Heating, Air Conditioning

Service
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Workshop Manual
Golf 2004
Edition 02.2008
Heating, air conditioning
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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
Repair Group
80 - Heating 87 - Air conditioning system
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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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Copyright 2010 Volkswagen AG, Wolfsburg
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All rights reserved. No reproduction without prior agreement from publisher.
K0058991220
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Golf 2004 Heating, air conditioning - Edition 02.2008
Contents
80 - Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 1.16 2 2.1 2.2 2.3 2.4 2.5 1 2 2.1 2.2 2.3 Repairing heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Passenger compartment heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing fresh air blower V2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fresh air blower series resistor with overheating fuse N24 . . . . . . Removing and installing dust and pollen filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing controls for heated and fresh air . . . . . . . . . . . . . . . . . . . . . . . . . . kswa Connectors on controlswfor n AG. Vol andgen AG dairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . fresh oe age heated not olks gu Removing and installing flexible shaft for air distribution . . . . . . . . . . . . . . . . . . . . . . . . . . yV ara db e ri Removing ands installing Bowden cable for temperaturentflap . . . . . . . . . . . . . . . . . . . . . . . . ee ho t or ac Removingau and installing fresh air and air recirculation flap control motor V154 . . . . . . . . ss Removing and installing heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing auxiliary air heater element Z35 on vehicles up to 1K-7P015628 and 1K-7B084800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing auxiliary air heater element Z35 on vehicles from 1K-7P015629 und 1K-7B084801 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing air intake screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling and assembling heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing air distribution housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling and assembling heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing air distribution flap actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing temperature flap actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1 1 3 3 4 4 7 8 9 10 11 12 15 16 18 18 19 23 23 24 25 26 26 28 29 29 31 33 33 35 36 36 36 38 39 39 41 42 43 44 45 47 50 52 53 54
87 - Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Notes on repair work to vehicles with air conditioning and on handling refrigerant . . . . . . Air conditioning system with manual controls Climatic . . . . . . . . . . . . . . . . . . . . . . . . . . Air conditioning and heating - passenger compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling and assembling heater and air conditioner unit Climatic . . . . . . . . . . . . . . . . Removing and installing heating and air conditioning controls, Climatic with air conditioning system control unit J301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connectors on controls for heating and air conditioning Climatic . . . . . . . . . . . . . . . . . . Removing and installing flexible shaft for air distribution . . . . . . . . . . . . . . . . . . . . . . . . . . Checking condensation water drainage hose on heater and air conditioner unit . . . . . . . . Removing and installing air recirculation flap control motor V113 . . . . . . . . . . . . . . . . . . . . Removing and installing temperature flap control motor V68 . . . . . . . . . . . . . . . . . . . . . . Removing and installing footwell vent temperature sender G192 . . . . . . . . . . . . . . . . . . . . Removing and installing centre vent temperature sender G191 . . . . . . . . . . . . . . . . . . . . Ambient temperature sensor G17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air conditioning system with automatic regulation Climatronic . . . . . . . . . . . . . . . . . . . . Procedure for checking and adjusting components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Function of operating and display unit for Climatronic air conditioning system E87 . . . . . . Removing and installing operating and display unit for Climatronic air conditioning system E87 with Climatronic control unit J255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connectors on Climatronic control unit J255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Climatronic - passenger compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling and assembling heater and air conditioner unit Climatronic . . . . . . . . . . . . Assembly overview - evaporator housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fresh air blower control unit J126 . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing left footwell vent temperature sender G261 . . . . . . . . . . . . . . . .
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3.4 3.5 3.6 3.7 3.8 3.9
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2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 3 3.1 3.2 3.3
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Contents
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3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20 3.21 3.22 3.23 3.24 3.25 3.26 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14 6 6.1 6.2
e ris ho ut a Removing ss
and installing right footwell sender G262 . . . . . . . . . . . . . . . . Removing and installing evaporator temperature sensor G308 or evaporator output temperature sender G263 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ambient temperature sensor G17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Function of air quality sensor G238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing air quality sensor G238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing left vent temperature sender G150 and right vent temperature sender G151 . . Removing sunlight penetration photosensor G107 or sunlight penetration photosensor 2 G134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking condensation water drainage hose on air conditioner unit . . . . . . . . . . . . . . . . . . Renewing control motors for air conditioning regulation . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing air recirculation flap control motor V113 . . . . . . . . . . . . . . . . . . . . Removing and installing air flow flap control motor V71 for vehicles up to calendar week 17/2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing control motor for fresh air and air recirculation flap and air flow flap V425 for vehicles from calendar week 18/2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing setting unit for fresh air and air recirculation flap and air flow flap ........................................................................ Removing and installing defroster flap control motor V107 . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing left temperature flap control motor V158 . . . . . . . . . . . . . . . . . . Removing and installing right temperature flap control motor V159 . . . . . . . . . . . . . . . . . . Removing and installing central flap control motor V70 . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing ancillary bracket for air conditioner compressor . . . . . . . . . . . . . . Engine codes: AZV, BDK, BJB, BKC, BKD, BLS, BMM, BMN, BRM, BRU, BVB, BXE, BXF and BXJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine codes: BCA, BUD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine codes: BLG, BMY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine codes: BAG, BKG, BLF, BLN, BLP and CAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine codes: AXW, AXX, BGU, BHY, BLR, BLX, BLY, BPY, BSE, BSF, BVX, BVY, BVZ, BWA, BYD, CAWB, CBFA and CCTA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine codes: BGP, BGQ, BTK, CBTA and CBUA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine codes: BUB, CBRA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair work on refrigerant circuit which may be performed only in appropriate workshops by specially trained mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing equipment and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing components of refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing high-pressure sender G65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing receiver with dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - poly V-belt pulley (air conditioner compressor from Denso) . . . . . . Removing and installing poly V-belt pulley (air conditioner compressor from Denso) . . . . Removing and installing poly V-belt pulley, Sanden air conditioner compressor . . . . . . . . Checking high-pressure safety valve on air conditioner compressor . . . . . . . . . . . . . . . . . . Expansion valve, function and removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Notes on installing air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refrigerant oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ran tee or ac vent temperature
54 55 55 56 57 58 59 59 59 60 60 61 62 63 64 65 66 67 67 69 71 73 75 77 79 82 83 84 88 92 92 94 97 99 100 100 100 103 103 106 109 109 109
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Contents
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Heating, n AG. Volkswagen AG do es n wage ot g olks V ua by ran ed tee ris o th or ac au ss
Golf 2004 air conditioning - Edition 02.2008
Heating
Repairing heater
Passenger compartment heating
1.1
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Disconnect battery before removing components marked ** Rep. Gr. 27 . 1 - Dash panel** 2 - Centre vents Removing vent page 5 . 3 - Right side vent 4 - Right vent Removing vent page 5 .
