Volkswagen Golf 2004 User Manual

Service

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Workshop Manual

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Golf 2004

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Heating, air conditioning

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Edition 02.2008

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Service Department. Technical Information

Service

List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups

Repair Group

80 - Heating

87 - Air conditioning system

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Technical information should

always be available to the foremen and mechanics, because theirn

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careful and constant adherence to the instructions is essential to ensure vehicle road-worthinessh

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safety. In addition, the normal basicrsafety precautions for working on motor vehicles must,o

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matter of course, be observed.

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All rights reserved.

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No reproduction without prior agreement from publisher.oc

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Copyright © 2010 Volkswagen AG, Wolfsburg

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K0058991220

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																																																					Golf 2004
																										Heating, air conditioning - Edition 02.2008
																							Contents
80 - Heating					.		. . . .	. .	.	.	.	.		.	.	.	.	.	.	.	.	. .	. .	. .	. .	.	.		.		.		.	.		.		.	. .	. .	.			.		.			.			.	. . . . . . . . . . . . . .	1
1			Repairing heater								.	.		.	.	. .	.	.	.	. .	.	. .	. . .	.	. . .	.	.	.		.	.		.	.		.	.		. . . .	.	.	.		.			.		.			.	. . . . . . . . . . . . . . . . .	1
1.1			Passenger compartment heating																			.	. . .	. .	. .	.	.	.			.	.	.	.		.		.	. . . .	.	.		.		.		.				.		. . . . . . . . . . . . . . . . .	1
1.2			Removing fresh air blower V2																		.	. .	. . .	. .	. .	.	.	.			.	.	.	.		.		.	. . . .	.	.		.		.		.				.		. . . . . . . . . . . . . . . . .	3
1.3			Removing and installing fresh air blower series resistor with overheating fuse N24 . . . . . .																																																			3
1.4			Removing and installing dust and pollen filter																								.			.	.		. .			.	.	.	. . .	.	.	.		.			.			.		.	. . . . . . . . . . . . . . . .	4
1.5			Removing vents								.	.	.		. .	.	. .		.	. .	.	. .	. . .	. .	. .	.	.	.		.	.		.	.		.	.	.	. . .	.	.	.	.		.				.			.	. . . . . . . . . . . . . . . . .	4
1.6			Removing and installing controls for heated and fresh air . .																																					. .		.	.		.				.		.		. . . . . . . . . . . . . . . . .	7
																					V	o
1.7																						lksw																																8
			Connectors on controlswfor heated and freshdairo																												.	.	.		.		.	.	. . .	.	.	.	.		.				.			.	. . . . . . . . . . . . . . . .
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1.8												o																																										9
			Removing and installing flexible shaft for air distributionu																																				. . .	. .		.	.		.			.				.	. . . . . . . . . . . . . . . .
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			Removing and installing Bowden cable for temperature flap																																					. .		.	.		.			.				.	. . . . . . . . . . . . . . . . .
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1.10			Removings					th																															e															11
								and installing fresh air and air recirculation flap control motor V154 . . . . . . . .
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1.11								and installing heat exchanger																																c														12
			Removingn																						. .	.	.	.		.	.		.	.		.	.		. . . .	.t.			. .				.	.					. . . . . . . . . . . . . . . . .
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1.12								andinstallingauxiliaryairheaterelementZ35onvehiclesi																																									upto1K-7P015628and
			Removingt
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			1Kr m-7B084800						.	.	.	.	.		. .	.	. .		.	. .	.	. .	. . .	. .	. .	.	.	.		.	.		.	.		.	.	.	. . .	.	.	.	.		.		i.					.	. . . . . . . . . . . . . . . . .
			e																																										b
1.13 Removing and installing auxiliary air heater element Z35 on vehicles from 1K-7P015629 und																																																						16
		s1K-7B084801							.	. .		.	.		. .	. .	.		.	. .	.	. .	. . . .	.	. .	.	.	.		.	.		.	.		.	.	.	. . .	.	.	.	.		.			.			h. . . . . . . . . . . . . . . . . .
	i		Checking ventilation																																																	r		18
1.14 l															. .	. .	.		.	. .	.	. .	. . . .		. . .	.	.	.			.	.	.	.		.		.	. . . .	.	.		. .					.			.	s. . . . . . . . . . . . . . . . .
	,																																																			e
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	o		Removing and installing air intake screen																																																		p	18
1.15w																									.	. .	.			.	.		. .			.	.	.	. . .	. .		.	.		.			.			.		.t. . . . . . . . . . . . . . . .
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	n		Removing and installing heater unit																																																		c	19
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1.16r																							. . .	.	. .	.	.	.			.	.	.	.		.		.	. . . .	.	.		. .				.	.
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2			Dismantling and assembling heater unit																																																		h	23
	a																								. .	. .	.			.	.		. .			.	.	.	. . .	.	.	.	.		.			.				.	.c. . . . . . . . . . . . . . .
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2.1	p		Assembly overview – heater unit																																																		o	23
	,																					.	. . . .	.	. .	.	.	.		.	.		.	.		.	.		. . . .	.	.		. .				.	.					. .e. . . . . . . . . . . . . . .
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	i		Removing and installing air distribution housing																																																		r	24
2.2s																															.	.	.		.		.	.	. . .	.	.	.	.		.			.				.	.n. . . . . . . . . . . . . . .
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	o		Dismantling and assembling heater unit																																																			25
2.3 r																									. .	. .	.			.	.		. .			.	.	.	. . .	.	.	.	.		.			.				.	.s. . . . . . . . . . . . . . .
	p																																																				s
2.4	a		Removing and installing air distribution flap actuator																																																		o	26
																																				.	.	.	. . .	.	.	.	.		.			.				.	.i. . . . . . . . . . . . . . . .
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2.5	l																																																				r	26
	eRemoving and installing temperature flap actuator																																.		.		.	.	. . .	.	.	.	.		.			.				.
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87 - Air conditioning system															.	. .	.		.	.	.	.	. . . .		. .	.	.	.			.		.	.		.		.	. . .	.		.	.		.			.				i . . . . . . . . . . . . . .
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1			c																																																		refrigerant	28
			Notes on repair work to vehicles with air conditioning and on handlingi
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2			Air conditioningp							system with manual controls “Climatic”																																	c	o										29
																																							. . .	.	.	.			.			.				.	. . . . . . . . . . . . . . . .
			r
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2.1						r				and heating - passenger compartment																												. . . .n			m													29
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			Air conditioningn																																						.	.	.		.			.				.	. . . . . . . . . . . . . . . . .
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2.2							i																																	t														31
			Dismantling and assembling heater and air conditioner unito “Climatic”																																																		. . . . . . . . . . . . . . . .
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2.3								C
			Removing andgiinstalling heating and air conditioning controls, “Climatic” with air conditioning
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			system control unitoc									J301					.		.	. .	.	. .	. . . .	.	. .	.	.	.			. . .o			b. .				.	. . . .	.	.		. .				.	.					. . . . . . . . . . . . . . . . .	33
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2.4												b																s										“Climatic”																33
			Connectors on controlscforetorheating and airAnconditioninge																																													.				.	. . . . . . . . . . . . . . . .
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2.5																																																						35
			Removing and installing flexible shaft for air distribution																																				. . .	. .		.	.		.			.				.	. . . . . . . . . . . . . . . .
2.6			Checking condensation water drainage hose on heater and air conditioner unit . . . . . . . .																																																			36
2.7			Removing and installing air recirculation flap control motor V113																																										.			.				.	. . . . . . . . . . . . . . . . .	36
2.8			Removing and installing temperature flap control motor V68																																					.		.	.		.			.				.	. . . . . . . . . . . . . . . .	36
2.9			Removing and installing footwell vent temperature sender G192																																										.			.				.	. . . . . . . . . . . . . . . . .	38
2.10 Removing and installing centre vent temperature sender G191																																											.		.			.				.	. . . . . . . . . . . . . . . .	39
2.11			Ambient temperature sensor G17																				. . . .	.	. .	.	.	.		.	.		.	.		.	.	.	. . .	.	.	.	.		.			.				.	. . . . . . . . . . . . . . . . .	39
3			Air conditioning system with automatic regulation “Climatronic”																																								.		.			.				.	. . . . . . . . . . . . . . . .	41
3.1			Procedure for checking and adjusting components																														.			.	.	.	. . .	.	.	.	.		.			.				.	. . . . . . . . . . . . . . . .	42
3.2			Function of operating and display unit for Climatronic air conditioning system E87 . . . . . .																																																			43
3.3			Removing and installing operating and display unit for Climatronic air conditioning system																																																			44
			E87 with Climatronic control unit J255 .																						. .	. .	.		.		.	.	.		.		.	.	. . .	. .	.		.		.			.			.		. . . . . . . . . . . . . . . . .
3.4			Connectors on Climatronic control unit J255																								.	.			. .		.	.		.	.		. . . .	.	.	.	.		.			.				.	. . . . . . . . . . . . . . . . .	45
3.5			Climatronic - passenger compartment .																					.	. .	.	.	.		.	.		.	.		.	.		. . . .	.	.		. .				.	.					. . . . . . . . . . . . . . . . .	47
3.6			Dismantling and assembling heater and air conditioner unit “Climatronic” . . . . . . . . . . . .																																																			50
3.7			Assembly overview - evaporator housing																						. .	.	.	.			.	.	.	.		.		.	. . . .	.	.		. .					.			.		. . . . . . . . . . . . . . . . .	52
3.8			Removing and installing fresh air blower control unit J126 .																																					.	.	.	.		.			.				.	. . . . . . . . . . . . . . . .	53
3.9			Removing and installing left footwell vent temperature sender G261																																																		. . . . . . . . . . . . . . . .	54

