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Whether it's a manual or automatic HVAC sys-tem, motorists just want it to work. Every time they get into their vehicles, either from the beach,or the air-conditioned shopping mall, the few minutes it takes to cool the cabin air feel like an eternity. Naturally, they are very appreciative of the service work you perform that keeps them comfortable. So, how can we keep their HVAC system functioning in a cost-effective and prof-itable manner?Knowing how Volkswagen systems work, and familiarizing yourself with the various functions and options involved, can help save a tremen-dous amount of time while you are trying to fig-ure out an issue a customer has brought you. Volkswagen manual AC systems get their durabil-ity from their simplicity. Their similarities from year to year and model to model can make work-ing on them a walk in the park in most instances,providing you are in the know. Electronically temperature-controlled HVAC systems are, of course, more complicated, but they have exten-sive self-diagnostic features to assist you. Here,we'll look at how the basic manual AC system works, and what to look for when there are prob-lems. We'll also investigate the more sophisticat-ed electronically-controlled systems, and what functions are useful for diagnosis.Keeping Y our CoolSince early 2000, Volkswagen vehicles have pre-dominantly been sold with manual AC. Despite what you may think, modern manual AC systems don't just rely on lever controls, vacuum switch-es, and cables. There's plenty of wiring, too.Mobile Comfort Zones.Manual AC systems are called that these days because there is no computer-controlled feed-back to adjust cabin temperature. The passengers simply set a temperature and the system puts out what it can to achieve it. Some electrical inputs are used to protect compressor operation. There is an ambient temperature sensor, a refrigerant pressure sensor, and coolant temperature sensor to make sure conditions are right to turn it on.Starting in the early 2000 model year, a cooling fan control unit monitors all these sensor inputs and manages the compressor clutch circuit as well as the cooling fans.With a manual system, all of these inputs need to be working properly to activate the compressor. If any input were to fail, the compressor clutch cir-cuit would open. Without a control unit with self-diagnostic capability, this means each input has to be checked using pin voltages. Whether you want to check the voltage signals at the cooling fan control unit, or each individual sensor, is up to you. The control unit is usually mounted on the driver’s side front frame rail. On a New Beetle,that would be under the battery tray, not all that easy to get to. Some cooling fan control units have strip-type fuses secured to the top, some do not, depending on the application.Testing InputConsider a 2002 J etta VR6 with manual AC. Itscoolant fan control unit has two connectors, oneA happy customer is a comfortable one. Y ouperform essential services to keep them rolling, but one indulgence they really enjoy is climate control.Here's how to keep them as comfortable in their vehicles as they are in their homes.four-pin, and a larger 14-pin. On the four-pin connector, you have the relay’s power supplies, a 6.0 millimeter solid Red in pin #1, and a 2.5mil-limeter R/Wtracer in pin #3. They should have battery voltage at all times. In pin #2 (a 2.5 mil-limeter R/W tracer) is the power supply out of the relay for low-speed fan operation. The final 6.0millimeter R/W tracer is the power supply output for the high-speed fan.The 14-pin connector is where the internal relays get activated, not only for the cooling fan, but also for the AC compressor clutch. Pin #6 is a Brown ground wire, and constant battery voltage