

d s
o
p

cu
r
fo

m
en
ng

i t.
py Co
t. Co py
rig
h g h
yri t by
by cop Vo
lksw
cte d ag e n
Prote AG.

3. A/C Compressor 59
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

4 Actuators
⇒ “4.1 Heater and A/C Unit Actuators, Removing and Installing”,
page 60
⇒ “4.2 Overview - Heater and A/C Unit Actuators”, page 61
⇒ “4.3 Defroster Door Motor V107 , Removing and Installing”,
page 62
⇒ “4.4 Left Side Vent Motor V299 , Removing and Installing”,
page 62
⇒ “4.5 Left Center Vent Motor V110 , Removing and Installing”,
nAG. Volkswag e nAG d o
page 63 lkswag e es n
o o V tgu
by a
⇒ “4.6 Left Footwell Doore d Motor V108 , Removing and Installing”,
ran
ris te e
page 63 tho or
u a ac
ss
⇒ “4.7 Left Temperature Door Motor V158 , Removing and In‐

ce
le
un

stalling”, page 64

pt
an
d
itte

y li
⇒ “4.8 Right Temperature Door Motor V159 , Removing and In‐
rm

ab
stalling”, page 64
e

ility
ot p

wit
, is n

⇒ “4.9 Fresh Air/Recirculating Air/Back Pressure Door Motor

h re
V425 , Removing and Installing”, page 65
h ole

spe
e s, inpart or inw

⇒ “4.10 Indirect Ventilation Door Motor V213 , Removing and

ct toth e
Installing”, page 65
⇒ “4.11 Right Indirect Ventilation Door Control Motor V453 , Re‐

corre ctne ss of in
moving and Installing”, page 66
l pu rpos

⇒ “4.12 Left Rear Temperature Door Motor V313 , Removing and

Installing”, page 67
e rcia

⇒ “4.13 Right Rear Temperature Door Motor V314 , Removing

form

and Installing”, page 68

m

a
om

tio

4.1 Heater and A/C Unit Actuators, Remov‐

nin
or c

th i

ing and Installing

te
iva

d s
o
pr

cu
r
fo

Prior to working on electrical wires, disconnect the corresponding

m
en
ng

fuse/fuses. Refer to ⇒ Wiring diagrams, Troubleshooting & Com‐

t.
yi Co
op
ponent locations. C py
ht. rig
g h
yri t by
cop by
Vo
lksw
cte d ag e n
Note Prote AG.

♦ After replacing an actuator, the address for all of the actuators

must be adapted again using the Vehicle Diagnostic Tester .
♦ For the malfunction “adaptation limit exceeded”, check con‐
necting element at motor/door, there must be no play between
the shaft of the actuator motor and the connecting element.

60 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

4.2 Overview - Heater and A/C Unit Actua‐

tors
Actuators at the Heating and A/C Unit, Arrangement

Note

♦ A new generation of actuators is installed. These actuators no longer have a potentiometer.

♦ After replacing an actuator, the address for all of the actuators must be adapted again using the Vehicle
Diagnostic Tester .
nAG. Volkswag e nAG d o
ks wag e s no e
♦ -A- shows ythe
Vol arrangement of the actuatorst g on
u
the left side of the heater and Air Conditioning (A/C) unit.
b ara
ed nte
ris
♦ -B- shows the arrangement of the actuators on the e oright side of the heater and A/C unit.
ho
ut a r ac
ss

ce
le
un

pt
1 - Defroster Door Motor -

an
d
itte

y li
V107-
rm

ab
pe

ility
❑ Removing and instal‐
ot

ling. Refer to

wit
, is n

h re
⇒ “4.3 Defroster Door
h ole

Motor V107 , Removing

spe c
and Installing”,
e s, inpart or inw

t toth e co tne ss of infor

page 62 .
2 - Left Side Vent Motor -
V299-
❑ Removing and instal‐ rre c
l pu rpos

ling. Refer to
⇒ “4.4 Left Side Vent
Motor V299 , Removing
e rcia

and Installing”,
m
m

page 62 .
a
com

tion
int

3 - Left Center Vent Motor -

r
te o

h is

V110-
iva

d o
r
rp

❑ Removing and instal‐

cu
fo

ling. Refer to
en
ng

t.
yi
⇒ “4.5 Left Center Vent
Co
op py
Motor V110 , Removing
C
h t. g
rig
h
yri
and Installing”,
t by
cop Vo
page 63 .
by lksw
cte d ag e n
Prote AG.
4 - Left Footwell Door Motor -
V108-
❑ Removing and instal‐
ling. Refer to
⇒ “4.6 Left Footwell
Door Motor V108 , Re‐
moving and Installing”,
page 63 .
5 - Left Temperature Door Mo‐
tor - V158-
❑ Removing and instal‐
ling. Refer to
⇒ “4.7 Left Temperature
Door Motor V158 , Removing and Installing”, page 64 .
6 - Right Temperature Door Motor - V159-
❑ Removing and installing. Refer to
⇒ “4.8 Right Temperature Door Motor V159 , Removing and Installing”, page 64 .

4. Actuators 61
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

Arrangement of the Indirect Ventilation Door Motor - V213- and

the Right Indirect Ventilation Door Control Motor - V453-

Note

The Indirect Ventilation Door Motor - V213- and the Right Indirect
Ventilation Door Control Motor - V453- are only installed on ve‐
hicles having a second evaporator/heater core.

Installed under the instrument panel on the air channel intermedi‐

ate piece
-1- Right Indirect Ventilation Door Control Motor - V453- , remov‐
ing and installing. Refer to
⇒ “4.11 Right Indirect Ventilation Door Control Motor V453 , Re‐
moving and Installing”, page 66 .
-2- Indirect Ventilation Door Motor - V213- , removing and instal‐
ling. Refer to
⇒ “4.10 Indirect Ventilation Door Motor V213 , Removing and
Installing”, page 65 .

4.3 Defroster Door Motor - V107- , Remov‐

ing and Installing
ksw
ag e n
AG. Volkswag e nAG d
oe s
n
ol ot g
yV ua
Removing e db ran
ris te e
th o
– Remove the instrument
s au panel. Refer to ⇒ Body Interior; Rep. or ac
Gr. 70 ; Instrument
s Panel; Instrument Panel, Removing and
ce
le

Installing .
un

pt
an
d
itte

y li

– Remove the vehicle electrical system control module with the

rm

ab

bracket. Refer to ⇒ Electrical Equipment; Rep. Gr. 97 ; Control

e

ility
ot p

Modules; Vehicle Electrical System Control Module - J519- .

wit
is n

h re

– Disconnect the connector from the Defroster Door Motor -

ole ,

spe c

V107- -A-.
u rpose s, inpart or inwh

t toth e co tne ss of infor

– Remove screws -1- and remove the Defroster Door Motor -

V107- -A- from the heater and A/C unit.
Installing
rre c

– Install the Defroster Door Motor - V107- in the reverse order

of removal.
cial p

– Install the vehicle electrical system control module with the

bracket. Refer to ⇒ Electrical Equipment; Rep. Gr. 97 ; Control
me r

ma

Modules; Vehicle Electrical System Control Module - J519- .

m

tion
o
or c

int

– Install the instrument panel. Refer to ⇒ Body Interior; Rep. Gr.

h is
te

70 ; Instrument Panel; Instrument Panel, Removing and In‐

iva

stalling .
o
pr

cu
r
fo

m
en

– Adapt the address again using the Vehicle Diagnostic Tester .

ng

i t.
py Co
t. Co py
rig
h h
4.4 Left Side Vent Motor - V299- , Removing
g
yri t by
by cop Vo
lksw
and Installing
cte d ag e n
Prote AG.

Removing
– Remove the instrument panel. Refer to ⇒ Body Interior; Rep.
Gr. 70 ; Instrument Panel; Instrument Panel, Removing and
Installing .

62 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Remove the vehicle electrical system control module with the

bracket. Refer to ⇒ Electrical Equipment; Rep. Gr. 97 ; Control
Modules; Vehicle Electrical System Control Module - J519- .
– Disconnect the connector from the Left Side Vent Motor -
V299- -B-.
– Loosen the screws -2- and remove the Left Side Vent Motor -
V299- -B- from the heater and A/C unit.
Installing
– Install the Left Side Vent Motor - V299- in the reverse order of
removal. nAG. Volkswag e nA ge G do
olk not swa es
– Install the vehicle y Velectrical system control module g uwith the
bracket. Refer e d b⇒ Electrical Equipment; Rep. Gr. 97
to
ara
; nControl
ris te e
o
Modules; uVehicle Electrical System Control Module - J519-
th or .
a ac
ss
– Install the instrument panel. Refer to ⇒ Body Interior; Rep. Gr.

ce
le
un

70 ; Instrument Panel; Instrument Panel, Removing and In‐

pt
an
d

stalling .
itte

y li
rm

ab
– Adapt the address again using the Vehicle Diagnostic Tester .
e

ility
ot p

wit
is n

h re
4.5 Left Center Vent Motor - V110- , Re‐
ole ,

spe c
moving and Installing
u rpose s, inpart or inwh

t toth e co tne ss of inform

Removing
– Remove the instrument panel. Refer to ⇒ Body Interior; Rep.

rre c
Gr. 70 ; Instrument Panel; Instrument Panel, Removing and
Installing .
cial p

– Remove the vehicle electrical system control module with the

bracket. Refer to ⇒ Electrical Equipment; Rep. Gr. 97 ; Control
me r

Modules; Vehicle Electrical System Control Module - J519- .

a
m

tion
o

– Disconnect the connector from the Left Center Vent Motor -

c

int
or

V110- -C-.
h is
te
iva

– Loosen the screws -3- and remove the Left Center Vent Motor
o
pr

cu
r
fo

- V110- -C- from the heater and A/C unit.

m
en
ng

i t.
py Co
Installing h t. Co py
rig
g h
yri
– Install the Left Center Vent Motor - V110- in the reverse order
t by
op Vo
by c
of removal. d lksw
cte ag e n
Prote AG.
– Install the vehicle electrical system control module with the
bracket. Refer to ⇒ Electrical Equipment; Rep. Gr. 97 ; Control
Modules; Vehicle Electrical System Control Module - J519- .
– Install the instrument panel. Refer to ⇒ Body Interior; Rep. Gr.
70 ; Instrument Panel; Instrument Panel, Removing and In‐
stalling .
– Adapt the address again using the Vehicle Diagnostic Tester .

4.6 Left Footwell Door Motor - V108- , Re‐

moving and Installing
Removing
– Remove the vehicle electrical system control module with the
bracket. Refer to ⇒ Electrical Equipment; Rep. Gr. 97 ; Control
Modules; Vehicle Electrical System Control Module - J519- .
– Disconnect the connector from the Left Footwell Door Motor -
V108- -D-.

4. Actuators 63
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Loosen the screws -4- and remove the Left Footwell Door Mo‐
tor - V108- -D- from the heater and A/C unit.
Installing
– Install the Left Footwell Door Motor - V108- in the reverse order
of removal.
– Install the vehicle electrical system control module with the
bracket. Refer to ⇒ Electrical Equipment; Rep. Gr. 97 ; Control
Modules; Vehicle Electrical System Control Module - J519- .
– Install the instrument panel. Refer to ⇒ Body Interior; Rep. Gr.
70 ; Instrument Panel; Instrument Panel, Removing and In‐
stalling .
– Adapt the address again using the Vehicle Diagnostic Tester .

4.7 Left Temperature Door Motor - V158- ,

Removing and Installing
Removing
n AG. Volkswag e nAG d
– Remove the instrument panel. Refer to ⇒ Body Interior; Rep. wag e oe s
olks not
Gr. 70 ; Instrument Panel; Instrument Panel, Removing db
y Vand gu
ara
Installing . or
ise nte
th e or
– Remove the vehicle electrical system control with the au
module ac
ss
bracket. Refer to ⇒ Electrical Equipment; Rep. Gr. 97 ; Control

ce
le
un

pt
Modules; Vehicle Electrical System Control Module - J519- .

an
d
itte

y li
– Disconnect the connector from the Left Temperature Door
rm

ab
e

ility
ot p

Motor - V158- -E-.

wit
is n

– Loosen the screws -5- and remove the Left Temperature Door

h re
ole ,

Motor - V158- -E- from the heater and A/C unit.

spe c
u rpose s, inpart or inwh

Installing

t toth e co tne ss of inform

– Install the Left Temperature Door Motor - V158- in the reverse
order of removal.

rre c
– Install the vehicle electrical system control module with the
bracket. Refer to ⇒ Electrical Equipment; Rep. Gr. 97 ; Control
Modules; Vehicle Electrical System Control Module - J519- .
cial p

– Install the instrument panel. Refer to ⇒ Body Interior; Rep. Gr.

me r

70 ; Instrument Panel; Instrument Panel, Removing and In‐

a
m

t
stalling . ion
o
or c

int

– Adapt the address again using the Vehicle Diagnostic Tester .

h is
te
iva

d o
pr

cu
r
fo

4.8 Right Temperature Door Motor - V159- ,

m
en
ng

i t.
Removing and Installing
py Co
t. Co py
rig
h g h
yri t by
Removing by cop Vo
lksw
cte d ag e n
– Remove the instrument panel. Refer to ⇒ Body Interior; Rep.
Prote AG.

Gr. 70 ; Instrument Panel; Instrument Panel, Removing and

Installing .
– Disconnect the connector from the Right Temperature Door
Motor - V159- -F-.

64 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Loosen the screws -1- and remove the Right Temperature

Door Motor - V159- -F- from the heater and A/C unit.
Installing
– Install the Right Temperature Door Motor - V159- in the re‐
verse order of removal.
– Install the instrument panel.
AG. VolkRefer
swag e nto
AG⇒d o
Body Interior; Rep. Gr.
70 ; Instrument ag e n Instrument Panel,
Panel; Removing
es n and In‐
olksw ot g
V
stalling .e d by ua
ra
is nte
th or eo
– Adapt
au the address again using the Vehicle Diagnostic
r a Tester .
ss c

ce
le
un

pt
an
d
itte

y li
4.9 Fresh Air/Recirculating Air/Back Pres‐
rm

ab
e

ility
ot p

sure Door Motor - V425- , Removing and

wit
is n

Installing

h re
ole ,

spe c
u rpose s, inpart or inwh

Removing

t toth e co tne ss of inform

– Remove the footwell trim panel on the front passenger side.
Refer to ⇒ Body Interior; Rep. Gr. 68 ; Storage Compart‐
ments, Covers and Trim; Footwell Covers, Removing and

rre c
Installing .
– Disconnect the connector -arrow A- from the Fresh Air/Recir‐
cial p

culating Air/Back Pressure Door Motor - V425- -1-.

– Remove screws -2-.
me r

a
m

tion

– Remove the adjustment motor.

co

int
or

Installing
h is
te
iva

do
pr

– Install the Fresh Air/Recirculating Air/Back Pressure Door Mo‐

cum
r
fo

tor - V425- in reverse order of removal.

en
ng

i t.
py Co
Co
– Adapt the address again using the Vehicle Diagnostic Tester .
py
h t. rig
g h
yri t by
y cop Vo
lksw
b
cte d ag e n
Prote AG.

4.10 Indirect Ventilation Door Motor - V213- ,

Removing and Installing
Special tools and workshop equipment required
♦ Trim Removal Wedge - 3409-

Note

Only vehicles with a second evaporator/heater core have an In‐

direct Ventilation Door Motor - V213- .

4. Actuators 65
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

Removing
The illustration shows the Right Indirect Ventilation Door Control
Motor - V453- . Removing and installing the other motor is iden‐
tical.

– Remove the instrument cluster. Refer to ⇒ Electrical Equip‐

ment; Rep. Gr. 90 ; Instrument Cluster; Instrument Cluster,
Removing and Installing .
– Remove the four screws -1- and the Indirect Ventilation Door
Motor - V213- -2-. Leave the kinematics lever -3- on the shaft
for the indirect ventilation door.
Installing
– Install the Indirect Ventilation Door Motor - V213- in reverse
order of removal. Tightening specification for the screws: 1.5
Nm.

– Adapt the address again using the Vehicle Diagnostic Tester .

Note

Is the kinematics lever -1- off the shaft?

– Remove the indirect ventilation grille (in the top of the instru‐
ment panel) using a -3409- .
– Set the indirect ventilation door vertical and the instrument
panel ventilation door horizontal and then install the kinemat‐
ics lever -1- on the shaft.
– Install the Indirect Ventilation Door Motor -G
nA . Volksw
V213- on
ag ethe
nAGkin‐
wag e d oe s
ematics lever mount. Volks not
gu
y b ara
ed nte
ris
th o e
4.11 Right Indirect Ventilation Door Control ss
au or
ac
Motor - V453- , Removing and Installing
ce
e
nl

pt
du

an
itte

Special tools and workshop equipment required

y li
e rm

ab
ility
ot p

♦ Trim Removal Wedge - 3409-

wit
is n

h re
ole ,

spe c

Note
u rpose s, inpart or inwh

t toth e co tne ss of inform

Only vehicles with a second evaporator/heater core have a Right

Indirect Ventilation Door Control Motor - V453- .
rre c

Removing
– Remove the front passenger side airbag unit. Refer to ⇒ Body
cial p

Interior; Rep. Gr. 69 ; Airbag; Front Passenger Side Airbag

Unit, Removing and Installing .
me r

– Remove the left airbag unit bracket.

m

tion
co

int
or

h is
ate

do
iv
pr

cum
or
f

en
ng

i t.
py Co
t. Co py
rig
h g h
yri t by
op Vo
e d by c lksw
ag e n
ct
Prote AG.

66 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Remove the three screws -1- and the Right Indirect Ventilation
Door Control Motor - V453- -2-. Leave the kinematics lever
-3- on the shaft for the indirect ventilation door.
Installing
– Install the Right Indirect Ventilation Door Control Motor - V453-
in reverse order of removal. Tightening specification for the
screws: 1.5 Nm.
– Adapt the address again using the Vehicle Diagnostic Tester .

The illustration shows the left kinematics lever.

Note

Is the kinematics lever -1- off the shaft?

– Remove the indirect ventilation grille (in the top of the instru‐
ment panel) using a -3409- .
– Remove the frame section. Refer to ⇒ Body Interior; Rep. Gr.
68 .
– Set the indirect ventilation door vertical and the instrument
panel ventilation door horizontal and then install the kinemat‐
ics lever -1- on the shaft.
– Install the Right Indirect Ventilation Door Control Motor - V453-
on the kinematics lever mount.