Contents i

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													Heating, air conditioning - Edition 02.2008
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								3.10 s									th																								e						sender G262
																	Removing and installing right footwell vent temperaturec
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																																									r
													s		a																										a
																																										c
								3.11 Removing and installing evaporator temperature sensor G308 or evaporator output
													le																													t
													n
												u					temperature sender G263																									p
											e d																																a
																														. .	.	. . . .		.	.	.	.	.		.	. . .	. .	.	y. .			. .	. . . . . . .	. . . . . . . . . . . . . . . . . . .
									t	t																																	n
								i									Ambient temperature sensor G17																												l
							m																																						i
						r																																							a
								3.12																										.	. .		. .	.		.	. . .	. .	.	.		.	i. .	. . . . . . .	. . . . . . . . . . . . . . . . . . .
					e			3.13									Function of air quality sensor G238																													b
			t																																												t
																																		.	. .		. .		.	.	. . .	.	.	.		.	.w. .	. . . . . .	. . . . . . . . . . . . . . . . . . .
				p																																											l
																																															i
		o																																													y
is	n							3.14									Removing and installing air quality sensor G238																														i
																																															r
																																										.	.	. .					. . . . . . . . . . . . . . . . . .
																																															t
,																																															h
								3.15																																							e
o																	Removing left vent temperature sender G150 and right ventptemperature sender G151 . .
e																																																s
l
h								3.16																																								e
w																	Removing sunlight penetration photosensor G107 or sunlightt penetration photosensor 2
n																	G134																															c
r																						.		.	. . . . . .		. .	. . . . .	.	. .	.	. . . .		.	. .		. .	.		.	. . .	. .	.	.		.	. .	. . . . . . . .t	. . . . . . . . . . . . . . . . . .
i																																																t
o																																																o
								3.17									Checking condensation water drainage hose on air conditionerc unit
a																																																	. . . . . . . . . . . . . . . . . .
t																																																h
r								3.18									Renewing control motors for air conditioning regulation																														. . . .r
i																																																	. . . . . . . . . . . . . . . . .
p																																																o
n																																																r
,								3.19																																								e
e																	Removing and installing air recirculation flap control motor V113t . .																																. . . . . . . . . . . . . . . . . .
s																																																c
s								3.20																																								n	up to calendar week
p																	Removing and installing air flow flap control motor V71 for vehicless
o																																																e
r																	17/2007																															s
p																								.	. . . . .	.	. .	. . . .	. .	.	.	. . . .	.		. .	.	.	.	.		. . .	. .	.	.	.		. .	. .f. . . . . .	. . . . . . . . . . . . . . . . . .
u																																																o
								3.21									Removing and installing control motor for fresh air and air recirculation flap and air flow flap
c
l
a
i																	V425 for vehicles from calendar week 18/2007																															m
r																																										. .	.	.	.		. .		. . . . . . . . . . . . . . . . . .
e																																																a
o								3.22
																	Removing and installing setting unit for fresh air and air recirculation flap and air flow flap
m
m
		r																																													ni
c
																																															t
						a3.23 Removing and installing defroster flap control motor V107s i																																										. . . . . .	. . . . . . . . . . . . . . . . . .
			o																																												h
																	.	.		.	. . .	.		.	. . . . . .	.	.	. . . . .	.	. .	.	. . . .		.	. .		. .	.		.	. . .	. .	.	.	.		. .	. . . . . . . .	. . . . . . . . . . . . . . . . . .
				e
					t																																									d
								3.24p																																								V158
																	Removing and installing left temperature flap control motorc																																. . . . . . . . . . . . . . . . .
								r																																					o
							v
							i																																					u
											r																																m		motor V159
												f
								3.25n									Removing and installing right temperature flap controln																																. . . . . . . . . . . . . . . . . .
											o																															e
													g
													i																													t
								3.26 Removing and installing central flap control motor V70																																							. .	. . . . . . .	. . . . . . . . . . . . . . . . .
															p																										.
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								4									.								and installing ancillary bracket for air conditioner compressor
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								4.1													o
																	Engine codes: AZV, BDK, BJB, BKC, BKD, BLS, BMM, BMN, BRM, BRU, BVB, BXE, BXF
																	and BXJ								. . . .o.rP. .		. .	. . . .	. ..	G.A.		. . . .	.		. .		. .	.		.	. . .	. .	.	.	.		. .	. . . . . . . .	. . . . . . . . . . . . . . . . . .
								4.2									Engine codes: BCA, BUD												.	. .	.	. . .	.	.	. .		. .		.	.	. .	. .	.	.	.		. . .	. . . . . . .	. . . . . . . . . . . . . . . . . .
								4.3									Engine codes: BLG, BMY												.	. . .		. . .	.	.	. .		. .		.	.	. .	. .	.	.	.		. . .	. . . . . . .	. . . . . . . . . . . . . . . . . .
								4.4									Engine codes: BAG, BKG, BLF, BLN, BLP and CAX																											.	.		. .	. . . . . . . .	. . . . . . . . . . . . . . . . . .
								4.5									Engine codes: AXW, AXX, BGU, BHY, BLR, BLX, BLY, BPY, BSE, BSF, BVX, BVY, BVZ,
																	BWA, BYD, CAWB, CBFA and CCTA																		.		. .	.		.	. . .	. .	.	.	.		. .	. . . . . . .	. . . . . . . . . . . . . . . . . .
								4.6									Engine codes: BGP, BGQ, BTK, CBTA and CBUA																										.	.	.		. .	. . . . . . .	. . . . . . . . . . . . . . . . . .
								4.7									Engine codes: BUB, CBRA													. . .		. . .	.		. .		. .	.		.	. . .	. .	.	.	.		. .	. . . . . . .	. . . . . . . . . . . . . . . . . .