comes in on pin #4, a R/Gr tracer. Power from the ignition switch comes in on in pin #9, usually a Bk/Bl tracer.In order for the compressor to turn on, inputs are needed. The first check is on pin #8, a Bl/R tracer. When the AC button is pressed and the blower is commanded on, you should see bat-tery voltage. Next, look at pin #2, a W wire. This is an unusual signal in that it is a five-volt square wave created by the refrigerant pressure sensor.The duty cycle of the signal will change with the refrigerant charge. This is to indicate if the charge is too low or too high to turn on/off and damage the compressor.Another signal that may inhibit compressor acti-vation is that of the ambient temperature switch. Test for voltage between pins #5 (Bl/R)and #14 (Gn/Bl). If the signal indicates the air temperature is too low, it will not allow the com-pressor to run. Check these inputs to the cooling fan control unit whenever the compressor clutch won't engage.A Brief Description of Climate ControlThe phrase "Automatic Climate Control" means that after setting the temperature in the cabin,an electronic unit monitors both outside and cabin temperature conditions and uses a pro-grammed plan for how best to achieve and maintain the chosen setting. These settings vary from full defrost heat to MAX AC. Once a tem-perature is set, the control unit will automatical-ly manipulate mode doors, temperature blend doors, and the recirculation door. There are manual overrides the passengers can select to control the mode doors' position, cabin air recirculation, and AC compressor operation.Since the electronics are overseeing system operation, Volkswagen has implemented the same self-diagnostic features found in other on-board control units.This is an ambient air temperature sensor found on an automatic climate control system, and is not to be confused with the ambient air temperature switch found on manual system. This sensor will only flag a code and affect temperature control. It will not suspend compressor operation.You may not realize what your current scan tool is capable of. You may not even realize how much useful information you have at your fin-gertips. You should hone your skills, reduce yourdiagnostic time and maybe get ahead of the “cost-effective diagnosis” game.Volkswagen/Audi Automatic Climate Controlled Systems are endowed with similar self-diagnostic features to powertrain control systems. While the scan-based diagnostic features in the Auto-HVAC systems are extensive, the interface is propri-etary, so without knowing what you are looking for it will be difficult to interpret the data being displayed. So how does this work?For those of you familiar with VAG scan-based diagnostics, this will be a review. For those not familiar with it, welcome to the future. VAG is the factory proprietary scan tool for Volkswagen and Audi vehicles. If you purchase the European bun-dle for your aftermarket scan tool, you should be able to display this “factory” software, which allows you to communicate with all of the various control units in the vehicle. Each control unit is programmed to use the same software architec-ture, so what we're about to describe will work onABS, as well as SRS.As you can see, there are many “address words”for all of the possible self-diagnostic systems on the vehicle. Select address word 08 – HVAC and you can talk to an automatic climate control sys-tem (not a manual system).The famous three dials of the Volkswagen HVAC system tell us when the AC button is pushed and the blow-er motor is turned on. The switch provides voltage to pin #8 on the cooling fan control unit indicating that AC has been requested.• Function 4 provides ‘basic settings.”• Function 5 clears codes.• Function 6 ends communication with the control unit.