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Service
Workshop Manual
Golf 2004 ➤
Heating, air conditioning
Edition 02.2008
Service Department. Technical Information
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Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Re pa ir G ro up
80 - Heating
87 - Air conditioning system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg 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
1.7 Connectors on controls for heated and fresh air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.8 Removing and installing flexible shaft for air distribution . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.9 Removing and installing Bowden cable for temperature flap . . . . . . . . . . . . . . . . . . . . . . . . 10
1.10 Removing and installing fresh air and air recirculation flap control motor V154 . . . . . . . . 11
1.11 Removing and installing heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.12 Removing and installing auxiliary air heater element Z35 on vehicles up to 1K-7P015628 and
1.13 Removing and installing auxiliary air heater element Z35 on vehicles from 1K-7P015629 und
1.14 Checking ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.15 Removing and installing air intake screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.16 Removing and installing heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2 Dismantling and assembling heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.1 Assembly overview – heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.2 Removing and installing air distribution housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.3 Dismantling and assembling heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.4 Removing and installing air distribution flap actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.5 Removing and installing temperature flap actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
87 - Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1 Notes on repair work to vehicles with air conditioning and on handling refrigerant . . . . . . 28
2 Air conditioning system with manual controls “Climatic” . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1K-7B084800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1K-7B084801 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1 Air conditioning and heating - passenger compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.2 Dismantling and assembling heater and air conditioner unit “Climatic” . . . . . . . . . . . . . . . . 31
2.3 Removing and installing heating and air conditioning controls, “Climatic” with air conditioning
system control unit J301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.4 Connectors on controls for heating and air conditioning “Climatic” . . . . . . . . . . . . . . . . . . 33
2.5 Removing and installing flexible shaft for air distribution . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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
E87 with Climatronic control unit J255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
3.10 Removing and installing right footwell vent temperature sender G262 . . . . . . . . . . . . . . . . 54
3.11 Removing and installing evaporator temperature sensor G308 or evaporator output
3.12 Ambient temperature sensor G17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.13 Function of air quality sensor G238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.14 Removing and installing air quality sensor G238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.15 Removing left vent temperature sender G150 and right vent temperature sender G151 . . 58
3.16 Removing sunlight penetration photosensor G107 or sunlight penetration photosensor 2
3.17 Checking condensation water drainage hose on air conditioner unit . . . . . . . . . . . . . . . . . . 59
3.18 Renewing control motors for air conditioning regulation . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.19 Removing and installing air recirculation flap control motor V113 . . . . . . . . . . . . . . . . . . . . 60
3.20 Removing and installing air flow flap control motor V71 for vehicles up to calendar week
3.21 Removing and installing control motor for fresh air and air recirculation flap and air flow flap
3.22 Removing and installing setting unit for fresh air and air recirculation flap and air flow flap
3.23 Removing and installing defroster flap control motor V107 . . . . . . . . . . . . . . . . . . . . . . . . 63
3.24 Removing and installing left temperature flap control motor V158 . . . . . . . . . . . . . . . . . . 64
3.25 Removing and installing right temperature flap control motor V159 . . . . . . . . . . . . . . . . . . 65
3.26 Removing and installing central flap control motor V70 . . . . . . . . . . . . . . . . . . . . . . . . . . 66
temperature sender G263 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
G134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
17/2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
V425 for vehicles from calendar week 18/2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4 Removing and installing ancillary bracket for air conditioner compressor . . . . . . . . . . . . . . 67
4.1 Engine codes: AZV, BDK, BJB, BKC, BKD, BLS, BMM, BMN, BRM, BRU, BVB, BXE, BXF
and BXJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.2 Engine codes: BCA, BUD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.3 Engine codes: BLG, BMY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.4 Engine codes: BAG, BKG, BLF, BLN, BLP and CAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.5 Engine codes: AXW, AXX, BGU, BHY, BLR, BLX, BLY, BPY, BSE, BSF, BVX, BVY, BVZ,
BWA, BYD, CAWB, CBFA and CCTA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.6 Engine codes: BGP, BGQ, BTK, CBTA and CBUA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.7 Engine codes: BUB, CBRA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5 Repair work on refrigerant circuit which may be performed only in appropriate workshops by
specially trained mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.1 Testing equipment and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.2 Removing and installing heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.3 Renewing components of refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.4 Removing and installing high-pressure sender G65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.5 Removing and installing receiver with dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.6 Removing and installing air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.7 Assembly overview - poly V-belt pulley (air conditioner compressor from “Denso”) . . . . . . 97
5.8 Removing and installing poly V-belt pulley (air conditioner compressor from “Denso”) . . . . 99
5.9 Removing and installing poly V-belt pulley, “Sanden” air conditioner compressor . . . . . . . . 100
5.10 Checking high-pressure safety valve on air conditioner compressor . . . . . . . . . . . . . . . . . . 100
5.11 Expansion valve, function and removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.12 Removing and installing evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.13 Removing and installing condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.14 Notes on installing air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
6 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6.1 Refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6.2 Refrigerant oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
ii Contents
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80 – Heating
1 Repairing heater
1.1 Passenger compartment heating
Disconnect battery before removing components marked ** ⇒
Rep. Gr. 27 .
1 - Dash panel**
2 - Centre vents
❑ Removing vent
3 - Right side vent
4 - Right vent
❑ Removing vent
5 - Controls for fresh and heat‐
ed air
❑ With fresh air and air re‐
⇒ page 5 .
⇒ page 5 .
circulation flap switch E159- .
❑ With heated driver seat
regulator -E94- and
heated front passenger
seat regulator -E95-
❑ For vehicles with sup‐
plementary heating hav‐
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
Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
10 - Baffle plate for heater unit
❑ Removing ⇒ 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
Page 6
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
13 - Connecting piece
❑ For centre console air duct (to rear vents)
❑ To remove, centre console must be removed ⇒ Rep. Gr. 68 .
14 - Air duct for right rear footwell
❑ Removing and installing ⇒ page 6
15 - Air duct for left rear footwell
❑ Removing and installing ⇒ page 6
16 - Securing bolt
❑ Qty. 8
❑ Various lengths.
17 - Adapter for controls
❑ Removing and installing ⇒ page 7
18 - Auxiliary air heater element -Z35-
❑ With auxiliary air heater control unit -J604- .
❑ Checking: with vehicle diagnostic, testing and information system -VAS 5051- (or later model), under
Heating, ventilation, air conditioning; Systems capable of self-diagnosis; Auxiliary heating; Electrical
components.
❑ Installed only in vehicles with diesel engines without supplementary heater.
❑ Removing and installing ⇒ page 15
19 - Heat exchanger
❑ 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 flap
❑ Removing 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-.
2 Rep. Gr.80 - Heating
Page 7
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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.
Note
To prevent water from entering vehicle interior, installation posi‐
tion must be observed.
1.2 Removing fresh air blower -V2-
1.2.1 Removing
Fresh air blower -V2- is accessible from footwell on front passen‐
ger side.
– Remove heater unit baffle plate ⇒ page 2 .
– Pull connector -A- off fresh air blower -V2- .
– Remove bolt -B- for fresh air blower -V2- (1 Nm).
– Release catch -2-, turn fresh air blower -V2- in direction of
-arrow- and remove.
1.3 Removing and installing fresh air blower
series resistor with overheating fuse N24-
Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
1.3.1 Removing
WARNING
Danger of burn injuries.
The fresh air blower series resistor with overheating fuse -N24can 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
Page 8
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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- .
– Press catch in -direction of arrow- and remove fresh air blower
series resistor with overheating fuse -N24- from heater unit.
1.3.2 Installing
Install in reverse order.
1.4 Removing and installing dust and pollen filter
1.4.1 Removing
– Remove footwell trim -1- on front passenger side.
– Remove baffle plate -2- from heater unit ⇒ page 2 .
– Release cover -3- in direction of arrow.
– Remove dust and pollen filter from heater unit downwards.
1.4.2 Installing
Install in reverse order.
Note
Observe installation position of dust and pollen filter.
1.5 Removing 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).
4 Rep. Gr.80 - Heating
Page 9
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1.5.1 Removing centre vents
– On vehicles with a storage compartment in the centre vent
trim, the rubber mat must be removed to reach bolt -1-.
– On vehicles with Climatronic, first remove the sunlight pene‐
tration photosensor -G107- or the sunlight penetration photo‐
sensor 2 -G134- ⇒ page 59 .
– Remove bolt -1-.
– Remove cover -2- (only in vehicles with Climatronic).
– Remove securing bolts -1-.
Note
For vehicles with a storage compartment in dash panel, bolts are
beneath a trim mat.
– Remove compartment from dash panel.
Heating, air conditioning - Edition 02.2008
– Remove central vents -2- upwards -arrow-.
– Separate connectors from central vents.
Golf 2004 ➤
1.5.2 Installing
Install in reverse order.
1.5.3 Removing 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
Page 10
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
1.5.4 Removing
– Using an appropriate tool, lever out vent -1-.
– Separate connector from vent.
1.5.5 Installing
Install in reverse order.
1.5.6 Removing and installing right and left rear footwell air ducts
Note
The procedure for removal of footwell air ducts is identical on both
sides.
– Remove driver or front passenger seat ⇒ Rep. Gr. 72 .
– Remove centre console ⇒ Rep. Gr. 68 .
– Raise floor covering, unclip rear footwell air duct from under‐
body and pull off heater unit.
1.5.7 Installing
Install in reverse order.
Note
When installing rear footwell air duct, ensure that duct is first
pushed onto heater unit -arrow- and then clipped to underbody.
6 Rep. Gr.80 - Heating
Page 11
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1.5.8 Removing right footwell vent
– Remove glove compartment ⇒ Rep. Gr. 68 .
– Remove securing bolt -2- (1.5 ± 0.2 Nm) and remove right
footwell vent -1-.
1.5.9 Installing
Install in reverse order.
Note
If vehicle has glove box cooling, ensure that refrigerant hose is
properly seated.
1.5.10 Removing left footwell vent
Heating, air conditioning - Edition 02.2008
– Remove driver side footwell cover ⇒ Rep. Gr. 68 .
– Remove securing bolt -2- (1.5 ± 0.2 Nm) and remove left foot‐
well vent -1-.
Golf 2004 ➤
1.5.11 Installing
Install in reverse order.
1.6 Removing and installing controls for heated and fresh air
1.6.1 Removing
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
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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
Figure shows “Climatic” version. The procedure for releasing con‐
nector is the same.
1.6.2 Installing
Installation is performed in the reverse order. Ensure that rotary
knobs are in the same positions as when removed.
1.7 Connectors on controls for heated and fresh air
1.7.1 Pin assignment for multi-pin connectors on back of controls for heated and fresh air
Special tools and workshop equipment required
♦ Test box -V.A.G 1598/42-
♦ Adapter cable -V.A.G 1598/47-
♦ Template -1598/47-2-
8 Rep. Gr.80 - Heating
Page 13
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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
1.8 Removing and installing flexible shaft for air distribution
1.8.1 Removing
– Remove radio ⇒ Rep. Gr. 91 .
– For vehicles without radio, remove centre dash panel trim ⇒
Rep. Gr. 68 .
– Remove glove compartment ⇒ Rep. Gr. 68 .
– Move flexible shaft to following position:
– Turn rotary switch for air distribution -1- until catch in shaft
-2- is visible in gears -3-.
Golf 2004 ➤
1. Repairing heater 9
Page 14
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
– Remove controls for fresh and heated air ⇒ page 7 .
– Reach into centre console and release locking lug -1- by
pressing in direction of arrow.
– Pull flexible shaft out of adapter -2-.
Note
When flexible shaft is installed, the adapter and the rotary knobs
of the controls for heated and fresh air must be aligned in a spe‐
cific position to one another or the system will malfunction
⇒ page 10 .
1.8.2 Checking
Flexible shaft for air distribution flap actuator:
– Run fresh air blower at highest speed. If air flows out of de‐
froster jet in the “defrost” position and no air flows out of
footwell vent, then the flexible shaft is correctly installed. Oth‐
erwise, remove flexible shaft from adapter. Position controls
for heated and fresh air on adapter and turn rotary knob for air
distribution 1/2 turn (180°). Then reconnect flexible shaft. Re‐
peat check.
1.9 Removing and installing Bowden cable for temperature flap
1.9.1 Removing
– 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
Page 15
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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-.
1.9.2 Installing
Install in reverse order. Ensure that Bowden cable lies under hook
-arrow-.
– Check whether temperature knob can be easily turned from
“cold” to “warm”.
1.10 Removing and installing fresh air and air
1.10.1 Removing
Note
The position of the air recirculation flap must not be changed.
– Remove glove compartment ⇒ Rep. Gr. 68 .
– Remove cover -1-.
– Separate connector from fresh air and air recirculation flap
control motor -V154- -2-.
– Remove fresh air and air recirculation flap control motor -
V154- -2- from mountings.
recirculation flap control motor -V154-
Golf 2004 ➤
1.10.2 Installing
Install in reverse order.
1. Repairing heater 11
Page 16
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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 5051- or successor models.
– Renewing: initiate basic setting using vehicle diagnosis, test‐
ing and information system -VAS 5051- or successor models
⇒ page 42 .
1.11 Removing and installing heat exchanger
Special tools and workshop equipment required
♦ Drip tray -V.A.G 1306-
♦ Hose clamps up to 40 mm Ø -VAS 3093-
♦ Compressed air gun, commercially available
1.11.1 Removing
– Place drip tray -V.A.G 1306- beneath 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
Page 17
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Heating, air conditioning - Edition 02.2008
– Clamp off coolant hoses -1- using hose clamps up to 40 mm Ø
-VAS 3093- and 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-.
Depending on the engine type, some parts must be removed ad‐
ditionally, e.g. the charge air pipe.
– Loosen bolt (6 mm hexagon socket head) -1- on flange be‐
tween heat exchanger connections, but do not remove com‐
pletely.
