Volkswagen Jetta 2005 User Manual
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Service
Workshop Manual
Golf Variant 2007 ➤
Golf Variant 2010 ➤
Jetta 2005 ➤
Jetta 2011 ➤
Heating, air conditioning
Edition 04.2010
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 MEX5R006020
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
Heating, air conditioning - Edition 04.2010
Contents
80 - Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Repairing heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Heater - passenger compartment (Golf Variant 2007►, Golf Variant 2010► und Jetta
2005►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Heater - passenger compartment (Jetta 2011►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Removing fresh air blower V2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Removing and installing fresh air blower series resistor with overheating fuse N24 . . . . . . 6
1.5 Removing and installing dust and pollen filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.6 Removing vent (Golf Variant 2007►, Golf Variant 2010► und Jetta 2005►) . . . . . . . . . . . . 7
1.7 Removing vent (Jetta 2011►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.8 Removing and installing controls for heated and fresh air . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.9 Connectors on controls for heated and fresh air (Golf Variant 2007►, Golf Variant 2010► und
Jetta 2005►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.10 Connectors on controls for heated and fresh air (Jetta 2011►) . . . . . . . . . . . . . . . . . . . . . . 16
1.11 Removing and installing flexible shaft for air distribution . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.12 Removing and installing Bowden cable for temperature flap . . . . . . . . . . . . . . . . . . . . . . . . 18
1.13 Removing and installing fresh air and air recirculation flap control motor V154 . . . . . . . . 19
1.14 Removing and installing heat exchanger (Golf Variant 2007►, Golf Variant 2010► und Jetta
2005►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.15 Removing and installing heat exchanger (Jetta 2010►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.16 Removing and installing auxiliary air heater element Z35 , vehicles ► 1K-7M 119 726 . . . . 26
1.17 Checking, removing and installing auxiliary air heater element Z35 , vehicles 1K-7M 119 727
► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.18 Checking ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.19 Removing and installing air intake grille (Golf Variant 2007►, Golf Variant 2010► und Jetta
2005►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.20 Removing and installing air intake grille (Jetta 2010►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.21 Removing and installing heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2 Dismantling and assembling heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.1 Dismantling and assembling heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.2 Removing and installing air distribution flap actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.3 Removing and installing temperature flap actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
87 - Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1 Notes on repair work to vehicles with air conditioning and on handling refrigerant . . . . . . 38
2 Air conditioning system with manual controls, Climatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.1 Air conditioning system and heater - passenger compartment (Golf Variant 2007►, Golf
Variant 2010► und Jetta 2005►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.2 Air conditioning system and heater - passenger compartment (Jetta 2011►) . . . . . . . . . . 41
2.3 Removing and installing heater and air conditioner unit (Climatic) . . . . . . . . . . . . . . . . . . 42
2.4 Dismantling and assembling heater and air conditioning unit (Climatic) . . . . . . . . . . . . . . 47
2.5 Removing and installing heating and air conditioning controls, Climatic . . . . . . . . . . . . . . 48
2.6 Connections on controls for heating and air conditioning, Climatic . . . . . . . . . . . . . . . . . . 49
2.7 Removing and installing flexible shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.8 Checking condensation water drainage hose on heater and air conditioner unit . . . . . . . . 51
2.9 Removing and installing air recirculation flap control motor V113 . . . . . . . . . . . . . . . . . . . . 51
2.10 Removing and installing temperature flap control motor V68 . . . . . . . . . . . . . . . . . . . . . . 51
2.11 Removing and installing footwell vent temperature sender G192 . . . . . . . . . . . . . . . . . . . . 53
2.12 Removing and installing centre vent temperature sender G191 . . . . . . . . . . . . . . . . . . . . 54
3 Climatronic air conditioning with automatic regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.1 Procedure for checking and adjusting components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.2 Function of operating and display unit for Climatronic air conditioning system E87 (Golf
Variant 2007►, Golf Variant 2010► und Jetta 2005►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Contents i
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
Heating, air conditioning - Edition 04.2010
3.3 Removing and installing operating and display unit for Climatronic air conditioning system
E87 with Climatronic control unit J255 (Golf Variant 2007►, Golf Variant 2010► und Jetta
2005►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.4 Function of operating and display unit for Climatronic air conditioning system E87 (Jetta
