Volkswagen Jetta 2011 User Manual

Service

o

G.

V lksw

ag

en

en

A

A

G

d

g

o

a

e

w

s

s

n

lk

ot

o

V

g

y

u

b

d

a

e

r

s

a

i

n

r

t

o

e

th

e

o

u

r

a

a

s

c

s

c

le

e

n

t

u

p

d

a

t

e

n

l

i

t

y

m

i

r

a

i

e

b

t

p

l

t

i

o

Workshop Manual

y

o

n

p

i

s

w

t

i

r

,

h

e

e

s

l

Golf Variant 2007

t

r

h

e

w

t

n

c

t

i

Golf Variant 2010

p

o

o

o

t

h

r

e

a

Jetta 2005

c

s

n

n

r

i

r

,

e

s

Jetta 2011

c

p

f

e

t

o

e

p

s

r

s

u

o

e

Heating, air conditioning

r

l

i

i

n

a

f

r

o

c

m

m

a

Edition 04.2010

n

t

c

m

i

o

n

i

o

r

t

o

t

s

i

h

a

e

r

o

d

v

i

c

p

u

r

m

f

o

e

g

n

n

i

t

p

.

C

y

o

o

C

p

y

.

t

r

h

g

g

h

i

i

t

r

y

b

p

o

c

y

y

V

o

kl

b

d

e

s

w

a

t

c

et

g

or

e

P

A

n

.G

Service Department. Technical Information

Service

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

Repair Group

80 - Heating

87 - Air conditioning system

.

enAG

g

a

w

s

lk

o

V

y

b

d

e

is

r

o

th

u

a

s

s

le

d

u

n

e

t

t

m

i

r

p

e

t

o

n

s

i

,

e

l

o

h

w

n

i

r

o

t

r

a

p

n

i

,

s

e

s

o

p

r

u

p

l

a

i

c

r

e

m

m

o

c

r

o

e

t

a

v

i

r

p

r

o

f

g

n

i

y

p

o

C

.

t

h

g

i

r

y

p

o

c

y

b

d

et

c

et

or

P

V

olk

s

wag

en

A

G

d

o

e

s

n

ot

g

u

a

r

a

n

t

e

e

o

r

a

c

c

e

p

t

a

n

y

l

i

a

b

i

l

i

t

y

w

i

t

h

r

e

s

p

e

c

t

t

o

t

h

e

c

o

r

r

e

c

t

n

e

s

s

o

f

i

n

f

o

r

m

a

t

i

n

i

n

o

t

d

s

i

h

c

o

u

m

e

n

t

.

C

o

p

y

r

i

g

h

t

b

y

V

o

kl

s

w

a

g

e

A

n

.G

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

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																																																1
	2005►) . . . . . . . . . . .	.		.	. . .	.	. . . .	.	. . .		.	.	.	.	. .	.	. .	.	. . . . .	.	. .		.	.	.		.	.	.	.	.	.	.	.	. . .	. .	.		.		.			.		.
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																																																15
	Jetta 2005►) . . . . . . .	.		.	. . .	.	. . .	. .	. . .	.	.		.	.	.	. .	. .	.	. . . .	. .	. .	.		.	.		.	.	.	.	.	.	.	.	. . . .	.	.	.		.			.			.
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																																																	19
	2005►) . . . . . . . . . . .	.	.		. . .	.	. . . .	.	. . .	.	.		.	.	. .	.	. .	.	. . . . .	.	. .	.		G.	.		.	.	.	.	.	.	.	.	. . . .	.	.	.		.				.		.
1.15 Removing and installing heat exchanger (Jetta g2010►) . . .																				. .	.	. .				.	.	.		. .	.	.	.	.	. . . .	.	.	.		.				.		.			23
																	G.		Volksw	ag
															a	en	A				en	A			d	o	e
														w
													s																				119 726 . . . .																26
1.16 Removing and installing auxiliary air heater element Z35 , vehicles ► 1K-7Mg
												lk																s	n	ot
											o
										V
									y																							u
									b
									d																							a
1.17 Checking, removing and installing auxiliary air heater element Z35 , vehicles 1Kt-7M 119 727
									e																								r
								is																									a
																																		n
								r
	►						o																												e														27
		.	.		. . .	.	. .u. .	.	. . .	.	.		.	.	. .	. .	.	. .	. . . .	. .	.	. .		.		.	.	.		. .	.	.	.	.	.o.r. .	.	.	.		.			.			.
							th																												e
1.18	Checking ventilation					le	a																												a														29
		.	.		. . .		s. . . .	.	. . .	.	.		.	.	. .	.	. .	.	. . . . .	.	. .	.		.	.		.	.	.	.	.	.	.	.	. . . .	e.	.	.		.			.			.
																																			c
						s																														c
																																				p
1.19 Removing and installing air intake grille (Golf Variant 2007►, Golf Variant 2010► und Jetta																																																	30
	2005►) . . . . . . . . . . .	.	.		i. . .	.	. . . .	.	. . .	.	.		.	.	. .	.	. .	.	. . . . .	.	. .	.		.	.		.	.	.	.	.	.	.	.	. . . .	.	.	.		a.				.		.
1.20 Removing and installingp				r	m																																						i						30
				air intake grille (Jetta 2010►)															. . . .	.	. .	.		.	.	.		.	.	.	.	.	.	.	. . . .	.	.	.		.			.	y.
			e																																						b
																																												t
																																											l
		t																																									i
				heater unit																																											h		31
1.21 Removing and installingn									. . .	.	.		.	.	. .	. .	.	.	. . . . .	.	. .	.		.	.		.	.	.	.	.	.	.	.	. . . .	.	.	.		.			.			.
	o																																													i
	s																																											w
																																															t
	i
2						heater unit																																										r	35
	Dismantling and assemblingl									.	.		.	.	.	. .	. .	.	. . . .	.	. .	.		.	.	.		.	.	.	.	.	.	.	. . . .	.	.	.		.			.			.		s
	,																																															e
2.1	o					heater unit																																										p
	Dismantling and assemblingw									.	.		.	.	.	. .	. .	.	. . . .	.	. .	.		.	.	.		.	.	.	.	.	.	.	. . . .	.	.	.		.			.			.		t35
	h																																															e
	n																																															c
2.2																																																	36
	Removing and installing air distribution flap actuator																	.	. . . .	. .	.	. .		.		.	.	.		. .	.	.	.	.	. . . .	.	.	.		.				.		.
	i																																															t
	r																																															o
	o																																															t
2.3	Removing and installinga			temperature flap actuator													.	.	. . . .	. .	.	. .			.	.	.		.	.	.	.	.	.	. . . .	.	.	.		.			.			.			36c
	t																																															h
	r																																																e
	p																																																o
	n																																																r
.87 - Air conditioning systeme			.		. . .		. . .	. .	. .	.	.		.		.	. .	.	.	. . . .	.	. .	.			.		.	.		.	.	.	.	.	. . .	.	.	.					.			.		38t
	i																																																r
	,																																																e
	s																																																c
1	s																																																n
	Notes on repair work to vehicles with air conditioning and on handling refrigerant .																																			.	.			.			.		.				38
	o																																																e
	p																																																s
	r																																																s
2	Air conditioning system with manual controls, Climatic																																																o
																				. .	. .	.		.	.		.	.	.	.	.	.	.	.	. . . .	.	.	.		.				.	.			i39
	u																																															f
	p
	i																																															n
2.1	l																																															r
	Air conditioning system and heater - passenger compartment (Golf Variant 2007►, Golf
	a																																															f
	r																																															o
	c																																															m
	Variant 2010► und Jettam			2005►)																																													39
								.	. . .	.	.		.	.	. .	. .	.	.	. . . . .	.	. .	. .			.	.	.	.		. .	.	.	.	.	. . . .	.	.	.		.				.	.			a
																																																t
2.2	Air conditioning systemcand heater - passenger compartment (Jetta 2011►)																																														n	i	41
																																		.	. . . .	.		.		.			.		.			o
	o																																												n	i
	r
2.3		o																																										h t		.			42
	Removing and installingeheater and air conditioner unit (Climatic)																								.	.		.	.	.	.	.	.		. . . .	. .		.		.		s	i.
2.4			t																																														47
				a																																				o
	Dismantling and assembling heater and air conditioning unit (Climatic)																													.	.	.	.	.	. . .	. .		.			d		.		.
					v
					i																																		c
					p
2.5					r																																												48
	Removing and installing heating and air conditioning controls, Climatic																													.	.	.	.	.	. . .	. .		u.		.			.		.
					r																																m
					f
					o																															e
2.6						g																																											49
						n																														n
	Connections on controls for heating and air conditioning, Climatic																								.		.	.	.	.	.	.	.		. . . .	t.	.	.		.			.		.
						i
							p																												.
																																			C
							y
2.7							o																												o														50
	Removing and installing flexible shaftt .									. .	.		.	.	.	. .	.	. .	. . . .	.	. .	.		.	.	.		.	.	.	.	.	.	.	i. . . .	.	.	.		.			.		.
							C																												p
																																			y
							.	h																											r
																																		g
2.8								g																									h																51
	Checking condensation water drainageyphose on heater and air conditioneryunit . . .																																			.		.		.			.		.
									i																								t
									r
									o	c																						b
											y																				V
																														o
2.9																		motor V113						e.ga					kl																				51
	Removing and installing air recirculation flapecontroltc																											s.		. .	.	.	.	.	. . . .	.	.	.		.				.	.
											b		d
															et	or							n				w
																					A
																P					.G																												51
2.10 Removing and installing temperature flap control motor V68																					. .	.		.		.	.	.		. .	.			.	. . . .	.	.	.		.			.		.
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																																																56
	Variant 2007►, Golf Variant 2010► und Jetta 2005►)																		. . . . .	.	. .	.		.		.	.	.		. .	.			.	. . . .	.	.	.		.			.		.