5Repair work on refrigerant circuit which may be performed only in appropriate workshops by specially trained mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1	Testing equipment and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2	Removing and installing heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3	Renewing components of refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4	Removing and installing high-pressure sender G65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5	Removing and installing receiver with dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6	Removing and installing air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7	Assembly overview - poly V-belt pulley (air conditioner compressor from “Denso”) . . . . . .
5.8	Removing and installing poly V-belt pulley (air conditioner compressor from “Denso”) . . . .
5.9	Removing and installing poly V-belt pulley, “Sanden” air conditioner compressor . . . . . . . .
5.10	Checking high-pressure safety valve on air conditioner compressor . . . . . . . . . . . . . . . . . .
5.11	Expansion valve, function and removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.12	Removing and installing evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.13	Removing and installing condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.14	Notes on installing air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54

55

55

56

57

58

59

59

59

60

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65

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67

67

69

71

73

75

77

79

82

83

84

88

92

92

94

97

99

100

100

100

103

103

106

6	Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	109
6.1	Refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	109
6.2	Refrigerant oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	109

ii Contents

Golf 2004

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Heating, air conditioning - Edition 02.2008

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Repairing heater

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1.1

Passenger compartment heating

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Disconnect battery before removing components marked **

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Rep. Gr. 27 .

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1 - Dash panel**

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2 - Centre vents

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Removing vent

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3 - Right side vent

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Removing vent

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page 5 .

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5 - Controls for fresh and heat

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flap switch -

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With heated driver seat

regulator -E94- and

heated front passenger

seat regulator -E95-

For vehicles with sup

plementaryheatinghav

ing instant heating but

ton -E537- .

Removing controls

page 7 .

6 - Fresh air and air recircula tion flap control motor -V154-

Removing page 11 7 - Right footwell vent

Removing and installing

page 7

8 - Fresh air blower -V2-Removing page 3

9 - Fresh air blower series re sistor with overheating fuse -N24-

Removing and installing page 3

10 - Baffle plate for heater unitRemoving page 2

11 - Sealing cap

Fitted only in vehicles without air duct to vent in rear centre console.

12 - Dust and pollen filter

With activated charcoal filter

Removing and installing page 4

1. Repairing heater 1

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Heating, air conditioning - Edition 02.2008

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13 - Connecting piece

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For centre console air duct (to rear vents)

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must be removed Rep. Gr. 68 .

To remove, centre consoler m

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14 - Air duct for right rearo footwell

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page 6

Removing and installing,

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15 - Air duct for left rearw footwell

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16 - Securing bolt

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17 - Adapter for controls

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18 - Auxiliary air heater element -Z35-

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control unit -J604- .

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19 - Heat exchanger

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After renewing heat exchanger, renew coolant completely

Removing and installing page 12

20 - Left footwell vent

Removing and installing page 7

21 - Bowden cable for temperature flapRemoving and installing page 10

22 - Flexible shaft for air distribution

Removing and installing page 9 23 - Heater unit

Removing and installing page 19

Dismantling and assembling page 23

24 - Left side vent

Removing heater unit baffle plate

– Remove plastic bolts -2- and remove baffle plate -1-.

2Rep. Gr.80 - Heating

Golf 2004

Heating, air conditioning - Edition 02.2008

Installation position of seal between heater unit and engine com partment

–First insert seal between heater unit and engine compartment -A- in bulkhead and then attach to heat exchanger.

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To prevents

water from entering vehicle interior, installationcposi

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tionumust be observed.

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1.2

Removing fresh air blower -V2-

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Removing

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Fresh air blower -V2- is accessible from footwell on front passen

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– Remove heater unit baffle plate page 2 .

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– Pull connector -A- off fresh air blower -V2- .

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– Remove bolt -B- for fresh air blower -V2- (1 Nm).

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o– Release catch -2-, turn fresh air blower -V2- in direction of

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-arrow- and remove.