2011►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.5 Removing and installing operating and display unit for Climatronic air conditioning system
E87 with Climatronic control unit J255 (Jetta 2011►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.6 Connectors on Climatronic control unit J255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.7 Climatronic - passenger compartment (Golf Variant 2007►, Golf Variant 2010► und Jetta
3.8 Climatronic - passenger compartment (Jetta 2011►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.9 Removing and installing fresh air blower control unit J126 . . . . . . . . . . . . . . . . . . . . . . . . 67
3.10 Removing and installing heater and air conditioning unit (Climatronic) . . . . . . . . . . . . . . . . 68
3.11 Dismantling and assembling heater and air conditioning unit (Golf Variant 2007►, Golf Variant
3.12 Dismantling and assembling heater and air conditioning unit (Jetta 2011►) . . . . . . . . . . . . 73
3.13 Dismantling and assembling evaporator housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.14 Removing and installing left footwell vent temperature sender G261 . . . . . . . . . . . . . . . . 76
3.15 Removing and installing right footwell vent temperature sender G262 . . . . . . . . . . . . . . . . 77
3.16 Removing and installing evaporator temperature sensor G308 . . . . . . . . . . . . . . . . . . . . 77
3.17 Removing left vent temperature sender G150 and right vent temperature sender G151 . . 78
3.18 Removing sunlight penetration photosensor G107 or sunlight penetration photosensor 2
2005►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2010► und Jetta 2005►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
G134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.19 Checking condensation water drainage hose on heater and air conditioner unit . . . . . . . . 79
3.20 Renewing control motors for air conditioning regulation . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.21 Removing and installing fresh air and air recirculation flap control motor V154 . . . . . . . . 79
3.22 Removing and installing air flow flap control motor V71 or fresh air/recirculated air, air flow
flap control motor V425 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.23 Removing and installing defroster flap control motor V107 . . . . . . . . . . . . . . . . . . . . . . . . 80
3.24 Removing and installing left temperature flap control motor V158 . . . . . . . . . . . . . . . . . . 81
3.25 Removing and installing right temperature flap control motor V159 . . . . . . . . . . . . . . . . . . 82
3.26 Removing and installing central flap control motor V70 . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4 Ancillary bracket for air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.1 Removing and installing ancillary bracket for air conditioner compressor (Jetta 2011►) . . 84
4.2 Removing and installing ancillary bracket for air conditioner compressor, engine codes BRM
and BXE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.3 Removing and installing ancillary bracket for air conditioner compressor, engine codes BGP
and BGQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.4 Removing and installing ancillary bracket for air conditioner compressor, engine codes BPY,
BWA, BSE, BSF, BLR, BLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5 Repair work on refrigerant circuit which may be performed only in appropriate workshops by
specially trained mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.1 Testing equipment and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.2 Renewing refrigerant circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.3 Removing high-pressure sender G65 (Golf Variant 2007►, Golf Variant 2010► und Jetta
2005►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.4 Removing high-pressure sender G65 (Jetta 2011►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.5 Removing and installing receiver with dryer cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.6 Removing and installing air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.7 Checking high-pressure safety valve on air conditioner compressor . . . . . . . . . . . . . . . . . . 97
5.8 Expansion valve, function and removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.9 Removing and installing evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.10 Removing and installing condenser (Golf Variant 2007►, Golf Variant 2010► und Jetta
2005►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.11 Removing and installing condenser (Jetta 2010►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.12 Notes on installing air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
6 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
6.1 Refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
ii Contents
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
Heating, air conditioning - Edition 04.2010
6.2 Refrigerant oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Contents iii
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
Heating, air conditioning - Edition 04.2010
iv Contents
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
Heating, air conditioning - Edition 04.2010
80 – Heating
1 Repairing heating system
1.1 Heater - passenger compartment (Golf Variant 2007►, Golf Variant 2010►
Disconnect battery before removing components marked ** ⇒
Rep. gr. 27 .
1 - Dash panel**
2 - Centre vents
❑ Removing vent
⇒ page 7 .
3 - Right side vent
4 - Right vent
❑ Removing vent
⇒ page 8 .