4.12 Left Rear Temperature Door Motor -

V313- , Removing and Installing
Removing nAG. Volkswag e nAG d o
wag e es n
Volks ot g
y
– d Conditioning (A/C) unit into the u ara
Bring the rear heater andriseAirb
nte
service position. Referu th to
o eo
ra
⇒ “6.2 Rear Heatersand
s a A/C unit, Service Position”, c
page 94 .
ce
le
un

pt
an
d

– Disengage the lever -1- on the Left Rear Temperature Door

itte

y li

Motor - V313- .
rm

ab
e

ility
ot p

– Remove the bolts -2-.

wit
is n

h re
ole ,

– Disconnect the connector -A- from the Left Rear Temperature

spe c

Door Motor - V313- -3- and remove the motor.

u rpose s, inpart or inwh

t toth e co tne ss of inform

Installing
Install in reverse order of removal. Note the following:
rre c

– Perform the basic setting function using the Vehicle Diagnostic

Tester .
cial p

Note
me r

a
m

tion
o

Hose to water drain valve must not be kinked or pinched. Refer

c

int

to ⇒ “6.9 Condensation Drain Hose, Checking”, page 102 .

or

h is
te
iva

do
pr

cum
r
fo

en
ng

i t.
py Co
t. Co py
rig
h g h
yri t by
y cop Vo
lksw
b
cte d
67
ag e n
Prote AG.
4. Actuators
 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

4.13 Right Rear Temperature Door Motor -

V314- , Removing and Installing
Removing
– Remove the side trim panel on the left side of the luggage
compartment. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Luggage
Compartment Trim Panels; Luggage Compartmentag Side e nAG.Trim
Volkswag e nAG
d oe s
Panels, Removing and Installing . ksw not
Vol g by ua
ed ran
– Disconnect the lever -3- from the Right rRear
is Temperature te e
Door Motor - V314- -2-. th o or
au ac
ss
– Remove the bolts -1-.

ce
le
un

pt
an
d

– Disconnect the connector -A- from the Right Rear Tempera‐

itte

y li
e rm

ab
ture Door Motor - V314- -2- and remove the actuator.

ility
ot p

Installing

wit
is n

h re
ole ,

Install in reverse order of removal. Note the following:

spe c
u rpose s, inpart or inwh

– Initiate the basic setting function using the Vehicle Diagnostic

t toth e co tne ss of inform

Tester .

rre c
cial p
me r

a
m

ti
r co

onin
o

th i
te
ir va

d s
o
p

cu
r
fo

m
en
ng

i t.
py Co
t. Co py
rig
h h
rig t by
py Vo
d by co lksw
cte ag e n
Prote AG.

68 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
olkswag e nAG
Heating, Ventilation and sAir e nAG. V
wagConditioning - Edition
d oe s06.2017
k not
Vol gu
d by ara
ise nte
or
5 Front Heater and A/C Unit au
th e or
ac
ss
⇒ “5.1 Overview - Heater and A/C Unit”, page 69

ce
le
un

pt
an
d
itte
⇒ “5.2 Auxiliary Heater Heating Element Z35 , Removing and

y li
rm

ab
Installing”, page 71

ility
ot p

wit
⇒ “5.3 Heater and A/C Unit, Removing and Installing”,

, is n

h re
page 74

h ole

spe
⇒ “5.4 Heater and A/C Unit, Disassembling and Assembling”,

e s, inpart or inw

ct toth e
page 76
⇒ “5.5 Dust and Pollen Filter, Removing and Installing”,

corre ctne ss of in
page 78
⇒ “5.6 Fresh Air Blower V2 , Removing and Installing”,

l pu rpos
page 80
⇒ “5.7 Evaporator Temperature Sensor G308 , Removing and
e rcia

form
Installing”, page 80
m

a
om

t
⇒ “5.8 Heater Core, Removing and Installing”, page 81

ionin
or c
⇒ “5.9 Condensation Water Drain, Checking”, page 83

th i
te
iva

d s
o
⇒ “5.10 Evaporator Housing, Disassembling and Assembling”,
pr

cu
r
fo

m
page 84

en
ng
t.
yi Co
op
⇒ “5.11 Evaporator, Removing and Installing”, page 86 C py
h t. g
rig
h
yri t by
⇒ “5.12 Rear Evaporator, Removing and Installing, with Heater y cop Vo
lksw
and A/C Unit Installed”, page 88
b
cte d ag e n
Prote AG.

5.1 Overview - Heater and A/C Unit

⇒ “5.1.1 Overview - Heater and A/C Unit, Climatronic”,
page 69

5.1.1 Overview - Heater and A/C Unit, Clima‐

tronic
Perform the Following Before Working on the Electrical System:
• Turn off all electric consumers.
• Turn off the ignition.
• Remove the key.

Note

♦ Under certain conditions, the desiccant bag/dryer cartridge no

longer needs to be replaced each time the refrigerant circuit is
opened on A/C systems with refrigerant R1234yf. Refer to ⇒
Refrigerant R1234yf General Information; Rep. Gr. 87 ; Re‐
frigerant Circuit; Components, Replacing .
♦ Under certain conditions, the dryer bag no longer needs to be
replaced each time the refrigerant circuit is opened on A/C
systems with refrigerant R134a. Refer to ⇒ Refrigerant R134a
Servicing; Rep. Gr. 00 ; Replacing Components .

5. Front Heater and A/C Unit 69

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

1 - Front A/C Display Control

Head - E87- with Climatronic
Control Module - J255-
2 - Left Front Upper Body Vent
Temperature Sensor - G385-
❑ Removing and instal‐
ling. Refer to
⇒ “10.8 Right Front Up‐
per Body Vent Temper‐
ature Sensor G386 and
Left Front Upper Body
Vent Temperature Sen‐
sor G385 , Removing
and Installing”,
page 129 .
3 - Left Actuators
❑ Arrangement of the con‐
trol motors at the heat‐
ing and Air Conditioning
(A/C) unit. Refer to
⇒ “4.2 Overview - Heat‐
er and A/C Unit Actua‐ nAG. Volkswag e nAG d o
tors”, page 61 wag e es n
Volks ot g
by ua
4 - Upper Part of the Distribu‐ e d ran
is te e
tion Box th or
or
au ac
ss
5 - Right Actuators

ce
e
nl

pt
❑ Arrangement of the con‐
du

an
itte

y li
trol motors at the heat‐
e rm

ab
ing and A/C unit. Refer

ility
ot p

to

wit
is n

⇒ “4.2 Overview - Heat‐

h re
ole ,

er and A/C Unit Actua‐

spe c
tors”, page 61
u rpose s, inpart or inwh

t toth e co tne ss of inform

6 - Evaporator Temperature
Sensor - G308-
❑ Removing and instal‐

rre c
ling. Refer to ⇒ “5.7 Evaporator Temperature Sensor G308 , Removing and Installing”, page 80 .
7 - Hose for Glove Compartment Cooling
cial p

8 - Right Front Upper Body Vent Temperature Sensor - G386-

me r

❑ Removing and installing. Refer to

a

⇒ “10.8 Right Front Upper Body Vent Temperature Sensor G386 and Left Front Upper Body Vent Tem‐
m

tion
o

perature Sensor G385 , Removing and Installing”, page 129 .

c

int
r
te o

h is
a

9 - Fresh Air Blower - V2-

do
riv
p

❑ Removing and installing. Refer to ⇒ “5.6 Fresh Air Blower V2 , Removing and Installing”, page 80 .
um
or
f

en
ng

i t.
10 - Fresh/Recirculated Air Door Motor - V154-
py Co
t. Co py
rig
❑ Removing and installing. Refer to
h g h
yri t by
⇒ “4.9 Fresh Air/Recirculating Air/Back Pressure Door Motor V425 , Removing and Installing”,
op Vo
d by c lksw
page 65 .
cte ag e n
Prote AG.

11 - Dust and Pollen Filter with Activated Charcoal Filter

❑ Removing and installing. Refer to ⇒ “5.5 Dust and Pollen Filter, Removing and Installing”, page 78 .
12 - Front Passenger Side Footwell Vent
❑ Removing and installing. Refer to
⇒ “7.5 Front Passenger Side Footwell Vent, Removing and Installing”, page 105 .
13 - Right Footwell Vent Temperature Sensor - G262-
❑ Removing and installing. Refer to
⇒ “10.7 Right Footwell Vent Temperature Sensor G262 , Removing and Installing”, page 128 .

70 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

14 - Heat Exchanger
❑ Removing and installing. Refer to ⇒ “5.8 Heater Core, Removing and Installing”, page 81 .
15 - Auxiliary Heater Heating Element - Z35-
Removing and Installing. Refer to
⇒ “5.2 Auxiliary Heater Heating Element Z35 , Removing and Installing”, page 71 .
16 - Driver Side Footwell Vent
❑ Removing and installing. Refer to
⇒ “7.4 Driver Side Footwell Vent, Removing and Installing”, page 104 .
ag e G do nAG. Volkswag e nA
17 - Left Footwell Vent Temperature
ksw Sensor - G261-es n
y Vol ot g
ua
❑ Removing and e d installing. Refer to
b ran
⇒ “10.6 Left ris te
ht o Footwell Vent Temperature Sensor G261 e, oRemoving and Installing”, page 128 .
au ra
c
ss

ce
le
un

pt
5.2 Auxiliary Heater Heating Element -

an
d
itte

y li
e rm

ab
Z35- , Removing and Installing

ility
ot p

wit
is n

h re
ole ,

Note

spe c
u rpose s, inpart or inwh

t toth e co tne ss of inform

If the vehicle has a TDI engine, but not an optional “auxiliary
heater”, then it may have an Auxiliary Heater Heating Element -
Z35- instead of a fuel-driven auxiliary heater (running change

rre c
depending on the engine). This is based on the emissions stand‐
ards. Refer to the Parts Catalog.
cial p

Removing
me r

– Remove the glove compartment. Refer to ⇒ Body Interior; a

Rep. Gr. 68 ; Storage Compartments, Covers and Trim; Glove
m

ti
r co

Compartment, Removing and Installing

nin
o

th i
e

– Remove the front heater and Air Conditioning (A/C) unit heater
t
ir va

d s
o

core. Refer to
p

cu
r
fo

⇒ “5.8 Heater Core, Removing and Installing”, page 81 .

en
ng

i t.
py Co
– Disconnect the battery. Refer to ⇒ Electrical Equipment; Rep. Co py
t. rig
Gr. 27 ; Battery, Disconnecting and Connecting .
h g h
yri t by
y cop Vo
lksw
b
cte d ag e n
CAUTION Prote AG.

Pyrotechnic components can unintentionally deploy.

Risk of injury.
– Discharge static electricity: Briefly touch the door striker pin.

– Disconnect the connectors -A and B- with the wire connection

from the Auxiliary Heater Heating Element - Z35- .
– Loosen the Auxiliary Heater Heating Element - Z35- Ground
(GND) wire from the ground point -C- on the instrument panel
crossmember (tightening specification: 9 ±1 Nm).

5. Front Heater and A/C Unit 71

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Disconnect the connector -A- and the mounting points -B- for
the wiring harness -C- from the heater and A/C unit.

Note

♦ The heater and A/C unit is shown without the instrument panel
crossmember.
♦ Unlock the brackets on the mounting points -B- with a screw‐
driver -E-, for example.
AG. Volkswag e nAG d
♦ The wiring harness -C- can only be removed downward to‐ ag e n oe s
olksw not
gether with the Auxiliary Heater Heating Element - Z35- -D-. d by
V gu
ara
se nte
ori eo
th
au ra
ss c
– Remove the bolt -A-.

ce
le
un

pt
– Loosen the Auxiliary Heater Heating Element - Z35- -B- from

an
d
itte

y li
the heater and A/C unit in direction of -arrow-. rm

ab
e

ility
ot p

– Loosen the wiring harness -C- from the heater and A/C unit.

wit
is n

h re
ole ,

spe c
u rpose s, inpart or inwh

t toth e co tne ss of inform

rre c
– When removing the Auxiliary Heater Heating Element - Z35-
cial p

-C- further, make sure that the wire connections to the other
electrical components on the heater and A/C unit are not
me r

pulled or damaged while removing the wiring harness -C-.

a
m

tion
co

Installing

int
or

h is
te
iva

Install in reverse order of removal. Note the following:

do
pr

cum
r
fo

en
ng

i t.
py Co
t. Co py
rig
h g h
yri t by
by cop Vo
lksw
cte d ag e n
Prote AG.

– Attach the grille -A- to the Auxiliary Heater Heating Element -

Z35- -B-.

Note

The grille -A- prevents electrically conductive objects from short

circuiting the heating elements -B- (which, for example, could
happen via the instrument panel vents on the Auxiliary Heater
Heating Element - Z35- ).

– Place the rubber grommets -C- on the pin -D-.

72 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Install the wiring harness -C- on the heater and A/C unit as
illustrated from the bottom toward the top. Be careful not to
pull on or damage the wire connections to other electrical
components on the heater and A/C unit when installing the
wiring harness -C-.

– Insert the Auxiliary Heater Heating Element - Z35- -B- pins with
the rubber grommets -C- into the heater and A/C unit mounts
. Volkswag e nAG
-D-. g e nAG d oe s
swa k not
Vol g
by
– Install the Auxiliary Heater Heating Element - Z35- u a -B- in the
ed ra
heater and orisA/C unit opposite the direction of -arrow-.nte e
th o
au ra
c
ss the bolt -A-.
– Tighten

ce
le
un

pt
an
d
itte

y li
e rm

ab
ility
ot p

wit
is n

h re
ole ,

spe c
u rpose s, inpart or inwh

– Reinstall the wiring harness -C- as shown and secure it to the

t toth e co tne ss of inform
mounting points -B- on the heater and A/C unit.
– Check the wiring harness routing -C-. The wiring harness
rre c

should be fastened in such a way so that it cannot make any

noises and that it cannot touch other components.
cial p

Note
me r

a
m

Secure the wiring harness with additional cable ties and foam
ion
r co

strips to keep it from moving or making noise.

int
o

h is
ate

do
ir v
p

cum
r
fo

en
ng

t.
yi Co
Cop py
h t. g
rig
h
yri t by
by cop Vo
lksw
cte d ag e n
Prote AG.

5. Front Heater and A/C Unit 73

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Secure the connector -B- to the heater and A/C unit and re‐
connect the connector -A-.
– Tighten the Auxiliary Heater Heating Element - Z35- Ground
(GND) wire to the ground point -C- on the instrument panel
crossmember (tightening specification: 9 Nm). Refer to ⇒ Wir‐
ing diagrams, Troubleshooting & Component locations.
– Install the heater core for the front heater and A/C unit.
– Install the glove compartment. Refer to ⇒ Body Interior; Rep.
Gr. 68 ; Storage Compartments, Covers and . VolksGlove
Trim;
nAG wag e nAG
wag e d oe s
Compartment, Removing and Installing
Volks not
gu
y b ara
ed nte
ris
u th o e or
Note a ac
ss

ce
le
un

pt
After all components outside of the glove compartment have been

an
d
itte

y li
installed, check the activation and function of the Auxiliary Heater
rm

ab
Heating Element - Z35- through the “output diagnostic test mode”
e

ility
ot p

function on the A/C system and the Engine Control Module

wit
is n

(ECM). Use the Vehicle Diagnostic Tester .

h re
ole ,

spe c
u rpose s, inpart or inwh

– Retrieve the front A/C display control head Diagnostic Trouble

t toth e co tne ss of inform

Code (DTC) memory, and delete the displayed errors for the
Climatronic Control Module - J255- (and the Rear A/C Display
Control Head - E265- ) if necessary, using the Vehicle Diag‐

rre c
nostic Tester .

5.3 Heater and A/C Unit, Removing and In‐

cial p

stalling
me r

a
Special tools and workshop equipment required
m

tion
co

int
♦ Hose Clamps - Up To 25 mm - 3094-
or

h is
te
iva

d
♦ Shop Crane - Drip Tray - VAS6208-
o
pr

cu
r
fo

♦ Torque Wrench 1331 5-50Nm - VAG1331-

en
ng

i t.
py Co
Co py
♦ Shop Crane - Drip Tray - VAS6208- h t.
g
rig
h
yri t by
♦ Commercially available compressed-air gun y cop Vo
lksw
b
cte d ag e n
Prote AG.
Removing
– Observe safety precautions when working on the high voltage
system. Refer to
⇒ “1.4 High Voltage System Safety Precautions”, page 2 .
– Pay attention to safety precautions for working near high volt‐
age components. Refer to
⇒ “1.5 Safety Precautions near High Voltage Components”,
page 3 .
– See notes. Refer to
⇒ “3.1 Working on Refrigerant Circuit”, page 6 .
– Note the high voltage system danger classification. Refer to
⇒ Electrical System Hybrid; Rep. Gr. 93 ; High Voltage Sys‐
tem General Warnings .

DANGER
Danger to life due to high voltage.
Death or serious bodily injury by electric shock.
– Have the high voltage system de-energized by a qualified
person.

74 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Switch off the high voltage system. Refer to ⇒ Electrical Sys‐

tem Hybrid; Rep. Gr. 93 ; Disabling the High Voltage System .
– Remove the instrument panel. Refer to ⇒ Body Interior; Rep.
Gr. 70 ; Instrument Panel; Instrument Panel, Removing and
Installing .
– Remove the air intake shroud. Refer to
⇒ “7.7 Fresh Air Intake, Removing and
g e nAG
. VInstalling”,
olkswag e nAGpage 106 .
a d oe s
o ot g lksw n
– Remove the expansiond bvalve.
yV Refer to ua
r
ir se Removing and Installing”, page 26 .ante
⇒ “2.6 Expansion Valve,
o h eo
a work, close the open lines and connec‐ ut ra
– For all the following
ss c
tions with clean plugs from the -VAS6122- .

ce
le
un

pt
an
d

– Remove the air guides for the heater and Air Conditioning (A/
itte

y li
C) unit.
rm

ab
e

ility
ot p

– Place the -VAS6208- under the engine.

wit
is n

h re
ole ,

CAUTION

spe c
u rpose s, inpart or inwh

t toth e co tne ss of inform

The cooling system is under pressure when the engine is warm.
There is a risk of scalding from hot steam and coolant.
Burns on the skin and other parts of the body is possible.

rre c
– Wear protective gloves.
– Wear protective eyewear.
cial p

– Reduce the pressure: cover the coolant reservoir cap with a

cloth and carefully open.
me r

a
m

tion
o

– Discharge the coolant circuit. Refer to ⇒ Rep. Gr. 19 .

c

int
or

h is
te

– Loosen the coolant lines on the heater core. Refer to

iva

d
⇒ “5.8 Heater Core, Removing and Installing”, page 81 .
o
pr

cu
r
fo

– Remove the condensation water drain hose from the heater

en
ng

t.
yi Co
and A/C unit. Cop py
h t. g
rig
h
– Disconnect the connectors from the heater and A/C unit.
yri t by
by cop Vo
lksw
cte d ag e n
Prote AG.

5. Front Heater and A/C Unit 75

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Remove the subframe. Refer to ⇒ Rep. Gr. 70 .

– Remove the nuts -1- from the heater and A/C unit on the en‐
gine compartment side.

Note
olkswag e nAG
wag with a second technician.
d oe s e nAG. V
The following steps must be performed
olks not
yV gu
e db ara
ris nte
– Remove the heater and
u th o A/C unit to the side. e or
a ac
Installing ss

ce
le
un

pt
Install in reverse order of removal and note the following:

an
d
itte

y li
e rm

ab
– Coat the new seals with refrigerant oil before installing the re‐

ility
ot p

frigerant lines.

wit
is n

h re
ole ,

NOTICE

spe c
u rpose s, inpart or inwh

There is a risk of damaging the A/C compressor if the refrigerant

t toth e co tne ss of inform

circuit is empty.
– Never start the engine with the refrigerant circuit empty.

rre c
Vehicles with Refrigerant R134a
– Fill the refrigerant circuit. Refer to ⇒ Refrigerant R134a Serv‐
cial p

icing; Rep. Gr. 00 ; Working with A/C Service Station .

me r

– Perform the leak test on the closed line connections of the

a
m

t
refrigerant circuit. Refer to ⇒ Refrigerant R134a Servicing;

ion
r co

Rep. Gr. 00 ; Refrigerant Circuit, Detecting Leaks .

int
o

h is
ate

Vehicles with Refrigerant R1234yf

do
riv
p

cum
r
fo

– Fill the refrigerant circuit. Refer to ⇒ Refrigerant R1234yf

en
ng

i t.
Servicing; Rep. Gr. 87 ; Working with A/C Service Station; py Co
Co py
Refrigerant Circuit, Filling . h t. rig
rig t by h
py
– Perform the leak test on the closed line connections of the
Vo
d by co lksw
cte ag e n
refrigerant circuit. Refer to ⇒ Refrigerant R1234yf Servicing; Prote AG.
Rep. Gr. 87 ; Refrigerant Circuit; Determining Leaks .
Continuation for All Vehicles
– Fill the coolant. Refer to ⇒ Rep. Gr. 19 ; Cooling System/
Coolant; Coolant, Draining and Filling .
– Check the heating and A/C system function.