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N24-

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1.3.1Removing

WARNING

Danger of burn injuries.

Thefreshairblowerseriesresistorwithoverheatingfuse-N24- can be hot.

Before removing fresh air blower series resistor with overheat ing fuse -N24- ,let it cool off.

First carry out the following work:

1. Repairing heater 3

Golf 2004

Heating, air conditioning - Edition 02.2008

–Remove heater unit baffle plate page 2 .

–Pull connector -1- off fresh air blower series resistor with over heating fuse -N24- .

–Presscatchin-directionofarrow-andremovefreshairblower series resistor with overheating fuse -N24- from heater unit.

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Installing

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Install in reverse order.

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dust and pollen

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filter

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1.4.1

Removing

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– Remove footwell trim -1- on front passenger side.

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– Remove baffle plate -2- from heater unit page 2 .

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– Release cover -3- in direction ofparrow.

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– Remove dust and pollen filter from heater unit downwards.

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Install in reverse order.

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Note

Observe installation position of dust and pollen filter.

1.5Removing vents

Note

Removal and installation of rear vents (in arm rest) is described in ELSA under General body repairs, interior; Rep.Gr. 68 ; Removing and installing centre console (Highline version).

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Removing centre vents

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centre vent

– On vehicles with a storage compartment in thesa

s

bolt -1-.

trim, the rubber mat must be removed to reachle

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the sunlight pene

– On vehicles with Climatronic, first removeitt

tration photosensor -G107- or the sunlightr m

penetration photo

sensor 2 -G134- page 59 .

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– Remove bolt -1-.

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– Remove cover -2- (only in vehiclesewith Climatronic).

– Remove securing bolts -1-.

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For vehicles with a storage compartment in dashppanel, bolts are

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– Remove compartment from dash panel.

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– Remove central vents -2- upwards -arrow-.

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– Separate connectors from central vents.

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- Edition 02.2008

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1.5.2Installing

Install in reverse order.

1.5.3Removing right or left vent

Note

♦The procedure for removal of vents is identical on both sides.

♦To avoid damage to dash panel, use a pad when levering out components.

1. Repairing heater 5

Golf 2004

Heating, air conditioning - Edition 02.2008

1.5.4Removing

–Using an appropriate tool, lever out vent -1-.

–Separate connector from vent.

1.5.5Installing

Install in reverse order.

1.5.6Removing and installing right and left rear footwell air ducts

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Note

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Theprocedureforremovaloffootwellairductsisidenticaln

sides.

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– Remove driver or front passenger seat t

p

Rep. Gr. 72 .

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– Remove centre console Rep. Gr. 68, .

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air duct from under

h

– Raise floor covering, unclip rear footwellw

body and pull off heater unit.

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1.5.7

Installing

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Install in reverse order.

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When installing rear footwell air duct, ensure that duct is first

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pushed onto heater unit -arrow- and then clipped to underbody.

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6Rep. Gr.80 - Heating

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1.5.8

Removing right footwellr m

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– Remove glove compartment o

Rep. Gr. 68 .

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± 0.2 Nm) and remove right

– Remove securing bolt -2- (1.5l

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footwell vent -1-.

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Installing

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Install in reverse order.

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If vehicle has glove box cooling, ensure that refrigerantbd hose is

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1.5.10Removing left footwell vent

–Remove driver side footwell cover Rep. Gr. 68 .

–Remove securing bolt -2- (1.5 ± 0.2 Nm) and remove left foot well vent -1-.

1.5.11Installing

Install in reverse order.

1.6Removing and installing controls for heated and fresh air

1.6.1Removing

Note

♦The control consists of two separable housings.Before re moving controls, set rotary knobs to the following positions:

♦Heater control to “cold”

♦Blower to “0”

♦Vent direction to “footwell”

– Remove radio Rep. Gr. 91 .

1. Repairing heater 7

Golf 2004

Heating, air conditioning - Edition 02.2008

–For vehicles without radio, remove centre dash panel trim Rep. Gr. 68 .

–Remove bolts -2- (4.2 x 45) and -3- (4.2 x 16) and remove the controls -1- from centre console.

Specified torque for bolts -2- and -3- (1.5 ± 0.2 Nm).

–Release connector catch -A- by pulling in direction of arrow -1-.

–Push connector catch -B- to connector -arrow 2- and remove connector -C-.

–Release connector catch -D- and remove connector -D-.

Note

Figureshows“Climatic”version.Theprocedureforreleasingcon

nector is the same.

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1.6.2

Installing

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order. Ensure that rotary

Installation is performed in the reversed

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knobs are in the same positions as when removed.

m

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1.7

Connectors onno

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fresh air

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for multi-pin connectors

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o

Special tools and workshopuequipment required

p

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♦

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Test box -V.A.G 1598/42r-

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♦

Adapter cable -V.A.G 1598/47-

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♦ Template -1598/47-2-

8Rep. Gr.80 - Heating

Golf 2004

Heating, air conditioning - Edition 02.2008

The 16-pin connector is vacant.

5-pin connector, T5 in current flow diagram

1 - 3rd blower speed

2 - 2nd blower speed

3 - 1st blower speed

4 - 4th blower speed

5 - X terminal

20-pin connector, T20c in current flow diagram

3 - Fresh air and air recirculation flap control motor -V154- 6 - Fresh air and air recirculation flap control motor -V154- 7 - With auxiliary air heater control unit -J604-

8 - Rear window

11 - Heated driver seat control unit -J131-

15 - Heated front passenger seat control unit -J132- 16 - Terminal 75, seat heating (optional)

18 - Terminal 30

19 - Terminal 15

20 - Terminal 31

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remove centre dash panel trim

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Rep. Gr.

68 .

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– Remove glove compartment Rep. Gr. 68 .

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– Move flexible shaft to following position:

n

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– Turn rotary switch for air distribution -1- until catch in shaft

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-2- is visible in gearsu-3-.

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1. Repairing heater 9

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Heating, airsa conditioning - Edition 02.2008

u

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le

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for fresh and heated air page 7 .

– Remove controlse d

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centre console and release locking lug -1-

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in direction of arrow.

pressingo

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shaft out of adapter -2-.

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Wheniflexible shaft is installed, the adapter and the rotary knobs

p

n

of the controls for heated and fresh air must be aligned in a spe

,

s

e

cific position to one another or the system will malfunction

s

o

pageu10 .

