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BoraR32
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Right guys after finally getting round to completing this swap last week I though I would complete a write up to help anyone planning a future install. I have not put full details of how to complete each section bit by bit, I have assumed you can follow a Haynes manual, have some knowledge of car wiring and have the ability to wire in connectors (if you have completed a cruise control kit or something similar you should be fine). If you cannot do any of the above then don't bother attempting the install as you will be left with a car you won't be able to drive.<o:p></o:p>

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First things first you need to source all the parts:<o:p></o:p>

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Climatronic Airbox with all motors, sunlight sensor and loom attached<o:p></o:p>

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Climatronic Control Panel<o:p></o:p>

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Kufatec Loom (or make your own loom using the donor vehicle wiring)<o:p></o:p>

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It is worth noting the Kufatec loom is designed to fit with the 17 & 12 pin airbox loom (the connector circled in red connects to the existing wiring on your car). There is another version of the climatronic airbox which has a 10 & 12 pin loom, another member on here Josh4949 made this install you can view his thread for wiring help:<o:p></o:p>

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http://uk-mkivs.net/forums/t/246654.aspx?PageIndex=1<o:p></o:p>

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Also get yourself a Haynes manual if you don't have one already this will help with removing the dash and old airbox.<o:p></o:p>

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Before you start any work the first thing needed is to get the air conditioning refrigerant removed from your existing system. Either ring a mobile air con specialist or go to visit one who will remove your old gas and then recharge your system after you have done the install.<o:p></o:p>

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DO NOT vent the gas to atmosphere yourself by undoing the T40 torx bolt on the air conditioning compressor (that's the one below the alternator). This is illegal and is punishable by a custodial sentence, not to mention the gas is released at -68oC and will freeze your fingers should you leave them there too long and they will drop off! Right that is the legalities out of the way onto the main bit.<o:p></o:p>

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The install:<o:p></o:p>

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You need to get from this:<o:p></o:p>

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To this:<o:p></o:p>

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If you have a Haynes manual just follow the procedures for removing the central facia panel. I am not going to type this all out as it is all in the manual.<o:p></o:p>

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The old airbox needs removing:<o:p></o:p>

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Again follow the Haynes manual for removing the heater matrix this will state for none air conditioned cars only, but the process is identical for both (they just say that as they don't want you messing with the air con as it is dangerous). This will involve draining all the coolant out of your car, remember if you connect the battery back up don't start your engine.<o:p></o:p>

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Right next comes the wiring, the kufatec loom is fairly straightforward to follow I have labelled up the 10 wires that need connecting:<o:p></o:p>

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http://i591.photobucket.com/albums/ss355/sneydy/Image220.jpg<o:p></o:p>

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The wires connect as follows:<o:p></o:p>

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<o:p>As mentioned the connector circled in red connects to the existing loom on the car.</o:p>