5.4 Heater and A/C Unit, Disassembling

and Assembling
– Remove the heater and A/C unit. Refer to
⇒ “5.3 Heater and A/C Unit, Removing and Installing”,
page 74 .

76 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

1 - Upper Part of the Distribu‐

tion Box
❑ The upper section is at‐
tached to the lower sec‐
tion with bolts -3- and
clips -2-.
2 - Expansion Valve AG. Volkswag e nAG d
ag e n oe s
❑ Removing and Instal‐ olksw not
V gu
ling. Refer to d by ara
⇒ “2.6 Expansion Valve, ir se nte
th o e or
Removing and Instal‐ au ac
ss
ling”, page 26 .

ce
le
un

pt
3 - Evaporator

an
d
itte

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rm
❑ Removing and Instal‐

ab
e

ility
ling. Refer to ot p

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is n
⇒ “5.11 Evaporator, Re‐

h re
moving and Installing”,
ole ,

spe c
page 86 .
u rpose s, inpart or inwh

❑ Note seal

t toth e co tne ss of inform

⇒ Fig. ““Seal at Evapo‐
rator”“ , page 78

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4 - Blower Housing
5 - Fresh Air Blower - V2-
cial p

❑ Removing and Instal‐

ling. Refer to
me r

⇒ “5.6 Fresh Air Blower

a
V2 , Removing and In‐
m

tion
o

stalling”, page 80 .
c

int
or

h is
te

6 - Condensation Water Drain

iva

d o
pr

Hose

cu
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fo

m
en
ng

t.
yi Co
Note Cop py
h t. g
rig
h
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The condensation water drain hose cop Vo
by lksw
with valve must not be kinked or cte d ag e n
Prote AG.
pinched. Refer to
⇒ “6.9 Condensation Drain Hose,
Checking”, page 102 .

7 - Front Passenger Side Footwell Vent

❑ Removing and installing. Refer to
⇒ “7.5 Front Passenger Side Footwell Vent, Removing and Installing”, page 105 .
8 - Driver Side Footwell Vent
❑ Removing and installing. Refer to
⇒ “7.4 Driver Side Footwell Vent, Removing and Installing”, page 104 .
9 - Heat Exchanger
❑ Removing and Installing. Refer to ⇒ “5.8 Heater Core, Removing and Installing”, page 81 .
10 - Auxiliary Heater Heating Element - Z35-
❑ Removing and Installing. Refer to
⇒ “5.2 Auxiliary Heater Heating Element Z35 , Removing and Installing”, page 71 .
❑ Depending on vehicle equipment
11 - Junction Box
12 - Lower Part of the Distribution Box

5. Front Heater and A/C Unit 77

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

Seal at Evaporator
Pay attention to the seal -arrows- all around the evaporator.

5.5 Dust and Pollen Filter, Removing and

Installing
Removing
The dust and pollen filter with activated charcoal filter element is
located in the front passenger footwell.
– Remove the footwell trim panel on the front passenger side.
Refer to ⇒ Body Interior; Rep. Gr. 68 ; Storage Compart‐
ments, Covers and Trim; Footwell Covers, Removing and
Installing .
– Remove the footwell vent on the front passenger side. Refer
to
⇒ “7.5 Front Passenger Side Footwell Vent, Removing and
Installing”, page 105 .
– Release the tab -B- and unhook the rear cover -1- -A-.
olkswag e nAG
wag e nAG. V d oe
– Pull the filter element
olks out of the housing. s no
tgu
yV
e db ara
ris nte
tho e or
Notes au ac
s
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le
un

Observe the replacement interval for dust and pollen filter with
pt
an
d

activated charcoal filter. Refer to ⇒ Maintenance ; Booklet 29.1 .

itte

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e rm

ab
ility
ot p

Installing
wit
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h re

Install in reverse order of removal. Note the following:

ole ,

spe c
u rpose s, inpart or inwh

t toth e co tne ss of inform

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cial p
me r

a
m

ti
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onin
o

th i
te
ir va

d s
o
p

cu
r
fo

m
en
ng

t.
yi Co
Cop py
ht. rig
g h
yri t by
cop by
Vo
lksw
cte d ag e n
Prote AG.

78 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, oVentilation
lksw
and Air Conditioning - Edition 06.2017
AG. V ag e nAG
ag e n d oe s
olksw not
– Note the filter installation location db
y V-arrows-. gu
ara
rise nte
Dust and Pollen Filter with Activated
th o Charcoal Insert e or
au ac
ss
♦ A dust and pollen filter with additional activated charcoal filter

ce
le
un
insert is installed together with the Air Quality Sensor - G238- .

pt
an
d
itte

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♦ The activated charcoal filter element continues to function as

rm

ab
a dust and pollen filter, however in addition the activated char‐

ility
ot p
coal filter can also filter out gaseous pollutants, for example,

wit
, is n
ozone, benzene, nitrogen dioxide from the air flow.

h re
h ole

spe
♦ The activated charcoal is designed to absorb the gaseous pol‐
e s, inpart or inw

ct toth e
lutants in the air flow until the fresh-air door is closed and the
air conditioner is operating in recirculated-air mode. The
change over from fresh to recirculating mode occurs via the

corre ctne ss of in
Climatronic Control Module - J255- , as soon as air quality
sensor detects gaseous pollutants in the surrounding air (the
“automatic air recirculation” mode must be selected).
l pu rpos

♦ The activated charcoal layer in the dust and pollen filter reacts
e rcia

differently to various pollutants in the air.

form
m

Certain pollutants bond permanently in the active-carbon layer.

a
om

tionin
or c

Others are converted into noxious bonds like in a catalytic con‐

th i
verter.
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iva

d s
o
pr

cu
For the rest the activated charcoal works as a condenser (capac‐
r
fo

m
itor). With increasing load pollutants are absorbed, until a certain

en
ng

i t.
saturation is reached. If the amount of pollutants decreases, the
py Co
Co py
activated charcoal layer continuously releases the absorbed par‐ h t. rig
g h
yri t by
ticles. by cop Vo
lksw
cte d ag e n
♦ Under the following operating conditions the dust and pollen Prote AG.
filter must be replaced earlier than required, because a certain
amount of pollutant particles is permanently bonded to the ac‐
tivated charcoal layer.
If the vehicle is driven in areas with heavy air pollution.
If the vehicle is predominantly driven with the “automatic air re‐
circulation” on.
On vehicles without an air quality sensor and without “automatic
air recirculation” mode.
♦ If possible, the Air Conditioning (A/C) system on vehicles with
an air quality sensor should always be operating in “automatic
recirculation” mode. However, if it is desired or necessary to
switch this mode off, the following must be observed:
The active carbon layer in the dust and pollen filter is saturated
after a certain time.
A saturated filter can no longer absorb pollutants and allows them
to pass unhindered.
♦ The most important task of the dust and pollen filter and air
quality sensor is keep the load peaks out from the passenger
compartment. For this the following must be observed:
If a vehicle is driven in an area with relatively clean air (with little
air pollution), the system will switch from fresh air mode to recir‐
culation mode occurs at a different point in time than when in an
area with heavy air pollution (such as an industrial area).
The switch from fresh to recirculating mode always occurs when
the level of pollutants increases, regardless of what the level orig‐
inally was (for example, when driving through an exhaust cloud).

5. Front Heater and A/C Unit 79

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

♦ The filter with activated charcoal can be installed in all vehicle

types (also vehicles without air quality sensor). The same lim‐
itations apply to these vehicles as on climate control systems
with the “automatic air recirculation” mode switched off.

5.6 Fresh Air Blower - V2- , Removing and

Installing

Note

The blower motor and series resistor form a single unit and can
only be replaced together. Refer to the Parts Catalog.

Removing

NOTICE wag e
nAG. Volkswag e nAG d o
es n
Volks ot g
Risk of damaging the fresh air blower if operated incorrectly.
e db
y ua
ran
ris te e
Imbalance and problems during operation is possible.
u
ht o or
a ac
– Avoid using force on the fan wheel. ss

ce
le
un

– Never move the balancing weight on the fan wheel.

pt
an
d
itte

y li
e rm

ab
– Remove the footwell trim panel on the front passenger side.

ility
ot p

Refer to ⇒ Body Interior; Rep. Gr. 68 ; Storage Compart‐

wit
is n

ments, Covers and Trim; Footwell Covers, Removing and

h re
ole ,

Installing .

spe c
u rpose s, inpart or inwh

– Remove the footwell vent on the front passenger side. Refer

t toth e co tne ss of inform

to
⇒ “7.5 Front Passenger Side Footwell Vent, Removing and
Installing”, page 105 .

rre c
– Remove screws -2-.
– Disconnect the connector -1- from the Fresh Air Blower - V2-
cial p

-3-.
me r

– Remove the Fresh Air Blower - V2- -3- downward.

a
m

tion
r co

Installing
int
o

h is
ate

NOTICE
do
ir v
p

cum
r
fo

Risk of damaging the fresh air blower if operated incorrectly.

en
ng

t.
yi Co
Imbalance and problems during operation is possible. Cop py
ht. rig
– Avoid using force on the fan wheel.
rig t by h
py Vo
y co lksw
– Never move the balancing weight on the fan wheel.
d b
cte ag e n
Prote AG.

– Install the Fresh Air Blower - V2- in reverse order of removal.

5.7 Evaporator Temperature Sensor -

G308- , Removing and Installing
Removing
– Remove the lower instrument panel trim panel. Refer to ⇒
Body Interior; Rep. Gr. 70 ; Instrument Panel; Instrument
Panel, Removing and Installing .

80 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Turn the sensor -1- approximately 90° in direction of -arrow-.

– Disconnect the connector from the sensor.
– Remove the sensor from the housing.
Installing
– Install in reverse order of removal.

5.8 Heater Core, Removing and Installing

Special tools and workshop equipment required
AG. Volkswag e nAG d
♦ Torque Wrench 1331 5-50Nm - VAG1331- (5 to 50 Nm) ag e n oe s
olksw not
V gu
by ara
♦ Hose Clamps - Up To 25mm - 3094- ir se
d
nte
th o e or
♦ Shop Crane - Drip Tray - VAS6208- au ac
ss

ce
le
♦ Engine Bung Set - VAS6122-
un

pt
an
d
itte

♦ A/C Service Station

y li
rm

ab
e

ility
ot p

♦ Commercially available compressed-air gun

wit
, is n

h re
h ole

Caution

spe
e s, inpart or inw

ct toth e
This procedure contains mandatory replaceable parts. Refer
to component overview prior to starting procedure.

corre ctne ss of in
Mandatory Replacement Parts
l pu rpos

♦ O-rings - Lines
e rcia

form
Removing
m

a
om

– Remove the knee airbag. Refer to ⇒ Body Interior; Rep. Gr.

tionin
or c

69 ; Airbag; Knee Airbag, Removing and Installing .

th i
te
iva

d s
CAUTION

o
pr

cu
r
fo

m
en
Pyrotechnic components can unintentionally deploy.
ng

t.
yi Co
op
Risk of injury.
C py
h t. g
rig
h
yri t by
– Discharge static electricity: Briefly touch the door striker pin. by cop Vo
lksw
cte d ag e n
Prote AG.
– Remove the instrument panel. Refer to ⇒ Body Interior; Rep.
Gr. 70 ; Instrument Panel; Instrument Panel, Removing and
Installing .
– Remove the vehicle electrical system control module. Refer to
⇒ Electrical Equipment; Rep. Gr. 97 ; Control Modules; Ve‐
hicle Electrical System Control Module - J519- .
– Completely detach the module carrier. Refer to ⇒ Body Inte‐
rior; Rep. Gr. 70 .
– Remove the driver footwell vent. Refer to
⇒ “7.4 Driver Side Footwell Vent, Removing and Installing”,
page 104 .
– Pull the module carrier forward off the studs.
– Cover the studs on the right side with a cloth or the like.

5. Front Heater and A/C Unit 81

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Press the module carrier up on the right side and place it on

the studs.

Note

♦ Bleed the coolant circuit after opening it. Refer to ⇒ Rep. Gr.
19 .
♦ The coolant system is under pressure when the engine is
warm. If necessary, release the pressure prior to repair work.

– Place the -VAS6208- under the engine.

– Discharge the coolant circuit. Refer to ⇒ Rep. Gr. 19 .
– Label the coolant hoses to the heating and Air Conditioning
(A/C) unit.
– Clamp off the coolant hoses to the heater core for the heater
and A/C unit (for example, with the -3094- ) and remove them.
– Insert one section of each hose -A and B- onto both connec‐
tions to the heater core.
– Hold a container -C- under the hose of lower connection -B-.
– Using a compressed air gun -D-, carefully blow coolant out of
the heater core (into container -C-) via hose -A-.
– Pull the interior carpet on the left away from the center tunnel.
– Remove the heater core cover -1-.

– Remove the bolts -2- and loosen the tabs -arrow-. nAG. Volkswag e nAG d o
wag e es n
Volks ot g
y ua
– Cover the carpet in the area under the heater score
e d b with wa‐ ran
i te e
terproof foil and water absorbing paper. th o r
or
au ac
ss
CAUTION
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le
un

pt
an
d

The cooling system is under pressure when the engine is warm.

itte

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e rm

There is a risk of scalding from hot steam and coolant.

ab
ility
ot p

Burns on the skin and other parts of the body is possible.

wit
is n

– Wear protective gloves.

h re
ole ,

spe c

– Wear protective eyewear.

u rpose s, inpart or inwh

t toth e co tne ss of inform

– Reduce the pressure: cover the coolant reservoir cap with a

cloth and carefully open.
rre c

– Pry retaining clips -1- off the coolant lines.

– Slowly remove the coolant lines from heater core and allow
cial p

escaping coolant to run into an accumulator reservoir.

me r

a
m

ti
r co

Note
nin
o

th i
te

There is a fastening pin on the left side below the heater core.
a

do s
ir v
p

This connects the lower heater core cover with the heater and A/
cum
r
fo

C unit.
en
ng

t.
yi Co
Cop py
ht. rig
g h
yri t by
cop by
Vo
lksw
cte d ag e n
Prote AG.

82 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Pull fastening pin -1- out of the locking mechanism in direction

of -arrow A- and then pull out the fastening pin in the direction
of -arrow B-.
– Fold the cover down wand AG. Volkswag e nAG d core to the left.
ag e nremove the heater oe s
olks not
Installing yV gu
e db ara
ris nte
ho e
– Install theau t heater core in the reverse order. or
ac
ss
• Always replace the O-rings.

ce
le
un

pt
an
d

– Secure all connections with the same type of clips used in

itte

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rm

series production. Refer to the Parts Catalog.

ab
e

ility
ot p

wit
is n

h re
ole ,

– After installing the retaining clips, make sure they are securely

spe c
seated -arrows- on the heater core.
u rpose s, inpart or inwh

t toth e co tne ss of inform

rre c
cial p
me r

a
m

tion
co

int
or

h is
te
iva

5.9 Condensation Water Drain, Checking do

pr

cum
r
fo

en

– Remove the footwell trim panel on the front passenger side.

ng

t.
yi Co
Refer to ⇒ Body Interior; Rep. Gr. 68 ; Storage Compart‐
. Cop py
ments, Covers and Trim; Footwell Covers, Removing and
ht rig
rig t by h
Installing .
py Vo
d by co lksw
cte ag e n
Prote
♦ Condensation water drain hose -1- must be able to be con‐
AG.

nected to the connection of heating and A/C unit -2- without

pre-tension.
♦ The condensation water hose must not be constricted in its
cross section through the insulation mat.
– Rework the insulation mat, if necessary.
♦ The condensation water hose must sit securely on the con‐
nection on the heating and A/C unit.
– The valve is located in the lower right of the engine compart‐
ment below the plenum chamber bulkhead.

Note

♦ For the purpose of a better illustration, the valve -1- is shown

with subframe removed.
♦ The condensation drainage valve may not be bonded by wax
or underbody protection, it must close correctly.

– Raise the vehicle and check the valve -1- from underneath.

5. Front Heater and A/C Unit 83

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

5.10 Evaporator Housing, Disassembling

and Assembling
Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Hose Clamps - Up To 25mm - 3094-
♦ Shop Crane - Drip Tray - VAS6208-
♦ Engine Bung Set - VAS6122-
♦ A/C Service Station
♦ Commercially available compressed-air gun

Note

♦ Extract the refrigerant usingsthe nAG. Volkswag e nAG d o .

wag eA/C Service Station es k not
y Vol g
♦ The previously used eservice
db stations can still be used seeu aran
equipment catalog. ris te e
u th o or
a ac
♦ To prevent thessingress of dampness all components of the re‐

ce
frigerant circuit which have been opened must be sealed with
le
un

pt
suitable plugs.

an
d
itte

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e rm

ab
♦ Environmentally hazardous draining of refrigerant is an of‐

ility
ot p

fense punishable by law.

wit
is n

h re
ole ,

– Observe safety precautions when working on the high voltage

spe c
u rpose s, inpart or inwh

system. Refer to
⇒ “1.4 High Voltage System Safety Precautions”, page 2 . t toth e co tne ss of inform

– Pay attention to safety precautions for working near high volt‐

age components. Refer to
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⇒ “1.5 Safety Precautions near High Voltage Components”,

page 3 .
– Note the high voltage system danger classification. Refer to
cial p

⇒ Electrical System Hybrid; Rep. Gr. 93 ; High Voltage Sys‐

me r

tem General Warnings .

a
m

ti
r co

– See notes. Refer to

nin
o

⇒ “3.1 Working on Refrigerant Circuit”, page 6 .

th i
ate

do s
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CAUTION
cum
r
fo

en
ng

t.
Danger or frostbite due to refrigerant coming out under pres‐
i
py Co
Co
sure.
py
h t. rig
g h
yri t by
Frostbite on the skin and other parts of the body is possible. by cop Vo
lksw
cte d
– Wear safety gloves.
ag e n
Prote AG.

– Wear protective eyewear.

– Extract refrigerant and open the refrigerant circuit immedi‐
ately.
– If more than 10 minutes elapse after extracting the refriger‐
ant and the refrigerant circuit was not opened, extract the
refrigerant again. Pressure can develop in the refrigerant
circuit due to evaporation.

