Volkswagen Jetta 2011 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.

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

Heating, air conditioning - Edition 04.2010

1.15.2 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.

– Moisten seals -2- with coolant before installing.

– Seat seals -2- onto unions of coolant pipes -1-.

– Connect coolant pipes to heat exchanger.

– Install clips -3-.

– Screw bolt -A- into union flange -B- ensuring that bolt actually

screws into intended securing point.

1. Repairing heating system 25

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

– 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.

1.16 Removing and installing auxiliary air heater element -Z35- , vehicles ► 1K-7M 119 726

Note

Installed only in vehicles with diesel engines without auxiliary coolant heater.

1.16.1 Removing

– Remove driver side footwell trim ⇒ Rep. gr. 68 .

– Remove left footwell vent ⇒ page 9 .

Note

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

26 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 -1- from cover -2-.

Caution

Danger of short circuit.

Disconnect battery before performing repair work.

– Remove securing nut for voltage supply -3- and earth con‐

nection -4- (6 ±1 Nm).

– Disconnect connector -5- from auxiliary air heater element -

Z35- .

WARNING

Danger of burn injuries.

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

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

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

1.16.2 Installing

Install in reverse order.

1.17 Checking, removing and installing aux‐

1.17.1 Checking auxiliary air heater element -

Auxiliary air heater element -Z35- with peripherals (load signal for alternator terminal DF, low heat output relay -J359- , high heat output relay -J360- , intake manifold temperature sender -G72- , coolant temperature sender -G62- ) can be read via the engine control unit self-diagnosis.

1.17.2 Checking auxiliary air heater element -

Special tools and workshop equipment required

iliary air heater element -Z35- , vehicles 1K-7M 119 727 ►

Z35- with peripherals

Z35-

1. Repairing heating system 27

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

♦ Vehicle diagnosis, testing and information system -VAS

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

1.17.3 Test conditions

• Intake temperature less than 19° C

• Coolant temperature less than 80° C

• Passenger compartment temperature about 20° C

• Battery voltage greater than 11 V

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

• Engine speed greater than 450 rpm

• Turn rotary knob for interior temperature to end position for

maximum temperature

1.17.4 Test procedure

– Remove left footwell vent ⇒ page 9 .

– Remove centre console trim from left footwell.

– Measure current consumption on earth wire -arrow- using ve‐

hicle diagnosis, testing and information system -VAS 5051Band 100 A pick-up clamp -VAS 5051B/7- .

Low heat output: ≈ 30 amps

Medium heat output: ≈ 60 amps

High heat output: ≈ 80 amps

1.17.5 Removing and installing

Removing

– Remove driver side footwell trim ⇒ Rep. gr. 68 .

28 Rep. gr.80 - Heating

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

– Remove left footwell vent ⇒ page 9 .

Note

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

– Disconnect battery ⇒ Rep. gr. 27 .

– Remove bolts -A- from cover -B-.

Caution

Danger of short circuit.

Disconnect battery before performing repair work.

– Remove nut -1- 9 ±1 Nm.

– Release locking device of connector strip -arrow-.

WARNING

Danger of burn injuries.

Heating, air conditioning - Edition 04.2010

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

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

– Undo bolt -2- 1.4 Nm and pull auxiliary air heater element -

Z35- out of blower box.

Installing

Note

Ensure that the earth wire is in proper position.

Install in reverse order.

1.18 Checking ventilation

Note

♦

The stale air escapes via ventilation openings in the luggage compartment trim.

♦

If the ventilation is to function properly, the exhaust openings must not be covered.

♦

The ventilation frames are located in the rear side panels be‐ hind the bumper.

1. Repairing heating system 29

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

1.18.1 Checking

– Remove rear bumper ⇒ Rep. gr. 63 .

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

must be free to move and close by themselves.

– Note installation position.

1.19 Removing and installing air intake grille

1.19.1 Removing

– Remove plenum chamber cover ⇒ Rep. gr. 64 .

– Remove securing nuts -arrows- and remove air intake grille

upwards.

(Golf Variant 2007►, Golf Variant 2010► und Jetta 2005►)

1.19.2 Installing

Install in reverse order.

Note

Seal must seat properly on air intake grille.

1.20 Removing and installing air intake grille (Jetta 2010►)

1.20.1 Removing

– Remove plenum chamber cover ⇒ Rep. gr. 64 .

30 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 securing nuts -arrows- and remove air intake grille

upwards.

1.20.2 Installing

Install in reverse order.

Note

Seal must seat properly on air intake grille.

1.21 Removing and installing heater unit

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. Repairing heating system 31

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

1.21.1 Removing

Note

To improve access, depending on engine version, additional com‐ ponents, e.g. engine cover must be removed ⇒ Rep. gr. 10 .

– Remove dash panel ⇒ Rep. gr. 70 .

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

– Remove left and right rear footwell air ducts ⇒ page 8 .

– Place drip tray -VAS 6208- beneath engine.

– Mark coolant hoses -1-.

WARNING

Danger of scalding injuries.

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

If necessary, release pressure 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.

– Carefully blow remaining coolant out through unions of heat

exchanger using a compressed air pistol.

– Cover carpet in interior of vehicle with a waterproof foil and

water absorbing paper.

Note

During removal, note lengths and locations of bolts for later installation.

32 Rep. gr.80 - Heating

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1 - Bolt

❑ 4 Nm

2 - Bolts

❑ Qty. 2 ❑ 4 Nm

3 - Cable retainer

4 - Heater unit

❑ Removing:

– Disconnect connectors

on heater unit.

Note

– Undo bolts

⇒ Item 6 (page 33)

from bracket

⇒ Item 5 (page 33) .

– Remove supports

⇒ Item 8 (page 33)

and

⇒ Item 9 (page 33) .

– Remove bolts

⇒ Item 10 (page 33)

and

⇒ Item 12 (page 34)

and remove bracket

⇒ Item 11 (page 34) .

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

Heating, air conditioning - Edition 04.2010

– Undo bolts

⇒ Item 1 (page 33) and ⇒ Item 2 (page 33) from

cable retainer

⇒ Item 3 (page 33) .

Note

– Remove heater unit.

Installing:

Install in reverse order. Note the following when doing this:

Note

Second mechanic must guide both coolant pipes though seal in engine compartment, from engine com‐

–

partment, to heat exchanger when installing heater unit ⇒ page 34 .

– Fill with coolant ⇒ Rep. gr. 19 .

5 - Bracket

6 - Bolts

❑ 8 Nm

7 - Assembly carrier

8 - Right support

9 - Left support

1. Repairing heating system 33

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

10 - Bolts

❑ Qty. 2 ❑ 8 Nm

11 - Bracket

12 - Bolts

❑ Qty. 2 ❑ 8 Nm

Seal between heater unit and engine compartment

Note

Observe position of seal -A- during installation.

34 Rep. gr.80 - Heating

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

Heating, air conditioning - Edition 04.2010

2 Dismantling and assembling heater

unit

2.1 Dismantling and assembling heater unit

1 - Temperature flap actuator

❑ Removing and installing

⇒ page 36

2 - Bracket

3 - Cover

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

❑ Checking: vehicle diag‐

nosis, testing and infor‐ mation system -VAS 5051B- .

❑ Removing and installing

⇒ page 79

❑ Renewing: initiate basic

setting using vehicle di‐ agnosis, testing and in‐ formation system -VAS 5051B- ⇒ page 55 .

5 - Air intake housing

❑ With air recirculation

flap

6 - Heater unit

7 - Fresh air blower -V2-

❑ Removing and installing

⇒ page 5

8 - Fresh air blower series re‐ sistor with overheating fuse N24-

❑ Removing and installing

⇒ page 6

9 - Dust and pollen filter

❑ Removing and installing

⇒ page 6

10 - Cover

❑ For dust and pollen filter.

11 - Heat exchanger

❑ Removing and installing heat exchanger (Golf Variant 2007►, Golf Variant 2010► und Jetta 2005►)

⇒ page 19 .

❑ Removing and installing heat exchanger (Jetta 2010►) ⇒ page 23 . ❑ After renewing heat exchanger, renew coolant completely ⇒ Rep. gr. 19 .

12 - Heat exchanger trim

13 - Auxiliary air heater element -Z35-

Vehicles ► 1K-7M 119 726

❑ With auxiliary air heater control unit -J604- .

2. Dismantling and assembling heater unit 35

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

❑ 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 three-level auxiliary air heater element -Z35- is fitted here; it is controlled by the respective engine

control unit via relays. ❑ Installed only in vehicles with diesel engines without supplementary heater. ❑ Removing and installing ⇒ page 27

14 - Air distribution housing

15 - Air distribution flap actuator

❑ Removing and installing ⇒ page 36

2.2 Removing and installing air distribution flap actuator

2.2.1 Removing

– Remove dash panel ⇒ Rep. gr. 70 .

– Unclip flexible shaft from adapter for controls ⇒ page 50 .

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

2.2.2 Installing

– Arrows on gears must align.

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

Note

After installation, check operation of air distribution flap

⇒ page 50 .

2.3 Removing and installing temperature flap actuator

2.3.1 Removing

– Remove driver side footwell trim ⇒ Rep. gr. 68 .

36 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 .

– Unclip cable on temperature flap actuator -2-.

– Release catch -1- and press temperature flap actuator in

-direction of arrow- to stop.

– Pull off temperature flap actuator.

2.3.2 Installing

Install in reverse order.

Note

After installation, check operation of temperature flap. Tempera‐ ture knob of control for heated and fresh air must move freely and without jerking from „cold“ position to „warm“ position.

2. Dismantling and assembling heater unit 37

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

87 – Air conditioning system

1 Notes on repair work to vehicles with

air conditioning and on handling re‐ frigerant

Note

♦

Notes on repair work to vehicles with air conditioning and on handling refrigerant can be found in ELSA under repair group ⇒ Rep. gr. 00 ; Technical information "Air conditioning system

- with refrigerant R134a VW" .