Contents i

			Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011
			Heating, air conditioning - Edition 04.2010
																o
															G.	V lksw	ag	en
														en	A				A
													g						G
													a							d
												w								o	e
											s
										lk											s	n	ot
									o
								V																	g
						y																					u
						b
		3.3			d																						a
				Removing and installing operating and display unitt for Climatronic air conditioning system
					e																							r
					is																							a
																													n
				r
				o																										e
				E87 with Climatronic control unit J255 (Golf Variantr2007►, Golf Variant 2010► und Jetta
				th																										e
																														o
				u
																														a
				a																																			57
				e2005►)s		.	.		.	.	.	.	.	. .	. .	. . . . .	.	. .	. .	. .	.	.	.			.	.	.	.	. . . .e. .	. .		.			. .	. . .	. . . . . . . . . . . . . . . . . . .
				s																										c
		3.4		l																										c
				Function of operating and display unit for Climatronic air conditioning system E87 (Jetta																																			57
			it	2011►)		.	.	.	.	.		.	.	. .	. .	. . . . .	.	. .	. .	. .	.	.	.		.		.	.	.	. . . . . . .	i.		.		.	.	. . .	. . . . . . . . . . . . . . . . . . .
			m																												l
				Removing and installing operating and display unit for Climatronic air conditioning system
		3.5																																					59
			o	E87 with Climatronic control unit J255 (Jetta 2011►) . . .																											. .			.		i. .	. . .	. . . . . . . . . . . . . . . . . . .
																																		w
			n	Connectors on Climatronic control unit J255																																r			59
,i3.6																												.	.	. . . . . . .	. .				.			. . . . . . . . . . . . . . . . . . .
	s																																			t
																																				h
e		3.7		Climatronic - passenger compartment (Golf Variant 2007►, Golf Variant 2010► und Jetta
o
l
h				2005►)																																			61
w						.	.	.	.	.		.	.	. .	. .	. . . . .	.	. .	. .	. .	.	.	.		.		.	.	.	. . . . . . .	.		.		.	.	.t. .	. . . . . . . . . . . . . . . . . . .
n		3.8		Climatronic - passenger compartment (Jetta 2011►)																																	h		65
o																															.			.	.	.		. . . . . . . . . . . . . . . . . . .
i																																					t
r																																					o
																																					t
a		3.9		Removing and installing fresh air blower control unit J126																																			67
																																		. . . .c. .				. . . . . . . . . . . . . . . . . .
t																																					e
r
p		3.10		Removing and installing heater and air conditioning unit (Climatronic)e																																			68
,
n																																					r
i		3.11																																			r
s				Dismantlingandassemblingheaterandairconditioningunit(GolfVariant2007►,GolfVariant
s																																					c
e																																					t
				2010► und Jetta 2005►)																																	n		71
p																. . . .	.	. .	. .	. .	.	.	.		.		.		.	. . . . . . .	. .			.	.	.	.s. .	. . . . . . . . . . . . . . . . . . .
o																																					e
r		3.12																																			s	2011►)	73
l				Dismantling and assembling heater and air conditioning unit (Jettai
u																																					o
p																																					f
i		3.13		Dismantling and assembling evaporator housing																																	n		75
r																														. . . . . .	.		.		.	.	o. . .	. . . . . . . . . . . . . . . . . . .
a																																					f
c																																					r
		3.14																																			m		76
e
m																																				t
m
		3.15																																		i	G262		77
				Removing and installing right footwell vent temperature sendern
	o																																			o
			r																																n	i
			o
		c		Removing and installing evaporator temperature sensor G308h																																			77
		3.16																																			. .	. . . . . . . . . . . . . . . . . .
																																s	i	t
			t
			a
			e	Removing left vent temperature sender G150 and right vento																															temperature sender G151 . .				78
		3.17r
			v																												d
			i																											u	c
		3.18
				Removing sunlight penetration photosensor G107 or sunlight penetration photosensor 2																																			78
				G134y	.	.	.	.	.	.		.	.	. .	. .	. . . . .	.	. .	. .	. .	.	.	.		.		.		.	. . . ..t. . . .	.			.	.	.	. . .	. . . . . . . . . . . . . . . . . . .
				i
		3.19		p																										C									79
				Checking.			condensation water drainage hose on heater and air conditioner unit . . . . . . . .
				o																										o
				C																										p
																														y
				t																										r
				h																									g
		3.20		Renewingy																										i									79
								control motors for air conditioning regulationb .																							.		.		.	.	. . .	. . . . . . . . . . . . . . . . . .
					g																							h
					r	p																				y		t
		3.21				o		c																V															79
																							o
				Removing andeinstallingtc												fresh air and air recirculation flap control motor V154 . . . . . . . .
									y													kl
									b												s
													e							aw
																				g
																			e
		3.22											to						n
				Removing and installing air flow flap control motor V71 or fresh air/recirculated air, air flow																																			79
				flap control motor V425												. . . .	.	. .	. .	. .	.	.	.		.		.		.	. . . . . . .	. .			.	.	.	. . .	. . . . . . . . . . . . . . . . . . .
		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																																			84
				and BXE				. .	.	.		.	. .	.	. . .	. . . . .	.	. .	. .	. .	.	.	.		.		.		.	. . . . . . .	. .			.	.	.	. . .	. . . . . . . . . . . . . . . . . . .
		4.3		Removing and installing ancillary bracket for air conditioner compressor, engine codes BGP																																			86
				and BGQ				.	.	.		.	.	. .	. .	. . . . .	.	. .	. .	. .	.	.	.		.		.	.	.	. . . . . . .	.	.			.	.	. . .	. . . . . . . . . . . . . . . . . . .
		4.4		Removing and installing ancillary bracket for air conditioner compressor, engine codes BPY,																																			88
				BWA, BSE, BSF, BLR, BLY .													.	. .	. .	. .	.	.	.		.		.	.	.	. . . . . . .	.	.			.	.	. . .	. . . . . . . . . . . . . . . . . . .
		5		Repair work on refrigerant circuit which may be performed only in appropriate workshops by																																			91
				specially trained mechanics .													.	. .	. .	. .	.	.	.		.		.	.	.	. . . . . . .	.	.			.	.	. . .	. . . . . . . . . . . . . . . . . . .
		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																																			94
				2005►)		.	.	.	.	.		.	.	. .	. .	. . . . .	.	. .	. .	. .	.	.	.		.		.	.	.	. . . . . . .	.	.			.	.	. . .	. . . . . . . . . . . . . . . . . . .
		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																																			100
				2005►)		.	.	.	.	.	.	.	.	. .	. .	. . . . .	.	. .	. .	. .	.	.	.		.		.	.	.	. . . . . . .	.	.			.	.	. . .	. . . . . . . . . . . . . . . . . . .
		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