Loosening the bolt -1- loosens the coolant pipe which eases the
removal of the heat exchanger.
– Remove driver side footwell trim ⇒ Rep. Gr. 68 .
– Remove left footwell vent ⇒ page 7 .
– Remove bolts -A- and remove cover -B-.
♦
There are two different versions of cover -B-.
♦
The figure shows the version with auxiliary air heater element
Note
Note
-Z35- .
♦
If the lever -C- to temperature flap is positioned so the the up‐
per bolt -A- is not accessible. Change the position of the
temperature flap at the heater and fresh air controls. On vehi‐
cles with Climatronic, at the control and display unit (e.g. the
setting “Hi”).
Golf 2004 ➤
– Cover carpet in area under heat exchanger with waterproof foil
and water absorbing paper.
– Open pipe clamps -A- and pull coolant pipes out of heat ex‐
changer.
– Remove heat exchanger from heater unit.
1. Repairing heater 13
Page 18
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
1.11.2 Installing
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.
– Moisten seals -1- with coolant before installing.
– Set seals -1- in connection of heat exchanger.
Note
♦
Ensure that seals are installed in the proper direction as shown
in figure.
♦
Renew deformed pipe clamps.
– Connect coolant pipes to heat exchanger.
– During assembly, pipe clamps -A- must turn easily on coolant
pipes.
– Pipe clamps -A- must be installed as shown in figure.
– Tighten pipe clamps -A- to 2 Nm.
14 Rep. Gr.80 - Heating
Page 19
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– Check seating of both clamps -A- after tightening bolts. They
– Tighten bolt -1- on connecting flange between heat exchanger
– Check that grommet -C- in bulkhead is properly seated.
– If necessary, seal flanges for coolant pipes to heat exchanger
♦
♦
♦
must fully enclose the flange on the heat exchanger and the
coolant pipe and the must not contact other components.
connections to 2 Nm.
-A- and for expansion valve to evaporator (only in vehicles with
air conditioning) -B- at apertures in grommet -C- with silicone
adhesive sealant against moisture intrusion.
Note
Always renew seals.
After renewing heat exchanger, renew coolant completely ⇒
Rep. Gr. 19 .
Check coolant circuit for leaks. Examine in particular connec‐
tions between coolant pipes and heat exchanger.
Heating, air conditioning - Edition 02.2008
Golf 2004 ➤
1.12 Removing 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.
1.12.1 Removing
– 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
Page 20
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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.
1.12.2 Installing
Install in reverse order.
1.13 Removing and installing auxiliary air heater element -Z35- on vehicles from 1K-7P015629 und 1K-7B084801
1.13.1 Checking auxiliary air heater element Z35- with peripherals
Auxiliary air heater element -Z35- peripherals (load signal for al‐
ternator terminal DF, low heat output relay -J359- , high heat
output relay -J360- , intake manifold temperature sender -G72- ,
coolant temperature sender -G62- ) can be read via the engine
control unit self-diagnosis.
1.13.2 Checking auxiliary air heater element Z35-
Special tools and workshop equipment required
♦ Vehicle diagnostic, testing and information system -VAS
5051B- with 100 A pick-up clamp -VAS 5051B/7-
16 Rep. Gr.80 - Heating
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Heating, air conditioning - Edition 02.2008
1.13.3 Test conditions
• Intake temperature less than 19° C
• Coolant temperature less than 80° C
• Passenger compartment temperature about 20° C
• Battery voltage greater than 11 V
• Alternator load not greater than 50% (terminal DF)
• Engine speed greater than 450 rpm
• Turn rotary knob for interior temperature to end position for
maximum temperature.
Golf 2004 ➤
1.13.4 Test procedure
– Remove left footwell vent ⇒ page 7 .
– Remove centre console trim from left footwell.
– Measure current consumption on earth wire -arrow- using ve‐
Low heating output: approx. 30 amps
Medium heating output: approx. 60 amps
High heating output: approx. 80 amps
1.13.5 Removing and installing
Removing
– Remove driver side footwell trim ⇒ Rep. Gr. 68 .
– Remove left footwell vent ⇒ page 7 .
hicle diagnostic, testing and information system -VAS 5051Band 100 A pick-up clamp -VAS 5051B/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”).
– 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
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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.
1.14 Checking ventilation
Note
♦
The stale air escapes via ventilation openings in the luggage
compartment trim.
♦
If the ventilation is to function properly, the ventilation open‐
ings must not be covered.
♦
The ventilation frames are located in the rear side panels be‐
hind the bumper.
1.14.1 Checking
– Remove rear bumper ⇒ Rep. Gr. 63 .
– Sealing lips -1- in ventilation frames on both sides of vehicle
must be free to move and close by themselves.
– Note installation position.
1.15 Removing and installing air intake screen
1.15.1 Removing
– Remove plenum chamber cover ⇒ Rep. Gr. 64 .
18 Rep. Gr.80 - Heating
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Heating, air conditioning - Edition 02.2008
– Remove cover -1- from plenum chamber.
Note
♦
On vehicles with Climatronic from week 45/2007, a retainer
with an air quality sensor -G238- is fitted on the air intake grille.
♦
Function of air quality sensor -G238- ⇒ page 56 .
– Release air quality sensor -G238- -1- and turn to right out of
retainer.
– Unscrew collar nuts -arrows- (2.5 ± 0.4 Nm) and remove air
intake grille upwards.
1.15.2 Installing
Install in reverse order.
Golf 2004 ➤
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.
1.16 Removing and installing heater unit
Special tools and workshop equipment required
1. Repairing heater 19
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
♦ Drip tray -V.A.G 1306-
♦ Hose clamps up to 40 mm Ø -VAS 3093-
♦ Compressed air gun, commercially available
1.16.1 Removing
Note
To improve access, depending on engine version, additional com‐
ponents must be removed e.g. engine cover ⇒ Rep. Gr. 10 .
– Remove dash panel ⇒ Rep. Gr. 70 .
– Remove right and left rear footwell air ducts ⇒ page 6 .
– Place drip tray -V.A.G 1306- beneath engine.
– Mark coolant hoses -1-
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.
20 Rep. Gr.80 - Heating
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Heating, air conditioning - Edition 02.2008
– Clamp off coolant hoses -1- using hose clamps up to 40 mm Ø
-VAS 3093- and 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-.
– Carefully blow remaining coolant out of heat exchanger using
a compressed air pistol at heat exchanger connection.
– Cover carpet in vehicle interior with waterproof foil and ab‐
sorbent paper.
Note
During removal, note lengths and locations of bolts for later installation.
1 - Bolt
❑ 4,5 ± 0.7 Nm
❑ Lower right on cable re‐
tainer to heater unit,
near bulkhead
2 - Bolts
❑ 4,5 ± 0.7 Nm
3 - Cable retainer
4 - Heater unit
Removing:
Golf 2004 ➤
– 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.
1. Repairing heater 21
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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 .
– Fill with coolant ⇒ Rep. Gr. 19 .
5 - Bracket
6 - Bolts
❑ 8 ± 1 Nm
7 - Mounting plate
8 - Bolts
❑ 9 ± 1.3 Nm
9 - Right support
10 - Bolts
❑ 20 ± 3 Nm
11 - Left support
12 - Bolts
❑ 9 ± 1.3 Nm
13 - Bracket
14 - Bolts
❑ 9 ± 1.3 Nm
Seal between heater unit and engine compartment
Note
Observe position of seal -A- during installation.
22 Rep. Gr.80 - Heating
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
2 Dismantling and assembling heater
unit
2.1 Assembly overview – heater unit
1 - Temperature flap actuator
❑ Removing and installing
⇒ page 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 installing
⇒ page 11
❑ Renewing: initiate basic
settings using vehicle
diagnosis, testing and
information system VAS 5051- or successor
model ⇒ page 42
5 - Air intake housing
❑ With air recirculation
flap
6 - Heater unit
7 - Fresh air blower -V2-
❑ Removing and installing
⇒ page 3
8 - Fresh air blower series re‐
sistor with overheating fuse N24-
9 - Dust and pollen filter
10 - Cover
11 - Heat exchanger
12 - Heat exchanger trim
13 - Auxiliary air heater element -Z35-
Vehicles up to 1K-7P015628 and 1K-7B084800
❑ Removing and installing
⇒ page 3
❑ Removing and installing ⇒ page 4
❑ For dust and pollen filter.
❑ Removing and installing ⇒ page 12
❑ With auxiliary air heater control unit -J604- .
❑ Checking: with vehicle diagnostic, testing and information system -VAS 5051- (or later model), under
Heating, ventilation, air conditioning; Systems capable of self-diagnosis; Auxiliary heating; Electrical
components.
❑ Removing and installing ⇒ page 15
2. Dismantling and assembling heater unit 23
Page 28
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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
2.2 Removing and installing air distribution housing
2.2.1 Removing
– Remove heater unit ⇒ page 19 .
– Separate all available connectors from air distribution housing.
24 Rep. Gr.80 - Heating
Page 29
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– Remove heat exchanger together with coolant pipes
⇒ page 12 .
– Remove bolts -arrows- (1.4 Nm).
– Remove air distribution housing -1- from heater unit -2-.
2.2.2 Installing
Install in reverse order.
2.3 Dismantling and assembling heater unit
2.3.1 Dismantling
Heating, air conditioning - Edition 02.2008
Golf 2004 ➤
– Remove heater unit ⇒ page 19 .
– Remove air distribution housing ⇒ page 24 .
– Remove clip -2- and bolts -arrows- from heater unit.
– Unfold heater unit.
2.3.2 Assembling
Assemble in reverse order.
2. Dismantling and assembling heater unit 25
Page 30
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
2.4 Removing and installing air distribution flap actuator
2.4.1 Removing
– Remove dash panel ⇒ Rep. Gr. 70 .
– Unclip flexible shaft from adapter for controls ⇒ page 9 .
– Remove bolts -1- and remove air distribution flap actuator.
2.4.2 Installing
– Arrows on gears must align.
– Position air distribution flap actuator and tighten bolts -1-.
Note
After installation, check operation of air distribution flap
⇒ page 9 .
2.5 Removing and installing temperature flap actuator
2.5.1 Removing
– 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 arrow- to stop.
– Pull off temperature flap actuator.
2.5.2 Installing
Install in reverse order.
26 Rep. Gr.80 - Heating
Page 31
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Heating, air conditioning - Edition 02.2008
Note
After installation, check operation of temperature flap. Tempera‐
ture knob of control for heated and fresh air must move freely and
without jerking from “cold” position to “warm” position.
Golf 2004 ➤
2. Dismantling and assembling heater unit 27
Page 32
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
87 – Air conditioning system
1 Notes on repair work to vehicles with
air conditioning and on handling re‐
frigerant
Note
♦
Notes on repair work to vehicles with air conditioning and on
handling refrigerant can be found in ELSA under Heating,
ventilation, air conditioning system; Air conditioning system
with refrigerant R134a ⇒ Rep. Gr. 00 ; Technical data.
♦
Notes on testing equipment and tools for repair work to vehi‐
cles with air conditioning can be found in ELSA under Heating,
ventilation, air conditioning system; Air conditioning system
with refrigerant R134a ⇒ Rep. Gr. 00 ; Technical data.
Caution
Do not kink or severely bend refrigerant lines.
There is a film in the refrigerant lines which can be destroyed.
Refrigerant lines must not be bent to a radius less than r =
100 mm.
Additional information:
♦ ⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations
28 Rep. Gr.87 - Air conditioning system
Page 33
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
2 Air conditioning system with manual
controls “Climatic”
2.1 Air conditioning and heating - passenger compartment
Note
♦
Disconnect battery before removing components marked ** ⇒
Rep. Gr. 27 .
♦
A label on the lock carrier indicates the type and quantity of
refrigerant used.
1 - Dash panel**
2 - Centre vents
❑ Removing and installing
⇒ page 5
3 - Right side vent
4 - Right vent
❑ Removing and installing
5 - “Climatic” heating and air
conditioning controls with air
conditioning system control
unit -J301-
❑ With dash panel tem‐
⇒ page 5
perature sensor -G56-
❑ With fresh air and air re‐
circulation flap switch E159- .
❑ With heated rear win‐
dow button -E230- .
❑ With fresh air blower
switch -E9-
❑ With air conditioning
system control unit J301- .
❑ With heated driver seat
regulator -E94- and
heated front passenger
seat regulator -E95-
❑ For vehicles with sup‐
plementary heating hav‐
ing instant heating but‐
ton -E537- .
❑ Removing and installing
⇒ page 33
6 - Air recirculation flap control motor -V113-
❑ Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
❑ Removing and installing ⇒ page 60
❑ Renewing: initiate basic settings using vehicle diagnosis, testing and information system -VAS 5051- or
successor model ⇒ page 42
2. Air conditioning system with manual controls “Climatic” 29
Page 34
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
7 - Right footwell vent
❑ Removing and installing ⇒ page 7
8 - Fresh air blower -V2-
❑ Removing and installing ⇒ page 3
9 - Fresh air blower series resistor with overheating fuse -N24-
❑ Removing and installing ⇒ page 3
10 - Baffle plate for heater unit
❑ Removing ⇒ page 2
11 - Evaporator temperature sensor -G308- or evaporator output temperature sender -G263-
❑ Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
Note
❑ Removing and installing ⇒ page 55
12 - Sealing cap
❑ Fitted only in vehicles without air duct to vent in rear centre console.
13 - Dust and pollen filter
❑ With activated charcoal filter
❑ Removing and installing ⇒ page 4
14 - Connecting piece
❑ For centre console air duct.
❑ To remove, centre console must be removed ⇒ Rep. Gr. 68 .
15 - Air duct for right rear footwell
❑ Removing and installing ⇒ page 6
16 - Air duct for left rear footwell
❑ Removing and installing ⇒ page 6
17 - Securing bolt
❑ Qty. 8
18 - Adapter for controls
19 - Auxiliary air heater element -Z35-
❑ Installed only in vehicles with diesel engines without supplementary heater.