♦

Notes on tools for repairs to vehicles with air conditioning and on handling refrigerant can be found in ELSA under repair group ⇒ Rep. gr. 00 ; Technical information "Air conditioning system - with refrigerant R134a VW" .

♦

The version in ELSA under the Internet button is no longer valid.

Additional information:

♦ ⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐

cations

♦ Repairs to evacuated refrigerant circuit that can only be car‐

ried out by specially trained mechanics at specialist service stations ⇒ Service Organisation Handbook (SOH) Volume 1a; Chapter 6.4 Workshop Equipment; Tools .

38 Rep. gr.87 - Air conditioning system

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

Heating, air conditioning - Edition 04.2010

2 Air conditioning system with manual

controls, Climatic

2.1 Air conditioning system and heater passenger compartment (Golf Variant 2007►, Golf Variant 2010► und Jetta 2005►)

Note

♦

Disconnect battery before removing components marked ** ⇒ Rep. gr. 27 .

♦

A label indicates the type and quantity of refrigerant used.

1 - Dash panel**

2 - Centre vents

❑ Removing and installing

⇒ page 7

3 - Right side vent

4 - Right vent

❑ Removing and installing

⇒ page 8

5 - Heating and air conditioning controls, Climatic

❑ With fresh air and air re‐

circulation flap switch E159- .

❑ With heated rear win‐

dow button -E230- .

❑ With fresh air blower

switch -E9-

❑ With air conditioning

system control unit J301- .

❑ For vehicles with sup‐

plementary heating hav‐ ing instant heating but‐ ton -E537- .

❑ Removing and installing

⇒ page 48

6 - Air recirculation flap control motor -V113-

❑ Checking: vehicle diag‐

nosis, testing and infor‐ mation system -VAS 5051B- .

❑ Removing and installing

⇒ page 51

❑ Renewing: initiate basic setting using vehicle diagnosis, testing and information system -VAS 5051B-

⇒ page 55 .

2. Air conditioning system with manual controls, Climatic 39

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

7 - Right footwell vent

❑ Removing and installing ⇒ page 9

8 - Fresh air blower -V2-

❑ Removing and installing ⇒ page 5

9 - Fresh air blower series resistor with overheating fuse -N24-

❑ Removing and installing ⇒ page 6

10 - Baffle plate for heater unit

❑ Removing ⇒ page 3

11 - Evaporator temperature sensor -G308-

❑ Removing and installing ⇒ page 77

12 - Sealing cap

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

13 - Dust and pollen filter

❑ With activated charcoal filter ❑ Removing and installing ⇒ page 6

14 - Connecting piece

❑ For centre console air duct. ❑ To remove, centre console must be removed ⇒ Rep. gr. 68 .

15 - Air duct for right rear footwell

❑ Removing and installing ⇒ page 8

16 - Air duct for left rear footwell

❑ Removing and installing ⇒ page 8

17 - Securing bolt

❑ Qty. 8

18 - Adapter for controls

19 - Auxiliary air heater element -Z35-

❑ Only in vehicles with diesel engines without auxiliary coolant heater. ❑ Removing and installing ⇒ page 26

20 - Heat exchanger

❑ Removing and installing heat exchanger (Golf Variant 2007►, Golf Variant 2010► und Jetta 2005►)

⇒ page 19 .

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

21 - Left footwell vent

❑ Removing and installing ⇒ page 9

22 - Temperature flap control motor -V68-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing ⇒ page 51 ❑ Renewing: initiate basic setting using vehicle diagnosis, testing and information system -VAS 5051B-

⇒ page 55 .

23 - Flexible shaft

❑ Removing and installing ⇒ page 50 .

24 - Footwell vent temperature sender -G192-

❑ Removing and installing ⇒ page 53

25 - Heater and air conditioning unit

❑ Removing and installing ⇒ page 42 ❑ Dismantling and assembling ⇒ page 47

40 Rep. gr.87 - Air conditioning system

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

Heating, air conditioning - Edition 04.2010

26 - Left side vent

27 - Centre vent temperature sender -G191-

❑ Removing and installing ⇒ page 54

2.2 Air conditioning system and heater - passenger compartment (Jetta 2011►)

1 - Dash panel

2 - Centre vents

❑ Removing and installing

⇒ page 10

3 - Right vent

❑ Removing and installing

⇒ page 12

4 - Heating and air conditioning controls, Climatic

❑ With fresh air and air re‐

circulation flap switch E159- .

❑ With heated rear win‐

dow button -E230- .

❑ With fresh air blower

switch -E9-

❑ With air conditioning

system control unit J301- .

❑ For vehicles with sup‐

plementary heating hav‐ ing instant heating but‐ ton -E537- .

❑ Removing and installing

⇒ page 48

5 - Air recirculation flap control motor -V113-

❑ Checking: vehicle diag‐

❑ Removing and installing

❑ Renewing: initiate basic

6 - Right footwell vent

❑ Removing and installing ⇒ page 9

7 - Fresh air blower series resistor with overheating fuse -N24-

❑ Removing and installing ⇒ page 6

8 - Fresh air blower -V2-

❑ Removing and installing ⇒ page 5

nosis, testing and infor‐ mation system -VAS 5051B- .

⇒ page 51

setting using vehicle diagnosis, testing and information system -VAS 5051B- ⇒ page 55 .

9 - Flexible shaft

❑ Removing and installing ⇒ page 50 .

10 - Baffle plate for heater unit

❑ Removing ⇒ page 3

2. Air conditioning system with manual controls, Climatic 41

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

11 - Dust and pollen filter

❑ With activated charcoal filter ❑ Removing and installing ⇒ page 6

12 - Sealing cap

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

13 - Air duct for right rear footwell

❑ Removing and installing ⇒ page 8

14 - Air duct for left rear footwell

❑ Removing and installing ⇒ page 8

15 - Securing bolt

❑ Qty. 8

16 - Adapter for controls

17 - Auxiliary air heater element -Z35-

❑ Only in vehicles with diesel engines without auxiliary coolant heater. ❑ Removing and installing ⇒ page 26

18 - Heat exchanger

❑ Removing and installing ⇒ page 23 ❑ After renewing heat exchanger, renew coolant completely ⇒ Rep. gr. 19 .

19 - Left footwell vent

❑ Removing and installing ⇒ page 9

20 - Temperature flap control motor -V68-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing ⇒ page 51 ❑ Renewing: initiate basic setting using vehicle diagnosis, testing and information system -VAS 5051B-

⇒ page 55 .

21 - Footwell vent temperature sender -G192-

❑ Removing and installing ⇒ page 53

22 - Evaporator temperature sensor -G308-

❑ Removing and installing ⇒ page 77

23 - Heater and air conditioning unit

❑ Removing and installing ⇒ page 42 ❑ Dismantling and assembling ⇒ page 47

24 - Centre vent temperature sender -G191-

❑ Removing and installing ⇒ page 54

2.3 Removing and installing heater and air conditioner unit (Climatic)

Special tools and workshop equipment required

42 Rep. gr.87 - Air conditioning system

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

♦ Drip tray for workshop hoist -VAS 6208-

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

Heating, air conditioning - Edition 04.2010

♦ Compressed air gun, commercially available

2.3.1 Removing

Note

To improve access, depending on engine version, additional com‐ ponents, e.g. engine cover must be removed ⇒ Rep. gr. 10 .

– Extract refrigerant, e.g. with air conditioner service station -

VAS 6007A- before opening refrigerant circuit. Comply with notes ⇒ page 38 .

– Remove dash panel ⇒ Rep. gr. 70 .

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

– Remove left and right rear footwell air ducts ⇒ page 8 .

– Place drip tray -VAS 6208- beneath engine.

– Mark coolant hoses -1-.

WARNING

Danger of scalding injuries.

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

If necessary, release pressure and reduce temperature before carrying out repairs.

2. Air conditioning system with manual controls, Climatic 43

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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.

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

– Carefully blow remaining coolant out through unions of heat

exchanger using a compressed air pistol.

WARNING

Danger of freezing injuries.

If refrigerant circuit has not been evacuated, refrigerant will escape.

Extract refrigerant before opening refrigerant circuit. If the re‐ frigerant circuit is not opened within 10 minutes after it has been evacuated, pressure may develop in coolant circuit due to re-evaporation. Extract refrigerant again.

– From engine compartment, undo bolts (12 Nm) -1- for refrig‐

erant lines -2-.

– Take refrigerant lines out of expansion valve -3-.

Note

♦

Seal open connections for lines.

♦

To seal open connections of expansion valve, use, for exam‐ ple, sealing cap of a spare expansion valve.

– Cover carpet in interior of vehicle with a waterproof foil and

water absorbing paper.

Note

During removal, note lengths and locations of bolts for later installation.

44 Rep. gr.87 - Air conditioning system

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

Heating, air conditioning - Edition 04.2010

1 - Bolt

❑ 4 Nm

2 - Bolts

❑ Qty. 2 ❑ 4 Nm

3 - Cable retainer

4 - Heater and air conditioning unit

❑ Removing:

– Take condensation wa‐

ter drainage hose off

Note

heater and air condition‐ er unit ⇒ page 79 .

– Disconnect connectors

from heater and air con‐ ditioner unit.

– Undo bolts

⇒ Item 6 (page 45)

from bracket

⇒ Item 5 (page 45) .

– Remove supports

⇒ Item 8 (page 46)

and

⇒ Item 9 (page 46) .

– Remove bolts

⇒ Item 10 (page 46)

and

⇒ Item 12 (page 46)

and remove bracket

⇒ Item 11 (page 46) .

– Undo bolts ⇒ Item 2 (page 45) and ⇒ Item 1 (page 45) from cable retainer ⇒ Item 3 (page 45) .

Note

– Remove heater and air conditioning unit.

Installing:

Install in reverse order. Note the following when doing this:

Note

– Second mechanic must guide both coolant pipes though seal in engine compartment, from engine com‐

partment, to heat exchanger when installing heater unit ⇒ page 46 .