84 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

1 - Bolt
❑ 1.5 Nm
❑ 4 x 16 mm nAG. Volkswag e nAG d o
wag e es n
Volks ot g
2 - Clamp by ua
d ran
rise te e
th o
3 - Bracket au
or
ac
ss
4 - Seal

ce
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un

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an
❑ Pay attention that the
d
itte

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seal is seated correctly.
rm

ab
e

ility
ot p

5 - Cylindrical Screw

wit
is n

h re
❑ 10 ± 1 Nm
ole ,

spe c
❑ Quantity: 2
u rpose s, inpart or inwh

t toth e co tne ss of inform

❑ M5x40x16
6 - Expansion Valve

rre c
❑ Removing and instal‐
ling. Refer to
⇒ “2.6 Expansion Valve,
Removing and Instal‐
cial p

ling”, page 26 .
me r

7 - Sealing Ring

a
m

tion
o

❑ Allocation. Refer to the

c

int
or

Parts Catalog.

h is
te
iva

do
8 - Sealing Ring
pr

cum
r
fo

❑ Allocation. Refer to the

en
ng

i t.
Parts Catalog. py Co
t. Co py
rig
9 - Expansion Valve Bracket
h h
rig t by
py Vo
by co lksw
10 - Seal cte d ag e n
Prote AG.
❑ Pay attention that the
seal is seated correctly.
11 - Evaporator
❑ Removing and instal‐
ling. Refer to ⇒ “5.11 Evaporator, Removing and Installing”, page 86 .
12 - Seal
❑ Pay attention that the seal is seated correctly.
13 - Seal
❑ Pay attention that the seal is seated correctly.
14 - Evaporator Housing Lower Section
15 - Evaporator Temperature Sensor - G308-
❑ Removing and installing. Refer to
⇒ “5.7 Evaporator Temperature Sensor G308 , Removing and Installing”, page 80 .
16 - Rubber Bushing
17 - Evaporator Housing Upper Section

Disassembling
– Remove the heater and Air Conditioning (A/C) unit. Refer to
⇒ “5.3 Heater and A/C Unit, Removing and Installing”,
page 74 .
– Disassemble the heater and A/C unit. Refer to
⇒ “5.4 Heater and A/C Unit, Disassembling and Assembling”,
page 76 .

5. Front Heater and A/C Unit 85

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Disassemble the evaporator housing.

Assembling
– Assemble in reverse order.
– Pay attention that the seals are seated correctly.

5.11 Evaporator, Removing and Installing

Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Hose Clamps - Up To 25mm - 3094-
♦ Shop Crane - Drip Tray - VAS6208-
♦ Engine Bung Set - VAS6122-
♦ A/C Service Station
♦ Commercially available compressed-air gun e nAG. Volkswag e nAG
wag d oe
ks s no
Vol tgu
d by ara
e nte
Note ris
u th o e or
a ac
ss
♦ Extract the refrigerant using the A/C Service Station .

ce
le
un

pt
an
♦ The previously used service stations can still be used see
d
itte

y li
equipment catalog.
rm

ab
e

ility
ot p

♦ To prevent the ingress of dampness all components of the re‐

wit
, is n

frigerant circuit which have been opened must be sealed with

h re
suitable plugs.
h ole

spe
e s, inpart or inw

♦ Environmentally hazardous draining of refrigerant is an of‐

ct toth e
fense punishable by law.

corre ctne ss of in
CAUTION
l pu rpos

Danger or frostbite due to refrigerant coming out under pres‐

sure.
e rcia

Frostbite on the skin and other parts of the body is possible.

form

– Wear safety gloves.

m

a
om

tio

– Wear protective eyewear.

nin
or c

th i

– Extract refrigerant and open the refrigerant circuit immedi‐

te
iva

d s

ately.
o
pr

cu
r
fo

– If more than 10 minutes elapse after extracting the refriger‐

en
ng

i t.
ant and the refrigerant circuit was not opened, extract the py Co
Co py
refrigerant again. Pressure can develop in the refrigerant h t. rig
g h
circuit due to evaporation. yri t by
by cop Vo
lksw
cte d ag e n
Prote AG.

86 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017
nAG. Volkswag e nAG d o
wag e es n
1 - Bolt Volks ot g
d by ua
ran
❑ 1.5 Nm ir se te e
th o
or
❑ 4 x 16 mm au ac
ss

ce
le
2 - Clamp

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3 - Evaporator Housing Upper

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Section

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4 - Seal

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❑ Pay attention that the

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seal is seated correctly. u rpose s, inpart or inwh

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5 - Evaporator with Expansion
Valve

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6 - Seal
❑ Pay attention that the
seal is seated correctly.
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7 - Evaporator Housing Lower

Section
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or

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Removing
– Observe safety precautions when working on the high voltage
system. Refer to
⇒ “1.4 High Voltage System Safety Precautions”, page 2 .
– Pay attention to safety precautions for working near high volt‐
age components. Refer to
⇒ “1.5 Safety Precautions near High Voltage Components”,
page 3 .
– Note the high voltage system danger classification. Refer to
⇒ Electrical System Hybrid; Rep. Gr. 93 ; High Voltage Sys‐
tem General Warnings .
– See notes. Refer to
⇒ “3.1 Working on Refrigerant Circuit”, page 6 .
– Disassemble the heater and Air Conditioning (A/C) unit. Refer
to
⇒ “5.4 Heater and A/C Unit, Disassembling and Assembling”,
page 76 .
– Disassemble the evaporator housing. Refer to
⇒ “5.10 Evaporator Housing, Disassembling and Assembling”,
page 84 .
– Remove the evaporator -5- from the evaporator housing lower
section -7-.

5. Front Heater and A/C Unit 87

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

Installing

Note

♦ Before inserting the evaporator, check condensation water

drain and clean drain if necessary. nAG. Volkswag e nAG d o
wag e es n
Volks ot g
y ua
♦ Before inserting evaporator, clean evaporator housing ise
and
d b the ran
evaporator if necessary. ht o
r te e
or
au ac
ss
♦ After assembling both housing halves, check that the seals/

ce
le
insulation are seated correctly.

un

pt
an
d
itte
♦ If heat protection insulation is missing or not installed correctly,

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rm

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it can cause reduced performance of the A/C system (change

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of adjusted control characteristics of expansion valve due to

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radiant heat).

h re
ole ,

spe c
u rpose s, inpart or inwh

– When inserting the evaporator -A- into the evaporator housing,

t toth e co tne ss of inform

make sure that the seal -arrows- is not damaged.
– Check the seal -arrows- (it must be glued all the way around)
before inserting the evaporator.

rre c
– Perform remaining installation operations in reverse order of
removal.
cial p
me r

a
m

tion
co

int
or

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iva

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5.12 Rear Evaporator, Removing and Instal‐

en
ng

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ling, with Heater and A/C Unit Installed Co py
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py
Removing
Vo
d by co lksw
cte ag e n
Prote AG.
– Observe safety precautions when working on the high voltage
system. Refer to
⇒ “1.4 High Voltage System Safety Precautions”, page 2 .
– Pay attention to safety precautions for working near high volt‐
age components. Refer to
⇒ “1.5 Safety Precautions near High Voltage Components”,
page 3 .
– Note the high voltage system danger classification. Refer to
⇒ Electrical System Hybrid; Rep. Gr. 93 ; High Voltage Sys‐
tem General Warnings .
– See notes. Refer to
⇒ “3.1 Working on Refrigerant Circuit”, page 6 .
– Extract the refrigerant using the A/C Service Station . See
notes. Refer to
⇒ “3.1 Working on Refrigerant Circuit”, page 6 .
– Remove the rear expansion valve. Refer to
⇒ “2.6.2 Expansion Valve, Removing and Installing, Rear”,
page 29 .
– Bring the rear heater and A/C unit into the service position.
Refer to
⇒ “6.2 Rear Heater and A/C unit, Service Position”,
page 94 .

88 Rep. Gr.87 - Air Conditioning

 AG. Volkswag e nAG d
ag e n oe s
olksw not
V gu
d by Touareg 2010 ➤ , Touareg ara 2015 ➤
ir se nte
th o
Heating, Ventilation and Air Conditioning - Editione o 06.2017
au r ac
ss
– Remove the bolts -A-.

ce
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un

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– Open the retainers -B-.

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– Remove evaporator housing -C- with the evaporator and the

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rear heater and A/C unit.

is n

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Installing

spe c
u rpose s, inpart or inwh
Install in reverse order of removal. Note the following:

t toth e co tne ss of inform

– Make sure the seals are seated correctly when installing.

rre c
Note
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Use the installed position of the seal on the old part.
me r

– Charging the refrigerant circuit

a
m

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onin
– Check the Diagnostic Trouble Code (DTC) memory for the
o

th i
e

Climatronic Control Module - J255- and Rear A/C Display

t
ir va

d s
Control Head - E265- . Delete the displayed errors if necessary

o
p

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using the Vehicle Diagnostic Tester .

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ng

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– Check the A/C function if necessary using the Vehicle Diag‐ Co py
nostic Tester . h t. rig
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Prote AG.

5. Front Heater and A/C Unit 89

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

6 Rear Heater and A/C Unit

⇒ “6.1 Overview - Heater and A/C Unit”, page 90
⇒ “6.2 Rear Heater and A/C unit, Service Position”, page 94
⇒ “6.3 Heater and A/C Unit, Removing and Installing”,
page 95
⇒ “6.4 Second Rear Heating and A/C Unit, Disassembling and
Assembling”, page 97 g e nAG
. Volkswag e nAG
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olks not
⇒ “6.5 Left Rear Vent Temperature Sensor
db
y V G405 , Removing and gu
ara
Installing”, page 99 ir se nte
o th e or
au ac
⇒ “6.6 Right Rear Vent Temperature
ss Sensor G406 , Removing
and Installing”, page 100

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⇒ “6.7 Rear Fresh Air Blower V80 , Removing and Installing”,

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page 100

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⇒ “6.8 Heater Core, Removing and Installing”, page 100

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⇒ “6.9 Condensation Drain Hose, Checking”, page 102

spe c
u rpose s, inpart or inwh

6.1 Overview - Heater and A/C Unit

t toth e co tne ss of inform

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Note

♦ Under certain conditions, the desiccant bag/dryer cartridge no

longer needs to be replaced each time the refrigerant circuit is
cial p

opened on A/C systems with refrigerant R1234yf. Refer to ⇒

Refrigerant R1234yf General Information; Rep. Gr. 87 ; Re‐
me r

a
frigerant Circuit; Components, Replacing .
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tion
co

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♦ Under certain conditions, the dryer bag no longer needs to be
or

h is
te

replaced each time the refrigerant circuit is opened on A/C

iva

do
systems with refrigerant R134a. Refer to ⇒ Refrigerant R134a
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Servicing; Rep. Gr. 00 ; Replacing Components .

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ng

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♦ Perform the following work after the repairs have been com‐ Cop py
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pleted: Conduct the basic setting using the Vehicle Diagnostic yri
g t by h
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Prote AG.

90 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

1 - Left B-Pillar Air Guide

Channel
❑ Removal and installa‐
tion
– Remove the front seat.
Refer to ⇒ Body Interior;
Rep. Gr. 72 ; Front
Seats; Seat, Removing
and Installing .

– Remove the left B-pillar

trim panel. Refer to ⇒
Body Interior; Rep. Gr.
70 ; Pillar Trim; B-Pillar
Trim, Removing and In‐
stalling .
AG. Volkswag e nAG d
ag e n oe s
lksw not
– Lift the carpet and re‐ by
Vo gu
ara
move the two air guide d
ir se nte
channel nuts (2 Nm). u th o e or
a ac
ss
2 - Left Footwell Air Guide

ce
le
un

pt
Channel

an
d
itte

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❑ Removal and installa‐
e rm

ab
tion

ility
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is n

– Remove the front seat.

h re
ole ,

Refer to ⇒ Body Interior;

spe c
Rep. Gr. 72 ; Front
u rpose s, inpart or inwh

Seats; Seat, Removing

t toth e co tne ss of inform

and Installing .
– Lift the carpet and re‐

rre c
move the air guide
channel screw (2 Nm).
cial p

3 - Left Air Guide Channel

❑ Connection to the B-pil‐
me r

lar air guide channel a

m

ti
r co

onin

❑ Removal and installation

o

th i
te

– Remove the front seat. Refer to ⇒ Body Interior; Rep. Gr. 72 ; Front Seats; Seat, Removing and Instal‐
ir va

d s
o
p

ling .
cu
r
fo

m
en
ng

t.
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– Lift the carpet and unclip the air guide channel.
Co
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4 - Left B-Pillar/Footwell Shut-Off Door Motor - V212- yri t by
by cop Vo
lksw
❑ Removal and installation cte d ag e n
Prote AG.

– Remove the front seat. Refer to ⇒ Body Interior; Rep. Gr. 72 ; Front Seats; Seat, Removing and Instal‐
ling .

– Remove the center console. Refer to ⇒ Body Interior; Rep. Gr. 68 ; Storage Compartments, Covers
and Trim; Center Console, Removing and Installing .

– Lift the carpet and remove the screws from the Left B-Pillar/Footwell Shut-Off Door Motor - V212- .
5 - Right Rear Upper Body Vent Motor - V316-
❑ Removal and installation
– Remove the center console. Refer to ⇒ Body Interior; Rep. Gr. 68 ; Storage Compartments, Covers
and Trim; Center Console, Removing and Installing .

– Remove screws from the Right Rear Upper Body Vent Motor - V316- .
6 - Right B-Pillar/Footwell Shut-Off Door Motor - V211-
❑ Removal and installation

6. Rear Heater and A/C Unit 91

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Remove the front seat. Refer to ⇒ Body Interior; Rep. Gr. 72 ; Front Seats; Seat, Removing and Instal‐
ling .
– Remove the center console. Refer to ⇒ Body Interior; Rep. Gr. 68 ; Storage Compartments, Covers
and Trim; Center Console, Removing and Installing .
– Lift the carpet and remove the screws from the Right B-Pillar/Footwell Shut-Off Door Motor - V211- .
7 - Air Guide Channel with B-Pillar Shut-Off Door and Right Footwell
❑ Removal and installation
– Remove the front seat. Refer to ⇒ Body Interior; Rep. Gr. 72 ; Front Seats; Seat, Removing and Instal‐
ling .
– Lift the carpet and remove the 2 nuts (2 Nm) at the air guide channel.
8 - Right Air Guide Channel
❑ Connection to the B-pillar air guide channel
❑ Removal and installation
– Remove the front seat. Refer to ⇒ Body Interior; Rep. Gr. 72 ; Front Seats; Seat, Removing and Instal‐
ling .

– Lift the carpet and unclip the air guide channel.

9 - Right Footwell Air Guide Channel
❑ Removal and installation
– Remove the front seat. Refer to ⇒ Body Interior; Rep. Gr. 72 ; Front Seats; Seat, Removing and Instal‐
ling . g e nAG
. Volkswag e nAG
d
a oe s
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y Vol gu
– Lift the carpet and remove e d the screw
b (2 Nm) at the air guide achannel
ran .
ris te e
th o or
10 - Right B-Pillar Air Guide
au Channel ac
ss
❑ Removal and installation
ce
le
un

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an
d

– Remove the front seat. Refer to ⇒ Body Interior; Rep. Gr. 72 ; Front Seats; Seat, Removing and Instal‐
itte

y li
rm

ling .
ab
e

ility
ot p

wit
, is n

– Remove the right B-pillar trim panel. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Pillar Trim; B-Pillar Trim,
h re

Removing and Installing .

h ole

spe
e s, inpart or inw

– Lift the carpet and remove the two air guide channel nuts (2 Nm).
ct toth e

11 - Right Air Guide Channel

corre ctne ss of in

❑ Removal and installation

– Remove the bench seat and rear backrest. Refer to ⇒ Body Interior; Rep. Gr. 72 ; Rear Seats; Rear
l pu rpos

Seats, Removing and Installing and ⇒ Body Interior; Rep. Gr. 72 ; Rear Seats; Rear Seat Backrest,
Removing and Installing .
e rcia

form

– Lift the carpet and remove the screw (1.4 Nm) at the air guide channel.
m

a
om

tio

12 - Right B-Pillar Air Guide Channel

nin
or c

th i

❑ Removal and installation

te
iva

d s
o
pr

cu

– Remove the front seat. Refer to ⇒ Body Interior; Rep. Gr. 72 ; Front Seats; Seat, Removing and Instal‐
r
fo

ling .
en
ng

t.
yi Co
Cop py
– Remove the right B-pillar trim panel. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Pillar Trim; B-Pillar Trim,
ht. rig
rig t by h
Removing and Installing .
py Vo
d by co lksw
cte ag e n
Prote AG.
13 - B-Pillar Vent, Right
❑ Removal and installation
– Remove the front seat. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Pillar Trim; B-Pillar Trim, Removing and
Installing .

92 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Remove the right B-pillar trim panel. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Pillar Trim; B-Pillar Trim,
Removing and Installing .
14 - Right Air Guide Channel AG. Volkswag e nAG d
ag e n oe s
olksw not
❑ Removal and installation d by
V gu
ara
ir se nte
– o
Remove the bench seat, the backrestu thand the luggage compartment floor. Refer to ⇒orBody Interior; Rep. e
sa
Gr. 72 ; Rear Seats; Rear Seats, sRemoving and Installing and ⇒ Body Interior; Rep.acGr. 72 ; Rear
Seats; Rear Seat Backrest, Removing and Installing .

ce
le
un

pt
an
d
itte
– Lift the carpet and remove the three screws (2 Nm) at the air guide channel.

y li
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ab
pe

ility
15 - Right Rear Vent Temperature Sensor - G406-

ot

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, is n
❑ Removing and installing. Refer to

h re
h ole
⇒ “6.6 Right Rear Vent Temperature Sensor G406 , Removing and Installing”, page 100 .

spe c
e s, inpart or inw

16 - Right Air Guide Channel

t toth e co tne ss of infor

❑ Removal and installation
– Remove the left luggage compartment side trim panel. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Luggage

rre c
Compartment Trim Panels; Luggage Compartment Side Trim Panels, Removing and Installing .
l pu rpos

17 - Second Heater and A/C Unit

❑ Removing and installing. Refer to ⇒ “6.3 Heater and A/C Unit, Removing and Installing”, page 95 .
e rcia

❑ Second heater and A/C unit, bringing into service position. Refer to

m
m

a
⇒ “6.2 Rear Heater and A/C unit, Service Position”, page 94 .
com

tion
int
r
te o

18 - Left Air Guide Channel

h is
iva

d
❑ Removal and installation

o
r
rp

cu
fo

m
– Remove the left luggage compartment side trim panel. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Luggage

en
ng

t.
yi
Compartment Trim Panels; Luggage Compartment Side Trim Panels, Removing and Installing .
Co
Cop py
h t. g
rig
h
yri t by
19 - Left Rear Vent Temperature Sensor - G405- by cop Vo
lksw
cte d
❑ Removing and installing. Refer to
ag e n
Prote AG.
⇒ “6.5 Left Rear Vent Temperature Sensor G405 , Removing and Installing”, page 99 .
20 - Left Air Guide Channel
❑ Removal and installation
– Remove the bench seat, the backrest and the luggage compartment floor. Refer to ⇒ Body Interior; Rep.
Gr. 72 .
– Lift the carpet and remove two screws (1.4 Nm) and one nut (2 Nm) at the air guide channel.
21 - Left Air Guide Channel
❑ Removal and installation
– Remove the bench seat and rear backrest. Refer to ⇒ Body Interior; Rep. Gr. 72 .

– Lift the carpet and remove the screw (1.4 Nm) at the air guide channel.

22 - B-Pillar Vent, Left

❑ Removal and installation
– Remove the front seat. Refer to ⇒ Body Interior; Rep. Gr. 72 ; Front Seats; Seat, Removing and Instal‐
ling .
– Remove the left B-pillar trim panel. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Pillar Trim; B-Pillar Trim,
Removing and Installing .

23 - Left B-Pillar Air Guide Channel

❑ Removal and installation
– Remove the front seat. Refer to ⇒ Body Interior; Rep. Gr. 72 ; Front Seats; Seat, Removing and Instal‐
ling .