Label No<o:p></o:p>



Labelled<o:p></o:p>



Source Connector<o:p></o:p>



Destination<o:p></o:p>



1<o:p></o:p>



17 Pin Connector<o:p></o:p>



2<o:p></o:p>



12 Pin Connector<o:p></o:p>



3<o:p></o:p>



'Diagnose pin 7 grau'<o:p></o:p>



pin 1 from 12 pin connector<o:p></o:p>



Pin 7 of the OBDII socket<o:p></o:p>



4<o:p></o:p>



'grun 3 grun' and 'braun pin 2'<o:p></o:p>



pin 8 of 12 pin connector & pin 8 of 17 pin connector<o:p></o:p>



Connect directly into the sunlight sensor<o:p></o:p>



5<o:p></o:p>



'pin 9 gelb'<o:p></o:p>



pin 4 of 17 pin connector<o:p></o:p>



T10/9 - pin 9 of the orange connector in the plenum<o:p></o:p>



6<o:p></o:p>



'wiwa pin 1 weiss'<o:p></o:p>



pin 10 of 12 pin connector<o:p></o:p>



T32/3 (pin 3 of blue connector on instrument cluster)<o:p></o:p>



7<o:p></o:p>



'pin 7 violett'<o:p></o:p>



pin 12 of 17 pin connector<o:p></o:p>



T10/7 - pin 7 of the orange connector in the plenum<o:p></o:p>



8<o:p></o:p>



No label (brown wire)<o:p></o:p>



pin 6 of 17 pin connector<o:p></o:p>



Earth<o:p></o:p>



9<o:p></o:p>



'pin 26 blau/rot'<o:p></o:p>



pin 12 of 12 pin connector<o:p></o:p>



T32a/26 (pin 26 of green connector on instrument cluster)<o:p></o:p>



10<o:p></o:p>



No label (red/white wire)<o:p></o:p>



pin 7 of 17 pin connector<o:p></o:p>



Fuse 16 (10A)<o:p></o:p>



11<o:p></o:p>



'pin 1 temp' and 'pin 2 temp'<o:p></o:p>



pin 5 of 12 pin connector & pin 8 of 17 pin connector<o:p></o:p>



Replace wiring to outside temp sensor (Kufatec loom comes with new connector) the signal is then sent to the dash by the connection you make in number 9<o:p></o:p>



12<o:p></o:p>



'lufter pin 12 swws' and 'lufter pin 8 gelb'<o:p></o:p>



pin 2 of 12 pin connector and pin 9 of 12 pin connector<o:p></o:p>



T14/8 (pin 8 of rad fan control unit below battery) & T14/12 (pin 12 of rad fan control unit below battery)<o:p></o:p>


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If any of you are making your own loom the full connector wires and pin numbers are below (thanks to Bazmcc for this):<o:p></o:p>

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T17a
1 - Fuse 25 in fuse box (S225) 25A
2 -
3 - T10/8 (orange connector in plenum)
4 - T10/9 (orange connector in plenum)
5 - Fuse 5 (7.5A)
6 - Earth connection
7 - Fuse 16 (10A) and T14/4 (Rad fan control unit below battery)
8 - Pin 2 of outside temp sensor (earth)
9 -
10 - Illumination wire (any grey/blue wire)
11 -
12 - T10/7 (orange connector in plenum)
13 -
14 -
15 -
16 -
17 - <o:p></o:p>

T12a
1 - K wire (pin 7 of OBDII port)
2 - T14/8 (rad fan control unit below battery)
3 -
4 -
5 - Pin 1 of outside temp sensor
6 -
7 -
8 - Pin 3 of sunlight sensor
9 - T14/12 (rad fan control unit below battery)
10 - T32/3 (blue connector on cluster)
11 -
12 - T32a/26 (Green connector on cluster)<o:p></o:p>

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<o:p>Supplied in the Kufatec loom will be a small wire shown below, this is for bridging pins 5 & 14 of the radiator fan control switch (mounted under the battery box).</o:p>

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<o:p>http://i591.photobucket.com/albums/ss355/sneydy/Image221.jpg</o:p>

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Just take your time and work through each wire step by step, zip tying them to the existing loom as you go.<o:p></o:p>

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Once all the wiring is in its time to fit the climatronic airbox, it mounts in exactly the same position as the old one, then connect the Kufatec loom. At this point you can connect the battery back up and turn the ignition on (remember not to start the engine) to check all is working with the system. If like me you find a horrible clicking sound coming from where the glovebox is, it will be the recirculation motor that needs replacing. Full details in the link below (current retail price is £98 from VW):<o:p></o:p>

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http://uk-mkivs.net/forums/p/52177/1404186.aspx#1404186<o:p></o:p>

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If it all works then scream/shout/have a lager, then its time to start putting your car back together, again follow the Haynes manual in reverse.<o:p></o:p>

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Once back together the final step is to get the aircon regassed and then enjoy the benefits of Climatronic!<o:p></o:p>

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Big thanks to Bazmcc for wiring help and Josh494949 for install help.<o:p></o:p>
 

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Congradulations ..... you'll find one is easy compared too having two and two is simply compared to three . If you want to come out to Ohio, I'll lend you the garage for as long as you need it. Good luck.
 

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Hi,

I'm going to have a go at this swap as I have climatronic in my other car and love it.

Just a couple or three questions though, I just got my loom from Kufatec(too lazy to make my own) and need to know what this wire is for :

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Also, is there a typo in the chart that explains the connections in the Kufatec loom : at no12 in the chart it looks like T12a/9 goes to T14/8 and T12a/2 goes to T14/12, but in the list that explains the pins in T17a and T12a it says T12a/9 goes to T14/12 and T12a/2 goes to T14/8?.