• Function 7 allows you to code the control unit to the particular car it is in.• Function 8 is for reading data.There are a few other functions to choose from,but we are going to focus on the most important ones.Starting with function 01, you will see that this merely identifies the control unit in the vehicle as well as its version coding. This information is useful if you feel the coding may have been changed in error, or a used control unit was installed and may not match the requirements of communicating with all of the other various con-trol units in the vehicle. Each control unit is pro-grammed to use the same software architecture,so what we're about to describe will work on ABSas well as SRS. You can enter the self-diagnosticOn the side of the cooling fan control unit, the pins are identified with their functions. You may be able to use them for testing once you learn what they are. Note that both strip and ATC fuses can be blown and prevent AC and cooling fan operation.You can enter the self-diagnostic feature with your scan tool by simply picking the address word you need. So, what’s an address word? With the factory scan tool, a series of numbers is used to identify the various systems we can enter. These numbers are called “address words” in your tech-nical literature.FunctionsEach system has its own address word. On the Volkswagen/Audi factory tester, you need to know what address word represents each system.Aftermarket diagnostic tools give the address word as well as a description of the system. In the case of automatic climate control, the address word is 08 (Auto – HVAC). Once you’ve selected the system, you will now be asked to select what function you would like to perform. You have numerous choices:• Function 01 identifies the control unit.• Function 2 is for pulling codes.• Function 3 is for actuation mode.feature with your scan tool by simply picking the address word.Providing the control unit is the proper one, you can correct coding if necessary. Function 02 is pretty self-explanatory. Auto-HVAC units are capable of self-diagnosis, and can identify faults in one or more components. These com-ponents are either sensor inputs, or actuator outputs. In the case of actuator outputs, you don't always have to access the component and start our testing there. The other option is scan tool activation.Function 03 is the mode in which you can take advantage of the scan tool and request that the HVAC control unit activate various outputs. You can listen for the activation, and/or perform elec-trical testing on the component being activated. This allows you to verify that the control unit’sdriver is capable of turning on any component in which you may suspect a fault.Moving along to function 04, this is referred to as “Basic Settings.” In general, this provides a “reset” or ‘re-sync” of computer-controlled fea-tures. The automatic climate control system needs to know the positions of the various tem-perature and mode doors in order to manipulate them if a change is requested by the occupant, or sensed by a temperature sensor. "Basic Settings" runs the control unit through the re-learn process, but more on this later.Function 05 simply clears codes, and once you are done communicating with the HVAC control unit, you need to shut down this communication by selecting Function 06. This prevents corrup-tion of software in the unit. Function 07 allows you to change the version coding, which is a way for you to tailor the control unit to the vehicle it is in. Vehicles come with more than one option. Each control unit must be made aware of these options in order to perform properly. This comes in especially handy when installing used parts. Although the replacement control unit may have the same part number, the coding must be changed to accommodate the requirements of the vehicle