5 - Controls for fresh and heat‐
ed air
❑ With fresh air and air re‐
circulation flap switch E159- .
und Jetta 2005►)
❑ For vehicles with sup‐
plementary heating hav‐
ing instant heating but‐
ton -E537- .
❑ Removing controls
⇒ page 14 .
6 - Fresh air and air recircula‐
tion flap control motor -V154-
❑ Removing ⇒ page 19
7 - Right footwell vent
❑ Removing and installing
⇒ page 9
8 - Fresh air blower -V2-
❑ Removing ⇒ page 5
9 - Fresh air blower series re‐
sistor with overheating fuse N24-
❑ Removing and installing
⇒ page 6
10 - Baffle plate for heater unit
❑ Removing ⇒ page 3
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 6
1. Repairing heating system 1
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
Heating, air conditioning - Edition 04.2010
13 - Connecting piece
❑ For centre console air duct.
❑ To remove, centre console must be removed ⇒ Rep. gr. 68 .
14 - Air duct for right rear footwell
❑ Removing and installing ⇒ page 8
15 - Air duct for left rear footwell
❑ Removing and installing ⇒ page 8
16 - Securing bolt
❑ Qty. 8
❑ Various lengths.
17 - Adapter for controls
❑ Removing and installing ⇒ page 18
18 - Auxiliary air heater element -Z35-
Vehicles ► 1K-7M 119 726
❑ With auxiliary air heater control unit -J604- .
❑ Checking: with vehicle diagnosis, 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 26
Vehicles 1K-7M 119 726 ►
❑ A 3-speed 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 27
19 - Heat exchanger
❑ After renewing heat exchanger, renew coolant completely ⇒ Rep. gr. 19 .
❑ Removing and installing ⇒ page 19
20 - Left footwell vent
❑ Removing and installing ⇒ page 9
21 - Bowden cable for temperature flap
❑ Removing and installing ⇒ page 18
22 - Flexible shaft
❑ Removing and installing ⇒ page 17
23 - Heater unit
❑ Removing and installing ⇒ page 31
❑ Dismantling and assembling ⇒ page 35
24 - Left side vent
2 Rep. gr.80 - Heating
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
Removing heater unit baffle plate
– Remove plastic bolts -2- and remove baffle plate -1-.
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.
Heating, air conditioning - Edition 04.2010
1. Repairing heating system 3
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
Heating, air conditioning - Edition 04.2010
1.2 Heater - passenger compartment (Jetta 2011►)
1 - Dash panel
2 - Centre vents
❑ Removing vent
⇒ page 10 .
3 - Right side vent
❑ Removing ⇒ page 12
4 - Controls for fresh and heat‐
ed air
❑ With fresh air and air re‐
circulation flap switch -
E159- .
❑ For vehicles with sup‐
plementary heating hav‐
ing instant heating but‐
ton -E537- .
❑ Removing controls
⇒ page 14 .
5 - Fresh air and air recircula‐
tion flap control motor -V154-
❑ Removing ⇒ page 19
6 - Right footwell vent
❑ Removing and installing
⇒ page 9
7 - Fresh air blower series re‐
sistor with overheating fuse N24-
❑ Removing and installing
⇒ page 6
8 - Fresh air blower -V2-
❑ Removing ⇒ page 5
9 - Baffle plate for heater unit
❑ Removing ⇒ page 5
10 - Dust and pollen filter
❑ With activated charcoal filter
❑ Removing and installing ⇒ page 6
11 - Sealing cap
❑ Fitted only in vehicles without air duct to vent in rear centre console.
12 - Air duct for right rear footwell
❑ Removing and installing ⇒ page 8
13 - Air duct for left rear footwell
❑ Removing and installing ⇒ page 8
14 - Securing bolt
❑ Qty. 8
❑ Various lengths.
15 - Adapter for controls
❑ Removing and installing ⇒ page 18
16 - Heat exchanger
❑ After renewing heat exchanger, renew coolant completely ⇒ Rep. gr. 19 .