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m Checking

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Flexible shafto for air distribution flap actuator:

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t

– Run fresh air blower at highest speed. If air flows out of de

a

v

i

r

froster jet in the “defrost” position and no air flows out of

u

r

p

m

f

o

footwell vent, then the flexible shaft is correctly installed. Oth

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g

n

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erwise, remove flexible shaft from adapter. Position controls

.

p

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y

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for heated and freshhairg on adapter and turn rotary knob for airh

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.

r

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distribution /

i

. Then reconnect flexible shaft.oRe

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turn (180°)oc

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2

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d

kl

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peat check.

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1.9Removing and installing Bowden cable for temperature flap

1.9.1Removing

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h

t

n

i

n

f i n f o r

oitam

–Remove controls for fresh and heated air page 7 .

–Reach into centre console and release catch -1- of Bowden cable sheath -2- and remove Bowden cable sheath from sup port.

–Release ball on Bowden cable -3- from operating lever -4-.

10 Rep. Gr.80 - Heating

Golf 2004

Heating, air conditioning - Edition 02.2008

–Remove driver side footwell trim Rep. Gr. 68 .

–Unclip Bowden cable from control unit for temperature flap -A- and heater unit -B-.

1.9.2Installing

Installinreverseorder.EnsurethatBowdencableliesunderhook -arrow-.

–Check whether temperature knob can be easily turned from “cold” to “warm”.

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1.10

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andinstallingfreshairandair

o

Removingn

s

flap control motor -V154-

i

,

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n

i

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aRemoving

p

n

i

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s

e

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Note o

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u

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l

a

of the air recirculation flap must not be changed.

The position i

c

r

–

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m

m

Remove glove compartment Rep. Gr. 68 .

–

o

c

r

o

Remove cover -1-.

e

t

a

v

i

r

– Separate connector from fresh air and air recirculation flap

p

r

o

control motor -V154- -2-.

f

g

n

i

y

– Remove fresh air andpair recirculation flap control motor -

o

C

V154- -2- from mountings..t

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1.10.2Installing

Install in reverse order.

b

i l i t

y

w

i t

h

r e s p e c t

t o

t h e

c o r r e c t n e s s o f i n f o r m

1. Repairing heater 11

Golf 2004

Heating, air conditioning - Edition 02.2008

Note

After installing fresh air and air recirculation flap control motor - V154- ,check operation of air recirculation flap.

– Checking: vehicle diagnosis, testing and information system -

VAS 5051or successor models.

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o

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w

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lk

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– Renewing: initiate basic setting using vehicle diagnosis, test

V

y

b

d

ing and information system -VAS 5051or successor models

e

is

r

page 42 .

o

a

th

u

s

s

1.11

le

installingheatexchanger

Removingandd u

i

t

t

e

equipment required

Special tools and workshopr m

t

p

e

-

♦ Drip tray -V.A.G 1306n

o

s

i

,

e

l

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h

w

n

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,

s

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♦ Hose clamps up to 40emm Ø -VAS 3093-

r

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y

		t
		i
i	n	o

♦ Compressed air gun, commercially available

1.11.1Removing

– Place drip tray -V.A.G 1306beneath engine.

WARNING

Danger of scalding injuries.

When the engine is warm, the coolant temperature may be above 100 °C.The cooling system is pressurised.

If necessary, release pressure before carrying out repairs.

12 Rep. Gr.80 - Heating

Golf 2004 Heating, air conditioning - Edition 02.2008

–Clampoffcoolanthoses-1-usinghoseclampsupto40mmØ -VAS 3093and disconnect coolant hoses to heat exchanger.

–Push a piece of hose -A- onto upper connection of heat ex changer.

–Hold a container -B- under lower connection -C-.

–Using a compressed air pistol, carefully blow coolant out of heat exchanger into container -B-.

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Depending on the engine type, some parts must be removed ad r

a

a

s

c

ditionally, e.g.sthe charge air pipe.

c

e

le

p

n

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t

– Loosene dbolt (6 mm hexagon socket head) -1- on flange be

t

i

t

tween heat exchanger connections, but do not remove com

r

m

pletely.p e

n

o

t

s

i

,

e

Note

l

o

w

n

the bolt -1- loosens the coolant pipe which eases the

i

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Looseningo

t

of the heat exchanger.

removalr

a

p

n

i

Rep. Gr. 68 .

,

s

– eRemove driver side footwell trim

s

o

p

r

u

p

– Remove left footwell vent page 7 .

l

a

i

c

r

– Remove bolts -A- and remove cover -B-.

e

m

m

o

c

r

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Note

e

t

a

v

two different versions of cover -B-.

i

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p

♦ There arer

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n

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i

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♦ The figure showsy

the version with auxiliary air heater element .

-Z35- .

p

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♦ If the lever -C- to temperaturep

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flap is positioned so the the up

o

c

y

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per bolt -A- is not accessible.bd

Change the positionwsof the

et

c

a

etor

A e

temperature flap at the heater Pand fresh air.Gcontrols.On vehi

cles with Climatronic, at the control and display unit (e.g.the setting “Hi”).

–Covercarpetinareaunderheatexchangerwithwaterprooffoil and water absorbing paper.

–Open pipe clamps -A- and pull coolant pipes out of heat ex changer.

–Remove heat exchanger from heater unit.

t n e s

1. Repairing heater 13

Golf 2004

Heating, air conditioning - Edition 02.2008

1.11.2Installing

Installation is carried out in the reverse order. When installing, note the following:

–Check seals attached to heat exchanger -A- and -B-. Install heat exchanger only with undamaged seals.

Note

♦An improperly bonded seal can roll up when heat exchanger is pushed into heater unit.

♦If seal is damaged or improperly attached, cold air can flow past heat exchanger.

– Check heater unit for cleanliness through shaft -A- for heat exchanger while heat exchanger is removed.

– If necessary, remove dirt or residue of leaked coolant from heater unit, e.g. after removing a leaking heat exchanger.

– Push heat exchanger into heater unit.