6. Rear Heater and A/C Unit 93

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017
. Volkswag e nAG
a d oe s g e nAG
– Remove the left B-pillar trim panel. Refer to ⇒ BodyVo Interior;
lksw Rep. Gr. 70 ; Pillar Trim;
not g B-Pillar Trim,
Removing and Installing . ed
by ua
ra
ris nte
ho e
aut or
ac
ss
6.2 Rear Heater and A/C unit, Service Po‐

ce
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un

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sition

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– Remove the side trim panel on the left side of the luggage

ility
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compartment. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Luggage

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is n
Compartment Trim Panels; Luggage Compartment Side Trim

h re
ole ,
Panels, Removing and Installing .

spe c
u rpose s, inpart or inwh

t toth e co tne ss of inform

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cial p
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tion
co

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or

h is
te
iva

d o
pr

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fo

m
en
ng

t.
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Cop py
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yri t by
cop by
Vo
lksw
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Prote AG.

– Remove the heater and Air Conditioning (A/C) unit -A- bolts
(8 Nm).
– Tip the heater and A/C unit to the right.

Note

♦ The refrigerant lines and hoses remain connected.

♦ Ensure the correct seating of the condensation water drain hose with the valve after installing the rear heater
and A/C unit. Refer to ⇒ “6.9 Condensation Drain Hose, Checking”, page 102 .

94 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

6.3 Heater and A/C Unit, Removing and In‐

stalling
Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50 Nm - VAG1331-
♦ Hose Clamps - Up To 25 mm - 3094-
♦ Shop Crane - Drip Tray - VAS6208-
♦ Engine Bung Set - VAS6122-
♦ Shop Crane - Drip Tray - VAS6208-
♦ Commercially available compressed-air gun
AG. Volkswag e nAG d
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Removing olksw not
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– Remove the left rear ori wheel housing liner. Refer to ⇒ Rep. Gr.nte e
s
h
66 . au
t or
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ss

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CAUTION

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The cooling system is under pressure when the engine is warm.
e rm

ab
Risk of scalding due to hot steam and hot coolant.

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Scalding the skin and other parts of the body is possible.

h re
ole ,

– Wear safety gloves.

spe c
u rpose s, inpart or inwh

– Wear protective eyewear.

t toth e co tne ss of inform

– Reduce the pressure by covering the coolant expansion tank
cap with a cloth and carefully opening it.

rre c
– Disconnect the coolant hoses with the -3094- and separate
them from the hose connections.
cial p

Vehicles with Refrigerant R134a

me r

– Drain the refrigerant circuit. Refer to ⇒ Refrigerant R134a

a

Servicing; Rep. Gr. 00 ; Working with A/C Service Station .

m

ti
r co

onin
o

Vehicles with Refrigerant R1234yf

th i
te
ir va

d s

– Drain the refrigerant circuit. Refer to ⇒ Refrigerant R1234yf

o
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fo

Servicing; Rep. Gr. 87 ; Working with A/C Service Station;

m
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ng

Refrigerant Circuit, Discharging .

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. Co py
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Continuation for All Vehicles
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by cop Vo
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CAUTION
ag e n
Prote AG.

Danger or frostbite due to refrigerant coming out under pres‐

sure.
Frostbite on the skin and other parts of the body is possible.
– Wear safety gloves.
– Wear protective eyewear.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately.
– If more than 10 minutes elapse after extracting the refriger‐
ant and the refrigerant circuit was not opened, extract the
refrigerant again. Evaporation can cause pressure to devel‐
op in the refrigerant circuit.

– For all the following work, close the open lines and connec‐
tions with clean plugs from the -VAS6122- .
– Remove refrigerant line bolts (12 Nm) and remove refrigerant
lines from retaining plate.

6. Rear Heater and A/C Unit 95

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Remove retaining plate bolts (10 Nm).

– Remove the side trim panel on the left side of the luggage
compartment. Refer to ⇒ Rep. Gr. 70 .

AG. Volkswag e nAG d

ag e n oe s
olksw not
V gu
d by ara
ise nte
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th or
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un

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ility
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is n

h re
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spe c
u rpose s, inpart or inwh

t toth e co tne ss of inform

rre c
cial p
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a
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tion
r co

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o

h is
ate

do
ir v
p

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fo

en
ng

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t. Co py
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yri t by
y cop Vo
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cte d ag e n
Prote AG.

– Disconnect the connector from the second heater and A/C

unit.
– Remove the bolts (8 Nm) -A-.
– Remove the heater and A/C unit.
Installing
Install in reverse order of removal and note the following:

96 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Check the condensation water drain hose for correct seating.

Refer to
⇒ “6.9 Condensation Drain Hose, Checking”, page 102 .
AG. Volkswag e n g en AG d
wa oe s
– Coat the new seals with refrigerant olks no
by V oil before installing the re‐ t g u a
frigerant lines. rise d ran
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NOTICE ss

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There is a risk of damaging the A/C compressor if the refrigerant

pt
an
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circuit is empty. itte

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– Never start the engine with the refrigerant circuit empty.
e

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h re
Vehicles with Refrigerant R134a
ole ,

spe c
u rpose s, inpart or inwh

– Fill the refrigerant circuit. Refer to ⇒ Refrigerant R134a Serv‐

t toth e co tne ss of inform

icing; Rep. Gr. 00 ; Working with A/C Service Station .
– Perform the leak test on the closed line connections of the
refrigerant circuit. Refer to ⇒ Refrigerant R134a Servicing;

rre c
Rep. Gr. 00 ; Refrigerant Circuit, Detecting Leaks .
Vehicles with Refrigerant R1234yf
cial p

– Fill the refrigerant circuit. Refer to ⇒ Refrigerant R1234yf

Servicing; Rep. Gr. 87 ; Working with A/C Service Station;
me r

Refrigerant Circuit, Filling .

a
m

tion
co

int
– Perform the leak test on the closed line connections of the
or

h is
te

refrigerant circuit. Refer to ⇒ Refrigerant R1234yf Servicing;

iva

do
Rep. Gr. 87 ; Refrigerant Circuit; Determining Leaks .
pr

cum
r
fo

en
Continuation for All Vehicles
ng

i t.
py Co
Co py
– Fill with coolant. Refer to ⇒ Rep. Gr. 19 ; Cooling System/ h t. rig
g h
yri
Coolant; Coolant, Draining and Filling .
t by
y cop Vo
lksw
b
cte d ag e n
– Check the heating and A/C system function. Prote AG.

6.4 Second Rear Heating and A/C Unit, Disassembling and Assembling

6. Rear Heater and A/C Unit 97

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

1 - Rear Heater Core

❑ Removing and instal‐
ling. Refer to
⇒ “6.8 Heater Core, Re‐
moving and Installing”,
page 100 .
2 - Seal
3 - Coolant Supply Line
4 - Coolant Return Line
5 - Right Rear Temperature
Door Motor - V314-
❑ Removing and instal‐ AG. Volkswag e nAG d
ag e n oe s
ling. Refer to olksw not
V gu
⇒ “4.13 Right Rear e d by ara
nte
is
Temperature Door th orMo‐ eo
tor V314 , Removing
au ra
c
ss
and Installing”,

ce
le
un

page 68 .

pt
an
d
itte

y li
6 - Securing Bolts
e rm

ab
ility
ot p

❑ 12 ± 1.5 Nm

wit
is n

❑ Refrigerant line

h re
ole ,

spe c
7 - O-ring
u rpose s, inpart or inwh

❑ Always replace

t toth e co tne ss of inform

❑ 14.3 mm; 2.4 mm
8 - O-ring

rre c
❑ Always replace
❑ 10.8 mm; 1.8 mm
cial p

9 - Securing Bolts
me r

❑ 10 ± 1 Nm
a
m

tion
r co

❑ Refrigerant line to ex‐

int
o

pansion valve
h is
ate

do
ir v

10 - O-ring
p

cum
r
fo

❑ Always replace
en
ng

i t.
py Co
❑ 14.3 mm; 2.4 mm h t. Co py
rig
g h
yri t by
11 - O-ring by cop Vo
lksw
cte d
❑ Always replace
ag e n
Prote AG.

❑ 10.8 mm; 1.8 mm

12 - Condensation Water Drain Hose with Valve

Note

Ensure that the condensation water

drain hose with valve is not kinked
or pinched during installation. Refer
to
⇒ “6.9 Condensation Drain Hose,
Checking”, page 102 .

13 - Cylindrical Screw
14 - Expansion Valve
15 - O-ring
❑ Always replace
❑ 10.8 mm; 1.8 mm

98 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

16 - O-ring
❑ Always replace
❑ 14.3 mm; 2.4 mm
17 - Rear Evaporator
❑ Removing and installing. Refer to
⇒ “5.12 Rear Evaporator, Removing and Installing, with Heater and A/C Unit Installed”, page 88 .
18 - Seal
19 - Left Rear Temperature Door Motor - V313-
❑ Removing and installing. Refer to
⇒ “4.12 Left Rear Temperature Door Motor V313 , Removing and Installing”, page 67 .
20 - Rear Fresh Air Blower - V80-
❑ Removing and installing. Refer to
⇒ “6.7 Rear Fresh Air Blower V80 , Removing and Installing”,Vpage
olkswa
100 .
AG. g e nAG
w es n ag e n do
21 - Left Rear Vent Temperature Sensor - G405- olks ot g
byV ua
d ran
❑ Removing and installing. Refer to rise te
o
t G405 , Removing and Installing”, page 99 .e or
⇒ “6.5 Left Rear Vent Temperature Sensor
au
h
a
ss c
22 - Right Rear Vent Temperature Sensor - G406-

ce
le
un

pt
❑ Removing and installing. Refer to

an
d
itte

y li
⇒ “6.6 Right Rear Vent Temperature Sensor G406 , Removing and Installing”, page 100 .
rm

ab
e

ility
ot p

23 - Rear Heater Core Seal

wit
, is n

h re
h ole

spe
6.5 Left Rear Vent Temperature Sensor -
e s, inpart or inw

ct toth e
G405- , Removing and Installing

corre ctne ss of in
Removing
– Remove the left rear backrest. Refer to ⇒ Body Interior; Rep.
l pu rpos

Gr. 72 ; Rear Seats; Rear Seat Backrest, Removing and In‐

stalling .
e rcia

form
– Lift the floor covering in the area of the Left Rear Vent Tem‐
m

perature Sensor - G405- .

a
om

tionin
or c

– Disconnect the connector from the Left Rear Vent Tempera‐

th i
te

ture Sensor - G405- and turn the sensor in direction of

iva

d s
-arrow-.
o
pr

cu
r
fo

m
en

– Pull the Left Rear Vent Temperature Sensor - G405- out of the
ng

i t.
py Co
air guide channel. h t. Co py
rig
rig h
Installing
t by
py Vo
d by co lksw
cte ag e n
Install in reverse order of removal. Prote AG.

6. Rear Heater and A/C Unit 99

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

6.6 Right Rear Vent Temperature Sensor -

AG. Volkswag e nAG d
ag e n
G406- , Removing and Installing
yV
olksw oe s
not
gu
b ara
ed nte
Removing oris e
th or
au ac
– Remove the luggage compartment
to ⇒ Body In‐
ss floor. Refer
terior; Rep. Gr. 70 ; Luggage Compartment Trim Panels;

ce
le
un

pt
Luggage Compartment Floor Supports, Removing and Instal‐

an
d
itte

y li
ling .
e rm

ab
ility
ot p
– Disconnect the connector from the Right Rear Vent Temper‐

wit
is n

ature Sensor - G406- and turn the sensor in direction of

h re
-arrow-.
ole ,

spe c
u rpose s, inpart or inwh

– Pull the Right Rear Vent Temperature Sensor - G406- out of

t toth e co tne ss of inform

the air guide channel.
Installing

rre c
Install in reverse order of removal.

6.7 Rear Fresh Air Blower - V80- , Remov‐

cial p

ing and Installing

me r

a
m

t
Removing

i
r co

onin
o

– Bring the rear heater and Air Conditioning (A/C) unit into the

th i
te
ir va

s
service position. Refer to

d o
p

cu
⇒ “6.2 Rear Heater and A/C unit, Service Position”, page 94 .
r
fo

m
en
ng

t.
– Disconnect the connector -A- from the Rear Fresh Air Blower
yi Co
op
- V80- -2-.
C py
ht. rig
g h
yri t by
– Remove the screws -1- from the Rear Fresh Air Blower - V80- cop Vo
by lksw
cte d
-2-.
ag e n
Prote AG.

– Remove the Rear Fresh Air Blower - V80- from the heater and
A/C unit.
Installing
– Install the Rear Fresh Air Blower - V80- in reverse order of
removal.

Note

The condensation water drain hose to the valve must not be

kinked or pinched. Refer to
⇒ “6.9 Condensation Drain Hose, Checking”, page 102 .

6.8 Heater Core, Removing and Installing

Special tools and workshop equipment required
♦ Shop Crane - Drip Tray - VAS6208-
♦ Hose Clamps - Up To 25mm - 3094-
♦ Compressed air gun, commercially available
♦ Engine Bung Set - VAS6122-
Removing
– Turn off the ignition.
– Open the cap on the coolant expansion tank and release the
pressure in the coolant system. Refer to ⇒ Rep. Gr. 19 .

100 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Bring the rear heater and Air Conditioning (A/C) unit into the
service position. Refer to
⇒ “6.2 Rear Heater and A/C unit, Service Position”, page 94 .
. Volkswag e nAG
a g e nAG d oe
– Disconnect the connectors from the heater ksw
Vol and A/C unit
s no
tgu
-arrows-. d by ara
e nte
ris
u th o e or
a ac
ss

ce
le
un

pt
an
d
itte

y li
e rm

ab
ility
ot p

wit
is n

h re
ole ,

spe c
– Remove the bolts -A- and the upper cover -B-.
u rpose s, inpart or inwh

t toth e co tne ss of inform

rre c
cial p
me r

a
m

tion
r co

int
o

h is
ate

do
riv
p

c
– Mark both coolant hoses -A and B- to the rear heater core

um
r
fo

-C- (to prevent interchanging them).

en
ng

t.
yi Co
op py
– Disconnect the coolant hoses -A and B- to the rear heater core
C
h t. rig
h
-C- (for example, with -3094- ).
g
yri t by
by cop Vo
lksw
cte d
– Remove the heater core -C- from the heater and A/C unit.
ag e n
Prote AG.

– Cover the area under the heater and A/C unit with absorbent
paper to prevent leaking coolant from running onto the heater
and A/C unit or floor covering.
– Place a container under both connections on the heater core
-C- and clamp the coolant hoses.
Installing
– Clean the rear heater and A/C unit (for example, from coolant
residue).

– Check the foam seals on the heater core -A-.

Note

The foam seals must be attached without gaps and must not be
damaged.

6. Rear Heater and A/C Unit 101

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Install the heater core -C- into the heater and A/C unit.
– Connect coolant hose -B- toagcoolant
e nAG. V pipeagto
olksw e nheater
AG d o core -C-
lksw es n
(coolant hose -A- is not
Voconnected for the time being). ot g
by ua
ed ran
ris te e
u th o or
Note ss
a ac

ce
le
un

pt
♦ Install the coolant hoses.

an
d
itte

y li
rm

♦ Coolant hose -A- to the return to the engine (over the hose

ab
e

ility
ot p

group under the left fender).

wit
is n

♦ Coolant hose -B- on the supply from the engine (over the hose

h re
ole ,

group under the left fender).

spe c
u rpose s, inpart or inwh

t toth e co tne ss of inform

– Fill the coolant reservoir up to the top mark with coolant. Refer
to ⇒ Rep. Gr. 19 .

rre c
– Cover the area under the heater and A/C unit with absorbent
paper to prevent leaking coolant from running onto the heater
and A/C unit or floor covering.
cial p

– Place a container under connection -A- on the heater core

-C-.
me r

a
m

– Open the -3094- on the coolant hose -B- just enough so that

tion
co

the coolant and flow slowly into the heater core (to pre-bleed

int
or

the heater core).

h is
te
iva

d o
pr

cu
r
fo

m
en

Note
ng

i t.
py Co
t. Co py
rig
h
If the coolant does not flow into the heater core on its own, use rig t by h
py Vo
the hand pump from the -VAG1274B- to build up pressure in the y co
d b lksw
cte ag e n
reservoir and increase the flow. Prote AG.

– Wait until coolant exits from coolant hose connection -A- on

coolant pipe to heater core.
– Attach the coolant hose -A- to the coolant pipe on the heater
core.
– Install the removed parts in the opposite order.
– Bleed the coolant circuit. Refer to ⇒ Rep. Gr. 19 .

6.9 Condensation Drain Hose, Checking

Checking
– Raise the vehicle and check the valve from underneath.
♦ The condensation water drain hose must sit securely on the
connection for the heater and A/C unit.
♦ Valve may not be bonded by wax or underbody protection, it
must close correctly.
♦ The condensation water drain hose to the valve must not be
kinked or pinched.

102 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning
. Volkswag e
- Edition 06.2017
AG nAG d
ag e n oe s
olksw not
yV gu
db ara
7 Air Guide ho
ris
e nte
e
aut or
ac
⇒ “7.1 Driver Vents in the Instrument Panel, ss and
Removing In‐

ce
e
stalling”, page 103

nl

pt
du

an
itte
⇒ “7.2 Front Passenger Vents in the Instrument Panel, Removing

y li
e rm

ab
and Installing”, page 104

ility
ot p

wit
is n
⇒ “7.3 B-Pillar Side Vents, Removing”, page 104

h re
ole ,
⇒ “7.4 Driver Side Footwell Vent, Removing and Installing”, page

spe c
u rpose s, inpart or inwh
104

t toth e co tne ss of inform

⇒ “7.5 Front Passenger Side Footwell Vent, Removing and In‐
stalling”, page 105

rre c
⇒ “7.6 Rear Vent, Removing and Installing”, page 105
⇒ “7.7 Fresh Air Intake, Removing and Installing”, page 106
⇒ “7.8 Passenger Compartment Forced Air Extraction, Check‐ cial p
ing”, page 107 me r

a
7.1 Driver Vents in the Instrument Panel,
m

tion
co

int
Removing and Installing
r
te o

h is
a

do
riv
p

Special tools and workshop equipment required

cum
or
f

en
ng

♦ Trim Removal Wedge - 3409-

t.
yi Co
Cop py
h t. g
rig
h
yri t by
cop Vo
Note by lksw
cte d ag e n
Prote AG.

♦ The vents are attached to the instrument cluster trim and are
removed together.
♦ For the sake of clarity, the steering wheel is removed in the
illustration.

Removing
– Use the -3409- to loosen instrument cluster trim panel -1- at
the indicated locations -arrows-.
– Remove the instrument cluster trim with vent -1- from the in‐
strument panel.
– Disconnect the vent illumination harness connector.

– Unclip the vents -1 and 2- from the marked positions

-arrows- with the -3409- .
Installing
– Install the vents in the reverse order while making sure that
the cables for the vent illumination are not crushed or bent.