– When installing, ensure that condensation water drainage hose is correctly seated ⇒ page 79 .

– Fill with coolant ⇒ Rep. gr. 19 .

5 - Bracket

6 - Bolts

❑ 8 Nm

2. Air conditioning system with manual controls, Climatic 45

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

7 - Assembly carrier

8 - Right support

9 - Left support

10 - Bolts

❑ Qty. 2 ❑ 8 Nm

11 - Bracket

12 - Bolts

❑ Qty. 2 ❑ 8 Nm

Heater and air conditioning unit/engine compartment seal

Note

Observe position of seal -A- during installation.

46 Rep. gr.87 - Air conditioning system

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

Heating, air conditioning - Edition 04.2010

2.4 Dismantling and assembling heater and air conditioning unit (Climatic)

1 - Temperature flap control motor -V68-

❑ Checking: vehicle diag‐

nosis, testing and infor‐ mation system -VAS 5051B- .

❑ Removing and installing

⇒ page 51

❑ Renewing: initiate basic

setting using vehicle di‐ agnosis, testing and in‐ formation system -VAS 5051B- ⇒ page 55 .

2 - Bracket

3 - Bolts

❑ Bolts must be removed

to separate air distribu‐ tion housing from evap‐ orator housing.

4 - Cover

5 - Air recirculation flap control motor -V113-

❑ Checking: vehicle diag‐

nosis, testing and infor‐ mation system -VAS 5051B- .

❑ Removing and installing

❑ Renewing: initiate basic

6 - Air intake housing

❑ With air recirculation

7 - Evaporator housing - upper part

❑ Dismantling and assembling evaporator housing ⇒ page 75

8 - Evaporator housing - lower part

⇒ page 51

setting using vehicle di‐ agnosis, testing and in‐ formation system -VAS 5051B- ⇒ page 55 .

flap

❑ Dismantling and assembling evaporator housing ⇒ page 75

9 - Evaporator

❑ Removing and installing ⇒ page 99

10 - Evaporator temperature sensor -G308-

❑ Removing and installing ⇒ page 77

11 - Connection for glove compartment cooling

12 - Cooling hose for glove compartment

13 - Fresh air blower series resistor with overheating fuse -N24-

❑ Removing and installing ⇒ page 6

14 - Fresh air blower -V2-

❑ Removing and installing ⇒ page 5

2. Air conditioning system with manual controls, Climatic 47

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

15 - Dust and pollen filter

❑ With activated charcoal filter ❑ Removing and installing ⇒ page 6

16 - Cover

❑ For dust and pollen filter.

17 - Heat exchanger

❑ After renewing heat exchanger, renew coolant completely ⇒ Rep. gr. 19 . ❑ Removing and installing heat exchanger (Golf Variant 2007►, Golf Variant 2010► und Jetta 2005►)

⇒ page 19 .

❑ Removing and installing heat exchanger (Jetta 2010►) ⇒ page 23 .

18 - Heat exchanger cladding

19 - Auxiliary air heater element -Z35-

❑ Only in vehicles with diesel engines without supplementary heater. ❑ Removing and installing ⇒ page 26

20 - Air distribution housing

2.5 Removing and installing heating and air conditioning controls, Climatic

2.5.1 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

48 Rep. gr.87 - Air conditioning system

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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-.

2.5.2 Installing

Install in reverse order. Note: the rotating knobs must be in the same position as when removed.

2.6 Connections on controls for heating and

2.6.1 Pin assignment for multi-pin connectors

Special tools and workshop equipment required

♦ Test adapter -V.A.G 1598/47-

20-pin connector, T20c in current flow diagram

3 - Centre vent temperature sender -G191-

5 - High-pressure sender -G65-

7 - CAN, low

8 - CAN, high

air conditioning, Climatic

on back of controls for heating and air conditioning, Climatic

12 - Right seat heating (optional)

13 - Left seat heating (optional)

15 - Terminal 75, seat heating (optional)

16 - Air conditioning system compressor regulating valve -N280-

19 - Terminal 30A

20 - Terminal 31

2. Air conditioning system with manual controls, Climatic 49

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

16-pin connector, T16e in current flow diagram

1 - Temperature flap control motor -V68- , warm

2 - Evaporator output temperature sender -G263-

4 - Footwell vent temperature sender -G192-

5 - Temperature flap control motor potentiometer -G92-

7 - + 5 V for temperature flap control motor potentiometer -G92-

8 - Ground for temperature flap control motor potentiometer G92- , centre vent temperature sender -G191- , footwell vent temperature sender -G192- and evaporator output temperature sensor -G263-

9 - Air recirculation flap control motor -V113- , open

10 - Air recirculation flap control motor -V113- , closed

11 - Temperature flap control motor -V68- , cold

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

2.7 Removing and installing flexible shaft

2.7.1 Removing

– Remove heating and air conditioning controls, Climatic

⇒ page 48 .

– Carefully pull out adapter for controls.

– Press in locking lug -arrow- of flexible shaft and pull out flexible

shaft.

Note

When flexible shaft is installed, the adapter and the rotary knobs of the controls for heater and air conditioning system (Climatic) must be aligned in a specific position to one another. Otherwise the system will malfunction.

2.7.2 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 Climatic heating and air conditioning system on adapter

50 Rep. gr.87 - Air conditioning system

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

Heating, air conditioning - Edition 04.2010

and turn rotary knob for air distribution 1/2 turn (180°). Then reconnect flexible shaft. Repeat check.

2.8 Checking condensation water drainage hose on heater and air conditioner unit

– Remove footwell cover on front passenger side .

Note

♦

It must be possible to push condensation drain hose -1- onto the heater and air conditioning unit connection without tension.

♦

The condensation drain hose must be fitted securely to the connection for condensation drainage of the heater and air conditioner unit.

2.9 Removing and installing air recirculation flap control motor -V113-

2.9.1 Removing

– Remove glove compartment ⇒ Rep. gr. 68 .

– Remove cover for control motors.

– Disconnect connector on air recirculation flap control motor -

V113- -1-.

– Pull off air recirculation flap control motor -V113- -1-.

2.9.2 Installing

Install in reverse order.

Note

♦

After installation, check operation of air recirculation flap.

♦

Initiate „basic setting“ function using vehicle diagnosis, testing and information system -VAS 5051B- ⇒ page 55 .

2.10 Removing and installing temperature flap control motor -V68-

2.10.1 Removing

– Remove left footwell vent ⇒ page 9 .

– Remove left trim panel in footwell ⇒ Rep. gr. 68 .

2. Air conditioning system with manual controls, Climatic 51

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

– Remove data bus diagnosis interface -J533- ⇒ Rep. gr. 97 .

– Remove bolts -3- (9 ± 1.3 Nm).

Do not remove bolts -1-.

– Do not remove bracket -2-.

– Press bracket -1- in direction of brake pedal -arrow- and se‐

cure it there with a cable tie.

– Mark connector -C- to control motor (danger of interchanging

with other connectors of same construction).

– Disconnect connector -C- on temperature flap control motor -

V68- .

– Remove cover -A-.

– Remove securing bolts -D- (1.4 Nm) and remove temperature

flap control motor -V68- -B-.

– Release control motor lever -E- from connecting rod -F-.

2.10.2 Installing

Note

Optimised control motors are marked with an „X“.

To ease assembly, use a ≈ 2 mm shorter oval-head bolt -N 103 254 01- .

52 Rep. gr.87 - Air conditioning system

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

Heating, air conditioning - Edition 04.2010

– Separate bracket -1- from old temperature flap control motor

-V68- , e.g. using side cutting pliers.

– Position new temperature flap control motor -V68- , marked

with an „X“, with shortened oval-head screw -2- and cut-off bracket -1- on bracket -3- on blower box.

Note

♦

After installation, check operation of left temperature flap.

♦

Initiate „basic settings“ function using vehicle diagnosis, test‐ ing and information system -VAS 5051- or successor model

⇒ page 55 .

2.11 Removing and installing footwell vent

2.11.1 Removing

– Remove dash panel ⇒ Rep. gr. 70 .

– Remove data bus diagnosis interface -J533- ⇒ Rep. gr. 97 .

– Remove left footwell vent ⇒ page 9 .

– Remove bolts -1- and -3- (9 ± 1.3 Nm).

temperature sender -G192-

2. Air conditioning system with manual controls, Climatic 53

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

– Remove bracket -2-.

– Pull connector off footwell vent temperature sender -G192-

-1-.

– Turn footwell vent temperature sender -G192- 90° and remove

it from housing.

2.11.2 Installing

Install in reverse order.

2.12 Removing and installing centre vent

2.12.1 Removing

– Remove cover on left of dash panel ⇒ Rep. gr. 70 .

– Pull connector off centre vent temperature sender -G191-

-1-.

– Turn centre vent temperature sender -G191- -2- 90° in direc‐

tion of -arrow- and remove from dash panel.

2.12.2 Installing

temperature sender -G191-

Install in reverse order.

54 Rep. gr.87 - Air conditioning system

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

Heating, air conditioning - Edition 04.2010

3 Climatronic air conditioning with au‐

tomatic regulation

Note

♦

Pressing the from automatic operation.

♦

Deviations from automatic operation ⇒ relevant Owner's Man‐ ual.

♦

In „ECON“ operation, only the air conditioner compressor is switched to almost zero delivery. The heating and ventilation operations continue to be controlled electronically.

3.1 Procedure for checking and adjusting

Select „guided fault finding“ on the vehicle diagnosis, testing and information system -VAS 5051B- .

After all control units have been read:

87)“.

– Press „GoTo“ button.

– Select „Function/component selection“.

– Select „Body“.

– „Heating, ventilation, air conditioning (Repair group 01; 80…

– Select „01-On Board Diagnostic (OBD) capable systems“.

– Select „Climatronic“ or „Climatic“.

– Select „Functions“.

– „Basic setting“

– „Coding Climatronic control unit“.