4 Rep. gr.80 - Heating
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
Heating, air conditioning - Edition 04.2010
❑ Removing and installing ⇒ page 23
17 - Bowden cable for temperature flap
❑ Removing and installing ⇒ page 18
18 - Left footwell vent
❑ Removing and installing ⇒ page 9
19 - Heater unit
❑ Removing and installing ⇒ page 31
❑ Dismantling and assembling ⇒ page 35
20 - Flexible shaft
❑ Removing and installing ⇒ page 17
Removing heater unit baffle plate
– Remove plastic bolts -2- and remove baffle plate -1-.
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.
1.3 Removing fresh air blower -V2-
1.3.1 Removing
Fresh air blower -V2- is accessible from footwell on front passen‐
ger side.
– Removing heater unit baffle plate ⇒ page 3 .
– 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. Repairing heating system 5
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.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
Heating, air conditioning - Edition 04.2010
1.4 Removing and installing fresh air blower
series resistor with overheating fuse N24-
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:
– Removing heater unit baffle plate ⇒ page 3 .
– 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.
Installing
Install in reverse order.
1.5 Removing and installing dust and pollen filter
Removing
– Remove footwell cover -1- on front passenger side.
– Remove baffle plate -2- from heater unit ⇒ page 3 .
– Release cover -3- in direction of arrow.
– Remove dust and pollen filter from heater unit downwards.
Installing
6 Rep. gr.80 - Heating
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
Install in reverse order.
Note
Observe installation position of dust and pollen filter.
1.6 Removing vent (Golf Variant 2007►, Golf Variant 2010► und Jetta 2005►)
Removing centre vents ⇒ page 7 .
Removing and installing left or right vent ⇒ page 8 .
Removing and installing right and left rear footwell air ducts
⇒ page 8 .
Remove right footwell vent ⇒ page 9 .
Removing left footwell vent ⇒ page 9 .
Removing and installing side vent ⇒ page 10 .
1.6.1 Removing and installing centre vent
Heating, air conditioning - Edition 04.2010
Removing
– Vehicles with Climatronic, photosensor must be removed
⇒ page 78 .
– Remove bolt -1-.
– Remove cover -2- (models with Climatronic only).
Note
For vehicles without Climatronic, bolts are beneath a trim mat.
1. Repairing heating system 7
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
Heating, air conditioning - Edition 04.2010
– Remove securing bolts -1-.
– Remove compartment from dash panel.
– Remove centre vent -2- upwards in direction of -arrow-.
– Disconnect connectors on centre vents.
Installing
Install in reverse order.
1.6.2 Removing and installing right or left vent
Note
♦
Removal of vents on both sides is identical, but one is a mirror
image of the other.
♦
To avoid damage to dash panel, use a pad when levering out
components.
Removing
– Using an appropriate tool, lever out vent -1-.
– Disconnect connector on vent.
Installing
Install in reverse order.
1.6.3 Removing and installing right and left rear footwell air ducts
Note
Removal of air ducts on both sides is identical, but one is a mirror
image of the other.
Removing
– Remove driver or front passenger seat ⇒ Rep. gr. 72 .
8 Rep. gr.80 - Heating
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
Heating, air conditioning - Edition 04.2010
– Remove centre console ⇒ Rep. gr. 68 .
– Raise floor covering, unclip rear footwell air duct from under‐
body and pull off heater unit.
Installing
Note
When installing rear footwell air duct, ensure that it is first pushed
onto heater unit -arrow- and then clipped to underbody.
Install in reverse order.
1.6.4 Removing right footwell vent
Removing
– Remove glove compartment ⇒ Rep. gr. 68 .
– Remove securing bolt -2- and remove right footwell vent -1-.
Installing
Install in reverse order.
Note
If vehicle has glove compartment cooling, ensure that cooling
hose is properly seated.
1.6.5 Removing and installing left footwell vent
Removing
– Remove compartment on driver passenger side ⇒ Rep. gr.
68 .
– Remove securing bolt -2- and remove left footwell vent -1-.
Installing
Install in reverse order.
1. Repairing heating system 9
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
Heating, air conditioning - Edition 04.2010
1.6.6 Removing and installing side vents
Side window vents -arrow- are installed in A-pillar trim.
– Remove left or right A-pillar trim, as appropriate ⇒ Rep. gr.
70 .
1.7 Removing vent (Jetta 2011►)
1.7.1 Removing and installing centre vent
Removing
Special tools and workshop equipment required
♦ Removal wedge -3409-
– Switch off ignition.