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011

Heating, air conditioning - Edition 04.2010

6.2

Refrigerant oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

105

.

enAG

g

a

w

s

lk

o

V

y

b

d

e

is

r

o

th

u

a

s

s

le

d

u

n

e

t

t

m

i

r

p

e

t

o

n

s

i

,

e

l

o

h

w

n

i

r

o

t

r

a

p

n

i

,

s

e

s

o

p

r

u

p

l

a

i

c

r

e

m

m

o

c

r

o

e

t

a

v

i

r

p

r

o

f

g

n

i

y

p

o

C

.

t

h

g

i

r

y

p

o

c

y

b

d

et

c

et

or

P

V

olk

s

wag

en

A

G

d

o

e

s

n

ot

g

u

a

r

a

n

t

e

e

o

r

a

c

c

e

p

t

a

n

y

l

i

a

b

i

l

i

t

y

w

i

t

h

r

e

s

p

e

c

t

t

o

t

h

e

c

o

r

r

e

c

t

n

e

s

s

o

f

i

n

f

o

r

m

a

t

i

n

i

n

o

t

d

s

i

h

c

o

u

m

e

n

t

.

C

o

p

y

r

i

g

h

t

b

y

V

o

kl

s

w

a

g

e

A

n

.G

Contents iii

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 Heating, air conditioning - Edition 04.2010

.

enAG

g

a

w

s

lk

o

V

y

b

d

e

is

r

o

th

u

a

s

s

le

d

u

n

e

t

t

m

i

r

p

e

t

o

n

s

i

,

e

l

o

h

w

n

i

r

o

t

r

a

p

n

i

,

s

e

s

o

p

r

u

p

l

a

i

c

r

e

m

m

o

c

r

o

e

t

a

v

i

r

p

r

o

f

g

n

i

y

p

o

C

.

t

h

g

i

r

y

p

o

c

y

b

d

et

c

et

or

P

V	o
	lk

s

wag

en

A

G

d

o

e

s

n

ot

g

u

a

r

a

n

t

e

e

o

r

a

c

c

e

p

t

a

n

y

l

i

a

b

i

l

i

t

y

w

i

t

h

r

e

s

p

e

c

t

t

o

t

h

e

c

o

r

r

e

c

t

n

e

s

s

o

f

i

n

f

o

r

m

a

t

i

n

i

n

o

t

d

s

i

h

c

o

u

m

e

n

t

.

C

o

p

y

r

i

g

h

t

b

y

V

o

kl

s

w

a

g

e

A

n

.G

iv Contents

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011

Heating, air conditioning - Edition 04.2010

o

G.

V lksw

ag

en

en

A

A

G

d

g

o

80 –

a

ar

eHeating

e

w

s

s

n

lk

o

V

ot

g

y

u

b

d

a

s

i

n

r

t

o

e

th

e

o

u

1

le

Repairing heating system

r

a

p

a

s

c

s

c

n

e

u

t

d

a

t

e

n

l

i

t

y

m

i

r

a

2007►, Golf Variant 2010►

i

t

p 1.1

Heater - passenger compartment (Golf Variantw

e

b

t

l

i

o

y

is

n

und Jetta 2005►)

i

r

t

,

h

e

e

s

l

p

o

Disconnect battery before removing components marked **

h

c

w

t

Rep. gr.

27 .

e

i

o

n

t

r

o

t

t

h

e

r

a

1 - Dash panel**

c

i

p

n

,

2 - Centre vents

s

s

e

o

Removing vent

u

p

r

page 7 .

l

p

a

3 - Right side vent

e

i

c

r

m

c4 - Right vent

m

o

Removing vent

e

r

o

page 8 .

i

t

a

v

r

p

for fresh and heat

5 - Controlsfg

r

o

ed air y

n

i

p

o

With.thfresh air and air re

C

flap switch -

circulationyp

g

i

r

o

E159- .

bd

c

y

et

c

et

or

For vehicles with sup

P

plementaryheatinghav

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 installingpage 9

8 - Fresh air blower -V2-

Removing page 5

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

Removing and installingpage 6

10 - Baffle plate for heater unitRemoving 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

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

o

G.