– „Check cooling output.“

– „Read measured value block“

AUTO

components

button will cancel all settings which deviate

3. Climatronic air conditioning with automatic regulation 55

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

3.2 Function of operating and display unit for Climatronic air conditioning sys‐ tem -E87- (Golf Variant 2007►, Golf Variant 2010► und Jetta 2005►)

1 - Display for selected left in‐ terior temperature

2 - Air recirculation button

❑ Pressing the air recircu‐

lation button will prevent polluted air from enter‐ ing the interior.

3 - Centre air distribution but‐ ton

4 - Lower air distribution button

5 - Upper air distribution button

6 - Display for selected right in‐ terior temperature

7 - Windscreen defrost button

8 - Rear window heating button

9 - Rotary knob for interior tem‐ perature, left

10 - Blower regulator

❑ Turn to change blower

speed.

11 - Interior temperature sen‐ sor

12 - Off button for heating, ven‐ tilation and air conditioning op‐ eration

13 - AUTO button

❑ Pressing AUTO

causes the Climatronic

button

to maintain the selected interior temperature completely automatical‐ ly. With this setting, the vent air temperature, the blower speed and the air distribution are controlled automatically.

14 - ECON button

❑ Pressing the ECON button will set the air conditioner compressor to near-zero delivery. The heating and

ventilation operations continue to be controlled electronically.

15 - Rotary knob for interior temperature, right

56 Rep. gr.87 - Air conditioning system

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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 condition‐ ing system -E87- with Climatronic con‐ trol unit -J255- (Golf Variant 2007►, Golf Variant 2010► und Jetta 2005►)

Note

The Climatronic control unit -J255- and the operating and display unit for Climatronic air conditioning system -E87- are a single component which cannot be dismantled.

3.3.1 Removing

– Remove dash panel centre trim ⇒ Rep. gr. 68 ; .

– Undo bolts -2- and remove operating and display unit for Cli‐

matronic air conditioning system -E87- -1- from dash panel.

– Disconnect connectors on operating and display unit for Cli‐

matronic air conditioning system -E87- .

3.3.2 Installing

Install in reverse order.

3.4 Function of operating and display unit

♦

for Climatronic air conditioning system E87- (Jetta 2011►)

Note

A warning lamp in the instrument panel controls will indicate that the selected function is active. In addition, the display of the radio or of the radio navigation system will indicate the selected function for a short period when a button is pressed or a regulator is operated.

♦

You can switch between °C and °F in the radio or radio navi‐ gation system display via the main menu in the dash panel insert. Press rocker switch in windscreen wiper lever (or in multifunction steering wheel) to call up main menu. Then se‐ lect Settings, Units and Temperature.

♦

If a new operating and display unit for Climatronic air condi‐ tioning system -E87- with Climatronic control unit -J255- is installed, the basic setting and an adaptation („Compressor first run“) must be carried out in the Guided Fault Finding or in the Guided Functions.

3. Climatronic air conditioning with automatic regulation 57

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

1 - Defrost function button for windscreen

2 - Upper air distribution button

3 - Centre air distribution but‐ ton

4 - Interior temperature sensor

5 - Lower air distribution button

6 - Button for air recirculation mode or for automatic recircu‐ lation mode

❑ Pressing the button for

air recirculation mode will switch on the air re‐ circulation mode and prevent polluted air from entering the interior.

❑ Pressing the air recircu‐

lation mode button again will activate the automatic recirculation mode.

7 - Rear window heating button

8 - Rotary knob for interior tem‐ perature, right

9 - Button for right seat heating (optional)

10 - AC button

❑ Press AC

switch cooling on and off.

❑ The warning lamp in the

button lights up when the air conditioner com‐ pressor is switched on.

11 - DUAL button

❑ If the lamp in the button is on, the left and right temperatures may be adjusted independently. ❑ If the Dual button is pressed (the warning lamp goes out), the passenger side will assume the temper‐

ature setting for the driver side.

12 - Instant heating button -E537-

Note

13 - Blower regulator

❑ Press briefly to change blower speed.

14 - Air conditioner OFF

❑ Switches Climatronic on or off

15 - AUTO button

❑ Pressing AUTO button causes the Climatronic to maintain the selected interior temperature completely

automatically. With this setting, the vent air temperature, the blower speed and the air distribution are controlled automatically.

16 - Rotary knob for interior temperature

button to

button

17 - Button for seat heating (optional)

58 Rep. gr.87 - Air conditioning system

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

Heating, air conditioning - Edition 04.2010

3.5 Removing and installing operating and display unit for Climatronic air condition‐ ing system -E87- with Climatronic con‐ trol unit -J255- (Jetta 2011►)

Note

♦

The Climatronic control unit -J255- and the operating and dis‐ play unit for Climatronic air conditioning system -E87- are a single component which cannot be dismantled.

♦

If a new operating and display unit for Climatronic air condi‐ tioning system -E87- with Climatronic control unit -J255- is installed, the basic setting and an adaptation („Compressor first run“) must be carried out in the Guided Fault Finding or in the Guided Functions.

3.5.1 Removing

– Remove air conditioning system/heater control panel trim ⇒

– Undo bolts -arrows- (1.5 ± 0.2 Nm) and remove operating and

– Disconnect connectors on operating and display unit for Cli‐

3.5.2 Installing

Rep. gr. 68 .

display unit for Climatronic air conditioning system -E87- from dash panel.

matronic air conditioning system -E87- .

Note

If a new operating and display unit for Climatronic air conditioning system -E87- with Climatronic control unit -J255- is installed, the basic setting and an adaptation („Compressor first run“) must be carried out in the Guided Fault Finding or in the Guided Functions.

Install in reverse order. Observe specified toque for bolts (1.5 ±

0.2 Nm).

3.6 Connectors on Climatronic control unit J255-

3.6.1 Pin assignment for multi-pin connectors A, B and C on back of Climatronic con‐ trol unit -J255-

Special tools and workshop equipment required

♦ Test adapter -V.A.G 1598/47-

3. Climatronic air conditioning with automatic regulation 59

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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 -A-

1 - Sunlight penetration photosensor 2 -G134- or sunlight pene‐ tration photosensor -G107- , signal

2 - High-pressure sender -G65-

3 - Sunlight penetration photosensor 2 -G134- or sunlight pene‐ tration photosensor -G107- , signal

5 - CAN, high

6 - CAN, low

9 - + 5 V for sunlight penetration photosensor 2 -G134- or sunlight penetration photosensor -G107-

16 - Positive connection (15a) for vehicles with supplementary heating.

17 - Signal earth for sensors

18 - Air conditioning system compressor regulating valve -N280-

20 - Positive connection (15a) or positive connection (30a) for vehicles with auxiliary heater

16-pin connector, T16g in current flow diagram -B-

1 - + 5V for control motors

2 - Potentiometer for left temperature flap control motor -G220-

3 - Potentiometer for right temperature flap control motor -G221-

4 - Potentiometer for defroster flap control motor -G135-

5 - Potentiometer for centre flap control motor -G112-

6 - Air recirculation flap control motor potentiometer -G143-

7 - Potentiometer for air flow flap control motor -G113-

8 - Left footwell vent temperature sender -G261-

9 - Right footwell vent temperature sender -G262-

10 - Fresh air intake duct temperature sensor -G89-

11 - Evaporator temperature sensor -G308-

14 - Signal earth, potentiometer

15 - Left vent temperature sender -G150-

16 - Right vent temperature sender -G151-

60 Rep. gr.87 - Air conditioning system

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

Heating, air conditioning - Edition 04.2010

16-pin connector, T16f in current flow diagram -C-

1 - Left temperature flap control motor -V158- , cold

2 - Left temperature flap control motor -V158- , warm

3 - Defroster flap control motor -V107- , closed

4 - Defroster flap control motor -V107- , open

5 - Central flap control motor -V70- , chest

6 - Central flap control motor -V70- , footwell

7 - Fresh air and air recirculation flap control motor -V154- , re‐ circulated air activation

8 - Fresh air and air recirculation flap control motor -V154- , fresh air activation

9 - Air flow flap control motor -V71- , open

10 - Air flow flap control motor -V71- , closed

11 - Right temperature flap control motor -V159- , cold

12 - Right temperature flap control motor -V159- , warm

15 - Fresh air blower -V2- (PWM actuated)

16 - Fresh air blower -V2- , feedback signal

3.7 Climatronic - passenger compartment

Note

♦

Disconnect battery before removing components marked ** ⇒ Rep. gr. 27 .

♦

A label indicates the type and quantity of refrigerant used.

(Golf Variant 2007►, Golf Variant 2010► und Jetta 2005►)

3. Climatronic air conditioning with automatic regulation 61

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

1 - Dash panel**

❑ Removing and installing

⇒ Rep. gr. 70

2 - Sunlight penetration photo‐ sensor -G107- or sunlight pen‐ etration photosensor 2 -G134-

❑ Checking: vehicle diag‐

nosis, testing and infor‐ mation system -VAS 5051B- .

❑ Function: controls tem‐

perature flap and fresh air blower depending on light intensity

❑ Emergency running in

event of failure: Clima‐ tronic control unit -J255assumes fixed value

❑ Removing and installing

⇒ page 78

3 - Centre vents

❑ Removing and installing

⇒ page 7

4 - Right side vent

5 - Vent

❑ Removing and installing

⇒ page 8

6 - Right vent temperature sender -G151-

❑ Checking: vehicle diag‐

nosis, testing and infor‐ mation system -VAS 5051B- .

❑ Removing and installing

⇒ page 78

7 - Climatronic control unit -J255-

❑ The Climatronic control unit -J255- and the operating and display unit for Climatronic air conditioning

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing ⇒ page 57 ❑ Renewing: initiate basic setting using vehicle diagnosis, testing and information system -VAS 5051B-

8 - Air flow flap control motor -V71-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing ⇒ page 79 ❑ Renewing: initiate basic setting using vehicle diagnosis, testing and information system -VAS 5051B-

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

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing ⇒ page 79 ❑ Renewing: initiate basic setting using vehicle diagnosis, testing and information system -VAS 5051B-

system -E87- are a single component which cannot be dismantled.