being repaired.Finally, Function 08 (sometimes referred to as data blocks, or measuring blocks) allows you to look at data, such as a temperature sensor read-ing, or actuator position. The tricky part is that these data blocks are also identified with num-bers and are displayed in blocks of four. You must look up in a table what the data blocks indicate for each display group.ResetOnce you have pulled codes, diagnosed a prob-lem, and done a repair, you may need to reset the climate control system, especially if a mode door motor was replaced. This can be achieved through the “Basic Settings” feature. You will be prompted to enter a three-digit code. Leave the code "000" in the display and enter this mode. The positions of the doors are recorded, and they will then cycle to their respective end stops. Now, the control unit knows what the maximum and minimum positions are for each mode/blend door. When it needs to make a temperature adjustment as a result of changing conditions, it can make the cor-rect change. Without knowing the proper position of the doors, it will make the wrong adjustment and output the wrong temperature.Knowing the system helps cut down on wasted diagnostic time, and can make you money on all but the most difficult problems. You will end up with fewer comebacks, less stress, and a cool,happy customerHere are your options once you have selected an address word. In 08, you can select “Basic Settings,” enter “000,” and the system will run through the initialization process. This should be performed after every mode door and tempera-ture blend door replacement.。
道奇锋哲维修技术资料小手册2008年2月道奇锋哲维修技术资料小手册目录1. 车辆识别号码 (3)2. 发动机舱国际符号说明 (4)3. 工作液类型与容量 (5)4. 公英制转换 (7)5. 保险丝位置和类型 (8)6. 车轮定位参数 (11)7. 世界发动机 (13)8. 发动机与自动变速器故障码 (21)9. ABS系统故障码 (31)10. 组合仪表 (34)11. 信息中心 (36)12. 空调系统故障码 (40)13. 雨刮与洗涤器故障码 (42)14. 气囊系统故障码 (43)15. 音响系统故障码 (48)16. 车辆防盗系统故障码 (52)道奇锋哲维修技术资料小手册1. 车辆识别号码车辆识别号码（VIN）牌挂在仪表板的左上侧上。
VIN包含提供关于车辆的数据的17个字符。
参见解码图以确定对车辆的识别。
道奇锋哲维修技术资料小手册为保护消费者免遭盗窃，也避免受欺骗，制造商必须将车辆识别号码的第9位数设为―检查数字‖。
制造商和政府机构可利用此检查数字检验车辆及政府文件是否为真。
检查数字的译码公式不对一般大众公布。
2. 发动机舱国际符号说明DaimlerChrysler 公司使用国际符号来标识发动机舱润滑剂和液体检查及加注位置。
道奇锋哲维修技术资料小手册3. 工作液类型与容量发动机道奇锋哲维修技术资料小手册底盘容量道奇锋哲维修技术资料小手册4. 公英制转换公制系统以一、十、百、千和百万为基数。
下表可协助您将公制单位换算为相等的英制和SAE单位，亦可由英制换算为公制。
转换公式和对应值道奇锋哲维修技术资料小手册5. 保险丝位置和类型完全集成电源模块位于发动机舱中的空气滤清器总成附近。
该中心含有封闭式保险丝和最小的保险丝。
道奇锋哲维修技术资料小手册道奇锋哲维修技术资料小手册注意:当更换熔断的保险丝时，重要的是仅使用具有正确额定电流的保险丝。
若使用不符合原厂规定安培数的保险丝，可能导致危险的电气系统过载。
0442017.10拆下转向柱上、下护罩，拆下并存放好组合仪表面板（图19），拆下并存放好组合仪表总成（图20）。
从WIN模块上断开WIN模块电气接插件和天线接插件，使用饰件撬棒，从仪表板轻轻撬起WIN模块装饰环（图21），拆下WIN模块下固定螺栓，旋转WIN模块和支架，从仪表板拆下。
拆除并丢弃原装无线点火节点模块和定位环（图22）。
在召回L25中可能已经安装了WIN模块定位环。
该定位环不能够转移或重新用在新的WIN模块上。
对于配备电子转向柱锁(ESCL)的车辆，执行下列步骤。
断开原装ESCL处的电气接插件，拆除并丢弃原装ESCL，将图18 膝部气囊面板和膝部气囊钢制支撑板图19 组合仪表面板图21 无线点火节点模块装饰环图20 组合仪表总成膝部气囊钢制支撑板组合仪表面板组合仪表总成无线点火节点模块装饰环膝部气囊面板0452017.10重新编程WIN模块（所有车型）。
车辆连接蓄电池充电器，连接故障诊断仪，开启wiTECH 会话，在“Vehicle View（查看车辆）”屏幕上选择“WCM（无线控制模块）”——“Miscellaneous Functions（其他功能）”—“WIN Replaced（要更换的WIN模块）”。
按照wiTECH屏幕上的提示操作，完成WIN模块编程。
出现提示时输入PIN码，程序结束后转动点火开关，返回至“Miscellaneous Functions（其他功能）”选项卡屏幕，选择“PCM Replaced（要更换的动力控制模块）”。
wiTECH诊断仪将显示以下信息，“重要提示！！！仅在更换动力控制模块后使用此功能。
警告！！！在任何其他情况下运行‘PCM Replaced（更换的动力控制模块）’都可能丢失动力控制模块中的有效密匙，此时需要修配并编程新钥匙！！！”。
点击“Continue（继续）”按钮。
按照wiTECH屏幕上的提示进行操作，完成动力控制模块更换程序。
对于配备电子转向柱锁(ESCL)的车辆，将新的ESCL重新编程入新的WIN模块。
第四章燃油系统第一节燃油供给系统一、燃油供给系统前轮驱动厢式车使用塑料燃油油箱，位于车的左侧。
燃油供给系统包括：电动油泵组件、燃油滤清器、油管、燃油箱和燃油喷射器。
燃油泵组件包括燃油泵和压力调节器。
燃油滤清器是可更换的轴向式过滤器，与安装在燃油箱上面的支架相连接。
关于滤清器的更换，请参看第二章润滑与保养中的内容。
所有的车辆采用回流燃油系统。
燃油通过燃油泵组件回流到燃油箱。
分离式燃油回流线路(油箱到发动机)不再使用。
二、燃油泵组件燃油泵组件安装在燃油箱的顶部(图4-1)。
此油泵组件包括：电动燃油泵；燃油泵储油腔；进口滤网；燃油压力调节器；燃油计输出元件；连接管路。
只有进口滤网，燃油压力调节器和燃油油量传感器是可维修件。
如果燃油泵需要维修，则更换整个燃油泵组件。
1．电动燃油泵电动燃油泵是一种滚子叶片，防水，永久磁铁式电动机。
燃油泵组件挂在油箱的燃油里。
油泵通过滤网吸入燃油，然后将燃油通过电动机推到出口。
油泵有两个检查阀：一个阀释放燃油泵内部压力并调节油泵最大输出；第二个阀在油泵的出口处，保持在发动机停车状况下的油泵压力。
燃油泵继电器给燃油泵提供电压。
燃油泵为最大压力输出，大约为655kPa。
调节器可调节压力到大约为338kPa。