Am I right or wrong?.

Lastly, is there any wires in the original car wiring that will need to be cut eg AC pressure switch, or does the Kufatec loom take care of all that?.

Cheers for any help.
 

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BoraR32
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Discussion Starter · #7 ·
Hi Dubster

Yeah your right, I have now ammended the list it was a typo. You shouldn't need to cut anything, you need to tap off a few wires and completely replace the outside temp sensor wiring.
 

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Yeah I've got my head round splicing in the wires into the likes of the fuses etc, but I'm unsure of what that little wire is for. I don't see that it is for the outside temp sensor ie to bridge the existing wires, since that would mean sticking the connectors from that wire into a female plug end. Surely Kufatec would have supplied the male plug for the temp sensor to stick each end of that wire into to make a nice and neat, waterproof, bridge.

Any ideas?.

Paul.
 

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BoraR32
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Discussion Starter · #10 ·
I never connected the little wire as I never found out what it is for [:$], my guess would be bridging either wires on the air con switch or the radiator fan switch. Everything seems to work without it, but if you find out what it is for let me know and i will connect it up.
 

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I got nearly all those. I didn't get the big red ring terminals, for the earths I presume, they were already attached to the loom. I got everything else though.

From what I have researched already I'm pretty sure that little purple wire is for bridging a couple of the contacts in the radiator fan control unit. From the wiring diagrams I've got it looks like cars from October 1999 on with manual aircon had a temp sensor to shut off the aircon compressor connected between terminals T14/14 and T14/5 on the radiator fan control, but on climatronic cars those two terminals are directly connected together.

I just wanted to ask you first if you knew.

Nice to know it makes no odds if its fitted or not.

When you did yours did you just splice and solder the wires in, or did you cut terminals off and recrimp two wires on with the terminals Kufatec supplied. I can't make up my mind which way would be easier?.
 

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Might be worth emailing Kufatec to find out for sure what that wire is for I suppose.

I wish they had done the easy thing and given us some instructions with the kit. We paid enough for some wires and connectors.
 

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BoraR32
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Discussion Starter · #13 ·
From the stuff I researched different models had different wiring setup's, i.e 1.8T is different to TDi etc. So I just assumed was for a different model.

Yeah I would agree connecting T14/14 and T14/5 on the radiator fan control unit. I will do that when I am fitting my coilovers next weekend.

Splice and soldered, I don't have the correct tool for the terminals so they never connect properly if I use them.
 

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BoraR32
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1,660 Posts
Discussion Starter · #14 ·
Yeah I have had a few looms off Kufatec (rain sensing wipers, TV tuner, Auto Levelling headlights) and they usually provide a link to wiring instructions. But nothing for the climatronic loom.
 

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Yeah, I got the whole climatronic airbox and headunit out of a 2002 TDi. Took what seemed like ages to get it out. Now I think about it, it was a piece of cake. It just took ages because I didn't know what I was doing eg where all the bolts/fixings were and what I had to remove first to get the thing out in one piece.

Putting it into my car will be much faster, when I can find the time to do, will probably be awhile yet.

I'm just at the stage of doing all the prep work for it, you know getting it sorted in my head so I know exactly what I'm doing, gathering as much info,wiring diagrams, photos as I can before starting.

You probably know the scary feeling that you don't want to fook your whole car for the sake of some fancy buttons. LOL.
 

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Cant believe i missed this thread

thanx for the gratitude means a lot to just the small words thank you said :)

im so glad it all worked out for you

wish i could have come up and let more of a hand :)

WELL DONE SIMON

i fully recommend this to ay one who is after a good project but only do this if you feel confident as it an result in a none runner

and as far as "If it all works then scream/shout/have a lager"

i went crazy when it all worked was running and jumping around in the snow in my street in a pair of shorts... neighbors think im crazy enough

just if any one is going to do this... dont do it in winter like me when its snowing, its freezing in the car lol
 

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BoraR32
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1,660 Posts
Discussion Starter · #18 ·
Yeah I know what you mean Paul, I think I spent 3 months researching before I did the install. Like you said it is pretty easy really just time consuming and the wiring is not that bad once you have your head round it.

No probs Josh it was reading your thread that gave me the kick to do this, it is the best feeling when you fire it up and it all works, and it works so much better than the manual heating.
 
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