⇒ page 55 .

10 - Fresh air intake duct temperature sensor -G89-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Function: temperature sensor controls temperature flap and fresh air blower, depending on temperature.

62 Rep. gr.87 - Air conditioning system

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

❑ Dash panel must be removed to remove and install the fresh air intake duct temperature sensor -G89-

⇒ Rep. gr. 70 .

11 - Right footwell vent

❑ Removing and installing ⇒ page 9

12 - Fresh air blower -V2- with fresh air blower control unit -J126-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing ⇒ page 5

13 - Connector

14 - Baffle plate for heater unit

❑ Removing ⇒ page 3

15 - Sealing cap

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

16 - Dust and pollen filter

❑ With activated charcoal filter ❑ Removing and installing ⇒ page 6

17 - Connecting piece

❑ For centre console air duct. ❑ To remove, centre console must be removed ⇒ Rep. gr. 68 .

18 - Air duct for right rear footwell

❑ Removing and installing ⇒ page 8

19 - Air duct for left rear footwell

❑ Removing and installing ⇒ page 8

20 - Evaporator temperature sensor -G308-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing ⇒ page 77

21 - Right temperature flap control motor -V159-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing ⇒ page 82 ❑ Renewing: initiate basic setting using vehicle diagnosis, testing and information system -VAS 5051B-

⇒ page 55 .

22 - Auxiliary air heater element -Z35-

❑ Installed only in vehicles with diesel engines without auxiliary coolant heater. ❑ Removing and installing ⇒ page 26

23 - Heat exchanger

❑ After renewing heat exchanger, renew coolant completely ⇒ Rep. gr. 19 . ❑ Removing and installing heat exchanger (Golf Variant 2007►, Golf Variant 2010► und Jetta 2005►)

⇒ page 19 .

24 - Central flap control motor -V70-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing ⇒ page 83 ❑ Renewing: initiate basic setting using vehicle diagnosis, testing and information system -VAS 5051B-

⇒ page 55 .

25 - Left footwell vent

❑ Removing and installing ⇒ page 9

26 - Left temperature flap control motor -V158-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing ⇒ page 81

Heating, air conditioning - Edition 04.2010

3. Climatronic air conditioning with automatic regulation 63

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

❑ Renewing: initiate basic setting using vehicle diagnosis, testing and information system -VAS 5051B-

⇒ page 55 .

27 - Left footwell vent temperature sender -G261-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing ⇒ page 76

28 - Defroster flap control motor -V107-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing ⇒ page 80 ❑ Renewing: initiate basic setting using vehicle diagnosis, testing and information system -VAS 5051B-

⇒ page 55 .

29 - Heater and air conditioning unit

❑ Removing and installing ⇒ page 68 ❑ Dismantling and assembling ⇒ page 71

30 - Right footwell vent temperature sender -G262-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing ⇒ page 77

31 - Left side vent

32 - Left vent temperature sender -G150-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing ⇒ page 78

64 Rep. gr.87 - Air conditioning system

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

Heating, air conditioning - Edition 04.2010

3.8 Climatronic - passenger compartment (Jetta 2011►)

1 - Dash panel

❑ Removing and installing

⇒ Rep. gr. 70

2 - Centre vents

❑ Removing and installing

⇒ page 10

3 - Vent

❑ Removing and installing

⇒ page 10

4 - Climatronic control unit J255-

❑ The Climatronic control

unit -J255- and the op‐ erating and display unit for Climatronic air con‐ ditioning system -E87are a single component which cannot be dis‐ mantled.

❑ Checking: vehicle diag‐

nosis, testing and infor‐ mation system -VAS 5051B- .

❑ Removing and installing

⇒ page 59

❑ Renewing: initiate basic

setting using vehicle di‐ agnosis, testing and in‐ formation system -VAS 5051B- ⇒ page 55 .

5 - Right vent temperature sender -G151-

❑ Checking: vehicle diag‐

nosis, testing and infor‐ mation system -VAS 5051B- .

❑ Removing and installing ⇒ page 78

6 - Right footwell vent

❑ Removing and installing ⇒ page 9

7 - Fresh air blower -V2-

❑ Removing and installing ⇒ page 5 .

8 - Fresh air blower control unit -J126-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing ⇒ page 67

9 - Baffle plate for heater unit

❑ Removing ⇒ page 3

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.

3. Climatronic air conditioning with automatic regulation 65

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

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 - Heat exchanger

❑ After renewing heat exchanger, renew coolant completely ⇒ Rep. gr. 19 . ❑ Removing and installing heat exchanger (Jetta 2010►) ⇒ page 23 .

15 - Auxiliary air heater element -Z35-

❑ Only in vehicles with diesel engines without auxiliary coolant heater. ❑ Removing and installing ⇒ page 26

16 - Left temperature flap control motor -V158-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing ⇒ page 81 ❑ Renewing: initiate basic setting using vehicle diagnosis, testing and information system -VAS 5051B-

⇒ page 55 .

17 - Left footwell vent

❑ Removing and installing ⇒ page 9

18 - Defroster flap control motor -V107-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing ⇒ page 80 ❑ Renewing: initiate basic setting using vehicle diagnosis, testing and information system -VAS 5051B-

⇒ page 55 .

19 - Central flap control motor -V70-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing ⇒ page 83 ❑ Renewing: initiate basic setting using vehicle diagnosis, testing and information system -VAS 5051B-

⇒ page 55 .

20 - Right temperature flap control motor -V159-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing ⇒ page 82 ❑ Renewing: initiate basic setting using vehicle diagnosis, testing and information system -VAS 5051B-

⇒ page 55 .

21 - Air flow flap control motor -V71-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing ⇒ page 79 ❑ Renewing: initiate basic setting using vehicle diagnosis, testing and information system -VAS 5051B-

⇒ page 55 .

22 - Evaporator temperature sensor -G308-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing ⇒ page 77

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

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing ⇒ page 79 ❑ Renewing: initiate basic setting using vehicle diagnosis, testing and information system -VAS 5051B-

⇒ page 55 .

24 - Fresh air intake duct temperature sensor -G89-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Function: temperature sensor controls temperature flap and fresh air blower, depending on temperature.

66 Rep. gr.87 - Air conditioning system

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

❑ Dash panel must be removed to remove and install the fresh air intake duct temperature sensor -G89-

⇒ Rep. gr. 70 .

25 - Connector

26 - Connecting piece

❑ For centre console air duct. ❑ To remove, centre console must be removed ⇒ Rep. gr. 68 .

27 - Left footwell vent temperature sender -G261-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing ⇒ page 76

28 - Heater and air conditioning unit

❑ Removing and installing ⇒ page 68 ❑ Dismantling and assembling ⇒ page 71

29 - Right footwell vent temperature sender -G262-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing ⇒ page 77

30 - Left side vent

31 - Left vent temperature sender -G150-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing ⇒ page 78

3.9 Removing and installing fresh air blower

3.9.1 Removing

– Remove fresh air blower -V2- ⇒ page 5 .

control unit -J126-

– Disconnect connector -1- to fresh air blower -V2- .

– Undo bolts -arrows-.

Heating, air conditioning - Edition 04.2010

3.9.2 Installing

Install in reverse order.

3. Climatronic air conditioning with automatic regulation 67

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

3.10 Removing and installing heater and air conditioning unit (Climatronic)

Special tools and workshop equipment required

♦ Hose clamps up to 40 mm

-3093-

♦ E.g. air conditioner service

station -VAS 6007A- or lat‐ er model

♦ Drip tray for workshop hoist

-VAS 6208-

3.10.1 Removing

Note

To improve access, depending on engine version, additional com‐ ponents, e.g. engine cover must be removed ⇒ Rep. gr. 10 .

– Extract refrigerant, e.g. with air conditioner service station -

VAS 6007A- before opening refrigerant circuit. Comply with notes ⇒ page 38 .

– Remove dash panel ⇒ Rep. gr. 70 .

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

– Remove left and right rear footwell air ducts ⇒ page 8 .

68 Rep. gr.87 - Air conditioning system

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

Heating, air conditioning - Edition 04.2010

– Place drip tray -VAS 6208- beneath engine.

– Mark coolant hoses -1-.

WARNING

Danger of scalding injuries.

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

If necessary, release pressure 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.

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

– Carefully blow remaining coolant out through unions of heat

exchanger using a compressed air pistol.

WARNING

Danger of freezing injuries.

If refrigerant circuit has not been evacuated, refrigerant will escape.

Extract refrigerant before opening refrigerant circuit. If the re‐ frigerant circuit is not opened within 10 minutes after it has been evacuated, pressure may develop in coolant circuit due to re-evaporation. Extract refrigerant again.

– From engine compartment, undo bolts -1- for refrigerant lines

-2-.

– Take refrigerant lines out of expansion valve -3-.

Note

♦

Seal open connections for lines.

♦

To seal open connections of expansion valve, use, for exam‐ ple, sealing cap of a spare expansion valve.

– Cover carpet in interior of vehicle with a waterproof foil and

water absorbing paper.

Note

During removal, note lengths and locations of bolts for later installation.

3. Climatronic air conditioning with automatic regulation 69

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

1 - Bolt

❑ 4 Nm

2 - Bolts

❑ Qty. 2 ❑ 4 Nm

3 - Cable retainer

4 - Heater and air conditioning unit

❑ Removing:

– Take condensation wa‐

ter drainage hose off heater and air condition‐ er unit ⇒ page 79 .

– Disconnect connectors

from heater and air con‐ ditioner unit.

Note

– Undo bolts

⇒ Item 6 (page 70)

from bracket

⇒ Item 5 (page 70) .

– Remove support

⇒ Item 8 (page 70) .