❑ Removing and installing ⇒ page 15
Vehicles up to 1K-7P015628 and 1K-7B084800
❑ With auxiliary air heater control unit -J604- .
❑ Checking: with vehicle diagnostic, testing and information system -VAS 5051- (or later model), under
Heating, ventilation, air conditioning; Systems capable of self-diagnosis; Auxiliary heating; Electrical
components.
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.
20 - Heat exchanger
❑ Removing and installing ⇒ page 12
21 - Left footwell vent
❑ Removing and installing ⇒ page 7
22 - Temperature flap control motor -V68-
❑ Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
❑ Removing and installing ⇒ page 36
30 Rep. Gr.87 - Air conditioning system
Page 35
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
❑ Renewing: initiate basic settings using vehicle diagnosis, testing and information system -VAS 5051- or
successor model ⇒ page 42
23 - Flexible shaft
❑ Removing and installing ⇒ page 9
24 - Footwell vent temperature sender -G192-
❑ Removing and installing ⇒ page 38
25 - Heater and air conditioning unit
❑ Removing and installing ⇒ page 84
❑ Dismantling and assembling ⇒ page 31
26 - Left side vent
27 - Centre vent temperature sender -G191-
❑ Removing and installing ⇒ page 39
2.2 Dismantling and assembling heater and air conditioner unit “Climatic”
1 - Temperature flap control
motor -V68-
❑ Checking: vehicle diag‐
nostic, testing and infor‐
mation system -VAS
5051- (or later model)
❑ Removing and installing
⇒ page 36
❑ Renewing: initiate basic
settings using vehicle
diagnosis, testing and
information system VAS 5051- or successor
model ⇒ page 42
2 - Bracket
3 - Bolts
❑ Bolts must be removed
to separate air distribu‐
tion housing from evap‐
orator housing.
4 - Cover
5 - Air recirculation flap control
motor -V113-
❑ Checking: vehicle diag‐
nostic, testing and infor‐
mation system -VAS
5051- (or later model)
❑ Removing and installing
⇒ page 36
❑ Renewing: initiate basic
settings using vehicle
diagnosis, testing and
information system VAS 5051- or successor
model ⇒ page 42
6 - Air intake housing
❑ With air recirculation flap
2. Air conditioning system with manual controls “Climatic” 31
Page 36
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
7 - Upper part of evaporator housing
❑ Dismantling and assembling evaporator housing ⇒ page 52
8 - Lower part of evaporator housing
❑ Dismantling and assembling evaporator housing ⇒ page 52
9 - Evaporator
❑ Removing and installing ⇒ page 103
10 - Evaporator temperature sensor -G308- or evaporator output temperature sender -G263-
❑ Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
Note
❑ Removing and installing ⇒ page 55
11 - Connections for glove box cooling
❑ To dismantle, remove glove compartment ⇒ Rep. Gr. 68
❑ Installation position of connections for glove compartment cooling ⇒ page 32
12 - Refrigerant hose for glove compartment cooling
❑ To dismantle, remove glove compartment ⇒ Rep. Gr. 68
13 - Fresh air blower series resistor with overheating fuse -N24-
❑ Removing and installing ⇒ page 3
14 - Fresh air blower -V2-
❑ Removing and installing ⇒ page 3
15 - Dust and pollen filter
❑ With activated charcoal filter
❑ Removing and installing ⇒ page 4
16 - Cover
❑ For dust and pollen filter.
17 - Heat exchanger
❑ Removing and installing ⇒ page 12
18 - Heat exchanger trim
19 - Auxiliary air heater element -Z35-
❑ Only in vehicles with diesel engines without supplementary heater.
❑ Checking: with vehicle diagnostic, testing and information system -VAS 5051- (or later model), under
Heating, ventilation, air conditioning; Systems capable of self-diagnosis; Auxiliary heating; Electrical
components.
❑ Removing and installing ⇒ page 15
20 - Air distribution housing
Installation position of connections for glove compartment cooling
1 - Connecting piece
2 - Valve
32 Rep. Gr.87 - Air conditioning system
Page 37
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2.3 Removing and installing heating and air conditioning controls, “Climatic” with air conditioning system control unit -J301-
2.3.1 Removing
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 .
– 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.
Heating, air conditioning - Edition 02.2008
Golf 2004 ➤
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-.
2.3.2 Installing
Installation is performed in the reverse order. Ensure that rotary
knobs are in the same positions as when removed.
2.4 Connectors on controls for heating and air conditioning “Climatic”
2.4.1 Pin assignment for multi-pin connectors on back of controls for heating and air conditioning “Climatic”
Special tools and workshop equipment required
2. Air conditioning system with manual controls “Climatic” 33
Page 38
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
♦ Test box -V.A.G 1598/42-
♦ Adapter cable -V.A.G 1598/47-
♦ Template -1598/47-2-
20-pin connector, T20c in current flow diagram
3 - Centre vent temperature sender -G191-
5 - High-pressure sender -G65-
7 - CAN, low
8 - CAN, high
12 - Right seat heating (optional)
13 - Left seat heating (optional)
15 - Terminal 75, seat heating (optional)
16 - Air conditioning system compressor regulating valve -N280-
19 - Terminal 30A
20 - Terminal 31
16-pin connector, T16e in current flow diagram
1 - Temperature flap control motor -V68- , warm
2 - Evaporator temperature sensor -G308- or evaporator output
temperature sender -G263-
4 - Footwell vent temperature sender -G192-
5 - Temperature flap control motor potentiometer -G92-
7 - + 5 V for temperature flap control motor potentiometer -G92-
8 - Earth for potentiometer for temperature flap control motor G92- , centre vent temperature sender -G191- , footwell vent
temperature sender -G192- and evaporator temperature sensor
-G308- or evaporator output temperature sender -G263-
9 - Air recirculation flap control motor -V113- , open
10 - Air recirculation flap control motor -V113- , closed
11 - Temperature flap control motor -V68- , cold
34 Rep. Gr.87 - Air conditioning system
Page 39
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Heating, air conditioning - Edition 02.2008
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
2.5 Removing and installing flexible shaft for air distribution
Golf 2004 ➤
2.5.1 Removing
– Remove radio ⇒ Rep. Gr. 91 .
– For vehicles without radio, remove centre dash panel trim ⇒
Rep. Gr. 68 .
– Move flexible shaft to following position:
– Turn rotary switch for air distribution -1- until catch in shaft
-2- is visible in gears -3-.
– Remove heating and air conditioning controls, Climatic
⇒ page 33 .
– Carefully pull out adapter for controls.
– Press in locking lug -arrow- of flexible shaft and pull out flexible
shaft.
Note
When the flexible shaft is installed, the adapter and the rotary
knob of the Climatic heating and air conditioning controls must be
aligned in a specific position to one another or the system will
malfunction.
2.5.2 Checking
Flexible shaft for air distribution flap actuator:
– Run fresh air blower at highest speed. If air flows out of de‐
froster jet in the “defrost” position, and no air flows out of
footwell vent, then the flexible shaft is correctly installed. Oth‐
erwise, remove flexible shaft from adapter. Position controls
for Climatic heating and air conditioning on adapter and turn
rotary knob for air distribution 1/2 turn (180°). Then reconnect
flexible shaft. Repeat check.
2. Air conditioning system with manual controls “Climatic” 35
Page 40
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
2.6 Checking condensation water drainage hose on heater and air conditioner unit
– Remove footwell trim on front passenger side.
Note
♦
It must be possible to push condensation drain hose -1- onto
heater and air conditioner unit connection without tension.
♦
The condensation drain hose must be fitted securely to the
connection for condensation drainage of the heater and air
conditioner unit.
2.7 Removing and installing air recirculation flap control motor -V113-
2.7.1 Removing
– Remove glove compartment ⇒ Rep. Gr. 68 .
– Remove cover -1- for control motor.
– Separate connector from recirculated air flap control motor -
V113- -2-.
– Pull off air recirculation flap control motor -V113- -2-.
2.7.2 Installing
Install in reverse order.
Note
♦
After installation, check operation of air recirculation flap.
♦
Initiate “basic settings” function using vehicle diagnosis, test‐
ing and information system -VAS 5051- or successor model
⇒ page 42 .
2.8 Removing and installing temperature flap control motor -V68-
2.8.1 Removing
– Remove left footwell vent ⇒ page 7 .
– Remove left footwell trim ⇒ Rep. Gr. 68 .
36 Rep. Gr.87 - Air conditioning system
Page 41
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Heating, air conditioning - Edition 02.2008
– Remove data bus diagnostic interface -J533- from ⇒ Rep. Gr.
97 .
– Remove bolts -3- (9 Nm ±1.3 Nm).
Do not remove bolts -1-.
– Do not remove bracket -2-.
– Press bracket -1- in direction of brake pedal -arrow- and se‐
cure it on brake pedal with a cable tie.
– Mark connector -C- to control motor (danger of interchanging
with other connectors of same construction).
– Separate connector -C- on temperature flap control motor -
V68- .
– Remove cover -A-.
– Remove securing bolts -D- (1.4 Nm) and remove temperature
flap control motor -V68- -B-.
– Remove lever -E- of control motor from connecting rod -F-.
2.8.2 Installing
Note
Optimised control motors are marked with an “X”.
To ease assembly, use an approx. 2 mm shorter oval-head screw
-N 103 254 01- .
Golf 2004 ➤
2. Air conditioning system with manual controls “Climatic” 37
Page 42
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
– Cut off bracket -1- from old temperature flap control motor -
V68- , e.g. using side cutting pliers.
– Position new temperature flap control motor -V68- marked
with an “X” with shortened oval-head screw -2- and cut-off
bracket -1- on bracket -3- on blower box.
Note
♦
After installation, check operation of left temperature flap.
♦
Initiate “basic settings” function using vehicle diagnosis, test‐
ing and information system -VAS 5051- or successor model
⇒ page 42 .
2.9 Removing and installing footwell vent temperature sender -G192-
2.9.1 Removing
– Remove dash panel ⇒ Rep. Gr. 70 .
– Remove data bus diagnostic interface -J533- from ⇒ Rep. Gr.
97 .
– Remove left footwell vent ⇒ page 7 .
– Remove bolts -1- and -3- (9 ± 1.3 Nm).
38 Rep. Gr.87 - Air conditioning system
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Heating, air conditioning - Edition 02.2008
– Remove bracket -2-.
– Pull connector off footwell vent temperature sender -G192-
-1-.
– Turn footwell vent temperature sender -G192- 90° and remove
it from housing.
2.9.2 Installing
Install in reverse order.
2.10 Removing and installing centre vent temperature sender -G191-
2.10.1 Removing
Golf 2004 ➤
– Remove left dash panel cover ⇒ Rep. Gr. 70 .
– Pull connector off centre vent temperature sender -G191-
-1-.
– Turn centre vent temperature sender -G191- -2- 90° in
-direction of arrow- and remove from dash panel.
2.10.2 Installing
Install in reverse order.
2.11 Ambient temperature sensor -G17-
2.11.1 Removing
– Pull centre grille out of fasteners in front bumper cover ⇒ Rep.
Gr. 63 .
– Unclip ambient temperature sensor -G17- -1- from retainer
and separate electrical connector.
2. Air conditioning system with manual controls “Climatic” 39
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
2.11.2 Installing
Installation is carried out in the reverse order. When installing,
note the following:
Note
Ensure proper seating of electrical connection to prevent intrusion
of splashed water.
40 Rep. Gr.87 - Air conditioning system
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Heating, air conditioning - Edition 02.2008
3 Air conditioning system with automat‐
ECON
or AC button.
ic regulation “Climatronic”
Note
♦
Switch from °C to °F and vice versa. Press and hold
button and then press
♦
Pressing the
from automatic operation.
♦
Deviations from automatic operation ⇒ appropriate operating
instructions.
♦
Vehicles up to calendar week 21/2007: if
vated, the air conditioner compressor will be switched to al‐
most zero delivery. Depending on vehicle equipment, the
auxiliary air heater element -Z35- or the auxiliary heater (in
supplementary heater function) will be switched off. If the aux‐
iliary heater is activated by the driver, it will remain on. The
respective surrounding conditions have to be fulfilled or the
activation signals must have been delivered. The heating and
ventilation operations continue to be controlled electronically.
♦ ECON
button deactivated, air conditioner compressor switched
on. Depending on vehicle equipment, the auxiliary air heater
element -Z35- or the auxiliary heater (in supplementary heater
function) will be switched on. If the auxiliary heater is activated
by the driver, it will remain on. The respective surrounding
conditions have to be fulfilled or the activation signals must
have been delivered. The heating and ventilation operations
continue to be controlled electronically.
♦ ON/OFF
button activated, Climatronic in operation.
AUTO
button will cancel all settings which deviate
ECON
AUTO
button is acti‐
Golf 2004 ➤
♦ ON/OFF
button deactivated, Climatronic out of operation.
There is no heating and ventilation.
♦
Vehicles from calendar week 22/2007: the
AC
discontinued. Replaced by
discontinued. Replaced by
♦ AC
button activated, air conditioner compressor switched on.
button.
OFF
button.
ECON
ON/OFF
button was
button was
Depending on vehicle equipment, the auxiliary air heater ele‐
ment -Z35- or the auxiliary heater (in supplementary heater
function) will be switched on. If the auxiliary heater is activated
by the driver, it will remain on. The respective surrounding
conditions have to be fulfilled or the activation signals must
have been delivered. The heating and ventilation operations
continue to be controlled electronically.
♦ AC
button deactivated, air conditioner compressor will be
switched to almost zero delivery. Depending on vehicle equip‐
ment, the auxiliary air heater element -Z35- or the auxiliary
heater (in supplementary heater function) will remain on. If the
auxiliary heater is activated by the driver, it will remain on. The
respective surrounding conditions have to be fulfilled or the
activation signals must have been delivered. The heating and
ventilation operations continue to be controlled electronically.
♦ OFF
button is activated. Climatronic is out of operation. There
is no heating and ventilation.