2．燃油泵电气控制油泵的电压是由燃油泵继电器提供的。
有关燃油泵电动控制说明，请参看燃油泵继电器输出。
3．电气燃油泵更换电动燃油泵是不可维修件。
如果燃油泵需要更换，那么整个燃油组件必须更换。
在维修燃油泵之前，先释放燃油压力。
4．燃油油量传感器油量传感器装在燃油泵组件的侧面，由一个浮子、一个臂和一个可变电阻器组成。
当油位增高时，浮子和臂向上移动，这样减小了输送元件电阻，使得仪表盘上的油量指示增加直到满量。
5．燃油压力调节器燃油系统使用一个不可调整式压力调节器，将燃油系统压力保持在大约338kPa。
燃油压力调节器包括一个膜片，校准弹簧和一个燃油回位阀。
弹簧压下膜片关闭燃油回流口。
系统燃油压力反应要求打开回流口的燃油压力量。
第十一章暖风系统和空调第一节 前暖风系统和空调一、概述道奇捷龙汽车选用了一种区域控制暖风和空调(HVAC)装置。
这种装置配置双气道，彼此可单独调整，驾驶员侧和乘客侧温度设置可有所不同。
当汽车配了区域控制装置后，还可选用后部(辅助)暖风装置和空调系统。
本装置通过挡风玻璃底座上的通风口向内吸进空气，送到空调一暖风机组件外壳上面的高压气室里，再流经蒸发器。
气流可以被引导穿过或绕过暖风机，这是通过用控制头上的温度(TEMP)控制装置来调整混合气门来完成。
当空气通过气道后，可以从仪表板、底板和除霜输气口等处流出。
气流速度也可以用控制头上的鼓风机速度选择开关调整。
关上回流空气门就可以关上外界空气吸口，这样按下控制头上的回流按钮，就可以使车内已有的空气多次循环利用。
将控制杆移到混合或除霜位置且按下A/C按钮可以起动压缩机。
这可将冷凝剂注入蒸发器，并在空气通过暖风机前除去热量和水分。
警告：在较冷的天气里，使用回流方式会使车窗起雾。
在混合和除霜方式下，回流方式自动取消，以增加车窗的清晰度。
1．安全预防措施和警告(1)在修理制冷剂装置时，必须佩戴眼睛保护装置。
着眼睛里溅入了制冷剂，可能会严重损伤眼睛，必须立即加以医疗护理。
在空旷场所制冷剂应远离火焰。
制冷剂在燃烧后会产生有毒气体。
建议使用电子泄漏检测工具。
在封闭工作场所里排出的大量的制冷剂会造成窒息。
在常温和平均海拔高度下，制冷剂蒸发速度很快，这时任何与之接触的物品都会冻住。
因此，皮肤和一些娇嫩的东西不要直接接触制冷剂。
对R-134a制冷剂维修设备和汽车空调装置不能用压缩空气进行压力测试或泄漏测试。
空气/R-134a制冷剂的混合物在增压时可能会燃烧。
这些混合物十分危险，极易造成火灾或爆炸，引起事故和伤亡。
如果汽车停止运行或存放时间达两周以上，应该在空调(A/C)通风、高速鼓风机方式下怠速运行A/C装置5min，以保证有足量的油流回A/C压缩机里。
(2)防冻剂为乙二醇基冷却剂，吞食或吸入体内后有伤害作用。
车身外部、车门、车顶和车辆安全CDEFGHIJLM章节GWABNOP目录玻璃和车窗系统注意事项 .........................................................3注意事项 ...............................................................3辅助约束系统 (SRS)“安全气囊”和“安全带预张紧器”的注意事项 ..................................................3断开蓄电池后转动方向盘的注意事项 . (3)拆卸蓄电池端子的注意事项 .......................................4在无前围上盖板盖情况下操作的注意事项 .................5粘合剂和底漆的处理 .. (5)准备作业 (6)准备作业 (6)通用维修工具 (6)症状诊断 (7)吱吱声和喀喀声故障诊断 .....................................7工作流程 .. (7)检查步骤 ....................................................................9诊断工作表 .. (11)拆卸和安装 (13)挡风玻璃 ..............................................................13分解图 (13)拆卸和安装 (16)检查 .........................................................................27侧车窗玻璃 ..........................................................28分解图 (28)拆卸和安装 ..............................................................29检查 . (31)后背门车窗玻璃 ...................................................32分解图 .....................................................................32拆卸和安装 ..............................................................33检查 . (39)前车门玻璃 ..........................................................40分解图 ......................................................................40前车门玻璃 .. (41)前车门玻璃: 拆卸和安装 ..........................................41前车门下窗框 . (43)前车门下窗框: 拆卸和安装 ......................................43前车门玻璃导槽下窗框 .. (45)前车门玻璃导槽下窗框: 拆卸和安装 ........................45前车门玻璃导槽 .........................................................48前车门玻璃导槽: 拆卸和安装 ..................................48检查和调整 (48)前车门调整器 (49)分解图 (49)拆卸和安装 ...............................................................50分解和组装 ...............................................................51检查和调整 (52)后车门玻璃 (53)分解图 ......................................................................53后车门玻璃 .................................................................54后车门玻璃: 拆卸和安装 ..........................................54后车门下窗框 .............................................................55后车门下窗框: 拆卸和安装 ......................................55后车门弯角 .................................................................57后车门弯角: 拆卸和安装 ..........................................57后车门玻璃导槽 .........................................................58后车门玻璃导槽: 拆卸和安装 . (58)检查和调整 ...............................................................58后车门调整器 .. (59)分解图 (59)拆卸和安装 ...............................................................60分解和组装 (61)检查和调整 (61)CDEFGHIJ L MABNOP注意事项注意事项辅助约束系统 (SRS)“安全气囊”和“安全带预张紧器”的注意事项INFOID:0000000010619867辅助约束系统如“安全气囊”和“安全带预张紧器”与前排座椅安全带一起使用，有助于减少车辆碰撞时驾驶员和前排乘客受伤的危险性或严重程度。