V lksw

ag

en

en

A

A

G

d

g

o

18 - Auxiliary air heater element -Z35-

V

a

e

ot

w

s

s

n

lk

y

o

g

u

b

Vehicles ► 1K-7M 119 726

o

d

a

e

e

r

s

a

i

n

r

t

e

th

u

o

With auxiliary air heater control unit -J604- .

r

c

s

a

a

le

s

c

e

Checking: with vehicle diagnosis, testing andu information system -VAS 5051- (or later model), under

n

n

t

d

p

a

Heating, ventilation, air conditioning; Systemsi

capable of self-diagnosis; Auxiliary heating; Electrical

a

t

e

l

t

y

components.

r

m

i

i

i

e

b

t

Removing and installing page 26

p

l

o

t

i

n

y

s

w

t

i

Vehicles 1K-7M 119 726 ►

r

l

s

,

h

e

e

o

p

h

e

A 3-speed auxiliary air heater element -Z35- is fitted here; it is controlled by the respective engine control

t

w

t

unit via relays.

n

c

t

r

i

o

o

h

Installed only in vehicles with dieselaengines without supplementary heater.

c

t

e

r

p

o

Removing and installing page 27,

e

n

r

i

r

s

c

19 - Heat exchanger

e

t

e

o

s

n

p

s

r

s

After renewing heat exchanger, renew coolant completely Rep. gr. 19 .

o

u

f

p

Removing and installing page 19

l

i

r

o

i

n

a

f

c

r

20 - Left footwell vent

m

m

it

e

a

m

Removing and installing page 9

o

n

i

n

o

o

c

r

t

21 - Bowden cable for temperature flap

v

d

s

i

h

t

a

e

r

o

Removing and installing page 18

i

c

p

u

o

r

m

f

e

g

22 - Flexible shaft

n

C

n

p

t

i

y

.

o

o

Removing and installing page 17

C

p

h

y

hg

.

r

t

i

i

t

g

r

y

b

p

o

c

y

23 - Heater unit

y

bd

ws

V

o

e

a

kl

t

c

et

g

or

e

Removing and installing page 31

P

A

n

.G

Dismantling and assembling page 35 24 - Left side vent

2Rep. gr.80 - Heating

o

G.

V lksw

ag

en

A

en

A

G

d

g

a

w

o

e

s

s

n

lk

2005 , Jetta 2011

o

Golf Variant 2007 , Golf Variant 2010 , Jettau

V

ot

g

y

b

a

d

e

r

Heating, air conditioning - Edition 04.2010

is

a

t

r

o

e

th

e

o

u

r

a

a

s

c

Removing heater unit baffle platele

s

d

u

n

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

e

p

e

r

m

t

o

n

s

i

,

e

l

o

h

w

n

i

r

o

t

r

a

p

n

i

,

s

e

s

o

s

p

r

s

Installation position oflseal between heater unit and engine com

u

partment

p

r

a

i

c

e

– First insert seal between heater unit and engine compartment

m

m

-A- in bulkhead and

then attach to heat exchanger.

r

o

c

o

e

t

a

Note

v

o

i

r

p

r

f

g

n

i

interior, installation posi

To prevent water from entering vehicleo

y

p

tion must be observed.

C

hg

.

t

i

r

y

p

o

c

y

b

d

e

g

t

c

et

or

e

P

A

.G

1. Repairing heating system 3

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 Heating, air conditioning - Edition 04.2010

1.2Heater - passenger compartment (Jetta 2011►)

1 - Dash panel

2 - Centre vents

Removing ventpage 10 .

3 - Right side vent

Removing page 12

4 - Controls for fresh and heat

ed air

th

is

r

o

u

With fresh air and airs

re

a

le

s

-

circulation flap switchun

E159- .

te

d

m

i

t

sup

For vehiclese withr

plementarytheatinghav

ing instants

o

p

heating but

i

n

ton -E537l- .

,

e

o

controls

Removingw

h

pager14 .

n

i

o

5 - Fresh air and air recircula

t

r

a

tion flap control motor -V154-

p

n

i

Removinge

page 19

s

,

s

o

6 - Right footwell vent

p

r

u

Removing and installing

p

l

a

page 9e

i

c

r

m

7 - Fresh air blower series re

m

sistor with overheating fuse -

o

c

N24-

r

a

o

e

t

Removing and installingr

v

i

r

page 6

p

g

o

f

n

i

8 - Fresh air blower -V2-

y

C

p

o

.

Removing page 5

t

h

g

i

9 - Baffle plate for heater unitRemoving 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 .

4Rep. gr.80 - Heating

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011

Heating, air conditioning - Edition 04.2010

o

G.

V lksw

ag

en

e

Removing and installing spage 23

en

A

A

G

d

g

o

a

lk

w

s

n

ot

o

V

g

y

flap

u

a

17 - Bowden cable for temperatures

b

d

a

i

e

r

n

r

t

or

Removing anduinstalling page 18

o

e

th

e

a

a

s

c

s

c

18 - Left footwellnvent

t

le

e

u

p

d

and installing page 9

a

i

Removingt

t

e

n

l

m

i

y

r

a

i

19 - Heater unitp

y

e

b

t

l

t

i

o

and installing page 31

i

Removingn

h

s

w

t

i

and assembling page 35

r

Dismantlingl

s

,

e

e

o

p

h

shaft

e

20 - Flexiblen

t

w

t

c

i

o

Removing and installing page 17

r

o

t

t

h

e

r

a

c

p

o

n

r

i

r

,

e

s

c

Removings

heater unit baffle plate

e

o

p

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

r

u

p

l

a

i

c

r

e

m

m

o

c

r

o

e

t

a

v

i

r

p

r

o

f

g

n

i

y

p

o

o

C

p

y

.

t

r

h

g

g

h

i

i

t

r

y

b

p

o

c

y

y

o

kl

b

d

s

w

et

a

Installation position of seal between oheaterrP

unit and.GAengine com

c

g

partment

et

e

–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.

1.3Removing fresh air blower -V2-

1.3.1Removing

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

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 Heating, air conditioning - Edition 04.2010

1.4Removingand installingfreshair blower series resistor with overheating fuse - N24-

Removing

WARNING

Danger of burn injuries.

G.

Volks

w

ag

enA

en

g

a

w

fuse-N24-

ThefreshairblowerseriesresistorwithoverheatingyV

s

lk

can be hot.

is

b

o

d

e

r

o

th

Before removing fresh air blower seriesa resistor with overheat

u

ing fuse -N24- ,let it cool off.

le

s

s

u

n

t

t

e

d

m

i

First carry out the following work:e

r

o

t

p

plate page 3 .

– Removing heater unit baffles

n

i

,

e

air blower series resistor with over

– Pull connector -1- off fresho

l

heating fuse -N24- .

h

w

n

i

r

– Presscatchindirectionof-arrow-andremovefreshairblower

o

t

series resistor with overheating fuse -N24- from heater unit.

r

a

p

Installing

n

i

,

s

e

Install in reverse order.

s

r

o

p

u

p

l

a

i

c

r

e

m

m

o

1.5

c

Removing andainstalling dust and pollen

r

o

e

filter

t

o

v

i

r

p

r

f

Removing

g

p

n

i

y

o

C

side.