♦ OFF
button is deactivated. Climatronic is in operation.
3. Air conditioning system with automatic regulation “Climatronic” 41
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
3.1 Procedure for checking and adjusting components
Select “guided fault finding” function in the vehicle diagnostic,
testing and information system -VAS 5051- (or later model).
After all control units have been read:
– Press “GoTo” button.
– Select “Function/component selection”.
– Select “Body”.
– “Heating, ventilation, air conditioning (Repair group 01; 80…
87)”.
– Select “01-On Board Diagnostic (OBD) capable systems”.
– Select “Climatronic” or “Climatic”.
– Select “Functions”.
– “Basic settings”
– “Checking cooling output”.
– “Read data block”.
42 Rep. Gr.87 - Air conditioning system
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
3.2 Function of operating and display unit for Climatronic air conditioning sys‐
tem -E87-
1 - Display for selected left in‐
terior temperature
Switch from °C to °F and vice
versa. Press and hold AUTO
button and then press ECON or
AC button.
2 - Air recirculation button
❑ Pressing air recircula‐
tion button prevents pol‐
luted air from entering
interior.
3 - Centre air distribution but‐
ton
4 - Lower air distribution button
5 - Upper air distribution button
6 - Display for selected right in‐
terior temperature
Switch from °C to °F and vice
versa. Press and hold AUTO
button and then press ECON or
button.
AC
7 - Button for air recirculation
mode or button for automatic
recirculation mode
❑ Pressing the air recircu‐
lation button switches to
the air recirculation
mode and prevents pol‐
luted air from entering
the interior.
❑ Vehicles from calendar
week 22/2007. Pressing
the air recirculation but‐
ton again activates the automatic recirculation mode.
Note
8 - Windscreen defroster button
9 - Rear window heating button
10 - Rotary regulator for interior temperature, left
11 - Rotary blower regulator
❑ Turn to change blower speed.
12 - Dual button or instant heating button -E537-
❑ If the lamp in the button is on, the left and right temperatures may be adjusted independently.
❑ If the Dual
button is pressed, the warning lamp goes out and the passenger side will assume the tem‐
perature setting for the driver side.
Note
3. Air conditioning system with automatic regulation “Climatronic” 43
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
13 - Dash panel temperature sensor -G5614 - Button for air conditioning system OFF or ON/OFF
15 - AUTO button
❑ Pressing AUTO button causes the Climatronic to maintain the selected interior temperature completely
automatically. With this setting, the vent air temperature, the blower speed and the air distribution are
controlled automatically.
16 - AC button
❑ Observe notes on vehicles up to calendar week 21/2007 and from calendar week 22/2007 ⇒ page 41 .
❑ Deactivating the AC button sets the compressor to near-zero delivery. The heating and ventilation op‐
erations continue to be controlled electronically.
17 - ECON
button
❑ Observe notes on vehicles up to calendar week 21/2007 and from calendar week 22/2007 ⇒ page 41 .
❑ Pressing the ECON button sets the air conditioner compressor to near-zero delivery. The heating and
ventilation operations continue to be controlled electronically. The optional supplementary heater will
likewise be switched off.
18 - Rotary regulator for interior temperature, right
3.3 Removing and installing operating and
display unit for Climatronic air condition‐
ing system -E87- with Climatronic con‐
trol unit -J255-
Note
The Climatronic control unit -J255- and the operating and display
unit for Climatronic air conditioning system -E87- are a single
component which cannot be dismantled.
3.3.1 Removing
– Remove centre dash panel trim ⇒ Rep. Gr. 68 .
– Remove bolts -2- (1.5 ± 0.2 Nm) and remove operating and
display unit for Climatronic air conditioning system -E87- -1from dash panel.
– Separate connectors on operating and display unit for Clima‐
tronic air conditioning system -E87- .
3.3.2 Installing
Install in reverse order.
44 Rep. Gr.87 - Air conditioning system
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
3.4 Connectors on Climatronic control unit J255-
3.4.1 Pin assignment for multi-pin connectors
A, B and C on back of Climatronic con‐
trol unit -J255-
Special tools and workshop equipment required
♦ Test box -V.A.G 1598/42-
♦ Adapter cable -V.A.G 1598/47-
♦ Template -1598/47-2-
20-pin connector, T20c in current flow diagram -A-
1 - Sunlight penetration photosensor 2 -G134- or sunlight pene‐
tration photosensor -G107- , signal
2 - High-pressure sender -G65-
3 - Sunlight penetration photosensor 2 -G134- or sunlight pene‐
tration photosensor -G107- , signal
4 - From calendar week 45/2007: air quality sensor -G238- , signal
5 - CAN, high
6 - CAN, low
9 - + 5 V for sunlight penetration photosensor 2 -G134- or sunlight
penetration photosensor -G107-
10 - Heated driver seat control unit -J131- (optional)
11 - Heated front passenger seat control unit -J132- (optional)
12 - Terminal 75 (optional)
13 - Left vent temperature sender -G150-
14 - Right vent temperature sender -G151-
16 - Positive connection (15a) or positive connection (30a) for
vehicles with supplementary heating and air quality sensor G238-
17 - Signal earth of senders
18 - Air conditioning system compressor regulating valve -N280-
19 - Terminal 31
20 - Positive connection (15a) or positive connection (30a) for
vehicles with supplementary heating.
3. Air conditioning system with automatic regulation “Climatronic” 45
Page 50
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
16-pin connector, T16c in current flow diagram -B-
1 - + 5V for control motor
2 - Potentiometer for left temperature flap control motor -G220-
3 - Potentiometer for right temperature flap control motor -G221-
4 - Potentiometer for defroster flap control motor -G135-
5 - Potentiometer for centre flap control motor -G112-
6 - Vehicles up to calendar week 17/2007: potentiometer for air
recirculation flap control motor -G143- . Vehicles from calendar
week 18/2007: potentiometer for air recirculation flap control mo‐
tor -G143- was discontinued.
7 - Vehicles up to calendar week 17/2007: potentiometer for air
flow flap control motor -G113- . Vehicles from calendar week
18/2007: potentiometer for control motor for fresh air and air re‐
circulation flap and air flow flap -G644- .
8 - Left footwell vent temperature sender -G261-
9 - Right footwell vent temperature sender -G262-
10 - Fresh air intake duct temperature sensor -G89- only installed
up to December 2005
11 - Evaporator temperature sensor -G308- or evaporator output
temperature sender -G263-
14 - Signal earth, potentiometer
16-pin connector, T16d in current flow diagram -C-
1 - Left temperature flap control motor -V158- , cold
2 - Left temperature flap control motor -V158- , warm
3 - Defroster flap control motor -V107- , closed
4 - Defroster flap control motor -V107- , open
5 - Central flap control motor -V70- , chest
6 - Central flap control motor -V70- , footwell
7 - Vehicles up to calendar week 17/2007: air recirculation flap
control motor -V113- , recirculation actuated. From calendar week
18/2007: air recirculation flap control motor -V113- was discon‐
tinued.
8 - Vehicles up to calendar week 17/2007: air recirculation flap
control motor -V113- , fresh air actuated. From calendar week
18/2007: air recirculation flap control motor -V113- was discon‐
tinued.
9 - Vehicles up to calendar week 17/2007: air flow flap control
motor -V71- open. From calendar week 18/2007: control motor
for fresh air and air recirculation flap and air flow flap -V425- (air
recirculation/partial air recirculation)
10 - Vehicles up to calendar week 17/2007: air flow flap control
motor -V71- closed. From calendar week 18/2007: control motor
for fresh air and air recirculation flap and air flow flap -V425- (air
recirculation/increased flow)
11 - Right temperature flap control motor -V159- , cold
12 - Right temperature flap control motor -V159- , warm
15 - Fresh air blower -V2- (PWM actuated)
16 - Fresh air blower -V2- , feedback signal
46 Rep. Gr.87 - Air conditioning system
Page 51
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
3.5 Climatronic - passenger compartment
Note
♦
Disconnect battery before removing components marked ** ⇒
Rep. Gr. 27 .
♦
A label indicates the type and quantity of refrigerant used.
1 - Dash panel**
❑ Removing and installing
⇒ Rep. Gr. 70
2 - Sunlight penetration photo‐
sensor -G107- or sunlight pen‐
etration photosensor 2 -G134-
3 - Centre vents
4 - Right side vent
5 - Vent
❑ Checking: vehicle diag‐
nostic, testing and infor‐
mation system -VAS
5051- (or later model)
❑ Function: controls tem‐
perature flap and fresh
air blower depending on
light intensity
❑ Emergency running in
event of failure: Clima‐
tronic control unit -J255assumes fixed value
❑ Removing and installing
⇒ page 59
❑ Removing and installing
⇒ page 5
❑ Removing and installing
⇒ page 5
6 - Right vent temperature
sender -G151-
❑ Checking: vehicle diag‐
nostic, testing and infor‐
mation system -VAS
5051- (or later model)
❑ Removing and installing
⇒ page 58
7 - Climatronic control unit -J255-
❑ The Climatronic control unit -J255- and the operating and display unit for Climatronic air conditioning
system -E87- are a single component which cannot be dismantled.
❑ Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
❑ Removing and installing ⇒ page 44
❑ Renewing: initiate basic settings using vehicle diagnosis, testing and information system -VAS 5051- or
successor model ⇒ page 42
8 - Vehicles up to calendar week 17/2007: air flow flap control motor -V71- ; from calendar week 18/2007: control
motor for fresh air and air recirculation flap and air flow flap -V425-
❑ Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
❑ Removing and installing ⇒ page 60 for vehicles up to calendar week 17/2007
3. Air conditioning system with automatic regulation “Climatronic” 47
Page 52
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
❑ Removing and installing ⇒ page 61 for vehicles up to calendar week 18/2007
❑ Renewing: initiate basic settings using vehicle diagnosis, testing and information system -VAS 5051- or
successor model ⇒ page 42
9 - Vehicles up to calendar week 17/2007: air recirculation flap control motor -V113- ; from calendar week
18/2007: air recirculation flap control motor -V113- was discontinued
❑ Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
❑ Removing and installing ⇒ page 60
❑ Renewing: initiate basic settings using vehicle diagnosis, testing and information system -VAS 5051- or
successor model ⇒ page 42
10 - Fresh air intake duct temperature sensor -G89-
❑ Only installed in vehicles up to 12.05
❑ Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
❑ Function: temperature sensor controls temperature flap and fresh air blower, depending on temperature
❑ To dismantle, remove dash panel ⇒ Rep. Gr. 70
11 - Right footwell vent
❑ Removing and installing ⇒ page 7
12 - Fresh air blower -V2- with fresh air blower control unit -J126-
❑ Vehicles as of 11.05; fresh air blower control unit -J126- can be renew individually
❑ Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
❑ Removing and installing fresh air blower -V2- ⇒ page 3
❑ Removing and installing fresh air blower control unit -J126- ⇒ page 53
13 - Connector
14 - Baffle plate for heater unit
❑ Removing ⇒ page 2
15 - Sealing cap
❑ Fitted only in vehicles without air duct to vent in rear centre console.
16 - Dust and pollen filter
❑ With activated charcoal filter
❑ Removing and installing ⇒ page 4
17 - Connection for centre console air duct (optional)
❑ To remove, centre console must be removed ⇒ Rep. Gr. 68 .
18 - Air duct for right rear footwell
❑ Removing and installing ⇒ page 6
19 - Air duct for left rear footwell
❑ Removing and installing ⇒ page 6
20 - Evaporator temperature sensor -G308- or evaporator output temperature sender -G263-
❑ Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
Note
❑ Removing and installing ⇒ page 55
21 - Right temperature flap control motor -V159-
❑ Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
❑ Removing and installing ⇒ page 65
❑ Renewing: initiate basic settings using vehicle diagnosis, testing and information system -VAS 5051- or
successor model ⇒ page 42
22 - Auxiliary air heater element -Z35-
❑ Installed only in vehicles with diesel engines without auxiliary coolant heater.
48 Rep. Gr.87 - Air conditioning system
Page 53
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❑ Checking: with vehicle diagnostic, testing and information system -VAS 5051- (or later model), under
Heating, ventilation, air conditioning; Systems capable of self-diagnosis; Auxiliary heating; Electrical
components.
❑ Removing and installing ⇒ page 15
23 - Heat exchanger
❑ Removing and installing ⇒ page 12
24 - Central flap control motor -V70-
❑ Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
❑ Removing and installing ⇒ page 66
❑ Renewing: initiate basic settings using vehicle diagnosis, testing and information system -VAS 5051- or
successor model ⇒ page 42
25 - Left footwell vent
❑ Removing and installing ⇒ page 7
26 - Left temperature flap control motor -V158-
❑ Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
❑ Removing and installing ⇒ page 64
❑ Renewing: initiate basic settings using vehicle diagnosis, testing and information system -VAS 5051- or
successor model ⇒ page 42
27 - Left footwell vent temperature sender -G261-
❑ Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
❑ Removing ⇒ page 54
28 - Defroster flap control motor -V107-
Heating, air conditioning - Edition 02.2008
Golf 2004 ➤
❑ Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
❑ Removing and installing ⇒ page 63
❑ Renewing: initiate basic settings using vehicle diagnosis, testing and information system -VAS 5051- or
successor model ⇒ page 42
29 - Heater and air conditioning unit
❑ Removing and installing ⇒ page 84
❑ Dismantling and assembling ⇒ page 50
30 - Right footwell vent temperature sender -G262-
❑ Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
❑ Removing ⇒ page 54
31 - Left side vent
32 - Left vent temperature sender -G150-
❑ Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
❑ Removing and installing ⇒ page 58
3. Air conditioning system with automatic regulation “Climatronic” 49
Page 54
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
3.6 Dismantling and assembling heater and air conditioner unit “Climatronic”
1 - Central flap control motor V70-
❑ Checking: vehicle diag‐
nostic, testing and infor‐
mation system -VAS
5051- (or later model)
❑ Removing and installing
⇒ page 66
❑ Renewing: initiate basic
settings using vehicle
diagnosis, testing and
information system VAS 5051- or successor
model ⇒ page 42
2 - Left temperature flap con‐
trol motor -V158-
❑ Checking: vehicle diag‐
nostic, testing and infor‐
mation system -VAS
5051- (or later model)
❑ Removing and installing
⇒ page 64
❑ Renewing: initiate basic
settings using vehicle
diagnosis, testing and
information system VAS 5051- or successor
model ⇒ page 42
3 - Defroster flap control motor
-V107❑ Checking: vehicle diag‐
nostic, testing and infor‐
mation system -VAS
5051- (or later model)
❑ Removing and installing
⇒ page 63
❑ Renewing: initiate basic settings using vehicle diagnosis, testing and information system -VAS 5051- or
successor model ⇒ page 42
4 - Bracket
5 - Bolts
❑ Bolts must be removed to separate air distribution housing from evaporator housing.