– Remove centre trim of dash panel ⇒ General body repairs,
interior; Rep. gr. 68 ; Removing and installing centre trim of
dash panel .
– Remove Radio, if fitted ⇒ Communication; Rep. gr. 91 ; Re‐
moving and installing radio units and navigation systems .
Vehicles with radio navigation systems
– Remove radio navigation system ⇒ Communication; Rep. gr.
91 ; Removing and installing radio units and navigation sys‐
tems .
For all vehicles
– Height adjustment: move steering wheel to lowest position.
10 Rep. gr.80 - Heating
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
Heating, air conditioning - Edition 04.2010
– Reach adjustment: move steering wheel so that the steering
wheel is as far into the passenger compartment as possible.
– Release gap cover from mounting in upper part of trim with
wedge -3409- . The complete steering column trim must not
be removed.
– Remove bolt -3- (1.5 Nm).
– Release clips of centre vent -arrows- using wedge -3409- and
pull out dash panel insert trim with centre vent -1- slightly.
– Release clips of left vent using wedge -3409- and pull out dash
panel insert trim with centre vent -1- slightly.
– Release fasteners -4- of dash panel insert trim -1- using wedge
-3409- and pull out slightly.
– Remove dash panel insert trim with centre and left vents -1-
from dash panel -2-, disconnect wiring harness to hazard
warning light switch -E3- when doing this.
Installing
Install in reverse order.
1. Repairing heating system 11
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
Heating, air conditioning - Edition 04.2010
Note
Before installing, check all securing elements for damage and re‐
place as necessary.
1.7.2 Removing and installing right dash pan‐
el vent
Removing
– Release upper and lower clips -arrows- of right vent using
wedge -3409- and pull vent out slightly.
– Remove right dash panel vent -1- from dash panel -2-.
Installing
– Installation is carried out in reverse order.
12 Rep. gr.80 - Heating
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Note
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
Heating, air conditioning - Edition 04.2010
Before installing, check all securing elements for damage and re‐
place as necessary.
1.7.3 Removing and installing right and left rear footwell air ducts
Note
Removal of air ducts on both sides is identical, but one is a mirror
image of the other.
Removing
– 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‐
Installing
When installing rear footwell air duct, ensure that it is first pushed
onto heater unit -arrow- and then clipped to underbody.
Install in reverse order.
body and pull off heater unit.
Note
1.7.4 Removing right footwell vent
Removing
– Remove glove compartment ⇒ Rep. gr. 68 .
– Remove securing bolt -2- and remove right footwell vent -1-.
Installing
Install in reverse order.
Note
If vehicle has glove compartment cooling, ensure that cooling
hose is properly seated.
1. Repairing heating system 13
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
Heating, air conditioning - Edition 04.2010
1.7.5 Removing and installing left footwell vent
Removing
– Remove compartment on driver passenger side ⇒ Rep. gr.
68 .
– Remove securing bolt -2- and remove left footwell vent -1-.
Installing
Install in reverse order.
1.8 Removing and installing controls for heated and fresh air
Connectors on controls for heated and fresh air (Golf Variant
2007►, Golf Variant 2010► und Jetta 2005►) ⇒ page 15
Connectors on controls for heated and fresh air (Jetta 2011►)
⇒ page 16
Removing
Note
♦
The control consists of 2 separable housings. Before removing
controls, set rotary knobs to the following positions:
♦
Heater control to „cold“
♦
Blower to „0“
♦
Vent direction to „footwell“
– Remove radio ⇒ Rep. gr. 91 .
– Models with no radio trim, removing centre part of dash panel
⇒ Rep. gr. 68 .
14 Rep. gr.80 - Heating
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
Heating, air conditioning - Edition 04.2010
– Remove bolts -2- (4.2 x 45) and -3- (4.2 x 16) and remove the
controls -1- from centre console.
– Release connector catch -A- by pulling it in direction of arrow
-1-.
– Push connector catch -B- towards 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.
Installing
Install in reverse order. Note: the rotating knobs must be in the
same position as when removed.
1.9 Connectors on controls for heated and
1.9.1 Pin assignment for multi-pin connectors
Special tools and workshop equipment required
♦ Auxiliary measuring set -V.A.G 1594 C-
fresh air (Golf Variant 2007►, Golf Var‐
iant 2010► und Jetta 2005►)
on back of controls for heated and fresh
air
16-pin connector is vacant.