.V

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a

w

s

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o

V

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b

d

e

is

r

o

th

u

a

s

– Moisten seals -1- with coolant before installing.le

s

u

n

– Set seals -1- in connection of heat exchanger.tte

d

r

m

i

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e

t

Note

o

n

s

i

,

e

l

o

♦ Ensurethatsealsareinstalledinh theproperdirectionasshown

in figure.

w

i

n

r

o

♦ Renew deformed pipe clamps.r

t

a

p

n

– Connect coolant pipes to heateexchanger.

i

,

s

s

– During assembly, pipe clampsr-A- must turn easily on coolant

o

pipes.

p

l

u

p

a

i

c

– Pipe clamps -A- must be installedm as shown in figure.

r

m

– Tighten pipe clamps -A- to 2 Nm. r

o

c

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e

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i

r

p

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i

y

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b

d

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c

et

or

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or a

s s o f i n f o r

14 Rep. Gr.80 - Heating

o

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s

y

u

a

Golf 2004

b

d

a

i

e

r

n

t

r

t

o

Heating, air conditioning - Edition 02.2008

o

e

h

e

u

r

a

a

s

c

s

c

–

le

uCheck seating of both clamps -A- after tightening bolts. They

n

e

t

p

t

d

must fully enclose the flange on the heat exchanger and thei

e

a

t

n

l

m

i

coolant pipe and the must not contact other components.

y

r

a

l

e

b

t

p

i

t

i

– Tightenbolt-1-onconnectingflangebetweenheatexchanger

t

o

y

n

i

i

connections to 2 Nm.

w

r

s

h

,

e

e

s

l

p

o

h

e

w

t

n

c

t

i

r

o

o

t

t

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p

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i

r

,

e

s

c

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t

n

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o

e

p

s

r

s

o

u

f

p

–

Check that grommet -C- in bulkhead is properly seated.

c

f

l

i

i

n

a

o

r

r

e

– If necessary, seal flanges for coolant pipes to heat exchanger

m

a

m

-A-andforexpansionvalvetoevaporator(onlyinvehicleswith

t

m

c

no

o

i

air conditioning) -B- at apertures in grommet -C- with silicone

n

i

o

r

adhesive sealant against moisture intrusion.

h

t

s

i

a

e

t

d

r

o

v

i

c

p

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m

yNote

.

n

n

i

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p

o

o

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♦

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seals.

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g

Always renewry

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i

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o

kl

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♦ After renewing heat exchanger, renew coolant completely

d

e

w

a

t

c

et

g

or

e

A

n

Rep.Gr. 19 .

P

.G

♦ Check coolant circuit for leaks.Examine in particular connec

tions between coolant pipes and heat exchanger.

1.12Removing and installing auxiliary air heater element -Z35- on vehicles up to 1K-7P015628 and 1K-7B084800

Note

♦Installed only in vehicles with diesel engines without supple mentary heater.

♦Checking: with vehicle diagnosis, testing and information sys tem -VAS 5051- (or later model), under Heating, ventilation, air conditioning; Systems capable of self-diagnosis; Auxiliary heating; Electrical components.

1.12.1Removing

–Remove driver side footwell trim Rep. Gr. 68 .

–Remove left footwell vent page 7 .

Note

If the lever -C- to temperature flap is positioned so the the upper bolt -A- is not accessible.Change the position of the temperature flap at the heater and fresh air controls.On vehicles with Clima tronic, at the control and display unit (e.g.the setting “Hi”).

1. Repairing heater 15

Golf 2004

Heating, air conditioning - Edition 02.2008

–Disconnect the battery Rep. Gr. 27 .

–Remove bolts -1- from cover -2-.

Caution

Danger of short circuit.

Disconnect battery before performing repair work.

–Remove securing nut for voltage supply -3- and earth con nection -4- (6 ± 1 Nm).

–Pull connectors -5- off auxiliary air heater element -Z35- .

WARNING

Danger of burn injuries.

The auxiliary air heater element -Z35- may be hot.

Before removing auxiliary air heater element -Z35- ,allow it to cool off.

– Pull auxiliary air heater element -Z35- out of heater unit.

1.12.2Installing

Install in reverse order.

1.13

Removing and installing auxiliary air

lkswa

en

heater element -Z35- on vehicles frome

g

o

V

y

b

d

1K-7P015629 und 1K-7B084801

u

is

r

o

th

a

s

s

le

d

u

n

-

1.13.1 Checking auxiliary air heater elementm

i

t

t

e

Z35with peripherals

t

p

e

r

s

n

o

signal for al

Auxiliary air heater element -Z35- peripherals (load,

i

e

ternator terminal DF, low heat output relay -J359o - , high heat

l

h

sender -G72- ,

output relay -J360- , intake manifold temperaturew

n

via the engine

coolant temperature sender -G62- ) can be readr

i

control unit self-diagnosis.

o

r

t

a

p

element -

1.13.2 Checking auxiliary air heaters

n

i

Z35-

,

o

e

s

p

r

Special tools and workshop equipment required

u

p

l

a

-VAS

♦ Vehicle diagnostic, testing and information systeme

i

c

r

5051Bwith 100 A pick-up clamp -VAS 5051B/7-

m

m

o

c

r

o

e

t

a

v

i

r

p

r

o

f

g

n

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.

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g

i

r

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AG.

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AG

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or a c c e p t a

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y

l

i

a

b

i

l

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w

i

t

h

r

e

s

p

e

c

t

t

o

t

h

e

c

o

r

r

e

c

t

n

e

s

s

o

f

i

n

f

o

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m

a

t

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n

i

n

o

t

d

s

i

h

c

o

u

m

e

n

t

.

16 Rep. Gr.80 - Heating

Golf 2004

Heating, air conditioning - Edition 02.2008

1.13.3Test conditions

•Intake temperature less than 19° C

•Coolant temperature less than 80° C

•Passenger compartment temperature about 20° C

•Battery voltage greater than 11 V

•Alternator load not greater than 50% (terminal DF)

•Engine speed greater than 450 rpm

•Turn rotary knob for interior temperature to end position for maximum temperature.

1.13.4

Test procedureo

G.

V lksw

ag

en

A

en

A

g

G

d

o

a

e

w

s

s

ot

– Remove leftVfootwell vent page 7 .

n

lk

y

o

g

u

b

d

a

s

r

a

ee

– Removecentre console trim from left footwell.

i

n

r

t

o

th

o

u

r

–

a

a

ve

Measures

current consumption on earth wire -arrow- usinge

s

c

le

c

u

hicle diagnostic, testing and information system -VAS 5051B-

n

t

p

t

e

d

and 100 A pick-up clamp -VAS 5051B/7- .

a

i

t

n

l

m

i

y

r

Low heating output: approx. 30 amps

a

p

i

y

e

b

t

l

t

i

n

o

Medium heating output: approx. 60 amps

is

i

r

w

t

,

h

e

e

High heating output: approx. 80 amps

s

h

e

l

p

o

w

t

n

c

t

i

r

o

o

t

t

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e

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n

r

i

r

,

e

s

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1.13.5

Removing and installing

s

l

i

u

o

p

f

i

n

a

f

r

Removing

o

c

m

e

r

a

m

t

m

c

–

Remove driver side footwell trim Rep. Gr. 68 .

n

i

o

o

n

i

r

t

o

a– Remove left footwell vent page 7 .

s i

h

e

t

d

r

o

v

i

c

p

m

u

y Note

e

.

n

p

C

t

o

o

C

p

y

.