6 - Cover
7 - Vehicles up to calendar week 17/2007: air recirculation flap control motor -V113- ; from calendar week
18/2007: air recirculation flap control motor -V113- was discontinued
❑ Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
❑ Removing and installing ⇒ page 60
❑ Renewing: initiate basic settings using vehicle diagnosis, testing and information system -VAS 5051- or
successor model ⇒ page 42
8 - Vehicles up to calendar week 17/2007: air flow flap control motor -V71- ; from calendar week 18/2007: control
motor for fresh air and air recirculation flap and air flow flap -V425-
❑ Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
❑ Removing and installing ⇒ page 60 for vehicles up to calendar week 17/2007
❑ Removing and installing ⇒ page 61 for vehicles up to calendar week 18/2007
50 Rep. Gr.87 - Air conditioning system
Page 55
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
❑ Renewing: initiate basic settings using vehicle diagnosis, testing and information system -VAS 5051- or
successor model ⇒ page 42
9 - Air intake housing
❑ With air recirculation flap
❑ With air flow flap (Climatronic).
10 - Fresh air intake duct temperature sensor -G89-
❑ Only installed in vehicles up to 12.05
❑ Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
❑ Function: temperature sensor controls temperature flap and fresh air blower, depending on temperature
❑ To dismantle, remove dash panel ⇒ Rep. Gr. 70
11 - Upper part of evaporator housing
❑ Dismantling and assembling evaporator housing ⇒ page 52
12 - Lower part of evaporator housing
❑ Dismantling and assembling evaporator housing ⇒ page 52
13 - Evaporator
❑ Removing and installing ⇒ page 103
14 - Evaporator temperature sensor -G308- or evaporator output temperature sender -G263-
❑ Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
Note
❑ Removing and installing ⇒ page 55
15 - Connections for glove box cooling
❑ To dismantle, remove glove compartment ⇒ Rep. Gr. 68
16 - Refrigerant hose for glove compartment cooling
❑ To dismantle, remove glove compartment ⇒ Rep. Gr. 68
❑ Installation position of connections for glove compartment cooling ⇒ page 52
17 - Fresh air blower -V2- with fresh air blower control unit -J126-
❑ Vehicles as of 11.05; fresh air blower control unit -J126- can be renew individually
❑ Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
❑ Removing and installing fresh air blower -V2- ⇒ page 3
❑ Removing and installing fresh air blower control unit -J126- ⇒ page 53
18 - Dust and pollen filter
❑ With activated charcoal filter
❑ Removing and installing ⇒ page 4
19 - Cover
❑ For dust and pollen filter.
20 - Heat exchanger
❑ Removing and installing ⇒ page 12
21 - Right temperature flap control motor -V159-
❑ Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
❑ Removing and installing ⇒ page 65
❑ Renewing: initiate basic settings using vehicle diagnosis, testing and information system -VAS 5051- or
successor model ⇒ page 42
22 - Heat exchanger trim
23 - Auxiliary air heater element -Z35-
❑ Installed only in vehicles with diesel engines with no supplementary heater
3. Air conditioning system with automatic regulation “Climatronic” 51
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
❑ Checking: with vehicle diagnostic, testing and information system -VAS 5051- (or later model), under
Heating, ventilation, air conditioning; Systems capable of self-diagnosis; Auxiliary heating; Electrical
components.
❑ Removing and installing ⇒ page 15 .
24 - Air distribution housing
Installation position of connections for glove compartment cooling
1 - Connecting piece
2 - Valve
3.7 Assembly overview - evaporator hous‐
ing
– Remove heating and air conditioning unit ⇒ page 84 .
– Separate air distribution housing/evaporator housing from
heater and air conditioning unit ⇒ page 24 .
52 Rep. Gr.87 - Air conditioning system
Page 57
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Heating, air conditioning - Edition 02.2008
1 - Lower part of evaporator
housing
❑ Dismantling and assem‐
bling ⇒ page 25
2 - Evaporator
❑ Check insulation. It
must be complete.
❑ Removing and installing
⇒ page 103
3 - Clip
4 - Upper part of evaporator
housing
❑ Dismantling and assem‐
bling ⇒ page 25
5 - Bolt
6 - Sealing and insulation
❑ Heat insulation for ex‐
pansion valve.
❑ Removing and installing
⇒ page 103
7 - Bracket
❑ Removing and installing
⇒ page 103
3.8 Removing and installing fresh air blower control unit -J126-
Golf 2004 ➤
3.8.1 Removing
– Remove fresh air blower -V2- ⇒ page 3 .
– Disconnect connector -1- to fresh air blower -V2- .
– Remove bolts -arrows-.
3.8.2 Installing
Install in reverse order.
3. Air conditioning system with automatic regulation “Climatronic” 53
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
3.9 Removing and installing left footwell vent temperature sender -G261-
3.9.1 Removing
– Remove dash panel ⇒ Rep. Gr. 70 .
– Remove bolts -1- and -3- (9 ± 1.3 Nm).
– Remove retainer -2-.
– Pull connector off left footwell vent temperature sender -G261-
-1-.
– Turn left footwell vent temperature sender -G261- -1- 90° and
remove it from housing.
3.9.2 Installing
Install in reverse order.
3.10 Removing and installing right footwell vent temperature sender -G262-
Note
3.10.1 Removing
For better illustration, right footwell vent temperature sender G262- is shown with dash panel removed. The dash panel need
not be removed.
54 Rep. Gr.87 - Air conditioning system
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Heating, air conditioning - Edition 02.2008
– Remove glove compartment ⇒ Rep. Gr. 68 .
– Pull connector off right footwell vent temperature sender -
G262- -1-.
– Turn right footwell vent temperature sender -G262- -1- 90° and
remove it from housing.
3.10.2 Installing
Install in reverse order.
3.11 Removing and installing evaporator
temperature sensor -G308- or evapora‐
tor output temperature sender -G263-
3.11.1 Removing
– Remove right footwell trim -1-.
– Pull connector off evaporator temperature sensor -G308- or
evaporator output temperature sender -G263- -1-.
– Turn evaporator temperature sensor -G308- or evaporator
output temperature sender -G263- in -direction of arrow- and
pull it out.
Golf 2004 ➤
3.11.2 Installing
Install in reverse order.
3.12 Ambient temperature sensor -G17-
3.12.1 Removing
– Pull centre grille out of fasteners in front bumper cover ⇒ Rep.
Gr. 63 .
3. Air conditioning system with automatic regulation “Climatronic” 55
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
– Unclip ambient temperature sensor -G17- from retainer and
separate electrical connector.
3.12.2 Installing
Note
Ensure proper seating of electrical connection to prevent intrusion
of splashed water.
3.13 Function of air quality sensor -G238-
♦ The air quality sensor detects noxious substances in the am‐
bient air (primarily petrol and/or diesel fumes).
♦ The Climatronic control unit -J255- evaluates the signal from
the air quality sensor -G238- . The air conditioning system is
actuated depending on the degree and manner of ambient air
pollution.
At an ambient temperature higher than approx. +2° C, air recir‐
culation is actuated even when there is a minimal increase in
noxious substances in the ambient air.
At an ambient temperature between approx. +2° C and approx.
-5° C, air recirculation is not actuated until there is a strong in‐
crease in noxious substances in the ambient air. The compressor
is also switched on at the same time.
At an ambient temperature less than approx. -5° C, air recircula‐
tion is not actuated until there is a strong increase in noxious
substances in the outside air, but only for approx. 15 seconds,
and the compressor is not started. When the concentration de‐
creases, the air conditioning system is switched back to fresh air
mode.
♦ The “automatic air recirculation” function can be switched off
at any time. If the function is active, the compressor will be
switched on even at an ambient temperature below +2° C
when “automatic air recirculation” is required. However, even
with this function, it is not possible to operate the compressor
at temperatures below -5° C.
♦ On vehicles with “automatic air recirculation”, the air condi‐
tioner compressor can also be switched on at temperatures
down to approx. -5° C even if the recirculated air function has
been activated manually.
♦ So that the air conditioning system does not operate continu‐
ally in air recirculation mode in areas with consistently high
levels of pollutants, the "intelligent" sensor adapts its sensitiv‐
ity to the prevailing environmental pollution.
♦ If the level of noxious substances in the ambient air remains
relatively high over a long period of time, the intelligent sensor
starts to adapt to the change in environmental conditions so
that, generally, the demand for recirculated air lasts less than
12 minutes in areas where the ambient air exhibits a constant
56 Rep. Gr.87 - Air conditioning system
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level of pollution. If a series of pollution peaks occur, the air
conditioning system may operate over a longer period of time
in air recirculation mode.
♦ A certain amount of time is required for repositioning of the air
conditioning system flaps. To prevent noxious substances
from entering the passenger compartment while the flaps are
closing (e.g. when driving through a cloud of diesel smoke), a
dust and pollen filter with an activated charcoal layer is instal‐
led. A saturated filter cannot perform this task and should be
renewed.
♦ To prevent too frequent operation of the recirculation/fresh air
flap, the flap is not actuated immediately if there is a minimal
increase in noxious substances in the ambient air (the sensor
does not send a request to the Climatronic control unit -J255- ).
The effect of the activated charcoal filter in the dust and pollen
filter is adequate for this.
♦ To prevent the air recirculation/fresh air flap from switching too
frequently, the sensor's request for “automatic air recircula‐
tion” continues for at least 25 seconds (minimum waiting pe‐
riod) even if the air pollutants decrease to a level that no longer
requires air recirculation.
♦ If the air conditioner compressor is switched off (e.g. in ECON
mode), the maximum period of “automatic air recirculation” is
limited to approx. 15 seconds by the Climatronic control unit J255- so that condensation does not develop on the windows.
♦ To clear condensation from windows as quickly as possible,
the Climatronic control unit -J255- does not permit air recircu‐
lation in the “defrost” mode.
♦ The air quality sensor -G238- requires approx. 30 seconds to
become operational once the ignition has been switched on
(warm-up time). During this time, the sensor can send no re‐
quest for “automatic air recirculation” to the Climatronic control
unit -J255- .
♦ The air quality sensor -G238- is a highly sensitive electronic
component which direct contact with solvents, fuels and cer‐
tain chemical compositions could damage beyond repair. For
this reason, do not install sensors that may have come into
contact with these substances.
Heating, air conditioning - Edition 02.2008
Golf 2004 ➤
3.14 Removing and installing air quality sen‐
sor -G238-
Note
♦
The air quality sensor -G238- is installed on the air intake grille
in the front right (from the driver's perspective) of the plenum
chamber.
♦
The air quality sensor -G238- is a highly sensitive electronic
component which direct contact with solvents, fuels and cer‐
tain chemical compositions could damage beyond repair.
♦
Do not install a sensor that has been kept, for example, in a
tool box.
♦
Do not place a removed sensor in an area where it can come
into contact with solvents, fuels and certain chemical com‐
pounds (fluids or vapours).
3.14.1 Removing
– Remove plenum chamber cover ⇒ Rep. Gr. 64 .
3. Air conditioning system with automatic regulation “Climatronic” 57
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
– Remove cover -1- from plenum chamber.
– Separate connector on air quality sensor -G238- .
– Release air quality sensor -G238- -1- and turn out of retainer
on air intake grille.
3.14.2 Installing
– Install in reverse order.
3.15 Removing left vent temperature sender
-G150- and right vent temperature send‐
er -G151-
Note
Removal of senders on both sides is identical, but one is a mirror
image of the other.
– Remove left or right dash panel cover ⇒ Rep. Gr. 70 .
– Pull connector -1- off vent temperature sender -2-.
– Turn vent temperature sender -2- 90° in -direction of arrow-
and remove from dash panel.
58 Rep. Gr.87 - Air conditioning system
Page 63
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Heating, air conditioning - Edition 02.2008
3.16 Removing sunlight penetration photo‐
sensor -G107- or sunlight penetration
photosensor 2 -G134-
– Unclip sunlight penetration photosensor -1- out of dash panel
using an appropriate tool.
– Pull connector off sunlight penetration photosensor.
3.17 Checking condensation water drainage
– Remove footwell trim on front passenger side.
Note
♦
It must be possible to push condensation water drainage hose
-1- onto air conditioner unit connection without tension.
♦
The condensation drain hose must be fitted securely to con‐
densation drain connection on heater and air conditioning unit.
3.18 Renewing control motors for air condi‐
Special tools and workshop equipment required
♦ Vehicle diagnosis, testing and information system -VAS 5051-
hose on air conditioner unit
tioning regulation
or successor models.
Golf 2004 ➤
First carry out the following work:
– Switch off all electrical consumers.
– Switch off ignition.
– Pull out ignition key.
3. Air conditioning system with automatic regulation “Climatronic” 59
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
3.19 Removing and installing air recirculation flap control motor -V113-
3.19.1 Removing
– Remove glove compartment ⇒ Rep. Gr. 68 .
– Remove cover for control motors.
– If necessary, mark connector -A- (to prevent interchanging if
several connectors are separated at the same time.)
– Separate connector -A-.
– Release catches -C- and -D- for retainer -B- on intake duct and
remove retainer -B- (to rear).