– Remove bolts

⇒ Item 10 (page 70)

and

⇒ Item 12 (page 71)

and remove bracket

⇒ Item 11 (page 71) .

– Undo bolts

⇒ Item 2 (page 70) and ⇒ Item 1 (page 70) from cable retainer ⇒ Item 3 (page 70) .

Note

– Remove heater and air conditioning unit.

Installing:

Install in reverse order. Note the following when doing this:

– During installation, observe position of heating and air conditioner unit/engine compartment seal

⇒ page 71 .

– When installing, ensure that condensation water drainage hose is correctly seated ⇒ page 79 .

– Fill with coolant ⇒ Rep. gr. 19 .

5 - Bracket

6 - Bolts

❑ 8 Nm

7 - Assembly carrier

8 - Right support

9 - Left support

70 Rep. gr.87 - Air conditioning system

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

Heating, air conditioning - Edition 04.2010

10 - Bolts

❑ Qty. 2 ❑ 8 Nm

11 - Bracket

12 - Bolts

❑ Qty. 2 ❑ 8 Nm

Heater and air conditioning unit/engine compartment seal

Note

Observe position of seal -A- during installation.

3.11 Dismantling and assembling heater and

Dismantling and assembling heater and air conditioning unit (Jet‐ ta 2011►) ⇒ page 73 .

air conditioning unit (Golf Variant 2007►, Golf Variant 2010► und Jetta 2005►)

3. Climatronic air conditioning with automatic regulation 71

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

1 - Central flap control motor V70-

❑ Checking: vehicle diag‐

nosis, testing and infor‐ mation system -VAS 5051B- .

❑ Removing and installing

⇒ page 83

❑ Renewing: initiate basic

setting using vehicle di‐ agnosis, testing and in‐ formation system -VAS 5051B- ⇒ page 55 .

2 - Left temperature flap con‐ trol motor -V158-

❑ Checking: vehicle diag‐

nosis, testing and infor‐ mation system -VAS 5051B- .

❑ Removing and installing

⇒ page 81

❑ Renewing: initiate basic

setting using vehicle di‐ agnosis, testing and in‐ formation system -VAS 5051B- ⇒ page 55 .

3 - Defroster flap control motor

-V107❑ Checking: vehicle diag‐

nosis, testing and infor‐ mation system -VAS 5051B- .

❑ Removing and installing

⇒ page 80

❑ Renewing: initiate basic

setting using vehicle di‐ agnosis, testing and information system -VAS 5051B- ⇒ page 55 .

4 - Bracket

5 - Bolts

❑ Bolts must be removed to separate air distribution housing from evaporator housing.

6 - Cover

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

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing ⇒ page 79 ❑ Renewing: initiate basic setting using vehicle diagnosis, testing and information system -VAS 5051B-

⇒ page 55 .

8 - Air flow flap control motor -V71-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing ⇒ page 79 ❑ Renewing: initiate basic setting using vehicle diagnosis, testing and information system -VAS 5051B-

⇒ page 55 .

9 - Air intake housing

❑ With air recirculation flap ❑ With air flow flap (Climatronic).

72 Rep. gr.87 - Air conditioning system

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

Heating, air conditioning - Edition 04.2010

10 - Evaporator housing - upper part

❑ Dismantling and assembling evaporator housing ⇒ page 75

11 - Evaporator housing - lower part

❑ Dismantling and assembling evaporator housing ⇒ page 75

12 - Evaporator

❑ Removing and installing ⇒ page 99

13 - Evaporator temperature sensor -G308-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing ⇒ page 77

14 - Connection for glove compartment cooling

15 - Cooling hose for glove compartment

16 - Fresh air blower -V2- with fresh air blower series resistor with overheating fuse -N24-

17 - Dust and pollen filter

18 - Cover

19 - Heat exchanger

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing ⇒ page 5

❑ With activated charcoal filter ❑ Removing and installing ⇒ page 5

❑ For dust and pollen filter.

❑ After renewing heat exchanger, renew coolant completely ⇒ Rep. gr. 19 . ❑ Removing and installing heat exchanger (Golf Variant 2007►, Golf Variant 2010► und Jetta 2005►)

⇒ page 19 .

20 - Right temperature flap control motor -V159-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing ⇒ page 82 ❑ Renewing: initiate basic setting using vehicle diagnosis, testing and information system -VAS 5051B-

⇒ page 55 .

21 - Heat exchanger cladding

22 - Auxiliary air heater element -Z35-

❑ Installed only in vehicles with diesel engines without auxiliary coolant heater. ❑ Removing and installing ⇒ page 26 .

23 - Air distribution housing

3.12 Dismantling and assembling heater and air conditioning unit (Jetta 2011►)

Dismantling and assembling heater and air conditioning unit (Golf Variant 2007►, Golf Variant 2010► und Jetta 2005►) ⇒ page 71 .

3. Climatronic air conditioning with automatic regulation 73

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

1 - Central flap control motor V70-

❑ Checking: vehicle diag‐

nosis, testing and infor‐ mation system -VAS 5051B- .

❑ Removing and installing

⇒ page 83

❑ Renewing: initiate basic

setting using vehicle di‐ agnosis, testing and in‐ formation system -VAS 5051B- ⇒ page 55 .

2 - Left temperature flap con‐ trol motor -V158-

❑ Checking: vehicle diag‐

nosis, testing and infor‐ mation system -VAS 5051B- .

❑ Removing and installing

⇒ page 81

❑ Renewing: initiate basic

setting using vehicle di‐ agnosis, testing and in‐ formation system -VAS 5051B- ⇒ page 55 .

3 - Defroster flap control motor

-V107❑ Checking: vehicle diag‐

nosis, testing and infor‐ mation system -VAS 5051B- .

❑ Removing and installing

⇒ page 80

❑ Renewing: initiate basic

setting using vehicle di‐ agnosis, testing and information system -VAS 5051B- ⇒ page 55 .

4 - Bracket

5 - Bolts

❑ Bolts must be removed to separate air distribution housing from evaporator housing.

6 - Cover

7 - Control motor for fresh air and air recirculation flap and air flow flap -V425-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing ⇒ page 79 ❑ Renewing: initiate basic setting using vehicle diagnosis, testing and information system -VAS 5051B-

⇒ page 55 .

8 - Air intake housing

❑ With air recirculation flap ❑ With air flow flap (Climatronic).

9 - Evaporator housing - upper part

❑ Dismantling and assembling evaporator housing ⇒ page 75

10 - Evaporator housing - lower part

❑ Dismantling and assembling evaporator housing ⇒ page 75

11 - Evaporator

❑ Removing and installing ⇒ page 99

74 Rep. gr.87 - Air conditioning system

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

12 - Evaporator temperature sensor -G308-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing ⇒ page 77

13 - Connection for glove compartment cooling

14 - Cooling hose for glove compartment

15 - Fresh air blower -V2- with fresh air blower control unit -J126-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing fresh air blower -V2- ⇒ page 5 ❑ Removing and installing fresh air blower control unit -J126- ⇒ page 67

16 - Dust and pollen filter

❑ With activated charcoal filter ❑ Removing and installing ⇒ page 6

17 - Cover

❑ For dust and pollen filter.

18 - Heat exchanger

❑ After renewing heat exchanger, renew coolant completely ⇒ Rep. gr. 19 . ❑ Removing and installing heat exchanger (Jetta 2010►) ⇒ page 23 .

19 - Right temperature flap control motor -V159-

❑ Checking: vehicle diagnosis, testing and information system -VAS 5051B- . ❑ Removing and installing ⇒ page 82 ❑ Renewing: initiate basic setting using vehicle diagnosis, testing and information system -VAS 5051B-

⇒ page 55 .

20 - Heat exchanger cladding

21 - Auxiliary air heater element -Z35-

❑ Installed only in vehicles with diesel engines without auxiliary coolant heater. ❑ Removing and installing ⇒ page 26 .

22 - Air distribution housing

Installation position of connections for glove compartment cooling

1 - Connecting piece

2 - Valve

3.13 Dismantling and assembling evaporator

– Separate evaporator housing from heater and air conditioner

unit ⇒ page 71 .

– Disconnect connectors from heater and air conditioner unit.

housing

Heating, air conditioning - Edition 04.2010

3. Climatronic air conditioning with automatic regulation 75

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

1 - Evaporator housing - lower part

2 - Evaporator

❑ Check insulation. It

must be complete.

❑ Removing and installing

⇒ page 99

3 - Clip

4 - Evaporator housing - upper part

5 - Bolt

6 - Sealing and insulation

❑ Heat insulation for ex‐

pansion valve.

❑ Removing and installing

⇒ page 46

7 - Bracket

❑ Removing and installing

⇒ page 98

3.14 Removing and installing left footwell

vent temperature sender -G261-

3.14.1 Removing

– Remove dash panel ⇒ Rep. gr. 70

– Undo bolts ⇒ Item 10 (page 70) from bracket

⇒ Item 11 (page 71) .

– Pull connector off left footwell vent temperature sender -G261-

-1-.

– Press bracket ⇒ Item 11 (page 71) slightly to left, turn left foot‐

well vent temperature sender -G261- -1- 90° and remove it from housing.

76 Rep. gr.87 - Air conditioning system

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

Heating, air conditioning - Edition 04.2010

3.14.2 Installing

Install in reverse order.

3.15 Removing and installing right footwell vent temperature sender -G262-

3.15.1 Removing

Note

For better illustration, right footwell vent temperature sender G262- is shown with dash panel removed. The dash panel need not be removed.

– Remove glove compartment ⇒ Rep. gr. 68 .

– Pull connector off right footwell vent temperature sender -

G262- -1-.

– Turn right vent temperature sender -G262- -1- 90° and remove

it from housing.

3.15.2 Installing

Install in reverse order.

3.16 Removing and installing evaporator

3.16.1 Removing

– Remove cover -1- in front passenger footwell.

temperature sensor -G308-

3. Climatronic air conditioning with automatic regulation 77

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

– Pull connector off evaporator temperature sensor -G308- -1-.