– Remove footwell cover -1- on front passengeri

.

t

h

g

r

y

p

o

c

3 .

– Remove baffle plate -2- from heater unit pagebd

y

et

cetor

P

.G

– Release cover -3- in direction of arrow.

– Remove dust and pollen filter from heater unit downwards. Installing

AG

does

not

guarant ee

or a c c e p t a

n y

l i a

b

i l i t

y

w

n

i

n

t

d

s

i

h

o

c

u

m

e

n

t

.

C

o

p

6Rep. gr.80 - Heating

o

G.

V lksw

ag

en

en

A

A

G

d

g

o

a

e

w

s

s

n

lk

ot

o

V

g

y

u

b

d

a

Golf Variant 2007 , Golfr Variant 2010 , Jetta 2005 , Jetta 2011nt

e

r

is

a

e

o

a

Heating, air conditioning - Edition 04.2010a

th

e

u

o

r

s

c

s

c

le

e

Install in reverse order.

d

u

n

p

e

m

i

t

t

p

e

r

Note

o

n

t

s

i

,

e

pollen filter.

Observe installation position of dust ando

l

h

w

n

i

r

o

t

r

a

p

n

i

,

s

e

s

o

p

r

u

1.6

p

Removing vent (Golf Variant 2007►,

l

a

i

c

r

Golf Variant 2010► und Jetta 2005►)

e

m

m

Removing centre vents page 7 .	o
	e
	c
	r
	o
	t
	a
	v
	i
	r
	p
Removing and installing left or right vent page 8 .
	r
	o	air ducts
	f
	g
	n
Removing and installing right and left rear footwelli
page 8 .	y
	p
	o
		C
		.
		t
Remove right footwell vent page 9 .		h
		g
		i
		ry
			p
			o
			c
			y
				b
Removing left footwell vent page 9 .				d
				e	tcet
					or
					P

Removing and installing side vent page 10 .

											e
											n
											t
										.
										C
										o
										p
										y
										r
										i
									g
									h
									t
								b
								y
								V
							o
						kl
					s
				w
			a
		g
	e
A	n
.G

m

u

c

o

d

s

i

h

t

n

i
	t
	h
		r
		e
		s
		p
		e
		c
		t
		t
		o
		t
		h
		e
		c
		o
		r
		r
		e
		c
		t
		n
		e
		s
		s
		o
		f
		i
		n
		f
		o
		r
		m
		a
		t
		i
i	n	o

1.6.1Removing and installing centre vent

Removing

–Vehicles with Climatronic, photosensor must be removedpage 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

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011

o

G.

V lksw

ag

en

A

en

A

G

Heating, air conditioning - Edition 04.2010g

d

o

a

e

w

s

s

n

lk

ot

o

V

g

–

Remove securing bolts -1-.

y

b

d

e

is

r

t

o

u

a

– Remove compartment from dash panel.

s

s

–

le

in direction of -arrow-.

n

Remove centre vent -2- upwardsu

–

Disconnect connectors

t

e

d

i

t

r

mon centre vents.

Installing

p

e

t

o

n

s

i

Install in reverse order.e,

l

o

h

w

n

i

r

o

t

r

a

p

n

i

,

s

e

s

o

p

r

u

p

l

a

i

c

r

e

1.6.2

m

m

o

c

Removingand installingright or leftvent

r

o

e

t

d

a

Note

v

o

i

r

u c

r

p

m

f

o

e

g

n

n

i

t

♦ Removal of vents on both sidesois identical, but one is a mirror

oC

y

.

image of the other.

p

gi

th

C

p

.

y

g

r

h

i

t

r

y

b

p

when levering out

s

y

♦ To avoid damage to dash panel, use a padb

V

o

c

y

o

components.

d

etor

Ane

w

kl

et

c

a

P

.G

g

s

i

h

t

n

i

n

r oitam

Removing

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

–Disconnect connector on vent.

Installing

Install in reverse order.

1.6.3Removing 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 .

8Rep. gr.80 - Heating

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.

o

G.

V lksw

ag

en

A

en

A

g

G

d

o

a

e

w

s

s

n

lk

o

Install in reverse order.

e

V

ot

y

b

is

d

r

o

th

u

a

s

s

le

d

u

n

e

t

t

m

i

r

p

e

t

o

n

s

i

,

e

l

o

h

w

n

i

r

o

t

r

a

p

1.6.4

n

right footwell vent

Removinge

i

,

s

s

Removing

o

u

p

r

p

–

Remove glove compartment Rep. gr. 68 .

l

a

i

c

–

r

bolt -2- and remove right footwell vent -1-.

Remove securingm

e

Installing

m

o

o

c

r

Install in reverse order.

e

i

t

a

v

r

p

r

o

f

g

Note

n

o

i

y

p

C

.

t

h

g

i

ensure that cooling

If vehicle has glove compartment cooling,oc

r

y

hose is properly seated.

p

y

etc

ega

b

d

s

et

or

P

A

n

w

.G

1.6.5Removing 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.

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

1. Repairing heating system 9

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011

Heating, air conditioning - Edition 04.2010

1.6.6Removing 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 .

1.7Removing vent (Jetta 2011►)

1.7.1Removing and installing centre vent

Removing

Special tools and workshop equipment required

♦ Removal wedge -3409-

G.

Volksw

ag

en

en

A

A

g

G

d

o

a

e

w

s

s

n

lk

ot

o

V

g

y

b

u

d

s

a

i

e

n

r

t

o

e

th

e

–

Switch off ignition.

o

u

r

s

c

a

a

s

c

le

e

–

Remove centre trimd

n

t

of dash panel General body repairs,

n

u

p

interior; Rep. gr.

e

a

a

i68 ; Removing and installing centre trim of

t

l

t

y

dash panel .

r

m

i

e

t

i

b

p

l

t

i

y

–

Remove Radio,n

if fitted Communication; Rep. gr. 91 ; Re

h

w

s

i

moving and installing,

radio units and navigation systems .

t

e

i

r

e

s

l

p

o

navigation systems

Vehicles with radiow

t

h

e

n

c

t

i

–

Remove radioo

navigation system Communication; Rep. gr.

h

r

o

91 ; Removinga

and installing radio units and navigation sys

t

c

t

e

tems .

r

i

r

p

o

n

r

,

e

s

c

For all vehicless

n

e

t

e

o

p

move steering wheel to lowest position.

s

– Height adjustment:p

f

r

s

u

o

l

i

i

n

a

f

r

o

c

r

e

m

m

a

t

m

i

o

i

n

o

c

n

r

t

o

t

s

i

h

a

e

r

o

d

v

i

c

p

u

r

m

f

o

e

g

n

n

i

t

p

.