– Remove control motor -A- from intake duct.
3.19.2 Installing
Install in reverse order.
Note
♦
After installation, check operation of air recirculation flap.
♦
Initiate “basic settings” function using vehicle diagnosis, test‐
ing and information system -VAS 5051- or successor model
⇒ page 42 .
3.20 Removing and installing air flow flap control motor -V71- for vehicles up to calendar week 17/2007
3.20.1 Removing
– Remove glove compartment ⇒ Rep. Gr. 68 .
Note
The position of the air flow flap must not be changed.
– Remove cover -1-.
60 Rep. Gr.87 - Air conditioning system
Page 65
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Heating, air conditioning - Edition 02.2008
– Remove air recirculation flap control motor -V113-
⇒ page 60 .
– Separate connector from air flow flap control motor -V71- -2-.
– Pull off air flow flap control motor -V71- -2-.
Golf 2004 ➤
3.20.2 Installing
Install in reverse order.
Note
♦
After installation, check operation of air flow flap.
♦
Initiate “basic settings” function using vehicle diagnosis, test‐
ing and information system -VAS 5051- or successor model
⇒ page 42 .
3.21 Removing and installing control motor
3.21.1 Removing
– Remove glove compartment ⇒ Rep. Gr. 68 .
– Remove bolts -1- (1.4 Nm).
– Turn control motor for fresh air and air recirculation flap and
for fresh air and air recirculation flap and
air flow flap -V425- for vehicles from cal‐
endar week 18/2007
air flow flap -V425- -2- approx. 15° in direction of -arrow- and
then pull off air intake housing.
3. Air conditioning system with automatic regulation “Climatronic” 61
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
– Disconnect connector -1- from control motor for fresh air and
air recirculation flap and air flow flap -V425- .
Note
The position of the air flow flap must not be changed.
3.21.2 Installing
Install in reverse order, noting the following:
The control motor for fresh air and air recirculation flap and air
flow flap -V425- fits on the cable cam in one position only.
Note
♦
After installation, check operation of air flow flap and air recir‐
culation flap.
♦
Initiate “basic setting” function using vehicle diagnostic, testing
and information system -VAS 5051- (or later model)
⇒ page 42 .
3.22 Removing and installing setting unit for fresh air and air recirculation flap and air flow flap
3.22.1 Removing
– Remove control motor for fresh air and air recirculation flap
and air flow flap -V425- ⇒ page 61 .
– Release catches -arrows- from adjusting lever -1-.
– Remove adjusting levers from cable cam.
– Pull off cable cam -2- from air intake housing.
3.22.2 Installing
Note
When fitting the cable cam, ensure that the guide pin of the ad‐
justing lever for the air flow flap sits in the groove.
62 Rep. Gr.87 - Air conditioning system
Page 67
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– Push cable cam -1- onto air intake housing.
When doing this, also ensure that the guide pin of the adjusting
lever for the air flow flap sits in the groove.
– Fit adjusting lever for air recirculation flap and lock.
3.23 Removing and installing defroster flap
3.23.1 Removing
– Remove dash panel ⇒ Rep. Gr. 70 .
– Remove bolts -1- and -3- (9 ± 1.3 Nm).
Note
control motor -V107-
Heating, air conditioning - Edition 02.2008
Golf 2004 ➤
– Remove bracket -2-.
– Mark connector -C- to control motor (danger of interchanging
with other connectors of same construction).
– Separate connector -C- on defroster flap control motor -
V107- .
– Unscrew securing bolts -A- (1.4 Nm) and remove defroster flap
control motor -V107- -B-.
– Remove lever -E- of control motor from connecting rod -D-.
3.23.2 Installing
Install in reverse order.
Note
♦
After installation, check operation of defroster flap.
♦
Initiate “basic settings” function using vehicle diagnosis, test‐
ing and information system -VAS 5051- or successor model
⇒ page 42 .
3. Air conditioning system with automatic regulation “Climatronic” 63
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
3.24 Removing and installing left tempera‐
ture flap control motor -V158-
3.24.1 Removing
– Remove left footwell vent ⇒ page 7 .
– Remove centre console trim from left footwell.
– Remove data bus diagnostic interface -J533- from ⇒ Rep. Gr.
97 .
– Remove bolts -3- (9 Nm ±1.3 Nm).
– Do not remove bolts -1-.
– Do not remove bracket -2-.
– Press bracket in direction of brake pedal -arrow- and secure it
on brake pedal with cable tie.
– Mark connector -C- to control motor (danger of interchanging
with other connectors of same construction).
– Separate connector -C- on left temperature flap control motor
-V158- .
– Remove cover -A-.
– Unscrew securing bolts -D- (1.4 Nm) and remove left temper‐
ature flap control motor -V158- -B-.
– Remove lever -E- of control motor from connecting rod -F-.
3.24.2 Installing
Note
Optimised control motors are marked with an “X”.
To ease assembly, use an approx. 2 mm shorter oval-head screw
-N 103 254 01- .
64 Rep. Gr.87 - Air conditioning system
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Heating, air conditioning - Edition 02.2008
– Cut off bracket -1- from old left temperature flap control motor
-V158- , e.g. using side cutting pliers.
– Position new left temperature flap control motor -V158-
marked with an “X” with shortened oval-head screw -2- and
cut off bracket -1- on bracket -3- on blower box.
Note
♦
After installation, check operation of left temperature flap.
♦
Initiate “basic settings” function using vehicle diagnosis, test‐
ing and information system -VAS 5051- or successor model
⇒ page 42 .
Golf 2004 ➤
3.25 Removing and installing right tempera‐
ture flap control motor -V159-
3.25.1 Removing
– Remove glove compartment ⇒ Rep. Gr. 68 .
– Remove right footwell vent ⇒ page 7 .
– Separate connector on right temperature flap control motor -
V159- .
– Unscrew securing bolts -1- (1.4. Nm) and remove right tem‐
perature flap control motor -V159- .
– Unhook lever -2- from right temperature flap control motor -
V159- .
3.25.2 Installing
Install in reverse order.
Note
♦
After installation, check operation of right temperature flap.
♦
Initiate “basic settings” function using vehicle diagnosis, test‐
ing and information system -VAS 5051- or successor model
⇒ page 42 .
3. Air conditioning system with automatic regulation “Climatronic” 65
Page 70
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
3.26 Removing and installing central flap control motor -V70-
3.26.1 Removing
– Remove dash panel ⇒ Rep. Gr. 70 .
– Separate connector on central flap control motor -V70- .
– Unscrew securing bolts -1- (1.4 Nm) and remove central flap
control motor -V70- .
3.26.2 Installing
Install in reverse order.
Note
♦
After installation, check operation of central flap.
♦
Initiate “basic settings” function using vehicle diagnosis, test‐
ing and information system -VAS 5051- or successor model
⇒ page 42 .
66 Rep. Gr.87 - Air conditioning system
Page 71
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Heating, air conditioning - Edition 02.2008
4 Removing and installing ancillary
bracket for air conditioner compres‐
sor
4.1 Engine codes: AZV, BDK, BJB, BKC, BKD, BLS, BMM, BMN, BRM, BRU, BVB, BXE, BXF and BXJ
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331/- (5…50 Nm)
Note
♦
The ancillary bracket for air conditioner compressor and rela‐
ted components can be removed and installed without the
refrigerant circuit being opened.
♦
To remove poly V-belt ⇒ Rep. Gr. 13 .
♦
Poly V-belt routing ⇒ page 69
Golf 2004 ➤
4. Removing and installing ancillary bracket for air conditioner compressor 67
Page 72
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
1 - Hexagon bolt M10×65
❑ 45 Nm
2 - Hexagon bolt M10×45
❑ 45 Nm
3 - Hexagon bolt M10×45
❑ 45 Nm
4 - Hexagon bolt M10x45
❑ 45 Nm
5 - Hexagon bolt M10×65
❑ 45 Nm
6 - Hexagon bolt M10×65
❑ 45 Nm
7 - Hexagon bolt M8x100
❑ Qty. 3
❑ 25 Nm
8 - Ancillary bracket for alter‐
nator and air conditioner com‐
pressor
♦ Number on ancillary unit
bracket -03G 903 143 A-
Removing
– Remove alternator ⇒
Rep. Gr. 27 .
– Loosen air conditioner
compressor and re‐
move hexagon bolt -7-.
Remove air conditioner
compressor from ancil‐
lary bracket and secure
to body with suitable
material (e.g.welding
wire) ⇒ page 69 .
– Remove bolts -1- through -6- and remove ancillary bracket from cylinder block.
♦ Strictly observe tightening sequence of securing bolts:
– Tighten bolts (positions -1-…-6-) one after the other
9 - Dowel sleeves
❑ Qty. 2
❑ Ensure proper seating between ancillary unit bracket and air conditioner compressor
10 - Dowel sleeves
❑ Qty. 2
❑ Ensure proper seating between ancillary unit bracket and engine block.
11 - Air conditioner compressor
❑ Removing and installing ⇒ page 94
68 Rep. Gr.87 - Air conditioning system
Page 73
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Heating, air conditioning - Edition 02.2008
Securing air conditioner compressor to body
If compressor is removed without opening refrigerant circuit, it
should be secured to body using suitable material, for example,
welding wire.
When doing this, ensure refrigerant hoses on air conditioner com‐
pressor are not stressed.
Note
♦
When installing poly V-belt, ensure that it is correctly seated
on poly V-belt pulley.
♦
Finally, place poly V-belt over pulley of air conditioner com‐
pressor.
Poly V-belt routing
1 - Tensioning roller
2 - Poly V-belt pulley for alternator
3 - Poly V-belt pulley for air conditioner compressor
4 - Poly V-belt
5 - Poly V-belt pulley for crankshaft
4.2 Engine codes: BCA, BUD
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331/- (5…50 Nm)
Note
♦
The ancillary bracket for air conditioner compressor and rela‐
ted components can be removed and installed without the
refrigerant circuit being opened.
♦
To remove poly V-belt ⇒ Rep. Gr. 13 .
♦
Poly V-belt routing ⇒ page 71
Golf 2004 ➤
4. Removing and installing ancillary bracket for air conditioner compressor 69
Page 74
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
1 - Hexagon bolt M10×55
❑ 50 Nm
❑ Qty. 2
2 - Ancillary bracket for alter‐
nator and air conditioner com‐
pressor
♦ Number on ancillary unit
bracket -036 260 885-
Removing
– Remove alternator ⇒
Rep. Gr. 27 .
– Loosen air conditioner
compressor and re‐
move hexagon bolt -4-.
Remove air conditioner
compressor from ancil‐
lary bracket and secure
to body with suitable
material (e.g.welding
wire) ⇒ page 70 .
– Remove bolts -1- and
-3- and remove ancillary
bracket from cylinder
block.
3 - Hexagon bolt M10×45
❑ 50 Nm
❑ Qty. 2
4 - Hexagon bolt M8x100
❑ 25 Nm
5 - Air conditioner compressor
❑ Removing and installing
⇒ page 94
6 - Dowel sleeves
❑ Qty. 2
❑ Ensure proper seating between ancillary unit bracket and air conditioner compressor
Securing air conditioner compressor to body
If compressor is removed without opening refrigerant circuit, it
should be secured to body using suitable material, for example,
welding wire.
When doing this, ensure refrigerant hoses on air conditioner com‐
pressor are not stressed.
Note
♦
When installing poly V-belt, ensure that it is correctly seated
on poly V-belt pulley.
♦
Finally, place poly V-belt over pulley of air conditioner com‐
pressor.
70 Rep. Gr.87 - Air conditioning system
Page 75
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Poly V-belt routing
1 - Poly V-belt pulley for crankshaft
2 - Tensioning roller
3 - Poly V-belt pulley for alternator
4 - Poly V-belt
5 - Poly V-belt pulley for air conditioner compressor
4.3 Engine codes: BLG, BMY
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331/- (5…50 Nm)
Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
Note
♦
The ancillary bracket for air conditioner compressor and rela‐
ted components can be removed and installed without the
refrigerant circuit being opened.
♦
To remove poly V-belt ⇒ Rep. Gr. 13 .
♦
Poly V-belt routing ⇒ page 73
4. Removing and installing ancillary bracket for air conditioner compressor 71
Page 76
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
1 - Air conditioner compressor
❑ Removing and installing
⇒ page 94
2 - Hexagon bolt M8x100
❑ 25 Nm
3 - Hexagon bolt M10×45
❑ 50 Nm
4 - Ancillary bracket for alter‐
nator and air conditioner com‐
pressor
♦ Number on ancillary unit
bracket -03C 903 143 A-
Removing
– Remove alternator ⇒
Rep. Gr. 27 .
– Loosen air conditioner
compressor and re‐
move hexagon bolt -2-.
Remove air conditioner
compressor from ancil‐
lary bracket and secure
to body with suitable
material (e.g.welding
wire) ⇒ page 72 .
– Remove bolts -3- and
remove ancillary brack‐
et from cylinder block.
5 - Dowel sleeves
❑ Qty. 2
❑ Ensure proper seating
between ancillary unit
bracket and air condi‐
tioner compressor
Securing air conditioner compressor to body
If compressor is removed without opening refrigerant circuit, it
should be secured to body using suitable material, for example,
welding wire.
When doing this, ensure refrigerant hoses on air conditioner com‐
pressor are not stressed.
Note
♦
When installing poly V-belt, ensure that it is correctly seated
on poly V-belt pulley.
♦
Finally, place poly V-belt over pulley of air conditioner com‐
pressor.
72 Rep. Gr.87 - Air conditioning system
Page 77
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.
Heating, air conditioning - Edition 02.2008
Poly V-belt routing
1 - Poly V-belt pulley for cooling system pump
2 - Poly V-belt pulley for crankshaft
3 - Lower tensioning roller
4 - Upper tensioning roller
5 - Poly V-belt pulley for alternator
6 - Poly V-belt pulley for air conditioner compressor
7 - Poly V-belt
4.4 Engine codes: BAG, BKG, BLF, BLN, BLP and CAX
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331/- (5…50 Nm)
Golf 2004 ➤
Note
♦
♦
♦
The ancillary bracket for air conditioner compressor and rela‐
ted components can be removed and installed without the
refrigerant circuit being opened.