7. Air Guide 103

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

7.2 Front Passenger Vents in the Instru‐

ment Panel, Removing and Installing
Special tools and workshop equipment required
♦ Trim Removal Wedge - 3409-
Removing
– Remove the trim -1- from the vent unit -2- at the indicated lo‐
cations -arrows- using the -3409- .

nAG. Volkswag e nAG d o

wag e es n
Volks ot g
y ua
e db ran
ris te e
th o
or
au ac
ss

ce
le

– Remove screws -2-.

un

pt
an
d
itte

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– Pull vent unit -1- out of the instrument panel using the -3409- .
rm

ab
e

ility
ot p

– Disconnect the vent illumination harness connector.

wit
is n

Installing h re
ole ,

spe c
– Install the vents and the trim in reverse order of removal. Be
u rpose s, inpart or inwh

t toth e co tne ss of inform

careful not to crush or bend the wire for the vent illumination.
rre c
cial p

7.3 B-Pillar Side Vents, Removing

me r

Special tools and workshop equipment required

m

tion
co

int

♦ Trim Removal Wedge - 3409-

or

h is
te
iva

Removing
do
pr

cum
r
fo

– Remove the B-pillar trim panel. Refer to ⇒ Rep. Gr. 70 .

en
ng

t.
yi Co
op
Also for Vehicles with 4-zone Climatronic:
C py
ht. rig
g h
yri t by
– Disconnect the connector from the vent. cop Vo
by lksw
cte d ag e n
Prote AG.
All Vehicles:
– Unclip the side vents.
Installing
– Install in reverse order of removal.

7.4 Driver Side Footwell Vent, Removing

and Installing
Special tools and workshop equipment required
♦ Trim Removal Wedge - 3409-
Removing
– Remove the knee airbag. Refer to ⇒ Body Interior; Rep. Gr.
69 ; Airbag; Knee Airbag, Removing and Installing .

104 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

CAUTION
Pyrotechnic components can unintentionally deploy.
Risk of injury.
– Discharge static electricity: Briefly touch the door striker pin.

– Remove the instrument panel. Refer to ⇒ Body Interior; Rep.

Gr. 70 ; Instrument Panel; Instrument Panel, Removing and
Installing .
– Completely detach the module carrier and pull slightly forward.
Refer to ⇒ Body Interior; Rep. Gr. 70
– Disconnect the connector from the Left Footwell Vent Tem‐
perature Sensor - G261- -1-.
– Unhook the footwell vent -3- from the mount -arrow A- and
remove it from the heater -2- in direction of -arrow-.
Installing
– Install the driver footwell vent in the reverse order while en‐
suring proper seating on the heater.
– Secure the module carrier. Refer to ⇒ wBody AG. Volkswag e n G d
ag e n Interior; Rep.AGr. oe s
70 . olks not
yV gu b ara
is ed nte
– Install the instrument panel.th Refer
or to ⇒ Body Interior; Rep. Gr. e or
70 ; Instrument Panel; Instrument
s au Panel, Removing and In‐ ac
stalling . s

ce
le
un

pt
– Install the knee airbag. Refer to ⇒ Body Interior; Rep. Gr. 69 ;

an
d
itte

y li
Airbag; Knee Airbag, Removing and Installing .
e rm

ab
ility
ot p

wit
is n

7.5 Front Passenger Side Footwell Vent,

h re
ole ,

Removing and Installing

spe c
u rpose s, inpart or inwh

t toth e co tne ss of inform

Special tools and workshop equipment required
♦ Trim Removal Wedge - 3409-
rre c
Removing
– Remove the footwell trim panel on the front passenger side.
Refer to ⇒ Body Interior; Rep. Gr. 68 ; Storage Compart‐
cial p

ments, Covers and Trim; Footwell Covers, Removing and

Installing .
me r

a
m

– Remove footwell vent -1- from the mount -arrow A-.

ion
r co

int
o

– Disconnect the connector from the Right Footwell Vent Tem‐

h is
ate

perature Sensor - G262- .

do
ir v
p

cum
r
fo

– Remove footwell vent -1- from the heater -arrow B-.

en
ng

t.
yi Co
op
Installing C py
h t. g
rig
h
yri t by
– Install the footwell vent in the reverse order while ensuring y cop Vo
lksw
proper seating on the heater.
b
cte d ag e n
Prote AG.

7.6 Rear Vent, Removing and Installing

Special tools and workshop equipment required
♦ Trim Removal Wedge - 3409-

7. Air Guide 105

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

Removing
– Unclip the rear vent -1- at the indicated locations -arrow- using
the -3409- and then remove it from the center console.
Installing
– Clip the rear vent into the center console.

7.7 Fresh Air Intake, Removing and Instal‐

ling AG. Volkswag e n n AG d o
wag e es n
Removing Volks ot g
y u
e db ara
ris nte
– Remove the plenum chamberth ocover. Refer to ⇒ Body Exterior; e or
Rep. Gr. 50 ; Plenum Chamber
s au Cover; Plenum Chamber ac
Cover . s

ce
le
un

pt
– Remove the Engine Control Module (ECM). Refer to ⇒ Rep.

an
d
itte

y li
Gr. 23 or for vehicles with a gasoline engine. Refer to ⇒ Rep.
rm

ab
Gr. 24 .
pe

ility
ot

wit
, is n

– Loosen the ECM bracket to gain access to the nuts -1-.

h re
h ole

spe c
– Remove the nuts -1- and the air grille -A-.
e s, inpart or inw

t toth e co tne ss of infor

rre c
l pu rpos
e rcia

m
m

a
com

tion
int
r
te o

– Grab the air intake shroud from the top and loosen the clamps
h is
iva

-1-.
d o
r
rp

cu
fo

– Remove the air intake shroud from the plenum chamber.

m
en
ng

i t.
py Co
Installing Co py
h t. rig
g h
yri t by
Install in reverse order of removal. Note the following: by cop Vo
lksw
cte d ag e n
Prote AG.

106 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Check the water drain valve -arrow- for dirt before installing it.
Clean water drain valve if necessary.

7.8 Passenger Compartment Forced Air Ex‐

traction, Checking

Note

♦ The stale air escapes through the vent openings in the luggage
compartment trim.
♦ If the ventilation is n . Volkswagproperly,
toAGfunction d oe the ventilation open‐
e nAG
wag e s no
olksbe covered.
ings musty Vnot tgu
e db ara
s nte
♦ Theth oventilation frames can be found on the right
ri
eand
or
left, re‐
spectively,
au in the side parts behind the bumper. ac
ss
ce
le
un

pt

Checking
an
d
itte

y li
rm

– Remove the rear bumper. Refer to ⇒ Body Exterior; Rep. Gr.

ab
e

ility
ot p

63 ; Rear Bumper Cover; Rear Bumper Carrier .

wit
, is n

– The sealing lips in the ventilation frame -1- must be free to

h re
h ole

move and close.

spe
e s, inpart or inw

ct toth e
corre ctne ss of in
l pu rpos
e rcia

form
m

a
om

tionin
or c

th i
te
iva

d s
o
pr

cu
r
fo

m
en
ng

i t.
py Co
t. Co py
rig
h g h
yri t by
y cop Vo
lksw
b
cte d ag e n
Prote AG.

7. Air Guide 107

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

8 Coolant Circuit
⇒ “8.1 Coolant Shut-Off Valve N82 , Removing and Installing”,
page 108
⇒ “8.2 Recirculation Pump V55 , Removing and Installing”, page
110

8.1 Coolant Shut-Off Valve - N82- , Remov‐

ing and Installing
Removing AG. Volkswag e nAG d
ag e n oe s
lksw not
Special tools and workshop equipment required by
Vo gu
ara
e d
ris nte
♦ Torque Wrench 1331 5-50Nm - VAG1331-
th o eo
u ra
sa c
♦ Hose Clip Pliers - VAS6362- s

ce
le
un

pt
♦ Hose Clamps - Up To 25 mm - 3094-

an
d
itte

y li
rm

ab
♦ Hose Clip Pliers - VAG1921-
e

ility
ot p

♦ Spring Clip Pliers - VAS6499-

wit
, is n

h re
♦ Hose Clip Pliers - VAS6340-
h ole

spe
e s, inpart or inw

ct toth e
– Remove the wheel housing liner. Refer to ⇒ Body Exterior;
Rep. Gr. 66 ; Wheel Housing Liner; Front Wheel Housing Lin‐
er .

corre ctne ss of in
– Remove the bolts -4- (8 ± 0.9 Nm) and nut -2- (6 ± 0.5 Nm).
l pu rpos

– Remove the brackets -1 and 3- with the hoses downward in

direction of -arrow-.
e rcia

form
m

a
om

tionin
or c

th i
te
iva

d s
o
pr

cu
r
fo

m
en
ng

i t.
py Co
t. Co py
rig
h g h
yri t by
by cop Vo
lksw
cte d ag e n
Prote AG.

108 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Remove the bolt -6- (9 ± 0.5 Nm) and clamp -1-.

CAUTION
The cooling system is under pressure when the engine is warm.
There is a risk of scalding from hot steam and coolant.
Burns on the skin and other parts of the body is possible.
– Wear protective gloves.
– Wear protective eyewear.
– Reduce the pressure: cover the coolant reservoir cap with a
cloth and carefully open.

– Loosen the clamps -2 and 4- and disconnect the coolant hoses

from the Coolant Shut-Off Valve - N82- .
– Remove the Coolant Shut-Off Valve - N82- -3- from the brack‐
et -5- in direction of -arrow-.
Installing
Install in reverse order of removal. Note the following:

Note

♦ Secure the hose connections with clamps. For the correct

clamp. Refer to the Parts Catalog.
♦ Make sure this parts do not come in direct contact with the
vehicle body or any other parts.

The coolant flow direction is marked on the Coolant Shut-Off

Valve - N82- .
– Be sure the coolant hoses are
olkconnected
swag e nAG correctly to the Cool‐
ant Shut-Off Valve wa- e nAG..V
g N82- d oe s
lks o n ot g
yV u
– Interchanged d b coolant hoses can result in failureaof
ranthe pas‐
ise te e
senger t or
h compartment heater due to the incorrect flow direction
or
of the
s au coolant. ac
s
ce
le

– Coolant hoses that are bent cannot allow enough coolant to

un

pt
an
d

flow causing the passenger compartment heating to fail.

itte

y li
rm

ab

– Check the coolant level and bleed the coolant system. Refer
e

ility
ot p

to ⇒ Rep. Gr. 19 .
wit
is n

h re

Function
ole ,

spe c
u rpose s, inpart or inwh

♦ The Coolant Shut-Off Valve - N82- is activated via the A/C

t toth e co tne ss of inform

system controls only at certain settings (for example, when

“OFF” is selected or when maximum cooling is required). The
engine RPM must be below 5000 and the coolant temperature
rre c

must be below 95 °C (203 °F).

♦ Shutting off the coolant circuit to the A/C heat exchanger ac‐
celerates the engine warming up when the coolant is cold.
cial p

♦ The Coolant Shut-Off Valve - N82- is open without activation.

me r

To be able to check the electrical function of the valve, acti‐

a
m

vation occurs at certain intervals (for example, brief activation

tion
co

lasting approximately 1 second at every twentieth engine

int
or

start).
h is
te
iva

do
pr

Incorporation into the Coolant Circuit

cum
r
fo

en
ng

t.
yi Co
Cop py
h t. g
rig
h
yri t by
by cop Vo
lksw
cte d ag e n
Prote AG.

8. Coolant Circuit 109

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

1 - Coolant Shut-Off Valve -

N82-
– Coolant Shut-Off Valve -
N82- function. Refer to
⇒ “8.1 Coolant Shut-Off
Valve N82 , Removing
and Installing”,
page 108 .

– Removing and instal‐

ling. Refer to
⇒ “8.1 Coolant Shut-Off
Valve N82 , Removing
and Installing”,
page 108 .
2 - Return - From the Second
Rear Heater Core to the En‐
gine
3 - Supply - From the Front
Heater Core to the Rear 2nd
Heater Core
4 - Return - from the Front
Heater Core to the Engine
5 - Supply - From the Engine to
the Coolant Shut-Off Valve -
N82-
nAG. Volkswag e nAG d o
wag e es n
Volks ot g
y ua
e db ran
ris te e
th o
or
au ac
ss
ce
le
un

pt
an
d
itte

y li
rm

ab
e

ility
ot p

wit
is n

h re
ole ,

spe c
u rpose s, inpart or inwh

8.2 Recirculation Pump - V55- , Removing

t toth e co tne ss of inform

and Installing
rre c

Special tools and workshop equipment required

♦ Torque Wrench 1331 5-50Nm - VAG1331-
cial p

♦ Hose Clamps - Up To 25 mm - 3094-

me r

♦ Hose Clip Pliers - VAG1921-

a
m

tion
o

♦ Spring Clip Pliers - VAS6499-

c

int
or

h is
te
iva

do
pr

Note
cum
r
fo

en
ng

t.
yi Co
♦ The Recirculation Pump - V55- is installed in the left front Cop py
wheel housing behind the wheel housing liner.
ht. rig
g h
yri t by
cop Vo
♦ The coolant system is under pressure when the engine is
by lksw
cte d ag e n
warm. If necessary, release the pressure prior to repair work.
Prote AG.

Removing
– Remove the left front wheel housing liner. Refer to ⇒ Body
Exterior; Rep. Gr. 66 ; Wheel Housing Liner; Front Wheel
Housing Liner .

110 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Discharge the coolant circuit. Refer to ⇒ Rep. Gr. 19 .

– Clamp off the coolant hoses using the -3094- .
– Remove the bracket -1- from the vehicle body and then re‐
move the Recirculation Pump - V55- -2-.
Installing

Note

♦ When installing the pump, make sure the coolant hoses are
secured with the clamps and the coolant pipes are installed
without tension. AG. Volkswag e nA g en G do
swa es n
♦ Coolant circuit, filling and bleeding.
by
Refer
Vol
k to ⇒ Rep. Gr. 19 . ot g
u ara
ed nte
ris
u th o e or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
e rm

ab
ility
ot p

wit
is n

h re
ole ,

spe c
u rpose s, inpart or inwh

t toth e co tne ss of inform

rre c
cial p
me r

a
m

tion
co

int
r
te o

h is
a

do
riv
p

cum
or
f

en
ng

i t.
py Co
t. Co py
rig
h h
rig t by
py Vo
d by co lksw
cte ag e n
Prote AG.

8. Coolant Circuit 111

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

9 Display and Control Head

⇒ “9.1 Overview - Display and Control Head”, page 112
⇒ “9.2 Display and Control Head, Removing and Installing”, page
120
⇒ “9.3 Function of the Climatronic via the Infotainment System”,
page 122

9.1 Overview - Display and Control Head

⇒ “9.1.1 Overview - Front Display and Control Head”, page 112
⇒ “9.1.2 Overview - Rear Display and Control Head”, page 117

9.1.1 Overview - Front Display and Control

Head

Note

♦ For the Climatronic with 2-zone temperature control and 4-

zone temperature control, there is only one Front A/C Display
Control Head - E87- .
♦ The Front A/C Display Control Head - E87- must be coded for
Volkswa AG. g e nAG
the corresponding version. ag e n d oe s
ksw not
y Vol gu
♦ In vehicles without seat ventilation,
ed
b covers are installed in‐ ara
nte
stead. ris
ht o e or
au ac
♦ ss Refer to
Note safety precautions. ce
le

⇒ “1.3 Start/Stop System Safety Precautions”, page 2 .

un

pt
an
d
itte

y li
rm

ab
e

ility
ot p

wit
is n

h re
ole ,

spe c
u rpose s, inpart or inwh

t toth e co tne ss of inform

rre c
cial p
me r

a
m

tion
co

int
or

h is
te
iva

do
pr

cum
r
fo

en
ng

i t.
py Co
t. Co py
rig
h g h
yri t by
y cop Vo
lksw
b
cte d ag e n
Prote AG.

112 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

1 - Defrost Button nAG. Volkswag e nAG d o

wag e es n
olks ot g
2 - Left Thermostat d by
V ua
ran
ir se te e
❑ Change front left tem‐ th o
or
perature setting by turn‐ au ac
ss
ing.

ce
le
un

pt
an
3 - AUTO Button

d
itte

y li
rm

ab
❑ In automatic mode the

ility
ot p
Climatronic maintains

wit
is n
the selected interior

h re
temperature automati‐
ole ,

spe c
cally. With this setting u rpose s, inpart or inwh
the vent air tempera‐

t toth e co tne ss of inform

ture, the blower speed
and the air distribution
are controlled automati‐

rre c
cally.
4 - Air Conditioning (A/C) Syn‐
chronization Button
cial p

❑ This button transfers all

me r

driver air conditioning

a
m

settings to the other

tion
co

seats.

int
or

h is
te
iva

5 - Display for Diagnostic

d o
pr

Function

cu
r
fo

m
en
❑ The display appears
ng

t.
yi Co
when there is communi‐ Cop py
h t. rig
cation between the ve‐ yri
g t by h
hicle and Vehicle Diag‐ cop Vo
by lksw
nostic Tester .
cte d ag e n
Prote AG.

6 - Selected Interior Tempera‐

ture Display, Left Side
❑ Can be changed from
degrees Celsius to de‐
grees Fahrenheit and
vice versa.
7 - Button for Lowering the Blower Speed
8 - Blower Speed Display
❑ In automatic operation the actual blower speed is displayed.
9 - Display of the “Auto” Function
10 - Parking Heater Display
❑ The display appears when the parking heater is switched on.
11 - Air Distribution Display
❑ Displays the front air distribution setting.
12 - “A/C” Display
❑ The A/C compressor is set to almost 0 delivery when the AC button is off. If the AUTO button is activated,
the heating and ventilation mode continues to be controlled electronically.
13 - Display of the Residual Heat Function
14 - Button for Increasing the Blower Speed
15 - Selected Interior Temperature Display, Right Side
❑ Can be changed from degrees Celsius to degrees Fahrenheit and vice versa.
16 - “OFF” Display
❑ Illuminates when the heating and A/C function is switched off via the 18 button.

9. Display and Control Head 113

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

17 - Recirculating Air Mode Button

AG. Volkswag e nAG
❑ Press the button for recirculating air function towprevent
ag e n polluted air from
d oe s entering interior.
olks not
❑ Setting indicated by the LED. db
y V gu
ar
e an
ris te e
th o or
Note au ac
ss

ce
le
un
♦ Recirculating air is switched on

pt
an
d
automatically under the following

itte

y li
rm
conditions:

ab
e

ility
ot p
♦ When the windshield washer

wit
is n
system is operated.

h re
ole ,

spe c
♦ When the Air Quality Sensor -
u rpose s, inpart or inwh

G238- is activated.

t toth e co tne ss of inform

♦ When the reverse gear is engag‐
ed (this function is only active for

rre c
two minutes after the engine is
started).
♦ Blower speed on the Front A/C
cial p

Display Control Head - E87- off.

me r

♦ Front A/C Display Control Head

a
m

t
- E87- “OFF”

ion
co

int
or

h is
te

18 - “OFF” Button
iva

do
pr

c
❑ Press the “OFF” button to turn off the heater and A/C.

um
r
fo

en
ng

i t.
19 - Right Thermostat py Co
. Co py
❑ Change front right temperature setting by turning.
h t rig
g h
yri t by
cop Vo
20 - Rear Window Defogger Button
by lksw
cte d ag e n
Prote AG.
❑ Rear window defroster remains on for 4 to 20 minutes, depending on exterior temperature.
21 - Right Seat Heater Button
❑ The seat heater has 3 settings. The LED indicates the current setting.
❑ If no LED is illuminated, the seat heater is switched off.
22 - Right Seat Ventilation Button
❑ The seat ventilation has 3 settings. The LED indicates the current setting.
❑ If no LED is illuminated, the seat ventilation is switched off.
23 - REST Button
❑ When residual heat function is switched on the residual heat of engine is pumped by a coolant pump to
the heat exchanger.
24 - Air Distribution Button
❑ Pressing the button regulates front air distribution.
❑ The air distribution display shows which setting is active -item 11- ⇒ Item 11 (page 113) .
25 - AC Button
❑ The A/C compressor is set to almost 0 delivery when the AC button is off. If the AUTO button is activated,
the heating and ventilation mode continues to be controlled electronically.
26 - Left Seat Ventilation Button
❑ The seat ventilation has 3 settings. The LED indicates the current setting.
❑ If no LED is illuminated, the seat ventilation is switched off.
27 - Left Seat Heater Button
❑ The seat heater has 3 settings. The LED indicates the current setting.
❑ If no LED is illuminated, the seat heater is switched off.