C

y

o

o

C

p

y

.

t

r

h

g

g

h

i

i

t

r

y

b

p

o

c

y

y

V

o

kl

b

d

e

s

w

a

t

c

et

g

or

e

P

A

n

10 Rep. gr.80 - Heating

.G

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 Heating, air conditioning - Edition 04.2010

			o	t	p
		n
	s
	i
	,
	e
	l
o
h
w
n
i
r
o
t
r
a
p	steering wheel so that the steering
– Reach adjustment: move,
n
i
wheel is as far into the passenger compartment as possible.
s
e
s

– Release gap cover fromrmounting in upper part of trim with
	o
	p
wedge -3409- . The complete steering column trim must not
	u
be removed.	p
	r
	l
	a
	i
	c
	e
– Remove bolt -3- (1.5 Nm).m
	m

o – Release clips of centre ventc-arrows- using wedge -3409- and r

pull out dash panel insert trimo with centre vent -1- slightly. e

t a

v i r p

– Releaseclipsofleftventusingwedger -3409-andpulloutdash

o

	f
	g
	n
panel insert trim with centre vent -1i- slightly.
	y
	p
	o	trim-1-usingwedge
	C
– Releasefasteners-4-ofdashpanelinsert.t
-3409- and pull out slightly.	h
	g
		i
		ry
			p
			o
				c
				y
				b
					d		-1-
					e
– Remove dash panel insert trim with centre and leftceventst
						or
						P

from dash panel -2-, disconnect wiring harness to hazard warning light switch -E3- when doing this.

Installing

Install in reverse order.

											e
											n
											t
										.
										C
										o
										p
										y
										r
										i
									g
									h
									t
								b
								y
								V
							o
						kl
					s
				w
			a
		g
	e
A	n
.G

m

u

c

o

d

s

i

h

t

n

i

n

o

t h e

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

oitam

1. Repairing heating system 11

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.

1.7.2Removing 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.							agen
						w
					s
				lk
			o
– Remove right dash panel vent -1- from dash panel -2-.
		V
	y
	b
	d
	e
	is
	r
	o
	th
	u
	a

n i

,

AG.

V

olk

swagen

AG

does

not

guarant ee

or a

Installing

– Installation is carried out in reverse order.

12 Rep. gr.80 - Heating

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.

agenA

o

nAGd

.V lkswa

ge

w

G

o

e

s

s

n

lk

ot

o

V

g

y

u

b

1.7.3

d

a

ee

Removing and installing right and left

e

r

s

a

i

n

r

t

o

th

o

c

rears

footwell air ducts

u

r

s

a

le

c

e

n

t

u

p

d

a

t

e

n

l

i

t

y

i

a

Noter

l

e

m

b

t

p

i

t

i

o

y

of air ducts on both sides is identical, but one is a mirror

i

Removals

h

n

w

i

t

of the other.

r

imagel

s

,

e

o

p

h

e

w

t

Removingr

c

o

n

t

i

o

t

– Remove driver or front passenger seat

Rep. gr. 72 .

h

c

t

e

r

a

o

p

n

r

– Remove centre console Rep. gr. 68 .

i

,

s

e

– Raise floor covering, unclip rear footwell air duct from under

s

o

p

and pull off heater unit.

bodyp

r

u

Installing

l

a

i

c

r

e

m

m

Note

o

c

r

o

e

t

a

rear footwell air duct, ensure that it is first pushed

When installingp

v

i

r

-arrow- and then clipped to underbody.

e

onto heater unitfg

r

o

n

n

i

t

p

.

C

y

o

o

C

p

y

.

t

r

h

g

g

h

i

i

t

r

y

b

Install in reverse order.

p

o

c

b

s

y

V

y

o

d

e

w

kl

a

t

c

g

e

et

or

A

n

P

.G

1.7.4Removing 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

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 Heating, air conditioning - Edition 04.2010

1.7.5Removing 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

enAG.VolkswagenA

G

d

g

wa

s

o

e

lk

s

Connectors on controls for heated and fresh air (Golf Variant

o

V

y

2007►, Golf Variant 2010► und Jettao

b

2005►) page 15

d

e

is

r

th

u

Connectors on controls for heateds

and fresh air (Jetta 2011►)

a

page 16

n

s

u

le

e

d

Removing

t

i

m

t

p

e

r

t

o

n

Note

is

,

e

l

o

h

♦ Thecontrolconsistsw of2separablehousings.Beforeremoving

controls, set rotaryr knobs to the following positions:

n

i

o

♦ Heater control toa„cold“

t

r

p

♦ Blower to „0“

n

s

i

,

e

„footwell“

♦ Vent direction tor

s

o

p

u

p

– Remove radio

Rep. gr. 91 .

r

l

a

i

c

e

– Models with no radio trim, removing centre part of dash panel

Rep. gr. 68 .

m

c

m

o

r

o

e

t

a

v

i

r

p

r

o

f

g

n

i

y

p

o

C

.

t

h

g

i

r

y

p

o

c

y

b

d

a

e

t

c

et

g

or

e

n

A

P

.G

not

guarant ee

or a c c e p t a

n y

l i a

b

i l i t

y

w

i t

h

r e s p e c t

t o

t h e

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

14 Rep. gr.80 - Heating

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-.

o

G.

V lksw

ag

en

en

A

A

G

d

g

o

a

e

w

s

s

n

lk

ot

Note

o

V

gu

y

b

d

a

e

r

s

a

i

n

r

t

o

e

th

e

u

Figure shows Climatica version.The procedure for releasing con

s

s

nector is the same.le

d

u

n

e

Installing

t

m

i

t

r

p

e

t

order. Note: the rotating knobs must be in the

Install in reverseo

n

as when removed.

same positionis

,

e

l

o

1.9

h

Connectors on controls for heated and

w

n

i

r

fresh air (Golf Variant 2007►, Golf Var

o

t

r

a

iant 2010► und Jetta 2005►)

p

n

i

,

s

e

s

1.9.1

o

Pin assignment for multi-pin connectors

p

r

u

p

l

on back of controls for heated and fresh

a

i

c

r

e

m

mair

o

c

r

o

Special tools and workshop equipment required

e

t

a

v

i

r

♦ Auxiliary measuring set -V.A.G 1594 C-

p

r

o

f

g

n

i

y

p

o

C

y

.

t

r

h

i

g

g

h

i

t

r

y

b

p

o

c

y

y

V

o

kl

b

d

e

s

w

a

t

c

et

g

or

P

A

n

.G

r a c c e p t a

n
y
l
i
a
b
	i
	l
		i
		t
		y
		w
				i
					t
					h
						r
						e
						s
						p
						e
						c
						t
						t
						o
						t
						h
						e
						c
						o
						r
						r
						e
						c
						t
						n
						e
						s
						s
						o
						f
						i
						n
						f
						o
						r
						m
						a
						t
						i
			n	i	n	o
		t
s	i	h

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

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 Heating, air conditioning - Edition 04.2010

20-pin connector, T20c in current flow diagram

agenA

o

w

G.