If the leverr-yC- to temperature flap is positioned sob the the upper

t

r

h

g

g

h

i

i

t

bolt -A- is not accessible.y

Change the positionklof the temperature

p

o

y

V

c

b

s

o

flap at the heater and freshr

air controls.On vehicles with Clima

d

e

w

a

t

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et

g

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e

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n

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tronic, at the control and display unit (e.g.the setting “Hi”).

–Disconnect the battery Rep. Gr. 27 .

–Remove bolts -A- from cover -B-.

Caution

Danger of short circuit.

Disconnect battery before performing repair work.

1. Repairing heater 17

Golf 2004

Heating, air conditioning - Edition 02.2008

–Unscrew nut -1- (9 ± 1 Nm).

–Release connector strip catch -arrow-.

WARNING

Danger of burn injuries.

The auxiliary air heater element -Z35- may be hot.

Before removing auxiliary air heater element -Z35- ,allow it to cool off.

–Remove screw -2- (1.4 Nm) and pull out auxiliary air heater element -Z35- from blower box.

Installing

Note

Ensure that the earth wire is in proper position.

Install in reverse order.

1.14Checking ventilation

Note

age

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n

AG

s

lk

o

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y

♦

b

The stale air escapes via ventilation openings in ther luggage

d

e

compartment trim.

is

u

o

th

a

s

s

open

♦ If the ventilation is to function properly, the ventilationn

le

ings must not be covered.

e

d

u

i

t

t

m

♦

The ventilation frames are located in ther

rear side panels be

hind the bumper.

t

p

e

o

is

n

1.14.1

Checking

,

ho

e

l

–

w

Remove rear bumper Rep. Gr. 63r .

n

i

o

t

– Sealing lips -1- in ventilation framesp on both sides of vehicle

r

a

must be free to move and close by,themselves.

n

i

–

Note installation position.

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m

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1.15

f

Removing and installing air intake

g

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y

p

screen

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gir

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.

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h

y

p

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b

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et

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or

1.15.1

Removing

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ee or a c c e p t a

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s

s

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f

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f

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m

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e

m

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.

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e

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n

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– Remove plenum chamber cover Rep. Gr. 64 .

18 Rep. Gr.80 - Heating

Golf 2004 Heating, air conditioning - Edition 02.2008

– Remove cover -1- from plenum chamber.

Note

♦On vehicles with Climatronic from week 45/2007, a retainer withanairqualitysensor-G238-isfittedontheairintakegrille.

♦Function of air quality sensor -G238- page 56 .

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– Release air quality sensor -G238-e-1- and turn to right out of

y

b

retainer.

o

d

is

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th

u

a

s

s

le

d

u

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e

t

t

m

i

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o

n

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i

,

e

l

o

h

w

n

i

r

o

t

r

a

p

n

-arrows- (2.5 ± 0.4 Nm) and remove air

– Unscrew collar nutss

i

,

intake grille upwards.

e

s

o

p

r

u

p

l

a

i

c

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e

m

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1.15.2

Installing

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d

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or

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Install in reverse order.

.G

Note

Seal must seat properly on air intake screen.

Assembly sequence:

–Adjust air intake grille on metal collar.

–Hold air intake grille and first tighten lateral collar nuts (2.5 ± 0.4 Nm), then tighten middle collar nut.

1.16Removing and installing heater unit

Special tools and workshop equipment required

o r r

1. Repairing heater 19

Golf 2004

Heating, air conditioning - Edition 02.2008

♦ Drip tray -V.A.G 1306-

♦ Hose clamps up to 40 mm Ø -VAS 3093-

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t

t

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available

♦ Compressed air gun, commerciallyp

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n

o

t

1.16.1

Removing

,

s

i

e

l

o

h

w

Note

n

o

i

r

t

r

a

Toimproveaccess,dependingionengineversion,additionalcom

p

n

ponents must be removed e.g.e engine cover Rep.Gr. 10 .

,

s

s

o

– Remove dash panel Repp. Gr. 70 .

r

u

l

– Remove right and left rear footwell air ducts page 6 .

a

i

c

r

e

– Place drip tray -V.A.G 1306-mbeneath engine.

m

– Mark coolant hoses -1-

o

e

c

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t

a

v

i

WARNING

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f

p

r

o

g

n

i

Danger of scalding injuries.

y

C.

p

o

t

h

g

i

may be

When the engine is warm, the coolant temperaturepoc

r

y

y

detc

above 100 °C.The cooling system is pressurised.

b

et

or

If necessary, release pressure before carrying out repairs.

P

y

l i a

b

i l i t

y

w

i t

h

r e s p e c t

t o

t h e

c o r r e c t n e s s o f i n f o r m

20 Rep. Gr.80 - Heating

Golf 2004 Heating, air conditioning - Edition 02.2008

– Clampoffcoolanthoses-1-usinghoseclampsupto40mmØ

o

G.

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ag

-VAS 3093and disconnect coolant hosesAto heat exchanger.en

en

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ot

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gu

y

– Push a piece of hose -A- ontobupper connection of heat ex

changer.

d

a

e

is

r

o

th

lower connection -C-.

u

a

– Hold a container -B- unders

s

le

n

coolant out of heat exchanger using

– Carefully blow remainingd u

t

e

a compressed airit

pistol at heat exchanger connection.

e

r

m

– Cover carpet int p

vehicle interior with waterproof foil and ab

o

sorbent paper.n

s

i

,

e

l

o

h

w

n

i

r

o

Note

t

r

a

p

n

i

,

note lengths and locations of bolts for later installation.

s

During removal,e

s

o

p

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u

p

1 - Bolt

l

a

i

c

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e

m

4,5 ± 0.7 Nm

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o

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Lower rightron cable re

o

e

tainer to heater unit,

t

a

v

near bulkheadi

r

2 - Bolts

p

r

o

fg

4,5 ± 0.7 Nm

n

i

y

p

o

C

.

t

3 - Cable retainer

h

g

ir

4 - Heater unit

Removing:

–Separate connectors from heater unit.