114 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

Climatronic Temperature Unit, Switching

The temperature display unit can be switched between Celsius
and Fahrenheit in the setup menu of the Infotainment system.
– Press the SETUP button in the Infotainment.
– Touch the SYSTEM button.
– Touch the UNITS button.
– Select the desired unit.
Climatronic Control Module - J255- Connectors
Terminal Assignment of Multi-Pin Connectors A, B, C and D on
the rear side of Climatronic Control Module - J255-
Special tools and workshop equipment required
♦ Test Box Kit - Basic Test Box - VAG1598/14-
♦ Test Box Kit - Adapter 11 - VAG1598/11-

nAG. Volkswag e nAG d o

wag e es n
Volks ot g
y ua
e db ran
ir s te e
th o
or
au ac
ss

ce
le
un

pt
an
d
itte

y li
e rm

ab
ility
ot p

wit
is n

h re
ole ,

spe c
u rpose s, inpart or inwh

t toth e co tne ss of inform

rre c
cial p
me r

a
m

tion
r co

int
o

h is
ate

do
riv
p

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
g h
yri t by
cop by
Vo
lksw
cte d ag e n
Prote AG.

8-Pin Harness Connector -A- in Wiring Diagram T8n

1 - Terminal 30
2 - Terminal 31

9. Display and Control Head 115

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

3 - Not assigned
4 - Not assigned
5 - Connected terminal 30 for control motors (bridge to C1, D2,
D3)
6 - Control motor ground
7 - Not assigned
8 - Coolant pump output (optional)
12-Pin Harness Connector -B- in Wiring Diagram T12b
1 - Coolant pump relay (high side)
2 - Coolant pump ground
3 - Not assigned
4 - High Pressure Sensor - G65-
5 - Not assigned
nAG. Volkswag e nAG d o
6 - Not assigned wag e es n
Volks ot g
y ua
db ran
7 - Coolant Shut-Off Valve - N82- oris l closed +
e
te e
u th or
8 - Coolant Shut-Off a
Valvess- N82- open + ac

ce
le
un

9 - Windshield Defogger - Z2- relay (high side)

pt
an
d
itte

y li
10 - Windshield Defogger - Z2- ground relay
e rm

ab
ility
ot p

11 - Not assigned

wit
is n

h re
12 - Not assigned
ole ,

spe c
u rpose s, inpart or inwh

20-Pin Harness Connector -C- in Wiring Diagram T20d

t toth e co tne ss of inform

1 - Connected terminal 30 for control motors (parallel to D2, D3
and A5)
rre c
2 - CAN bus high
3 - CAN bus low
cial p

4 - LIN 2 (LIN for vehicle electrical system)

me r

5 - Control motor ground

a
m

tion
r co

6 - Not assigned
int
o

h is
te

7 - Not assigned
a

do
riv
p

8 - Not assigned
um
r
fo

en
ng

t.
yi
9 - +5V Sunlight Photo Sensor - G107- (bridge to D14, C18)
Co
Cop py
ht. rig
10 - Ground signal for Left Front Upper Body Vent Temperature rig t by h
py Vo
Sensor - G385- , Right Front Upper Body Vent Temperature Sen‐ y co
d b lksw
cte ag e n
sor - G386- and Sunlight Photo Sensor - G107- Prote AG.

11 - Left Sunlight Photo Sensor - G107-

12 - Right Sunlight Photo Sensor - G107-
13 - Not assigned
14 - Right Front Upper Body Vent Temperature Sensor - G386-
(bridge to D8)
15 - Not assigned
16 - Not assigned
17 - Not assigned
18 - +5V Sunlight Photo Sensor - G107- (bridge to D14, C9)

116 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

19 - Left Front Upper Body Vent Temperature Sensor - G385-

(bridge to D9)
20 - Not assigned
16-Pin Harness Connector -D- in Wiring Diagram T16k
1 - LIN 1
2 - Connected terminal 30 for control motors (bridge to C1, D3,
A5)
3 - Connected terminal 30 for control motors (bridge to C1, D3,
A5)
4 - Control motor ground
5 - Control motor ground
6 - LIN 2 (LIN for vehicle electrical system, bridge to C4)
7 - Evaporator Temperature Sensor - G308-
8 - Right Front Upper Body Vent Temperature Sensor - G386-
(bridge to C14)
9 - Left Front Upper Body Vent Temperature Sensor - G385-
(bridge to C19)
10 - Right Footwell Vent Temperature Sensor - G262-
11 - Left Footwell Vent Temperature Sensor - G261-
12 - Not assigned
13 - Ground signal for Left Footwell Vent Temperature Sensor -
G261- , Right Footwell Vent Temperature Sensor - G262- and
Evaporator Temperature Sensor - G308-
14 - +5V Sunlight Photo Sensor - G107- (bridge to C9, C18)
nAG. Volkswag e nAG d o
15 - Not assigned wag e es n
Volks ot g
y ua
db ran
16 - Not assigned orise
te e
th or
au ac
9.1.2 Overview
ss - Rear Display and Control Head
ce
le
un

pt
an
d
itte

y li
rm

ab
e

ility
ot p

wit
is n

h re
ole ,

spe c
u rpose s, inpart or inwh

t toth e co tne ss of inform

rre c
cial p
me r

a
m

tion
co

int
or

h is
te
iva

do
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
g h
yri t by
cop by
Vo
lksw
cte d ag e n
Prote AG.

9. Display and Control Head 117

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

1 - Left Thermostat
❑ Change left rear tem‐
perature setting by turn‐ nAG. Volkswag e nAG d o
wag e es n
ing. Volks ot g
y ua
e db ran
2 - AUTO Button ris te e
th o
or
au ac
❑ In automatic mode the ss
Climatronic maintains

ce
le
un

pt
the selected rear interior

an
d
itte

y li
temperature automati‐
rm

ab
cally. With this setting e

ility
ot p

the vent air tempera‐

wit
is n

ture, the blower speed

h re
ole ,

and the air distribution

spe c
are controlled automati‐
u rpose s, inpart or inwh

cally.

t toth e co tne ss of inform

3 - Display for Diagnostic
Function

rre c
❑ The display appears
when there is communi‐
cation between the ve‐
cial p

hicle and Vehicle Diag‐

nostic Tester .
me r

a
4 - Selected Interior Tempera‐
m

tion
o

ture Display, Left Side

c

int
or

h is
te

❑ Can be changed from

iva

d
degrees Celsius to de‐

o
pr

cu
r
fo

grees Fahrenheit and

m
en
ng

vice versa
t.
yi Co
Cop py
.
5 - Blower Speed Display
ht rig
rig t by h
py Vo
❑ In automatic operation d by co lksw
cte ag e n
the actual blower speed Prote AG.
is displayed.
6 - Display of the “Auto” Func‐
tion
7 - Air Distribution Display
❑ Displays the rear air distribution setting.
8 - Selected Interior Temperature Display, Right Side
❑ Can be changed from degrees Celsius to degrees Fahrenheit and vice versa
9 - “OFF” Display
❑ Illuminates when the heating and A/C function is switched off via the 11 button.
10 - Right Thermostat
❑ Change right rear temperature setting by turning.
11 - “OFF” Button
❑ Press the “OFF” button to turn off the heater and A/C.
12 - Right Seat Heater Button
❑ The seat heater has 3 settings. The LED indicates the current setting.
❑ If no LED is illuminated, the seat heater is switched off.
13 - Button for Increasing the Blower Speed
14 - Air Distribution Button
❑ Pressing the button regulates front air distribution.
❑ The air distribution display shows which setting is active. Refer to -item 7- ⇒ Item 7 (page 118) .

118 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

15 - Button for Lowering the Blower Speed

16 - Left Seat Heater Button
❑ The seat heater has AG. VolkswThe
ag e nAG
ag 3
e nsettings. LEDd oeindicates the current setting.
olksw s no
tgu
V
❑ If no LED eisd billuminated, the seat heater is switched
y ara off.
ris nte
u th o e or
a ac
ss
Rear A/C Display Control Head - E265- Connectors

ce
le
un

pt
an
d

Terminal assignment of multi-pin connectors A and B on rear side

itte

y li
e rm

of Rear A/C Display Control Head - E265-

ab
ility
ot p

Special tools and workshop equipment required

wit
is n

h re
ole ,

♦ Test Box Kit - Basic Test Box - VAG1598/14-

spe c
u rpose s, inpart or inwh

♦ Test Box Kit - Adapter 47 - VAG1598/47-

t toth e co tne ss of inform

♦ Test Box Kit - Adapter 47 - Cover Plate - VAG1598/47-2-

rre c
cial p
me r

a
m

ti
r co

onin
o

th i
te
ir va

d s
o
p

cu
r
fo

m
en
ng

t.
yi Co
Cop py
h t. g
rig
h
yri t by
by cop Vo
lksw
cte d ag e n
Prote AG.

3-Pin Harness Connector -A-

1 - Left Rear Seat Heating Element - Z98- Activation
2 - Terminal 30 power supply for seat heating
3 - Right Rear Seat Heating Element - Z99- Activation

9. Display and Control Head 119

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

20-Pin Harness Connector -B- in Wiring Diagram T20e

1 - LIN bus 1
2 - CAN bus high
3 - CAN bus low
4 - Analog input 1
5 - Analog Input 2
6 - Ground signal for Left Rear Upper Body Vent Temperature
Sensor - G635- and Right Rear Upper Body Vent Temperature
Sensor - G636-
nAG. Volkswag e nAG d o
7 - Analog Input 3 wag e es n
Volks ot g
y ua
db ran
8- Left Rear Upper Body Vent Temperature Sensor - G635-ris e
te e
th o
u or
9- Right Rear Upper Body Vent Temperature Sensor -ssG636-
a ac

ce
le
10 - Terminal 30 power supply for control motors
un

pt
an
d
itte

y li
11 - Control motor ground
rm

ab
e

ility
ot p

12 - Output 1

wit
is n

h re
13 - Analog Input 4
ole ,

spe c
14 - Output 3
u rpose s, inpart or inwh

t toth e co tne ss of inform

15 - Output 2
16 - Right Rear Heated Seat Temperature Sensor - G95-

rre c
17 - Left Rear Heated Seat Temperature Sensor - G94-
18 - Terminal 30 electronics (optional)
cial p

19 - Terminal 30
me r

20 - Terminal 31

a
m

tion
co

9.2 Display and Control Head, Removing

int
or

h is
te
iva

and Installing

do
pr

cum
r
fo

⇒ “9.2.1 Front Display and Control Head, Removing and Instal‐

en
ng

t.
yi Co
ling”, page 120 . Cop py
rig
ht g h
⇒ “9.2.2 Rear Display and Control Head, Removing and Instal‐ yri t by
cop Vo
ling”, page 122
by lksw
cte d ag e n
Prote AG.

9.2.1 Front Display and Control Head, Re‐

moving and Installing
Special tools and workshop equipment required
♦ Trim Removal Wedge - 3409-
Removing

Note

If a new Front A/C Display Control Head - E87- with a Climatronic

Control Module - J255- is installed, the Replace control module
function and a basic setting must be performed in the Guided
Fault Finding or the Guided Functions.

Prior to working on electrical wires, disconnect the corresponding

fuse/fuses. Refer to ⇒ Wiring diagrams, Troubleshooting & Com‐
ponent locations.
– Open the ashtray cover.

120 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Unclip and remove the trim -2- at the indicated locations

-arrows- from the Front A/C Display Control Head - E87- -1-
using the -3409- .

– Carefully insert the -3438- in the area -arrow B- underneath

and then behind the Front A/C Display Control Head - E87-
-1-. Press frame -2- slightly downward in this process.

– Insert both -T10315- horizontally into the slits -arrows- first on

one side (be sure to protect AtheG. Vcenter
olkswagconsole)
e nAG and push them
gently toward the outsideag e n
to release the tabs. d oe s
lksw no
Vo tgu
ara by
– Use both tools ris
e dto remove the Front A/C Display Control
nte Head
ho
- E87- -1-u ttoward the front. eo
r ac
sa
– Use thes -3409- to press the retaining tabs inward as needed.
ce
le
un

pt

– Disconnect the connectors and remove the Front A/C Display

an
d
itte

y li

Control Head - E87- with the Climatronic Control Module -

rm

ab

J255- .
e

ility
ot p

wit
is n

Installing
h re
ole ,

spe c

Install in reverse order of removal. Note the following:

u rpose s, inpart or inwh

t toth e co tne ss of inform

Note
rre c

♦ If a new Front A/C Display Control Head - E87- with a Clima‐

tronic Control Module - J255- is installed, the replace control
module function and a basic setting must be performed in the
cial p

Guided Fault Finding or the Guided Functions.

me r

♦ When installing the Front A/C Display Control Head - E87- , it

a

must be ensured that pressure is not exerted on the surfaces

m

tion
o

of the temperature regulator and the display while inserting.

c

int
or

Excessive pressure can result in damage to the Front A/C

h is
te
iva

Display Control Head - E87- .

d o
pr

cu
r
fo

m
en
ng

i t.
py Co
t. Co py
rig
h g h
yri t by
by cop Vo
lksw
cte d ag e n
Prote AG.

9. Display and Control Head 121

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Engage the Front A/C Display Control Head - E87- into the
frame by pressing on the indicated locations -arrows-. Ensure
that no pressure is exerted on display -1- and regulator -2-.
– Clip in the Front A/C Display Control Head - E87- trim.

9.2.2 Rear Display and Control Head, Remov‐

ing and Installing
Special tools and workshop equipment required
♦ Trim Removal Wedge - 3409-
Removing

Note

If a new Rear A/C Display Control Head - E265- is installed, the

replace control module function and a basic setting must be per‐
formed in the Guided Fault Finding or the Guided Functions.

– Remove the rear vent. Refer to

⇒ “7.6 Rear Vent, Removing and Installing”, page 105 .
– Pull the Rear A/C Display Control Head - E265- -1- on the
indicated points -arrows- to the right or left with one hand and
remove it from the center console. olksw AG. V ag e nAG
w ag e n d oe s
– Disconnect the connector from the Rear
olks A/C Display Control not
yV gu
Head - E265- -1-. se db ara
nte
ri
ho e
Installing aut or
ac
ss
ce
le
un

pt
an
d

Note
itte

y li
e rm

ab
ility
ot p

♦ If a new Rear A/C Display Control Head - E265- is installed,

wit
is n

the replace control module function and a basic setting must

h re

be performed in the Guided Fault Finding or the Guided Func‐

ole ,

spe c

tions.
u rpose s, inpart or inwh

t toth e co tne ss of inform

♦ When installing the Rear A/C Display Control Head - E265- ,

it must be ensured that pressure is not exerted on the surfaces
of the temperature regulator and the display when inserting.
rre c

Excessive pressure can result in damage to the Rear A/C Dis‐

play Control Head - E265- .
cial p

– Connect the connector of the Rear A/C Display Control Head

- E265- .
me r

– Clip the Rear A/C Display Control Head - E265- into the center
a
m

tion
r co

console by pressing on the edge.

int
o

h is
ate

9.3 Function of the Climatronic via the Infotainment System

do
riv
p

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
g h
yri t by
cop by
Vo
lksw
cte d ag e n
Prote AG.

122 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

1 - Buttons for Setting the Front

Air Distribution
❑ Air distribution to the
windshield, the upper
body, and the footwell.
2 - “Back” Button
❑ Return to the previous
menu.
3 - Display of the Front Pas‐
senger Air Distribution and
Temperature Setting AG. Volkswag e nAG d
ag e n oe s
olksw not
V gu
4 - Windshield Defroster But‐ d by ara
ise nte
ton th or eo
au ra
❑ Only works withss the en‐ c
gine running and

ce
e
nl

pt
switches off automati‐
du

an
itte

cally after several mi‐

y li
e rm

ab
nutes.

ility
ot p

wit
is n

5 - OFF Button

h re
ole ,

❑ The rear Climatronic is

spe c
switched off.
u rpose s, inpart or inwh

t toth e co tne ss of inform

6 - Button for Increasing the
Front Blower Speed

rre c
7 - Button for Lowering the
Front Blower Speed
8 - “Back” Button
cial p

❑ Return to the previous

menu.
me r

a
m

tion
o

9 - Display of the Right Rear Air

c

int
Distribution and Temperature
r
te o

h is

Setting
a

do
riv
p

cum

10 - Buttons for Setting the

or
f

en

Rear Air Distribution

ng

t.
yi Co
op py
❑ Air distribution to the windshield, the upper body, and the footwell.
C
h t. g
rig
h
yri t by
11 - Right Rear Temperature Control by cop Vo
lksw
cte d ag e n
Prote AG.
12 - OFF Button
❑ The rear Climatronic is switched off.
13 - Button for Increasing the Rear Blower Speed
14 - Button for Lowering the Rear Blower Speed
15 - AUTO - Rear Button
❑ Automatic control for temperature, blower, and air distribution.
16 - Left Rear Temperature Control
17 - Display of the Left Rear Air Distribution and Temperature Setting
18 - AUTO - Front Button
❑ Automatic control for temperature, blower, and air distribution.
19 - Button for Residual Heat Function
❑ When residual heat function is switched on the residual heat of engine is pumped by a coolant pump to
the heat exchanger.
20 - Steering Wheel Heating Button
❑ The steering wheel is heated to approx. 25 °C (77 °F) and is kept almost constant.

9. Display and Control Head 123

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

21 - Parking Heater Button

❑ Menu for setting the parking heater. nAG. Volkswag e nAG d o
wag e es n
Volks ot g
22 - Display of the Driver Air Distribution and Temperature Settinge db
y ua
ran
ris te e
ht o or
au ac
ss

ce
le
un

pt
an
d
itte

y li
e rm

ab
ility
ot p

wit
is n

h re
ole ,

spe c
u rpose s, inpart or inwh

t toth e co tne ss of inform

rre c
cial p
me r

a
m

ti
r co

onin
o

th i
te
ir va

d s
o
p

cu
r
fo

m
en
ng

t.
yi Co
Cop py
ht. rig
rig t by h
py Vo
d by co lksw
cte ag e n
Prote AG.