To remove poly V-belt ⇒ Rep. Gr. 13 .
Poly V-belt routing ⇒ page 75
4. Removing and installing ancillary bracket for air conditioner compressor 73
Page 78
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
1 - Hexagon bolt M8×45
❑ Qty. 3
❑ 25 Nm
2 - Hexagon bolt M8x100
❑ Qty. 3
❑ 25 Nm
3 - Air conditioner compressor
❑ Removing and installing
⇒ page 94
4 - Dowel sleeves
❑ Qty. 2
❑ Ensure proper seating
between ancillary unit
bracket and air condi‐
tioner compressor
5 - Ancillary bracket for air con‐
ditioner compressor
Number on ancillary unit
bracket -1K0 260.885 B-
Removing
– Loosen air conditioner
compressor and re‐
move hexagon bolt -2-.
Remove air conditioner
compressor from ancil‐
lary bracket and secure
to body with suitable
material (e.g.welding
wire) ⇒ page 74 .
– Remove bolts -1- and
remove ancillary brack‐
et -5- from cylinder
block.
Securing air conditioner compressor to body
If compressor is removed without opening refrigerant circuit, it
should be secured to body using suitable material, for example,
welding wire.
When doing this, ensure refrigerant hoses on air conditioner com‐
pressor are not stressed.
Note
♦
When installing poly V-belt, ensure that it is correctly seated
on poly V-belt pulley.
♦
Finally, place poly V-belt over pulley of air conditioner com‐
pressor.
74 Rep. Gr.87 - Air conditioning system
Page 79
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.
Heating, air conditioning - Edition 02.2008
Poly V-belt routing
1 - Poly V-belt pulley for cooling system pump
2 - Poly V-belt pulley for crankshaft
3 - Lower tensioning roller
4 - Upper tensioning roller
5 - Poly V-belt pulley for alternator
6 - Poly V-belt pulley for air conditioner compressor
7 - Poly V-belt
4.5 Engine codes: AXW, AXX, BGU, BHY,
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331- (5…50 Nm)
BLR, BLX, BLY, BPY, BSE, BSF, BVX,
BVY, BVZ, BWA, BYD, CAWB, CBFA
and CCTA
Golf 2004 ➤
Note
♦
The ancillary bracket for air conditioner compressor and rela‐
ted components can be removed and installed without the
refrigerant circuit being opened.
♦
To remove poly V-belt ⇒ Rep. Gr. 13 .
♦
Poly V-belt routing ⇒ page 77
4. Removing and installing ancillary bracket for air conditioner compressor 75
Page 80
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
1 - Socket head flange bolt
M10×45
❑ Dowel hole
❑ Observe different tor‐
ques:
❑ 1.6 l injection engine
and 2.0 l FSI engine:
52 Nm
❑ 2.0 l turbo FSI engine:
40 Nm
2 - Socket head flange bolt
M10×45
❑ Observe different tor‐
ques:
❑ 1.6 l injection engine
and 2.0 l FSI engine:
52 Nm
❑ 2.0 l turbo FSI engine:
40 Nm
3 - Socket head flange bolt
M10×45
❑ Observe different tor‐
ques:
❑ 1.6 l injection engine
and 2.0 l FSI engine:
52 Nm
❑ 2.0 l turbo FSI engine:
40 Nm
4 - Socket head flange bolt
M10×45
❑ Observe different tor‐
ques:
❑ 1.6 l injection engine
and 2.0 l FSI engine:
52 Nm
❑ 2.0 l turbo FSI engine: 40 Nm
5 - Air conditioner compressor
❑ Removing and installing ⇒ page 94
6 - Hexagon bolt M8x100
❑ Qty. 3
❑ 25 Nm
7 - Socket head flange bolt M10×45
❑ Dowel hole
❑ Observe different torques:
❑ 1.6 l injection engine and 2.0 l FSI engine: 52 Nm
❑ 2.0 l turbo FSI engine: 40 Nm
8 - Socket head flange bolt M10×45
❑ Observe different torques:
❑ 1.6 l injection engine and 2.0 l FSI engine: 52 Nm
❑ 2.0 l turbo FSI engine: 40 Nm
9 - Dowel sleeves
❑ Qty. 2
❑ Ensure proper seating between ancillary bracket and air conditioner compressor.
76 Rep. Gr.87 - Air conditioning system
Page 81
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
10 - Ancillary bracket for air conditioner compressor
Number on ancillary unit bracket -06F 903 143 E/FRemoving
– Remove alternator ⇒ Rep. Gr. 27 .
– Loosen air conditioner compressor and remove hexagon bolt -6-. Remove air conditioner compressor
from ancillary bracket and secure to body with suitable material (e.g.welding wire) ⇒ page 77 .
– Remove bolts -1- through -4-, -7- and -8- and remove ancillary bracket -10- from cylinder block.
Installing
♦ Strictly observe tightening sequence of securing bolts:
– Tighten socket head flange bolts, positions -1- (dowel hole), -7- (dowel hole), -4-, -8-, -3- and -2- one
after the other.
Securing air conditioner compressor to body
If compressor is removed without opening refrigerant circuit, it
should be secured to body using suitable material, for example,
welding wire.
When doing this, ensure refrigerant hoses on air conditioner com‐
pressor are not stressed.
Poly V-belt routing
1 - Tensioning roller
2 - Poly V-belt pulley for alternator
3 - Poly V-belt pulley for air conditioner compressor
4 - Poly V-belt
5 - Poly V-belt pulley for crankshaft
♦
When installing poly V-belt, ensure that it is correctly seated
on poly V-belt pulley.
♦
Finally, place poly V-belt over pulley of air conditioner com‐
pressor.
4.6 Engine codes: BGP, BGQ, BTK, CBTA
Special tools and workshop equipment required
Note
and CBUA
4. Removing and installing ancillary bracket for air conditioner compressor 77
Page 82
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
♦ Torque wrench -V.A.G 1331/- (5…50 Nm)
Note
♦
The ancillary bracket for air conditioner compressor and rela‐
ted components can be removed and installed without the
refrigerant circuit being opened.
♦
To remove poly V-belt ⇒ Rep. Gr. 13 .
♦
Poly V-belt routing ⇒ page 79
1 - Ancillary bracket for alter‐
nator and air conditioner com‐
pressor
♦ Number on ancillary unit
bracket -07K 903 143 B-
Removing
– Loosen air conditioner
compressor and re‐
move hexagon bolt -6-.
Remove air conditioner
compressor from ancil‐
lary bracket and secure
to body with suitable
material (e.g.welding
wire) ⇒ page 79 .
– Remove bolts from an‐
cillary bracket.
2 - Multi-point socket head bolt
M8X60
❑ 25 Nm
3 - Multi-point socket head bolt
M8X110
❑ 25 Nm
4 - Hexagon socket head bolt
M8X30
❑ 25 Nm
❑ Qty. 4
5 - Air conditioner compressor
❑ Removing and installing
⇒ page 94
6 - Hexagon bolts M8×85
❑ Qty. 3
78 Rep. Gr.87 - Air conditioning system
Page 83
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❑ 25 Nm
7 - Dowel sleeves
❑ Qty. 2
❑ Ensure proper seating between ancillary unit bracket and air conditioner compressor
Securing air conditioner compressor to body
If compressor is removed without opening refrigerant circuit, it
should be secured to body using suitable material, for example,
welding wire.
When doing this, ensure that refrigerant hoses on air conditioner
compressor are not strained.
Poly V-belt routing
1 - Upper idler pulley
2 - Poly V-belt pulley for alternator
3 - Lower idler pulley
4 - Poly V-belt for alternator and air conditioner compressor
Heating, air conditioning - Edition 02.2008
5 - Poly V-belt pulley for air conditioner compressor
6 - Poly V-belt for air conditioner compressor
7 - Poly V-belt pulley for crankshaft
8 - Tensioning roller for poly V-belt for air conditioner compres‐
sor
9 - Tensioning roller for poly V-belt for alternator and cooling
system pump
10 - Poly V-belt pulley for cooling system pump
Golf 2004 ➤
4.7 Engine codes: BUB, CBRA
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331/- (5…50 Nm)
4. Removing and installing ancillary bracket for air conditioner compressor 79
Page 84
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G
.
Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
Note
♦
The ancillary bracket for air conditioner compressor and rela‐
ted components can be removed and installed without the
refrigerant circuit being opened.
♦
To remove poly V-belt ⇒ Rep. Gr. 13 .
♦
Poly V-belt routing ⇒ page 81
1 - Poly V-belt
❑ Removing and installing
⇒ Rep. Gr. 13
2 - Poly V-belt pulley for cool‐
ing system pump
3 - Tensioning roller
4 - Ancillary bracket for alter‐
nator and air conditioner com‐
pressor
♦ Number on ancillary unit
bracket -038 903 143 AF -
Removing
– Loosen air conditioner
compressor and re‐
move hexagon bolt -9-.
Remove air conditioner
compressor from ancil‐
lary bracket and secure
to body with suitable
material (e.g.welding
wire) ⇒ page 81 .
– Remove bolts from an‐
cillary bracket.
Note tightening sequence
when installing ⇒ page 81 .
5 - Fit bolt
❑ 25 Nm
6 - Alternator
7 - Dowel sleeves
❑ Qty. 2
❑ Ensure proper seating
between ancillary unit bracket and air conditioner compressor
8 - Air conditioner compressor
❑ Removing and installing ⇒ page 94
9 - Hexagon bolt M8x100
❑ Qty. 3
❑ 25 Nm
10 - Fitted bolt
❑ 25 Nm
80 Rep. Gr.87 - Air conditioning system
Page 85
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
Securing air conditioner compressor to body
If compressor is removed without opening refrigerant circuit, it
should be secured to body using suitable material, for example,
welding wire.
When doing this, ensure refrigerant hoses on air conditioner com‐
pressor are not stressed.
Note
♦
When installing poly V-belt, ensure that it is correctly seated
on poly V-belt pulley.
♦
Finally, place poly V-belt over pulley of air conditioner com‐
pressor.
Tightening sequence for ancillary bracket
Note
Bolts -1- and -2- are fit bolts.
– First tighten bolts in sequence 1...5 by hand.
– Then tighten bolts in sequence 1...5 to 25 Nm.
Poly V-belt routing
1 - Tensioning roller
2 - Poly V-belt pulley for alternator
3 - Idler rollers
4 - Poly V-belt
5 - Poly V-belt pulley for air conditioner compressor
6 - Poly V-belt pulley for crankshaft
7 - Poly V-belt pulley for cooling system pump
4. Removing and installing ancillary bracket for air conditioner compressor 81
Page 86
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
5 Repair work on refrigerant circuit
which may be performed only in ap‐
propriate workshops by specially
trained mechanics
Note
♦
Notes on repair work to vehicles with air conditioning and on
handling refrigerant can be found in ELSA under Heating,
ventilation, air conditioning system; Air conditioning system
with refrigerant R134a ⇒ Rep. Gr. 00 ; Technical data.
♦
Notes on testing equipment and tools for repair work to vehi‐
cles with air conditioning can be found in ELSA under Heating,
ventilation, air conditioning system; Air conditioning system
with refrigerant R134a ⇒ Rep. Gr. 00 ; Technical data.
WARNING
Danger of freezing injuries.
If refrigerant circuit has not been evacuated, refrigerant will
escape.
Extract refrigerant before opening refrigerant circuit. If the re‐
frigerant circuit is not opened within 10 minutes after it has
been evacuated, pressure may develop in coolant circuit due
to re-evaporation. Extract refrigerant again.
Note
♦
The refrigerant circuit must be purged with refrigerant R134a
under the following circumstances:
♦
If dirt or other contamination is in the circuit.
♦
If during the evacuation of a leak-tight refrigerant circuit the
vacuum is not maintained at the gauge (there is moisture in
the refrigerant circuit and this generates vapour pressure).
♦
If the refrigerant circuit has been left open for longer than nor‐
mally required for repairs (e.g. following an accident).
♦
When pressure and temperature measurements in the refrig‐
erant circuit indicate that there is moisture in the refrigerant
circuit.
♦
There is doubt about the amount of refrigerant oil in the refrig‐
erant circuit.
♦
The air conditioner compressor has to be exchanged because
of internal damage (e.g. noisy or lack of power).
The procedure for purging with refrigerant R134a is described in
ELSA under Heating, ventilation, air conditioning system; Air con‐
ditioning system with refrigerant R134a ⇒ Rep. Gr. 00 Technical
data; Clearing refrigerant circuit of contaminants.
Notes on repair work to vehicles with air conditioning and on han‐
dling refrigerant can be found in ELSA under Heating, ventilation,
air conditioning system; Air conditioning system with refrigerant
R134a ⇒ Rep. Gr. 00 ; Technical data.
82 Rep. Gr.87 - Air conditioning system
Page 87
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Heating, air conditioning - Edition 02.2008
Notes on testing equipment and tools for repair work to vehicles
with air conditioning can be found in ELSA under Heating, venti‐
lation, air conditioning system; Air conditioning system with re‐
frigerant R134a ⇒ Rep. Gr. 00 ; Technical data.
5.1 Testing equipment and tools
Notes on testing equipment and tools for repair work to vehicles
with air conditioning can be found in ELSA under Heating, venti‐
lation, air conditioning system; Air conditioning system with re‐
frigerant R134a ⇒ Rep. Gr. 00 ; Technical data.
Special tools and workshop equipment required
♦ E.g. air conditioner service station -VAS 6007A- (or later mod‐
el)
♦ Adapter set for service connections -T10364-
♦ Torque wrench -V.A.G 1783- (2…10 Nm) for adapter set for
service connections -T10364-
Golf 2004 ➤
5. Repair work on refrigerant circuit which may be performed only in appropriate workshops by specially trained mechanics 83
Page 88
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
♦ Ratchet insert tool 1/4" -VAS 6234- for adapter set for service
connections -T10364-
5.2 Removing and installing heater and air conditioning unit
Special tools and workshop equipment required
♦ Air conditioner service station -VAS 6007A- or later model.