Note

–Remove both securing nuts from convenience system central control unit -J393- and hang central control unit to side Rep. Gr. 97 .

–Unscrew bolts -6- and remove bracket -5-.

–Unscrew bolts -8- and -10- and remove sup ports -9- and -11-.

–Unscrew bolts -12- and -14- and remove retain er -13-.

–Remove bolts -2- and

-1- from cable retainer -3-.

Note

–Remove heater unit.

e c t

t o

t h e

c o r r e c t n e s s o f i

1. Repairing heater 21

Golf 2004

Heating, air conditioning - Edition 02.2008

Installing:

Installation is carried out in the reverse order. When installing, note the following:

First tighten bolts -8- when installing supports -9- and -11-.

Note

– Have second mechanic guide both coolant pipes to heat exchanger through seal during installation of

heater unit page 22 .

o

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– Fill with coolant Rep. Gr. 19 .

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5 - Bracket

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a

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6 - Bolts

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p

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8 ± 1 Nm

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i

7 - Mounting plate

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8 - Bolts

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9 ± 1.3 Nm

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9 - Right support

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10 - Bolts

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20 ± 3 Nm

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e

11 - Left support

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12 - Bolts

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9 ± 1.3 Nm

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13 - Bracket

m

m

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m

i

14 - Bolts

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n

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t

9 ± 1.3 Nm

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n

i

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Seal between heater unit and engine compartment

.

o

y

p

C

.

t

h

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i

r

y

p

o

c

Note

y

e

b

d

Observe position of seal -A- during installation.

22 Rep. Gr.80 - Heating

Golf 2004

Heating, air conditioning - Edition 02.2008

2Dismantling and assembling heater unit

2.1Assembly overview – heater unit

1 - Temperature flap actuator

Removing and installingpage 26

2 - Bracket

3 - Cover

4 - Fresh air and air recircula tion flap control motor -V154-

Checking: vehicle diag nosis, testing and infor mation system -VAS 5051- (or later model)

Removing and installingpage 11

Renewing: initiate basic settings using vehicle diagnosis, testing and information system - VAS5051-orsuccessor model page 42

5 - Air intake housing

With air recirculation flap

e

6 - Heater unit

o

g

a

w

s

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lk

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b

7 - Fresh air blower -V2-

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Removinga

and installing

u

s

3

pagele

s

d

u

n

8 - Freshitt

air blower series re

e

overheating fuse -

sistor withr m

N24-

t

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is

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Removing and installing

l

page 3

,

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o

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9 n- Dust and pollen filter

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i

Removing and installing page 4

o

t

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a

- Cover

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10i

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p

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r

,

For dust and pollen filter.

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e

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11u- Heat exchanger

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i Removing and installing page 12

f

p

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i

a

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12 m- Heat exchanger trim

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e

a

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i

o

o

13 - Auxiliary air heater element -Z35-

i

n

c

n

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t

o

Vehiclesvup to 1K-7P015628 and 1K-7B084800

s

i

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d

a

o

r

i

c

p

m

Withfauxiliary air heater control unit -J604- .

u

r

o

e

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n

n

Checking:p

with vehicle diagnostic, testing and informationCsystem -VAS 5051- (or later model), under

i

t

y

.

air conditioning; Systems capablerof self-diagnosis; Auxiliary heating; Electrical

Heating, ventilation,.

o

o

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components.ry

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t

Removing and installingbde

page 15

aws

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et

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or

A

P

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2. Dismantling and assembling heater unit 23

Golf 2004

Heating, air conditioning - Edition 02.2008

Vehicles from 1K-7P015629 and 1K-7B084801

A three-level auxiliary air heater element -Z35- is fitted here; it is controlled by the respective engine control unit via relays.

Installed only in vehicles with diesel engines without supplementary heater.

Removing and installing page 16

14 - Air distribution housing

15 - Air distribution flap actuator

Removing and installing page 26

2.2Removing and installing air distribution housing

2.2.1Removing

c

e

p

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i

a

b

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–Remove heater unit page 19 .

–Separateallavailableconnectorsfromairdistributionhousing.

24 Rep. Gr.80 - Heating

o

Heating,lk

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air conditioning -

enA

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– Remove heat exchanger together with coolant pipeso

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is

page 12 .

r

a

th

u

s

s

– Remove bolts -arrows- (1.4 Nm).

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e

d

un

t

– Remove air distribution housing -1- from heater unit -2-.

m

i

t

2.2.2

Installing

p

e

r

no

t

s

Install in reverse order.

i

l

,

e

o

h

2.3

w

heater unit

Dismantling and assemblingr

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o

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a

2.3.1

Dismantling

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e

s

o

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Golf 2004

Editionoes		02.2008
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			i	h

–Remove heater unit page 19 .

–Remove air distribution housing page 24 .

–Remove clip -2- and bolts -arrows- from heater unit.

–Unfold heater unit.

2.3.2Assembling

Assemble in reverse order.

2. Dismantling and assembling heater unit 25

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en

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en

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Golf 2004

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Heating, air conditioningu

- Edition 02.2008

o

th

a

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s

2.4

Removingd

le

and installing air distribution

u

n

e

flap actuatorr m

t

i

t

t

p

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o

2.4.1

n

Removing,i

s

e

l

o

– Remove dashwpanel Rep. Gr. 70 .

h

n

– Unclip flexibleoshaft from adapter for controls page 9 .

i

r

t

r

– Remove boltsp-1- and remove air distribution flap actuator.

a

n

i

,

s

e

s

o

p

r

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a

i

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e

m

m

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2.4.2

Installing

n

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y

p

.

t

h

– Arrows on gears must align.

g

po

i

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y

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kl

y

b

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s

w

– Position air distribution flap actuator and tighten bolts -1-..

a

e

t

c

et

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or

e

P

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G

Note

After installation, check operation of air distribution flappage 9 .

guarant ee

or a c c e p t a

n y

l i a

b

i l i t

y

w

i t

h

r e s p e c t

t

ne

2.5Removing and installing temperature flap actuator

2.5.1Removing

–Remove driver side footwell trim Rep. Gr. 68 .

–Remove left footwell vent page 7 .

–Unclip cable on temperature flap actuator -2-.

–Release catch -1- and press temperature flap actuator in -direction of arrowto stop.

–Pull off temperature flap actuator.

2.5.2Installing

Install in reverse order.

26 Rep. Gr.80 - Heating