V

lk

s

lk

o

3 - Fresh air and air recirculation flap control motor -V154-

V

y

b

d

e

is

r

6 - Fresh air and air recirculation flap control motor -V154-

th

u

a

s

s

7 - With auxiliary air heater control unitn

-J604-

le

8 - Rear window

e

d

u

it

m

t

e

r

-J131-

11 - Heated driver seat control unitt p

n

o

control unit -J132-

15 - Heated front passenger seat,i

s

e

l

o

(optional)

16 - Terminal 75, seat heatingh

w

18 - Terminal 30

n

o

i

r

19 - Terminal 15

t

p

r

a

20 - Terminal 31

n

e

i

,

s

s

o

1.10

p

Connectorslon controls for heated and

r

u

p

fresh air (Jetta 2011►)

a

i

c

r

e

m

m

o

1.10.1

c

Pin assignmentafor multi-pin connectors

r

o

e

t

on back of controls for heated and fresh

v

i

r

p

air

r

i

o

f

g

n

y

p

o

Special tools and workshop equipment required.th

C

g

i

r

y

♦ Auxiliary measuring set -V.A.G 1594 C-

p

cyb

o

d

et

c

et

or

P

swag

		e
		n
		t
	.
	C
	o
	p
	y
	r
	i
g
h
t
b

m

u

c

o

d

s

i

h

t

n

i

n

t h e

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

oitam

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

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

1.11Removingandinstallingflexibleshaftfor 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

wage

-D- is visible in gears -F-.

n

s

lk

o

V

y

b

d

e

is

r

o

th

u

a

s

s

le

d

u

n

e

t

t

m

i

r

p

e

t

o

n

s

air page 14 .

– Remove controls for fresh and heatede

i

,

l

o

h

locking lug -1- by

– Reach into centre console and releasew

pressing in direction of -arrow-.

r

n

i

o

– Pull flexible shaft out of adapter -2p-.

t

r

a

n

i

,

s

Note

e

p

s

o

r

u

p

When flexible shaft is installed, the adapter and the rotary knobs

l

a

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

i

c

r

cific position to one another.Otherwise the system will malfunc

e

tion page 17 .

m

c

m

o

r

o

e

t

a

1.11.1

Checking

v

f

i

r

p

r

o

g

Flexible shaft for air distribution flap actuator:

n

o

i

y

p

–Run fresh air blower at highest speed. If air flowsC.outthgiryof de froster vent in the „defrost“ position, and no air flows outpocofyb footwell vent, then the flexible shaft is correctly installed. OthdetcetorP erwise, remove flexible shaft from adapter. Position controls

for heated and fresh air on adapter and turn rotary knob for air

											e
											n
											t
										.
										C
										o
										p
										y
										r
										i
									g
									h
									t
								b
								y
								V
							o
						kl
					s
				w
			a
		g
	e
A	n
.G

m

u

c

o

d

s

i

y
w
		i
			t
			h
				r
				e
				s
				p
				e
				c
				t
				t
				o
				t
				h
				e
				c
				o
				r
				r
				e
				c
				t
				n
				e
				s
				s
				o
				f
				i
				n
				f
				o
				r
				m
				a
				t
				i
		i	n	o
t	n
h

1. Repairing heating system 17

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.

1.12Removing and installing Bowden cable for temperature flap

1.12.1Removing

–Remove controls for fresh and heated air page 14 .

–Reach into centre console and release locking lug -1- of Bow dencablesleeve-2-.TakeBowdencablesleeveoutofmount ing.

–Release ball of Bowden cable -3- from operating lever.

.V

enAG

g

a

w

s

lk

o

V

y

b

d

e

is

r

o

th

u

a

s

s

le

d

u

n

e

t

t

m

i

r

p

e

t

o

n

s

i

,

e

l

o

h

w

– Remove driver side footwell trimr Rep. gr. 68 .

n

i

o

– Unclip Bowden cable from control unit for temperature flap

t

r

-A- and heater unit -B-.

a

i

p

n

,

s

e

s

o

p

r

u

p

l

a

i

c

r

e

m

m

o

c

r

o

e

t

a

v

i

r

p

r

o

1.12.2

Installing

f

p

g

n

i

y

o

C

.

Installinreverseorder.EnsurethatBowdencableliesgir underhook

t

h

-arrow-.

y

cy

p

o

b

d

et

c

et

– Check whether temperature knob can be easily turned from

or

„Cold“ to „Warm“.

P

	e
	n
	t
.
C
o
p
y

m

p e c

e

c o r r e c t n e s

u

18 Rep. gr.80 - Heating

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011

Heating, air conditioning - Edition 04.2010

1.13Removingandinstallingfreshairandair recirculation flap control motor -V154-

1.13.1Removing

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.

G.

Volksw

ag

en

A

en

A

G

d

g

o

a

e

w

s

s

n

lk

o

V

ot

g

y

u

b

d

a

e

r

s

a

i

n

r

t

1.13.2

o

e

Installings

c

th

e

u

o

r

a

a

s

c

le

e

n

t

Install in reverse order.d

n

u

p

a

t

e

l

i

t

y

m

i

r

a

i

e

b

t

p

l

Note

o

t

i

i

n

y

s

w

t

i

r

,

h

fresh air and air recirculation flap control motor -

e

After installingo

p

e

s

l

operation of air recirculation flap.

t

V154- ,checkw

h

e

n

c

t

i

r

o

o

t

– Checking:r Vehicle diagnostic, testing and information sys

h

t

e

a

5051

c

tem VASn

r

p

o

i

r

,

initiate basic setting using vehicle diagnosis, test

e

– Renewing:s

n

s

c

e

t

ing and information system -VAS 5051B- page 55 .

e

o

p

s

r

s

u

o

1.14

iRemovingandinstallingheatexchanger

f

c

f

p

l

i

a

n

o

r

(Golf Variant 2007►, Golf Variant 2010►

r

e

m

m

a

n

t

und Jetta 2005►)

m

i

o

n

i

o

r

o

c

t

Special tools and workshop equipment required

s

i

h

t

e

d

a

o

r

v

i

♦ Drip tray for workshop hoist -VAS 6208-

p

r

o

f

g

n

i

y

p

o

C

.

t

h

h

g

i

t

r

y

b

p

o

c

y

y

V

o

kl

b

d

e

s

w

a

t

c

et

g

or

e

A

n

P

.G

1. Repairing heating system 19

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-

l

o

V

y

b

d

e

is

r

o

th

u

a

c

s

s

c

le

e

p

n

u

t

d

a

t

e

n

t

y

i

l

♦ Compressed air gun, commercially available

m

i

r

a

e

b

i

p

l

i

t

t

1.14.1

Removing

o

y

n

w

is

i

t

h

r

,

e

e

s

l

gr. 50 .

p

o

– Remove bulkhead in plenum chamber Rep.h

e

w

c

t

n

t

i

o

– Place drip tray -VAS 6208beneath engine.r

t

o

h

t

e

r

a

c

WARNING

p

o

n

r

r

i

,

e

s

c

e

t

n

Danger of scalding injuries.

s

o

e

p

s

r

s

u

may be

o

f

l

i

When the engine is warm, the coolant temperaturea

i

n

c

f

o

r

above 100 °C.The cooling system is pressurised.

r

e

m

m

a

If necessary, release pressure and reduce temperaturem

before

t

i

carrying out repairs.

o

i

n

o

c

n

r

t

o

e

s

i

h

t

d

a

v

o

i

r

c

p

u

r

m

o

f

e

g

n

n

i

t

– Clamp off coolant hoses -1- with hose clamps up to 40ymm Ø

.

p

o

-VAS 3093and disconnect coolant hoses to heat exchanger.C.

t

h

g

i

r

y

– Push a piece of hose -A- onto upper union of heat exchanger. poc

y

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

b

–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

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.