♦ Drip tray -V.A.G 1306-
♦ Hose clamps up to 40 mm Ø -VAS 3093-
♦ Compressed air gun, commercially available
84 Rep. Gr.87 - Air conditioning system
Page 89
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Heating, air conditioning - Edition 02.2008
5.2.1 Removing
Note
To improve access, additional components must be removed de‐
pending on engine version e.g. engine cover ⇒ Rep. Gr. 10 .
– Extract refrigerant, e.g. with air conditioner service station -
VAS 6007A- before opening refrigerant circuit. Observe notes
⇒ page 88 .
– Remove dash panel ⇒ Rep. Gr. 70
– Remove right and left rear footwell air ducts ⇒ page 6 .
– Place drip tray -V.A.G 1306- beneath engine.
– Mark coolant hoses -1-
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.
Golf 2004 ➤
– Clamp off coolant hoses -1- using hose clamps up to 40 mm Ø
-VAS 3093- and disconnect coolant hoses to heat exchanger.
– Push a piece of hose -A- onto upper connection.
– Hold a container -B- under lower connection -C-.
– Carefully blow remaining coolant out of heat exchanger using
a compressed air pistol at heat exchanger connection.
Applies only to vehicles with a protective plate before the expan‐
sion valve.
Note
On right-hand drive vehicles, lock washers are installed instead
of a clip and a nut.
– Unscrew nut -1- (6 ± 0.9 Nm).
– Release clips -2- and remove protective plate -3-.
5. Repair work on refrigerant circuit which may be performed only in appropriate workshops by specially trained mechanics 85
Page 90
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
Continuation for all vehicles
WARNING
Danger of freezing injuries.
If refrigerant circuit has not been evacuated, refrigerant will
escape.
Extract refrigerant before opening refrigerant circuit. If the re‐
frigerant circuit is not opened within 10 minutes after it has
been evacuated, pressure may develop in coolant circuit due
to re-evaporation. Extract refrigerant again.
– With access from engine compartment, remove bolts
(10 ± 1 Nm) -1- for refrigerant lines -2-.
– Remove refrigerant lines from expansion valve -3-.
Note
♦
Seal open connections for lines.
♦
To seal open connections of expansion valve, use, for exam‐
ple, sealing cap of a spare expansion valve.
– Cover carpet in vehicle interior with waterproof foil and ab‐
sorbent paper.
Note
During removal, note lengths and locations of bolts for later installation.
86 Rep. Gr.87 - Air conditioning system
Page 91
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1 - Bolt
❑ 4,5 ± 0.7 Nm
❑ Lower right on cable re‐
tainer to heater and air
conditioning unit, near
bulkhead
2 - Bolts
❑ 4,5 ± 0.7 Nm
3 - Cable retainer
4 - Heater and air conditioning
unit
❑ Removing:
– Remove condensation
water drain hose from
air conditioner unit
⇒ page 59 .
– Separate connectors on
air conditioner unit.
Note
Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
– 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 retainer -13-.
– Remove bolts -1- and -2- from cable retainer -3-.
Note
– Remove heater and air conditioner unit.
Installing:
Installation is carried out in the reverse order. When installing, note the following:
Note
– Have second mechanic guide both coolant pipes to heat exchanger through seal during installation of
heater unit ⇒ page 88 .
– During installation, ensure proper seating of condensation drain hose ⇒ page 59 .
– Fill with coolant ⇒ Rep. Gr. 19 .
– Refilling with refrigerant R134a and refrigerant oil ⇒ page 109 .
5. Repair work on refrigerant circuit which may be performed only in appropriate workshops by specially trained mechanics 87
Page 92
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
5 - Bracket
6 - Bolts
❑ 8 Nm
7 - Mounting plate
8 - Bolts
❑ 9 ± 1.3 Nm
9 - Right support
10 - Bolts
❑ 20 ± 3 Nm
11 - Left support
12 - Bolts
❑ 9 ± 1.3 Nm
13 - Bracket
14 - Bolts
❑ 9 ± 1.3 Nm
Note
First tighten bolts -8- when installing supports -9- and -11-.
Heater and air conditioner unit/engine compartment seal
Note
Observe position of seal -A- during installation.
5.3 Renewing components of refrigerant cir‐
cuit
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331/- (5…50 Nm)
88 Rep. Gr.87 - Air conditioning system
Page 93
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♦ Drip tray for workshop hoist -VAS 6208-
♦ Hose clamps up to 40 mm Ø -3093-
Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
♦ Air conditioner service station -VAS 6007A- or later model.
5. Repair work on refrigerant circuit which may be performed only in appropriate workshops by specially trained mechanics 89
Page 94
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
Note
♦
The refrigerant must be extracted beforehand, e.g. with air
conditioner service station -VAS 6007A- .
♦
The previously used service stations can still be used ⇒ Volks‐
wagen Workshop Equipment catalogue.
♦
All of the refrigerant circuit's components that have been
opened must be sealed with suitable plugs to prevent the in‐
gress of moisture.
♦
The colour coding of O-rings for R134a refrigerant circuits has
been discontinued. Coloured and black O-rings are used.
♦
Under certain conditions, it is not necessary to renew the re‐
ceiver with dryer every time that the refrigerant circuit is
opened. Refer to ELSA under Heating, ventilation, air condi‐
tioning system; Air conditioning system with refrigerant R134a
⇒ Rep. Gr. 00 ; Technical data; Renewing components.
♦
Notes on repair work to vehicles with air conditioning and on
handling refrigerant can be found in ELSA under Heating,
ventilation, air conditioning system; Air conditioning system
with refrigerant R134a ⇒ Rep. Gr. 00 ; Technical data.
♦
Notes on repair work to vehicles with air conditioning and on
handling refrigerant can be found in ELSA under Heating,
ventilation, air conditioning system; Air conditioning system
with refrigerant R134a ⇒ Rep. Gr. 00 ; Technical data.
Danger of freezing injuries.
WARNING
If refrigerant circuit has not been evacuated, refrigerant will
escape.
Extract refrigerant before opening refrigerant circuit. If the re‐
frigerant circuit is not opened within 10 minutes after it has
been evacuated, pressure may develop in coolant circuit due
to re-evaporation. Extract refrigerant again.
90 Rep. Gr.87 - Air conditioning system
Page 95
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1 - Receiver with dryer
Note
❑ Removing and installing
⇒ page 92
2 - Air conditioner compressor
❑ Manufacturer: Denso,
designation 7SEU17C
❑ Observe remarks on in‐
stallation of air condi‐
tioner compressor
⇒ page 106 .
❑ Removing and installing
⇒ page 94
3 - Condenser
❑ Removing and installing
⇒ page 103
4 - High-pressure sender G65-
Removing and installing
⇒ page 92
5 - Bracket
❑ Nuts, 6 Nm
6 - Evacuating and charging
valve
❑ High-pressure side
❑ Releasing refrigerant in‐
to the environment is a
punishable offence.
❑ Removing and installing
⇒ page 107
❑ Capacities ⇒ page 109
Heating, air conditioning - Edition 02.2008
Golf 2004 ➤
7 - Retainer
❑ Bolt 3.5 Nm
8 - Evacuating and charging valve
❑ Low-pressure side
❑ Releasing refrigerant into the environment is a punishable offence.
❑ Removing and installing ⇒ page 107
❑ Capacities ⇒ page 109
9 - Expansion valve
❑ Function and removal ⇒ page 100 .
10 - Hexagon nut
❑ 20 Nm
11 - Bracket
5. Repair work on refrigerant circuit which may be performed only in appropriate workshops by specially trained mechanics 91
Page 96
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
5.4 Removing and installing high-pressure sender -G65-
5.4.1 Removing
– Remove noise insulation tray from engine ⇒ Rep. Gr. 50 .
– Separate connector from high-pressure sender -1-.
– Unscrew high-pressure sender -G65- -1- from refrigerant line
connection.
Note
♦
Renew O-ring -2-.
♦
Depending on engine version, the high-pressure sender -G65-
-1- may be installed in another location near the condenser.
5.4.2 Installing
Install in reverse order.
5.5 Removing and installing receiver with dryer
Note
Under certain conditions, it is not necessary to renew the receiver
with dryer every time that the refrigerant circuit is opened. Refer
to ELSA under Heating, ventilation, air conditioning system; Air
conditioning system with refrigerant R134a ⇒ Rep. Gr. 00 ;
Technical data; Renewing components.
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331/- (5…50 Nm)
92 Rep. Gr.87 - Air conditioning system
Page 97
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.
Heating, air conditioning - Edition 02.2008
♦ Air conditioner service station -VAS 6007A- or later model.
5.5.1 Removing
Note
♦
Observe notes ⇒ page 88 .
♦
The refrigerant must be extracted beforehand, e.g. with air
conditioner service station -VAS 6007A- .
♦
The previously used service stations can still be used ⇒ Volks‐
wagen Workshop Equipment catalogue.
♦
All of the refrigerant circuit's components that have been
opened must be sealed with suitable plugs to prevent the in‐
gress of moisture.
– Extract refrigerant, e.g. with air conditioner service station -
VAS 6007A- before opening refrigerant circuit.
– Move lock carrier to service position ⇒ Rep. Gr. 50 .
– Remove radiator securing bolts -arrows- (7 Nm).
Golf 2004 ➤
5. Repair work on refrigerant circuit which may be performed only in appropriate workshops by specially trained mechanics 93
Page 98
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
– Hang radiator on workshop hoist -V.A.G 1202/A- and lifting
tackle -VAS 2024A- using workshop material (cable ties or
uncoated wire) and unhook radiator from lock carrier. Coolant
hoses and refrigerant lines remain connected.
– Remove securing bolt -2- and remove retaining clip.
WARNING
Danger of freezing injuries.
If refrigerant circuit has not been evacuated, refrigerant will
escape.
Extract refrigerant before opening refrigerant circuit. If the re‐
frigerant circuit is not opened within 10 minutes after it has
been evacuated, pressure may develop in coolant circuit due
to re-evaporation. Extract refrigerant again.
– Remove bolts -1- and pull out receiver with dryer upwards.
Note
Depending on condenser, only one bolt -1- may be present.
5.5.2 Installing
Install in reverse order.
Note
♦
First tighten bolt(s) -1- to 4.2 Nm ± 0.7 Nm and then tighten
securing bolt -2-.
♦
When installing radiator, ensure that sealing strips on radiator
are properly seated.
5.6 Removing and installing air conditioner compressor
5.6.1 Removing
Note
♦
Zexel air conditioner compressors have to be replaced by
Denso air conditioner compressors. Refer to technical solution
(TPL) 2011410.
♦
A software update of the engine control unit is only required
for the 1.6 l 75 kW engine with engine code BSE. These soft‐
ware versions are only available online via SVM (Software
Versions Management) and can be flashed with the code for
the repair measure.
Special tools and workshop equipment required
94 Rep. Gr.87 - Air conditioning system
Page 99
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.
Heating, air conditioning - Edition 02.2008
♦ Torque wrench -V.A.G 1331/- (5…50 Nm)
♦ Air conditioner service station -VAS 6007A- or later model.
Golf 2004 ➤
Note
♦
The refrigerant circuit must be purged with refrigerant R134a
under the following circumstances:
♦
If dirt or other contamination is in the circuit.
♦
If during the evacuation of a leak-tight refrigerant circuit the
vacuum is not maintained at the gauge (there is moisture in
the refrigerant circuit and this generates vapour pressure).
♦
If the refrigerant circuit has been left open for longer than nor‐
mally required for repairs (e.g. following an accident).
♦
When pressure and temperature measurements in the refrig‐
erant circuit indicate that there is moisture in the refrigerant
circuit.
♦
There is doubt about the amount of refrigerant oil in the refrig‐
erant circuit.
♦
The air conditioner compressor has to be exchanged because
of internal damage (e.g. noisy or lack of power).
The procedure for purging with refrigerant R134a is described in
ELSA under Heating, ventilation, air conditioning system; Air con‐
ditioning system with refrigerant R134a ⇒ Rep. Gr. 00 Technical
data; Clearing refrigerant circuit of contaminants.
Notes on repair work to vehicles with air conditioning and on han‐
dling refrigerant can be found in ELSA under Heating, ventilation,
air conditioning system; Air conditioning system with refrigerant
R134a ⇒ Rep. Gr. 00 ; Technical data.
Notes on testing equipment and tools for repair work to vehicles
with air conditioning can be found in ELSA under Heating, venti‐
lation, air conditioning system; Air conditioning system with re‐
frigerant R134a ⇒ Rep. Gr. 00 ; Technical data.
5. Repair work on refrigerant circuit which may be performed only in appropriate workshops by specially trained mechanics 95
Page 100
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Golf 2004 ➤
Heating, air conditioning - Edition 02.2008
– Extract refrigerant, e.g. with air conditioner service station -
VAS 6007A- before opening refrigerant circuit. Observe notes
⇒ page 88 .
– Remove noise insulation under engine ⇒ Rep. Gr. 50 .
– Remove front right wheel housing liner ⇒ Rep. Gr. 66 .
– Remove poly V-belt ⇒ Rep. Gr. 13 .
WARNING
Danger of freezing injuries.
If refrigerant circuit has not been evacuated, refrigerant will
escape.
Extract refrigerant before opening refrigerant circuit. If the re‐
frigerant circuit is not opened within 10 minutes after it has
been evacuated, pressure may develop in coolant circuit due
to re-evaporation. Extract refrigerant again.
– Remove bolts (22 Nm ± 1 Nm) -1- from air conditioner com‐
pressor and separate refrigerant lines from air conditioner
compressor.
96 Rep. Gr.87 - Air conditioning system
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