– Turn evaporator temperature sender -G308- in

-direction of arrow- and pull out.

3.16.2 Installing

Install in reverse order.

3.17 Removing left vent temperature sender

-G150- and right vent temperature send‐ er -G151-

Note

Removal of senders on both sides is identical, but one is a mirror image of the other.

– Remove cover on left or right of dash panel ⇒ Rep. gr. 70 .

– Pull connector -1- off vent temperature sender -2-.

– Turn vent temperature sender -2- 90° in direction of -arrow-

and remove it from dash panel.

3.18 Removing sunlight penetration photo‐ sensor -G107- or sunlight penetration photosensor 2 -G134-

– Unclip sunlight penetration photosensor -1- out of dash panel

using an appropriate tool.

– Pull connector off sunlight penetration photosensor.

78 Rep. gr.87 - Air conditioning system

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

3.19 Checking condensation water drainage hose on heater and air conditioner unit

– Remove footwell cover on front passenger side .

Note

♦

It must be possible to push condensation drain hose -1- onto the heater and air conditioning unit connection without tension.

♦

The condensation drain hose must be fitted securely to the connection for condensation drainage of the heater and air conditioner unit.

3.20 Renewing control motors for air condi‐

First carry out the following work:

– Switch off all electrical consumers.

– Switch off ignition.

– Remove ignition key.

tioning regulation

3.21 Removing and installing fresh air and air recirculation flap control motor -V154-

Heating, air conditioning - Edition 04.2010

3.21.1 Removing

– Remove glove compartment ⇒ Rep. gr. 68 .

– Remove cover for control motors.

– Disconnect connector on fresh air and air recirculation flap

control motor -V154- -1-.

– Separate fresh air and air recirculation flap control motor -

V154- -1-.

3.21.2 Installing

Install in reverse order.

Note

♦

After installation, check operation of air recirculation flap.

♦

Initiate „basic setting“ function using vehicle diagnosis, testing and information system -VAS 5051B- ⇒ page 55 .

3.22 Removing and installing air flow flap control motor -V71- or fresh air/recircu‐

3. Climatronic air conditioning with automatic regulation 79

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

lated air, air flow flap control motor V425-

3.22.1 Removing

– Remove glove compartment ⇒ Rep. gr. 68 .

Note

The position of the air flow flap must not be changed.

– Remove cover -1-.

– Remove fresh air and air recirculation flap control motor -

V154- ⇒ page 79 .

– Disconnect connector on air flow flap control motor -V71- -2-.

– Pull off air flow flap control motor -V71- -2-.

3.22.2 Installing

Install in reverse order.

Note

♦

After installation, check operation of air flow flap.

♦

Initiate „basic setting“ function using vehicle diagnosis, testing and information system -VAS 5051B- ⇒ page 55 .

3.23 Removing and installing defroster flap control motor -V107-

3.23.1 Removing

– Remove driver side compartment ⇒ Rep. gr. 68 .

– Remove left footwell vent ⇒ page 9 .

– Remove bracket ⇒ Item 11 (page 71) .

– Disconnect connector on defroster flap control motor -V107-

-2-.

– Remove securing bolts -1- remove defroster flap control motor

-V107- -2- and unhook strut.

80 Rep. gr.87 - Air conditioning system

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

Heating, air conditioning - Edition 04.2010

3.23.2 Installing

Install in reverse order.

Note

♦

After installation, check operation of defroster flap.

♦

Initiate „basic setting“ function using vehicle diagnosis, testing and information system -VAS 5051B- ⇒ page 55 .

3.24 Removing and installing left tempera‐

3.24.1 Removing

– Remove left footwell vent ⇒ page 9 .

– Remove centre console trim from left footwell.

– Remove data bus diagnosis interface -J533- ⇒ Rep. gr. 97 .

– Remove bolts -3- (9 ± 1.3 Nm).

– Do not remove bolts -1-.

– Do not remove bracket -2-.

ture flap control motor -V158-

– Press bracket -1- in direction of brake pedal and secure it there

with a cable tie.

– Mark connector -C- to control motor (danger of interchanging

with other connectors of same construction).

– Disconnect connector -C- on left temperature flap control mo‐

tor -V158- .

– Remove cover -A-.

– Undo securing bolts -D- (1.4 Nm) and remove left temperature

flap control motor -V158- -B-.

– Release control motor lever -E- from connecting rod -F-.

3. Climatronic air conditioning with automatic regulation 81

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

3.24.2 Installing

Note

Optimised control motors are marked with an „X“.

To ease assembly, use a ≈ 2 mm shorter oval-head bolt -N 103 254 01- .

– Separate bracket -1- from old left temperature flap control mo‐

tor -V158- , e.g. using side cutting pliers.

– Position new left temperature flap control motor -V158- ,

marked with an „X“, with shortened oval-head screw -2- and cut-off bracket -1- on bracket -3- on blower box.

Note

♦

After installation, check operation of left temperature flap.

♦

Initiate „basic settings“ function using vehicle diagnosis, test‐ ing and information system -VAS 5051- or successor model

⇒ page 55 .

3.25 Removing and installing right tempera‐ ture flap control motor -V159-

3.25.1 Removing

– Remove glove compartment ⇒ Rep. gr. 68 .

– Remove right footwell vent ⇒ page 9 .

– Disconnect connector on right temperature flap control motor

-V159- .

– Remove securing bolts -1- and remove right temperature flap

control motor -V159- .

– Unhook lever -2- from right temperature flap control motor -

V159- .

3.25.2 Installing

Install in reverse order.

82 Rep. gr.87 - Air conditioning system

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

Heating, air conditioning - Edition 04.2010

Note

♦

After installation, check operation of right temperature flap.

♦

Initiate „basic setting“ function using vehicle diagnosis, testing and information system -VAS 5051B- ⇒ page 55 .

3.26 Removing and installing central flap control motor -V70-

3.26.1 Removing

– Remove dash panel. ⇒ Rep. gr. 70

– Disconnect connector on centre flap control motor -V70- .

– Remove securing bolts -1- and remove central flap control

motor -V70- .

3.26.2 Installing

Install in reverse order.

Note

♦

After installation, check operation of central flap.

♦

Initiate „basic setting“ function using vehicle diagnosis, testing and information system -VAS 5051B- ⇒ page 55 .

3. Climatronic air conditioning with automatic regulation 83

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

4 Ancillary bracket for air conditioner

compressor

4.1 Removing and installing ancillary brack‐

Note

The removal of ancillary bracket for Jetta 2011► is described in ⇒ Rep. gr. 13 .

4.2 Removing and installing ancillary brack‐

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331/- (5…50 Nm)

et for air conditioner compressor (Jetta 2011►)

et for air conditioner compressor, engine codes BRM and BXE

Note

♦

The ancillary bracket for air conditioner compressor and rela‐ ted components can be removed and installed without the refrigerant circuit being opened.

♦

To remove poly V-belt ⇒ Rep. gr. 13 .

84 Rep. gr.87 - Air conditioning system

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

1 - Hexagon bolt M10×65

❑ 50 Nm

2 - Hexagon bolt M10×45

❑ 50 Nm

3 - Hexagon bolt M10×45

❑ 50 Nm

4 - Hexagon bolt M10x45

❑ 50 Nm

5 - Hexagon bolt M10×65

❑ 50 Nm

6 - Hexagon bolt M10×65

❑ 50 Nm

7 - Hexagon bolt M8x100

❑ Qty. 3 ❑ 25 Nm

8 - Ancillary bracket for alter‐ nator and air conditioner com‐ pressor

♦ Number on ancillary brack‐

et -03G 903 143 A-

Removing

Heating, air conditioning - Edition 04.2010

– Remove alternator ⇒

Rep. gr. 27 .

– Loosen air conditioner

compressor and re‐ move hexagon bolt -7-. Remove air conditioner compressor from ancil‐ lary bracket and secure to body with suitable material (e.g. uncoated wire) ⇒ page 86 .

– Remove bolts -1- to -6- and remove ancillary bracket from cylinder block.

♦ Strictly observe tightening sequence of securing bolts:

– Tighten hexagon bolts position -1-, -2-, -3-, -4-, -5- and -6- one after the other.

9 - Dowel sleeves

❑ Qty. 2 ❑ Ensure proper seating between ancillary bracket and air conditioner compressor.

10 - Dowel sleeves

❑ Qty. 2 ❑ Ensure proper seating between ancillary bracket and cylinder block.

11 - Air conditioner compressor

❑ Removing and installing ⇒ page 96

4. Ancillary bracket for air conditioner compressor 85

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

Securing air conditioner compressor to body

Poly V-belt routing

1 - Tensioning roller

2 - Poly V-belt pulley for alternator

3 - Poly V-belt pulley for air conditioner compressor

4 - Poly V-belt

5 - Poly V-belt pulley for crankshaft

If compressor is removed without opening refrigerant circuit, it should be secured to body using suitable material, for example, welding wire.

When doing this, ensure refrigerant hoses on air conditioner com‐ pressor are not stressed.

Note

♦

When installing poly V-belt, ensure that it is correctly seated on poly V-belt pulley.

♦

Finally, place poly V-belt over pulley of air conditioner com‐ pressor.

4.3 Removing and installing ancillary brack‐ et for air conditioner compressor, engine codes BGP and BGQ

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331/- (5…50 Nm)

86 Rep. gr.87 - Air conditioning system

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

Note

♦

The ancillary bracket for air conditioner compressor and rela‐ ted components can be removed and installed without the refrigerant circuit being opened.

♦

To remove poly V-belt ⇒ Rep. gr. 13 .

1 - Ancillary bracket for alter‐ nator and air conditioner com‐ pressor

♦ Number on ancillary brack‐

et -07K 903 143 B-

Removing

– Loosen air conditioner

compressor and re‐ move hexagon bolt -6-. Remove air conditioner compressor from ancil‐ lary bracket and secure to body with suitable material (e.g. uncoated wire) ⇒ page 88 .