124 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

10 Additional Components for Control

and Regulation
⇒ “10.1 Sunlight Photo Sensor G107 , Removing and Installing”,
page 125
⇒ “10.2 Air Quality Sensor G238 , Removing and Installing”, page
126
⇒ “10.3 Function of Air Quality Sensor G238 ”, page 126
⇒ “10.4 Outside Air Temperature Sensor G17 , Removing and
Installing”, page 127
⇒ “10.5 A/C Humidity Sensor G260 , Removing and Installing”,
page 128
⇒ “10.6 Left Footwell Vent Temperature Sensor G261 , Removing
and Installing”, page 128
⇒ “10.7 Right Footwell Vent Temperature Sensor G262 , Re‐
moving and Installing”, page 128
⇒ “10.8 Right Front Upper Body Vent Temperature Sensor G386
and Left Front Upper Body Vent Temperature Sensor G385 , Re‐
moving and Installing”, page 129

10.1 Sunlight Photo Sensor - G107- , Remov‐

ing and Installing
Special tools and workshop equipment required
nAG. Volkswag e nAG d o
♦ Trim Removal Wedge - 3409- wag e es n
Volks ot g
d by ua
ran
Removing o
ir se te e
h
a ut or
ac
– Completely detach the instrument panel
ss -1- and pull it forward
slightly. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Instrument

ce
le
un

pt
Panel; Instrument Panel, Removing and Installing .

an
d
itte

y li
– Use the -3409- to unclip the Sunlight Photo Sensor - G107-
rm

ab
pe

ility
-2- on the right and left -arrows-.
ot

wit
, is n

– Disconnect the connector from the Sunlight Photo Sensor -

h re
h ole

G107- -2-.
spe c
e s, inpart or inw

Installing
t toth e co tne ss of inform
– Install the Sunlight Photo Sensor - G107- in the reverse order
of removal.
rre c

– Install the instrument panel. Refer to ⇒ Body Interior; Rep. Gr.

l pu rpos

70 ; Instrument Panel; Instrument Panel, Removing and In‐

stalling .
me rcia

at
com

ionint
r
te o

h is
iva

d o
r
rp

cu
fo

m
en
ng

t.
yi Co
Cop py
h t. g
rig
h
yri t by
by cop Vo
lksw
cte d ag e n
Prote AG.

10. Additional Components for Control and Regulation 125

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

10.2 Air Quality Sensor - G238- , Removing

and Installing

Note

♦ The Air Quality Sensor - G238- is installed in the plenum

chamber at front left in direction of travel.
♦ The Air Quality Sensor - G238- contains a highly sensitive
electronic component that can be damaged if it comes in direct
contact with solvents, fuels or chemicals.
♦ Do not install a sensor that has been kept, for example, in a
tool box.
♦ Do not store removed sensors in areas where they can come
into contact with solvents, fuels and certain chemical compo‐
sitions (fluids or vapors).

Removing
– Remove the right plenum chamber cover -2-. Refer to ⇒ Body
Exterior; Rep. Gr. 50 ; Plenum Chamber Cover; Plenum
Chamber Cover .
– Disconnect the connector from the Air Quality Sensor - G238- .
– Unclip the Air Quality Sensor - G238- -1- from the bracket on
the plenum chamber cover.
Installing
– Install in reverse order of removal.

. Volkswag e nAG
g e nAG d oe
10.3 Function of Air Quality Sensor - G238-
yV
olks
wa s no
tgu
b ara
ed nte
♦ Sensor for air quality detects pollutants in the ambient oris air e
th or
(mostly gasoline and/or diesel fumes). au ac
ss
♦ The Climatronic Control Module - J255- evaluates the signal ce
le
un

pt
from the Air Quality Sensor - G238- . The Air Conditioning (A/ an
d
itte

y li
C) system is activated depending on the strength and type of
rm

ab
heavily polluted air.
pe

ility
ot

wit
, is n

At an outside temperature above approximately +2 °C (35.6 °F)

h re

the recirculating air mode is switched on when there is only a

h ole

spe c

slight increase in pollutants in the ambient air.

e s, inpart or inw

t toth e co tne ss of infor

At an outside temperature between approximately +2 °C (35.6 °

F) and approximately -5 °C (23 °F), the change over to recircu‐
lating air mode only occurs at a sharp increase of pollutant
rre c

concentration, during which the compressor is switched on si‐

multaneously.
l pu rpos

At an outside temperature less than approximately -5 °C (23 °F),

the system still only changes to recirculation mode when there is
e rcia

a strong increase in the level of pollutants. However, it only

m

switches on for approximately 15 seconds and the A/C compres‐

m

a
com

tion

sor does not switch on. If the concentration decreases, the A/C
int

system switches to the fresh air mode.

r
te o

h is
iva

♦ “Automatic recirculating air mode” can be switched off at any

d o
r
rp

cu

time. If the function is active, the A/C compressor is switched

fo

m
en

on with a request for “automatic recirculating air mode” and

ng

t.
yi Co
also when the outside air temperature is below +2 °C (35.6 ° Cop py
. rig
F). If the temperature is below -5 °C (23 °F), it is not possible
ht g h
yri t by
to use the A/C compressor. cop Vo
by lksw
cte d ag e n
Prote AG.

126 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

♦ If the vehicles has “automatic recirculating air mode”, the A/C

compressor can also be manually switched on when the tem‐
perature is approximately -5 °C (23 °F).
♦ To ensure that the A/C system does not operate constantly in
the recirculating air mode in areas with a consistently higher
pollution, the sensor is self-learning (it adjusts its sensitivity to
the environmental conditions).
♦ If the pollutant level in the ambient air remains relatively high
for a lengthy period, the sensor starts to adapt to the change
in ambient conditions by way of an adaptation program, with
the result that a recirculated-air request is generally applied
for less than 12 minutes given uniform ambient air pollution. If
a succession of peaks in the polluted air is detected, the A/C
system can operate over a longer period of time in recirculating
air mode.
♦ A certain amount of time is required for repositioning of the air
conditioning system doors. In the event that a sudden increase
in pollutants is encountered (for example, when driving
through a diesel exhaust cloud) gaseous pollutants can be
taken in with the fresh air into the passenger compartment until nAG. Volkswag e nA
G do
the door can be closed. For this reason, a dust and pollen wag e
filter es n
olks ot g
is installed with a charcoal layer. A filter that is saturated
d by V with ua
ran
e
pollutants is no longer effective and needs to beorreplaced.
is te e
h
a ut or
ac
♦ In order to avoid frequent shifting of the recirculated
ss air/fresh
air door, a slight increase of pollutants in the ambient air will

ce
le
un

pt
not allow for immediate shifting (the sensor does not send a

an
d
itte

request to the Climatronic Control Module - J255- ). The filter‐

y li
e rm

ab
ing of the activated charcoal insert in the dust and pollen filter

ility
ot p

will be sufficient.

wit
is n

h re
♦ In order to avoid frequent shifting of the recirculating air/fresh
ole ,

spe c
air door, the requirement from the sensor for “Automatic air
u rpose s, inpart or inwh

recirculation” mode remains for at least 25 seconds (minimum

t toth e co tne ss of inform

duration period), even if the pollutant concentration is so far
reduced that recirculating air mode is no longer necessary.

rre c
♦ If the A/C compressor is switched off (the AC button is off),
then the Climatronic Control Module - J255- limits the “auto‐
matic recirculating air mode” to approximately 15 seconds to
prevent the windows from fogging up.
cial p

♦ So that fogged windows are cleared as quickly as possible,

me r

the Climatronic Control Module - J255- does not permit recir‐

a
m

t
culated air operation during the “Defrost” operating mode.

i
r co

onin
o

♦ The Air Quality Sensor - G238- requires approximately 30 th i

te
ir va

s
seconds to become operational once the ignition has been
d o
p

cu

switched on (warm-up time). During this time there is no re‐

r
fo

quirement from the sensor to Climatronic Control Module -

en
ng

t.
yi Co
J255- for “automatic recirculating air mode”. . Cop py
rig
ht g h
♦ The Air Quality Sensor - G238- contains a highly sensitive yri t by
cop Vo
electronic component which can be damaged if it comes in
by lksw
cte d ag e n
Prote
direct contact with solvents, fuels or chemicals. For this rea‐
AG.

son, do not install sensors that may have come into contact
with these substances.

10.4 Outside Air Temperature Sensor -

G17- , Removing and Installing
Removing
– Remove the front bumper cover -2-. Refer to ⇒ Body Exterior;
Rep. Gr. 63 ; Front Bumper Cover; Front Bumper Cover .

10. Additional Components for Control and Regulation 127

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Disconnect the connector from the Outside Air Temperature

Sensor - G17- -1-.
– Remove the Outside Air Temperature Sensor - G17- -1- from
the mount.
Installing
– Install in reverse order of removal.

10.5 A/C Humidity Sensor - G260- , Remov‐

ing and Installing
The A/C Humidity Sensor - G260- and the Rain/Light Recognition
Sensor - G397- are one component and are vehicle-specific.
– The removal and installation is described under. Refer to ⇒
Electrical Equipment; Rep. Gr. 92 ; Windshield Wiper System;
Rain/Light Recognition Sensor - G397- .

nAG. Volkswag e nAG d o

Note wag e es n
Volks ot g
y ua
e db ran
s
The diagnosis occurs via the Vehicleth ori Electrical System Control te e
or
Module - J519- . au ac
ss

ce
le
un

pt
10.6 Left Footwell Vent Temperature Sensor
an
d
itte

y li
- G261- , Removing and Installing
e rm

ab
ility
ot p

wit
is n

Removing
h re
ole ,

– Remove the lower instrument panel trim panel. Refer to ⇒ spe c

u rpose s, inpart or inwh

Body Interior; Rep. Gr. 70 ; Instrument Panel; Instrument t toth e co tne ss of inform
Panel, Removing and Installing .
– Disconnect the connector from the Left Footwell Vent Tem‐
perature Sensor - G261- -1-.
rre c

– Turn the Left Footwell Vent Temperature Sensor - G261- -1-

approximately 90° direction of -arrow- and then remove it from
the footwell vent -2-.
cial p

Installing
me r

a
m

– Install the Left Footwell Vent Temperature Sensor - G261- in

i
r co

onin

the reverse order.

o

th i
ate

do s
ir v
p

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
g h
yri t by
cop by
Vo
lksw
cte d ag e n
Prote
10.7 Right Footwell Vent Temperature Sen‐
AG.

sor - G262- , Removing and Installing

Removing
– Remove the lower instrument panel trim panel. Refer to ⇒
Body Interior; Rep. Gr. 70 ; Instrument Panel; Instrument
Panel, Removing and Installing .

128 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

– Disconnect the connector from the Right Footwell Vent Tem‐

perature Sensor - G262- -2-.
– Turn the Right Footwell Vent Temperature Sensor - G262-
-2- approximately 90° in direction of -arrow- and then remove
it from the footwell vent -1-. Volkswa AG. g e nAG
ag e n d oe s
olksw not
yV gu
db ara
Note or
ise nte
th e or
au ac
The Right Footwell Vent ss Sensor
Temperature- G262- is located

ce
le
on the rear side of the footwell vent. To improve the clarity of the

un

pt
illustration, it is shown from a different view.

an
d
itte

y li
e rm

ab
ility
ot p

Installing

wit
is n

h re
– Install the Right Footwell Vent Temperature Sensor - G262- in
ole ,

the reverse order of removal.

spe c
u rpose s, inpart or inwh

t toth e co tne ss of inform

10.8 Right Front Upper Body Vent Tempera‐
ture Sensor - G386- and Left Front Up‐

rre c
per Body Vent Temperature Sensor -
G385- , Removing and Installing
cial p
me r

Note

a
m

tion
r co

Removal on the right side is shown. Removal on the left side is

int
o

h is
te

symmetrical.
a

do
riv
p

cum
r
fo

Removing

en
ng

t.
yi Co
op
– Remove the side instrument panel trim panel. Refer to ⇒ Body
C py
h t. rig
Interior; Rep. Gr. 70 ; Instrument Panel; Instrument Panel,
g h
yri t by
cop Vo
Removing and Installing . by lksw
cte d ag e n
Prote AG.
– Remove the fuse panel and move it to the side. Refer to ⇒
Electrical Equipment; Rep. Gr. 97 ; Fuse Panel; Connection/
Conjunction Box - SX3- with Fuse Panel D - SD- , Removing
and Installing .
– Disconnect the connector from the temperature sensor -2-.
– Turn the temperature sensor approximately 90° in direction of
-arrow- out of air guide channel -1-.
Installing
– Install the temperature sensor in the reverse order.

10. Additional Components for Control and Regulation 129

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

11 Special Tools
Special tools and workshop equipment required
♦ Counterhold - Multiple Use - T10172A- with Counterhold - Kit
- Multiple Use - Adapter - T10172/1-

AG. Volkswag e nAG d

ag e n oe s
olksw not
V gu
d by ara
ir se nte
th o e or
au ac
ss

ce
le
un

pt
an
d
itte

y li
rm

ab
♦ Refrigerant Sockets - T10364-
e

ility
ot p

wit
is n

h re
ole ,

spe c
u rpose s, inpart or inwh

t toth e co tne ss of inform

rre c
cial p
me r

a
m

tion
♦ Socket - 24mm - T40284-
co

int
or

h is
te
iva

do
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
h t. g
rig
h
yri t by
by cop Vo
lksw
cte d ag e n
Prote AG.

♦ Torque Wrench 1331 5-50Nm - VAG1331-

130 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

♦ Torque Wrench 1331 Insert - Open Jaw - 17mm - VAG1331/6-

♦ Torque Wrench 1332 40-200Nm - VAG1332-

nAG. Volkswag e nAG d o

wag e es n
Volks ot g
by ua
d ran
ise
♦ Test Box Kit - Basic Test Boxth o- VAG1598/14-
r te e
or
au ac
ss

ce
e
nl

pt
du

an
itte

y li
e rm

ab
ility
ot p

wit
is n

h re
ole ,

spe c
u rpose s, inpart or inwh

t toth e co tne ss of inform

rre c

♦ Test Box Kit - Adapter 11 - VAG1598/11-

cial p
me r

a
m

tion
co

int
r
te o

h is
a

do
riv
p

cum
or
f

en
ng

i t.
py Co
t. Co py
rig
h g h
yri t by
op Vo
e d by c lksw
ag e n
ct
Prote AG.

11. Special Tools 131

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

♦ Torque Wrench 1783 - 2-10Nm - VAG1783-

♦ Hose Clip Pliers - VAG1921-

♦ Spring Clip Pliers - VAS6499-

nAG. Volkswag e nAG d o

wag e es n
Volks ot g
y ua
e db ran
ir s te e
th o
or
au ac
ss
ce
le
un

pt
an
d
itte

y li
rm

ab
e

ility
ot p

♦ Engine Bung Set - VAS6122-

wit
is n

h re
ole ,

spe c
u rpose s, inpart or inwh

t toth e co tne ss of inform

rre c
cial p
me r

a
m

tion
co

int
or

h is
te
iva

d o
pr

cu
r
fo

m
en
ng

t.
yi Co
Cop py
ht. rig
g h
yri t by
cop by
Vo
lksw
cte d ag e n
Prote AG.

132 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

♦ Shop Crane - Drip Tray - VAS6208-

nAG. Volkswag e nAG d o

wag e es n
Volks ot g
d by ua
ran
ir se te e
th o
or
au ac
ss

ce
le
un

pt
an
d
itte

y li
e rm

ab
♦ Torque Wrench 1783 - 1/4" Drive Ratchet - VAS6234-

ility
ot p

wit
is n

h re
ole ,

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u rpose s, inpart or inwh

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♦ Hose Clamps - Up To 25mm - 3094-

11. Special Tools 133

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

♦ Multi-Tooth Adapter - 3400-

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134 Rep. Gr.87 - Air Conditioning

 Touareg 2010 ➤ , Touareg 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 06.2017

12 Revision History
DRUCK NUMBER: K0058966021
Fac‐ Edit Job Feed Notes Quality
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tion

06.2 08/08 Fac‐ N/A Eric P.

017 /2017 tory
Up‐
date
03.2 05/24 Fac‐ N/A Eric P.
017 /2017 tory
Up‐
date
12.2 02/13 Fac‐ N/A Performed Factory up‐ Juan S.
016 /2017 tory date.
Up‐
date
06.2 06/28 Fac‐ N/A Eric P.
016 /2016 tory
Up‐
date
09.2 02/25 Lo‐ 1082 Changed link to R134a Tom P.
014 /2015 cal 053 Fluid Capacity so it
Feed doesn’t link to Mainte‐
back nance Intervals
09.2 10/20 Fac‐ N/A Jim H.
014 /2014 tory
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12. Revision History 135

 Cautions & Warnings

Please read these WARNINGS and CAUTIONS before proceeding with maintenance
and repair work. You must answer that you have read and you understand these
WARNINGS and CAUTIONS before you will be allowed to view this information.

•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
wholly or in part by any of the extensive warranties issued by Volkswagen.

•= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.

•= Volkswagen is constantly improving its vehicles and sometimes these changes, G. Vboth ing eparts
olkswa nAG d and specifications,
are made applicable to earlier models. Therefore, part numbers listed in g e nAmanual
wathis are oe s
for reference only. Always
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check with your authorized Volkswagen retailer parts department
ed
b the latest information. ara
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ut or
•= Any time the battery has been disconnected on an vehicle, it will be necessary to a
automatic
ss transmission ac
reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).

ce
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un

pt
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•= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support
e rm

ab
ility
a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
ot p

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vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.

h re
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•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
u rpose s, inpart or inwh

battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and

t toth e co tne ss of inform

become inoperable, even if the correct code is used in a later attempt.

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•= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
starting the vehicle while you are under it.
cial p

•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
me r

others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from

a
m

tion
being fully alert.
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•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
a

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•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear en
ng

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goggles, gloves and other protective clothing whenever the job requires working with harmful substances. . Cop py
rig
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•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near cop Vo
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machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe Prote AG.
injury could result.

•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
new parts where indicated, and any other time it is deemed necessary by inspection.

Page 1 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
 Cautions & Warnings
AG. Volkswag e nAG d
w e s n inside or under the vehicle. ag e n o
•= olks
Illuminate the work area adequately but safely. Use aVportable safety light for working ot g
by ua
Make sure the bulb is enclosed by a wire cage. The se d hot filament of an accidentally broken ranbulb can ignite spilled
ri te e
fuel or oil. tho or
u a ac
ss

ce
•=

le
Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by

un

pt
an
d
grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.

itte

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Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.

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ility
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•= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be

h re
crushed by heavy parts.
h ole

spe
e s, inpart or inw

ct toth e
•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only

corre ctne ss of in
replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
repairs.
l pu rpos

•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
e rcia

form
once, but do not store the oily rags, which can ignite and burn spontaneously.
m

a
om

tio
•= Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten

nin
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fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque

th i
te
iva

s
listed.

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•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
ng

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ignited, it will ignite gas trapped in the cells and cause the battery to explode. h t. Co py
rig
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•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of cte d
by lksw
ag e n
the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that Prote AG.

govern the disposal of wastes.

•= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be
serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
trained in related safety precautions, and familiar with regulations governing the discharging and disposal of
automotive chemical refrigerants.

•= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
negative terminal (ground strap) and the ABS control module connector.

•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase
system pressure and may cause the system to burst.

•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
components is not separately fused, disconnect the control module connector(s).

•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
should test, disassemble or service the airbag system.

Page 2 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
 Cautions & Warnings
n AG. Volkswag e nA
G d o than one minute, and do not exceed 16.5 volts at the
•= wag e starting) for longer
Do not quick-charge the battery (forlksboost es n
Vo ot g
battery with the boosting cables
db
yattached. Wait at least one minute u before
ar boosting the battery a second time.
e an
ris te e
u th o o
•= Never use a test light electrical tests of the airbag system. Ther asystem
tos conduct
ca must only be tested by trained
s
Volkswagen Service technicians using the VAG 1551 Scan Tool (ST) or an approved equivalent. The airbag unit

ce
le
un

pt
must never be electrically tested while it is not installed in the vehicle.

an
d
itte

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•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been
e

ility
ot p

inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair

wit
is n

h re
area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the
ole ,

spe c
tire from the rim before attempting any repair.
u rpose s, inpart or inwh

t toth e co tne ss of infor

•= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.

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I have read and I understand these Cautions and Warnings.
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Prote AG.

Page 3 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0