5-pin connector, T5 in current flow diagram
1 - Blower 3rd speed
2 - Blower 2nd speed
3 - Blower 1st speed
4 - Bower 4th speed
5 - X terminal
1. Repairing heating system 15
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
Heating, air conditioning - Edition 04.2010
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
1.10 Connectors on controls for heated and fresh air (Jetta 2011►)
1.10.1 Pin assignment for multi-pin connectors on back of controls for heated and fresh air
Special tools and workshop equipment required
♦ Auxiliary measuring set -V.A.G 1594 C-
16-pin connector is vacant.
5-pin connector, T5 in current flow diagram
1 - Blower 3rd speed
2 - Blower 2nd speed
3 - Blower 1st speed
4 - Bower 4th speed
5 - X terminal
16 Rep. gr.80 - Heating
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
Heating, air conditioning - Edition 04.2010
20-pin connector, T20c in current flow diagram
3 - Fresh air and air recirculation flap control motor -V154-
5 - Auxiliary heater (optional)
6 - Fresh air and air recirculation flap control motor -V154-
7 - With auxiliary air heater control unit -J604-
8 - Rear window
11 - Left seat heating (optional)
12 - LED for heated rear window
14 - LED for auxiliary heater
15 - Right seat heating (optional)
17 - Terminal 58d
18 - Terminal 30
19 - Terminal 15
20 - Terminal 31
1.11 Removing and installing flexible shaft for air distribution
Removing
– Remove glove compartment ⇒ Rep. gr. 68 .
– Move flexible shaft to following position:
– Turn rotary switch for air distribution -B- until catch in shaft
-D- is visible in gears -F-.
– Remove controls for fresh and heated air ⇒ page 14 .
– 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. Otherwise the system will malfunc‐
tion ⇒ page 17 .
1.11.1 Checking
Flexible shaft for air distribution flap actuator:
– Run fresh air blower at highest speed. If air flows out of de‐
froster vent 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
1. Repairing heating system 17
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
Heating, air conditioning - Edition 04.2010
distribution 1/2 turn (180°). Then reconnect flexible shaft. Re‐
peat check.
1.12 Removing and installing Bowden cable for temperature flap
1.12.1 Removing
– Remove controls for fresh and heated air ⇒ page 14 .
– Reach into centre console and release locking lug -1- of Bow‐
den cable sleeve -2-. Take Bowden cable sleeve out of mount‐
ing.
– Release ball of Bowden cable -3- from operating lever.
– Remove driver side footwell trim ⇒ Rep. gr. 68 .
– Unclip Bowden cable from control unit for temperature flap
-A- and heater unit -B-.
1.12.2 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“.
18 Rep. gr.80 - Heating
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
Heating, air conditioning - Edition 04.2010
1.13 Removing and installing fresh air and air recirculation flap control motor -V154-
1.13.1 Removing
Note
The position of the air recirculation flap must not be changed.
– Remove glove compartment ⇒ Rep. gr. 68 .
– Remove cover -1-.
– Disconnect connector from fresh air and air recirculation flap
control motor -V154- -2-.
– Remove fresh air and air recirculation flap control motor -
V154- -2- from mounting.
1.13.2 Installing
Install in reverse order.
Note
After installing fresh air and air recirculation flap control motor V154- , check operation of air recirculation flap.
– Checking: ⇒ Vehicle diagnostic, testing and information sys‐
tem VAS 5051
– Renewing: initiate basic setting using vehicle diagnosis, test‐
ing and information system -VAS 5051B- ⇒ page 55 .
1.14 Removing and installing heat exchanger
Special tools and workshop equipment required
♦ Drip tray for workshop hoist -VAS 6208-
(Golf Variant 2007►, Golf Variant 2010►
und Jetta 2005►)
1. Repairing heating system 19
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
Heating, air conditioning - Edition 04.2010
♦ Hose clamps up to 40 mm Ø -VAS 3093-
♦ Compressed air gun, commercially available
1.14.1 Removing
– Remove bulkhead in plenum chamber ⇒ Rep. gr. 50 .