– Covercarpetinareaunderheatexchangerwithwaterprooffoil and water absorbing paper.

V

o

G.

lksw

ag

en

en

A

A

g

G

d

o

a

e

w

s

s

n

lk

ot

o

V

g

y

u

b

d

a

e

r

is

a

– Open hose clips -A- andrpull coolant pipes out of heat ex

changer.

o

th

u

a

s

s

out of heater unit.

le

– Take heat exchangern

e

d

u

t

t

m

i

r

p

e

t

o

n

s

i

,

e

l

o

h

w

n

i

r

o

t

r

a

p

n

i

,

1.14.2

s

e

s

o Installing

p

r

order. Note the following when doing this:

u

p

Install in reversel

a

i

c

r

e

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

m

heat exchanger only with undamaged seals.

m

o

c

r

Note

o

e

t

a

v

i

r

p

r

o

seal can roll up when heat exchanger

f

g

♦ An improperly bondedn

i

y

p

is pushed into heaterounit.

C

.

t

attached, cold air can flow

h

h

g

♦ If seal is damaged or improperlyir

t

y

b

past heat exchanger.

p

o

c

y

y

V

o

kl

b

d

e

s

w

a

t

c

et

g

or

e

P

A

n

.G

–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.

r r e c t n e s s

1. Repairing heating system 21

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 Heating, air conditioning - Edition 04.2010

– Moisten seals -1- with coolant before installing.

o

G.

V lksw

ag

en

A

en

A

g

G

d

o

a

ot

– Seat seals -1- into unionsVon heat exchanger.

e

w

s

lk

s

n

y

o

g

b

u

d

a

e

r

s

a

i

n

r

t

o

e

th

e

Note

s

o

u

r

a

s

le

u

n

♦ Ensurethattesealsareinstalledintheproperdirectionasshown

d

in figure.

m

i

t

p

e

r

hose clips.

♦ Renew deformedo

n

t

s

i

,

coolant pipes to heat exchanger.

– Connecto

l

h

w

assembly, hose clips -A- must turn easily on coolant

– Duringi

pipes.

r

o

t

r

a

p

– Hose clips -A- must be installed as shown in figure.

n

i

,

s

e

hose clips -A- to 2.0 Nm.

– Tightenp

s

o

r

– Check seating of both clips -A- after tightening screws. They

u

p

mustrfully enclose the flange on the heat exchanger and the

l

a

i

c

coolant pipe and they must not contact other components.

e

m

m

o

c

r

o

e

t

a

v

i

r

p

r

o

f

g

n

i

y

p

o

o

C

p

y

.

t

r

h

g

g

h

i

i

r

t

y

b

p

y

– Screw bolt -A- into union flangeb

-B- ensuring that bolt actuallys

o

V

c

y

o

d

Ane

w

kl

screws into intended securing point.etor

a

et

c

P

.G

g

–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/connectionsbetweencoolantpipesandheatexchang er.

t

t o

t h e

c o r

22 Rep. gr.80 - Heating

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011

Heating, air conditioning - Edition 04.2010

1.15Removingandinstallingheatexchanger (Jetta 2010►)

Special tools and workshop equipment required ♦ Drip tray for workshop hoist -VAS 6208-

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

G.

Volksw

ag

en

en

A

A

G

d

g

o

a

e

w

s

s

lk

o

t

V

g

y

u

b

d

a

e

r

s

a

i

n

r

available

t

o

♦ Compressed air gun, commerciallyt

o

e

h

e

u

r

a

a

1.15.1 Removing u

s

c

s

c

a

le

e

n

t

p

t

e

d

n

l

– Remove bulkhead in plenum chamber Rep. gr. 50 .

b

i

t

y

r

m

a

e

i

p

l

6208beneath engine.

i

– Place drip tray -VASot

s

n

i

,

e

WARNINGho

l

w

n

Danger of scaldingo injuries.

i

r

t

r

When the engine is warm, the coolant temperature may be

a

p

above 100 °C.The cooling system is pressurised.

n

i

,

s

e

pressure and reduce temperature before

If necessary, releasep

s

o

carrying out repairs.u

r

p

l

a

i

c

r

e

m

m

o

i

r

n

o

c

t

t

s

i

h

a

e

r

o

d

v

i

c

p

u

r

m

f

o

e

g

n

n

i

t

p

.

C

y

o

o

C

p

y

.

r

t

h

g

g

h

i

i

t

r

y

b

p

o

c

y

y

V

o

kl

b

d

e

s

w

a

t

c

et

g

or

e

P

A

n

.G

n

oit

1. Repairing heating system 23

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 3093and 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 .

.

enAG

g

a

w

– Remove left footwell vent page 9 .

b

s

lk

o

V

d

y

e

is

– Remove bolts -1- and remove heat exchanger cladding.

r

o

th

u

a

– Covercarpetinareaunderheatexchangerwithlewaterprooffoil

s

and water absorbing paper.

u

s

d

n

t

t

e

m

i

r

p

e

t

o

n

s

i

,

e

l

o

h

w

n

i

r

o

t

r

a

p

– Remove clips -2- and pull coolant pipes -1- out of heat ex

n

changer.

i

s

,

s

e

o

– Take heat exchanger out of heater unit.

p

r

u

p

l

a

i

c

r

e

m

m

o

c

r

o

e

t

a

v

i

r

p

r

o

f

g

n

i

y

p

o

C

.

t

h

g

i

r

y

p

o

c

y

b

d

et

c

et

or

P

V

agenAGdoes

										r
										i
									g
									h
									t
								b
								y
								V
							o
						kl
					s
				w
			a
		g
	e
A	n
.G

b
		i
		l
			i
			t
			y
			w
					i
						t
						h
							r
							e
							s
							p
							e
							c
							t
							t
							o
							t
							h
							e
							c
							o
							r
							r
							e
							c
							t
							n
							e
							s
							s
							o
							f
							i
							n
							f
							o
							r
							m
							a
							t
							i
				n	i	n	o
			t
	s	i	h

24 Rep. gr.80 - Heating