– Undo bolts -2, 3 and 4-

Heating, air conditioning - Edition 04.2010

and remove ancillary bracket -1- from cylinder block.

2 - Multi-point socket head bolt M8x60

❑ 25 Nm

3 - Multi-point socket head bolt M8x110

❑ 25 Nm

4 - Hexagon socket head bolt M8x30

❑ 25 Nm ❑ Qty. 4

5 - Air conditioner compressor

❑ Removing and installing

⇒ page 96

6 - Hexagon bolts M8x85

❑ 25 Nm ❑ Qty. 3

7 - Dowel sleeves

❑ Qty. 2 ❑ Ensure proper seating between ancillary bracket and air conditioner compressor.

4. Ancillary bracket for air conditioner compressor 87

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

Securing air conditioner compressor to body

Poly V-belt routing

1 - Upper idler pulley

2 - Pulley - Alternator

3 - Lower idler pulley

4 - Poly V-belt for alternator and coolant pump

5 - Pulley - Air conditioner compressor

6 - Poly V-belt for air conditioner compressor

7 - Pulley - Crankshaft

8 - Tensioning roller for air conditioner compressor poly V-belt

9 - Tensioning roller for poly V-belt for alternator and coolant

pump

10 - Coolant pump pulley

4.4 Removing and installing ancillary brack‐ et for air conditioner compressor, engine codes BPY, BWA, BSE, BSF, BLR, BLY

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331/- (5…50 Nm)

Note

♦

The ancillary bracket for air conditioner compressor and related components can be removed and installed without the refrigerant circuit being opened.

♦

To remove poly V-belt ⇒ Rep. gr. 13 .

88 Rep. gr.87 - Air conditioning system

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1 - Socket head flange bolt M10×45

❑ Dowel hole ❑ Observe different tor‐

ques:

❑ 1.6 l injection engine

and 2.0 l FSI engine: 52 Nm

❑ 2.0 l turbo FSI engine:

40 Nm

2 - Socket head flange bolt M10×45

❑ Observe different tor‐

ques:

❑ 1.6 l injection engine

and 2.0 l FSI engine: 52 Nm

❑ 2.0 l turbo FSI engine:

40 Nm

3 - Socket head flange bolt M10×45

❑ Observe different tor‐

ques:

❑ 1.6 l injection engine

and 2.0 l FSI engine:

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

52 Nm

❑ 2.0 l turbo FSI engine:

40 Nm

4 - Socket head flange bolt M10×45

❑ Observe different tor‐

ques:

❑ 1.6 l injection engine

and 2.0 l FSI engine: 52 Nm

❑ 2.0 l turbo FSI engine: 40 Nm

5 - Air conditioner compressor

❑ Removing and installing ⇒ page 96

6 - Hexagon bolt M8x100

❑ Qty. 3 ❑ 25 Nm

7 - Socket head flange bolt M10×45

❑ Dowel hole ❑ Observe different torques: ❑ 1.6 l injection engine and 2.0 l FSI engine: 52 Nm ❑ 2.0 l turbo FSI engine: 40 Nm

Heating, air conditioning - Edition 04.2010

8 - Socket head flange bolt M10×45

❑ Observe different torques: ❑ 1.6 l injection engine and 2.0 l FSI engine: 52 Nm ❑ 2.0 l turbo FSI engine: 40 Nm

9 - Dowel sleeves

❑ Qty. 2 ❑ Ensure proper seating between ancillary bracket and air conditioner compressor.

4. Ancillary bracket for air conditioner compressor 89

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

10 - Ancillary bracket for air conditioner compressor

Number on ancillary bracket -06F 903 143 E/FRemoving

– Remove alternator ⇒ Rep. gr. 27 . – Loosen air conditioner compressor and remove hexagon bolt -6-. Remove air conditioner compressor

from ancillary bracket and secure to body with suitable material (e.g. uncoated wire) ⇒ page 90 .

– Remove bolts -1- to -4-, -7- and -8- and remove ancillary bracket -10- from cylinder block. Installing ♦ Strictly observe tightening sequence of securing bolts:

– Tighten socket head flange bolts, positions -1- (dowel hole), -7- (dowel hole), -4-, -8-, -3- and -2- one

after the other.

Securing air conditioner compressor to body

If compressor is removed without opening refrigerant circuit, it should be secured to body using suitable material, for example, welding wire.

When doing this, ensure refrigerant hoses on air conditioner com‐ pressor are not stressed.

Note

♦

When installing poly V-belt, ensure that it is correctly seated on poly V-belt pulley.

♦

Finally, place poly V-belt over pulley of air conditioner com‐ pressor.

90 Rep. gr.87 - Air conditioning system

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

Heating, air conditioning - Edition 04.2010

5 Repair work on refrigerant circuit

which may be performed only in ap‐ propriate workshops by specially trained mechanics

Special tools and workshop equipment required

♦ Notes on repair work to vehicles with air conditioning and on

handling refrigerant can be found in ELSA under repair group ⇒ Rep. gr. 00 Technical information „Air conditioning system

- with refrigerant R134a VW“.

♦ Notes on tools for repair work to vehicles with air conditioning

can be found in ELSA under repair group ⇒ Rep. gr. 00 Technical information „Air conditioning system - with refriger‐ ant R134a VW“.

♦ The version in ELSA under the Internet button is no longer

valid.

Note

♦

The refrigerant must be extracted beforehand, e.g. with air conditioner service station -VAS 6007A- .

♦

The previously used air conditioner service stations can still be used ⇒ Volkswagen Workshop Equipment catalogue.

♦

To prevent the intrusion of moisture, all components of the re‐ frigerant circuit which have been opened must be sealed with suitable plugs.

♦

The colour coding of O-rings for R134a refrigerant circuits has been discontinued. Coloured and black O-rings are used.

♦

Coat threaded connections of refrigerant circuit with polyethy‐ lene glycol (PEG) VW part number 294440 before installation.

♦

Under certain conditions, it is no longer necessary to renew the receiver with dryer cartridge each time the refrigerant cir‐ cuit is opened ⇒ Rep. gr. 00 Technical information „Air conditioning systems - with refrigerant R134a VW“ Renewing parts.

5.1 Testing equipment and tools

Notes on testing equipment and tools for repair work to vehicles with air conditioning can be found in ELSA under Heating, venti‐ lation, air conditioning system; Air conditioning system with re‐ frigerant R134a ⇒ Rep. gr. 00 ; Technical data.

5. Repair work on refrigerant circuit which may be performed only in appropriate workshops by specially trained mechanics 91

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

Special tools and workshop equipment required

♦ Torque wrench -V.A.G

1783-

♦ E.g. air conditioner service

station -VAS 6007A- (or lat‐ er model)

♦ Ratchet insert tool 1/4" -

VAS 6234-

♦ Socket -T10364-

5.2 Renewing refrigerant circuit compo‐

nents

5.2.1 Renewing components of refrigerant cir‐

cuit (Golf Variant 2007►, Golf Variant 2010► und Jetta 2005►)

WARNING

Danger of freezing injuries.

If refrigerant circuit has not been evacuated, refrigerant will escape.

Extract refrigerant before opening refrigerant circuit. If the re‐ frigerant circuit is not opened within 10 minutes after it has been evacuated, pressure may develop in coolant circuit due to re-evaporation. Extract refrigerant again.

92 Rep. gr.87 - Air conditioning system

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

1 - Receiver with dryer car‐ tridge

❑ Removing and installing

⇒ page 95

2 - Air conditioner compressor

❑ Observe remarks on in‐

stallation of air condi‐ tioner compressor

⇒ page 103 .

❑ Removing and installing

⇒ page 96

3 - Condenser

❑ Removing and installing

⇒ page 100

4 - High-pressure sender G65-

Removing ⇒ page 95

5 - Bracket

6 - Evacuating and charging valve

❑ High-pressure side ❑ Releasing refrigerant in‐

to the environment is a punishable offence.

❑ Capacities ⇒ page 105

7 - Retainer

8 - Evacuating and charging valve

❑ Low-pressure side ❑ Releasing refrigerant in‐

to the environment is a punishable offence.

❑ Capacities ⇒ page 105

9 - Expansion valve

❑ Function and removal ⇒ page 98 .

10 - Hexagon nut

❑ 20 Nm

11 - Bracket

Heating, air conditioning - Edition 04.2010

5. Repair work on refrigerant circuit which may be performed only in appropriate workshops by specially trained mechanics 93

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

5.2.2 Renewing components of refrigerant circuit (Jetta 2010►)

1 - Condenser

❑ Removing and installing

⇒ page 100

2 - Air conditioner compressor

❑ Observe remarks on in‐

stallation of air condi‐ tioner compressor

⇒ page 103 .

❑ Removing and installing

⇒ page 96

3 - Hexagon nut

❑ 6 Nm

4 - Bracket

5 - High-pressure sender G65-

❑ Removing ⇒ page 95

6 - Expansion valve

❑ Function and removal

⇒ page 98 .

7 - Evacuating and charging valve

❑ Low-pressure side

❑ Releasing refrigerant in‐

to the environment is a punishable offence.

❑ Capacities ⇒ page 105

8 - Evacuating and charging valve

❑ High-pressure side

❑ Releasing refrigerant in‐

to the environment is a punishable offence.

❑ Capacities ⇒ page 105

5.3 Removing high-pressure sender -G65-

(Golf Variant 2007►, Golf Variant 2010► und Jetta 2005►)

– Remove noise insulation from engine ⇒ Rep. gr. 50 .

– Disconnect connector from high-pressure sender -1-.

– Unscrew high-pressure sender -G65- -1- from refrigerant line

connection.

Note

♦

Renew O-ring -2-.

♦

Depending on engine version, the high-pressure sender -G65-

-1- may be installed in another location near the condenser.

94 Rep. gr.87 - Air conditioning system