– Place drip tray -VAS 6208- 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 and reduce temperature before
carrying out repairs.
– Clamp off coolant hoses -1- with hose clamps up to 40 mm Ø
-VAS 3093- and disconnect coolant hoses to heat exchanger.
– Push a piece of hose -A- onto upper union of heat exchanger.
– Hold a container -B- under lower connection -C-.
– Using a compressed air pistol, carefully blow coolant out of
heat exchanger into container -B-.
– Undo bolt (6 mm hexagon socket head) -1- from union flange
between heat exchanger unions.
Note
This makes it possible to move the coolant pipes in order to re‐
move heat exchanger.
– Remove driver side footwell trim ⇒ Rep. gr. 68 .
20 Rep. gr.80 - Heating
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
Heating, air conditioning - Edition 04.2010
– Remove left footwell vent ⇒ page 9 .
– Remove bolts -1- and remove heat exchanger cladding.
– Cover carpet in area under heat exchanger with waterproof foil
and water absorbing paper.
– Open hose clips -A- and pull coolant pipes out of heat ex‐
changer.
– Take heat exchanger out of heater unit.
1.14.2 Installing
Install in reverse order. Note the following when doing this:
– 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.
– Slide heat exchanger into heater unit.
1. Repairing heating system 21
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
Heating, air conditioning - Edition 04.2010
– Moisten seals -1- with coolant before installing.
– Seat seals -1- into unions on heat exchanger.
Note
♦
Ensure that seals are installed in the proper direction as shown
in figure.
♦
Renew deformed hose clips.
– Connect coolant pipes to heat exchanger.
– During assembly, hose clips -A- must turn easily on coolant
pipes.
– Hose clips -A- must be installed as shown in figure.
– Tighten hose clips -A- to 2.0 Nm.
– Check seating of both clips -A- after tightening screws. They
must fully enclose the flange on the heat exchanger and the
coolant pipe and they must not contact other components.
– Screw bolt -A- into union flange -B- ensuring that bolt actually
screws into intended securing point.
– Check grommet -C- is seating correctly in bulkhead.
– If necessary, seal flanges for coolant pipes to heat exchanger
-A- and for expansion valve (to evaporator, only vehicles with
air conditioning system) -B- at apertures in grommet -C- with
silicone adhesive sealant against water intrusion.
Note
♦
Always renew seals.
♦
Renew deformed hose clips.
♦
After renewing heat exchanger, renew coolant completely ⇒
Rep. gr. 19 .
♦
Check coolant circuit is not leaking. Pay particular attention to
unions/connections between coolant pipes and heat exchang‐
er.
22 Rep. gr.80 - Heating
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
Heating, air conditioning - Edition 04.2010
1.15 Removing and installing heat exchanger (Jetta 2010►)
Special tools and workshop equipment required
♦ Drip tray for workshop hoist -VAS 6208-
♦ Hose clamps up to 40 mm Ø -VAS 3093-
♦ Compressed air gun, commercially available
1.15.1 Removing
– Remove bulkhead in plenum chamber ⇒ Rep. gr. 50 .
– Place drip tray -VAS 6208- 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 and reduce temperature before
carrying out repairs.
1. Repairing heating system 23
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
Heating, air conditioning - Edition 04.2010
– Clamp off coolant hoses -1- with hose clamps up to 40 mm Ø
-VAS 3093- and disconnect coolant hoses to heat exchanger.
– Push a piece of hose -A- onto upper union of heat exchanger.
– Hold a container -B- under lower connection -C-.
– Using a compressed air pistol, carefully blow coolant out of
heat exchanger into container -B-.
– Undo bolt (6 mm hexagon socket head) -1- from union flange
between heat exchanger unions.
Note
This makes it possible to move the coolant pipes in order to re‐
move heat exchanger.
– Remove driver side footwell trim ⇒ Rep. gr. 68 .
– Remove left footwell vent ⇒ page 9 .
– Remove bolts -1- and remove heat exchanger cladding.
– Cover carpet in area under heat exchanger with waterproof foil
and water absorbing paper.
– Remove clips -2- and pull coolant pipes -1- out of heat ex‐
changer.
– Take heat exchanger out of heater unit.
24 Rep. gr.80 - Heating
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