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6 - Fresh air and air recircula tion flap control motor -V154 Removing page 11 7 - Right footwell vent Removing and installing page 7 8 - Fresh air blower -V2 Removing page 3 9 - Fresh air blower series re sistor with overheating fuse -N24 Removing and installing page 3 10 - Baffle plate for heater unit Removing page 2 11 - Sealing cap Fitted only in vehicles without air duct to vent in rear centre console. 12 - Dust and pollen filter With activated charcoal filter Removing and installing page 4
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5 - Controls for fresh and heat ed air With fresh air and air re circulation flap switch E159- . With heated driver seat regulator -E94- and heated front passenger seat regulator -E95 For vehicles with sup plementary heating hav ing instant heating but ton -E537- . Removing controls page 7 .
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1. Repairing heater
14 - Air duct for right rear footwell Removing and installing page 6 15 - Air duct for left rear footwell Removing and installing page 6 16 - Securing bolt Qty. 8 Various lengths.
13 For centre console air duct (to rear vents) To remove, centre console must be removed Rep. Gr. 68 .
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17 - Adapter for controls Removing and installing page 7
18 - Auxiliary air heater element -Z35 With auxiliary air heater control unit -J604- . Checking: with vehicle diagnostic, testing and information system -VAS 5051- (or later model), under Heating, ventilation, air conditioning; Systems capable of self-diagnosis; Auxiliary heating; Electrical components. Installed only in vehicles with diesel engines without supplementary heater. Removing and installing page 15
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20 - Left footwell vent Removing and installing page 7 21 - Bowden cable for temperature flap Removing and installing page 10 22 - Flexible shaft for air distribution Removing and installing page 9 23 - Heater unit Removing and installing page 19 Dismantling and assembling page 23 24 - Left side vent Removing heater unit baffle plate Remove plastic bolts -2- and remove baffle plate -1-.
Rep. Gr.80 - Heating
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19 - Heat exchanger After renewing heat exchanger, renew coolant completely Removing and installing page 12
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Golf 2004 Heating, air conditioning - Edition 02.2008 Installation position of seal between heater unit and engine com partment First insert seal between heater unit and engine compartment -A- in bulkhead and then attach to heat exchanger.
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1.2 1.2.1
Removing fresh air blower -V2Removing
Fresh air blower -V2- is accessible from footwell on front passen ger side. Remove heater unit baffle plate page 2 . Pull connector -A- off fresh air blower -V2- . Remove bolt -B- for fresh air blower -V2- (1 Nm). Release catch -2-, turn fresh air blower -V2- in direction of -arrow- and remove.
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1.3.1
Removing
WARNING
Danger of burn injuries. The fresh air blower series resistor with overheating fuse -N24can be hot. Before removing fresh air blower series resistor with overheat ing fuse -N24- , let it cool off.
First carry out the following work:
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1.3
Removing and installing fresh air blower series resistor with overheating fuse N24-
1. Repairing heater
Golf 2004 Heating, air conditioning - Edition 02.2008 Remove heater unit baffle plate page 2 . Pull connector -1- off fresh air blower series resistor with over heating fuse -N24- . Press catch in -direction of arrow- and remove fresh air blower series resistor with overheating fuse -N24- from heater unit.
1.3.2 1.4
Installing
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Install in reverse order.
Removing and installing dust and pollen filter Removing
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1.4.1
Remove footwell trim -1- on front passenger side. Remove baffle plate -2- from heater unit page 2 . Release cover -3- in direction of arrow. Remove dust and pollen filter from heater unit downwards.
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Note
Observe installation position of dust and pollen filter.
1.5
Note
Removing vents
Removal and installation of rear vents (in arm rest) is described in ELSA under General body repairs, interior; Rep. Gr. 68 ; Removing and installing centre console (Highline version).
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1.4.2
Installing
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1.5.1
Removing centre vents

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On vehicles with Climatronic, first remove the sunlight pene tration photosensor -G107- or the sunlight penetration photo sensor 2 -G134- page 59 . Remove bolt -1-.
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On vehicles with a storage compartment in trim, the rubber mat must be removed to reach bolt -1-.
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Remove cover -2- (only in vehicles with Climatronic). Remove securing bolts -1-. Note
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Remove central vents -2- upwards -arrow-. Separate connectors from central vents.
1.5.2 1.5.3
Note
Installing Removing right or left vent
The procedure for removal of vents is identical on both sides. To avoid damage to dash panel, use a pad when levering out
components.
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Remove compartment from dash panel.
1. Repairing heater
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For vehicles with a storage compartment in dash panel, bolts are beneath a trim mat.
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1.5.4
Removing
Using an appropriate tool, lever out vent -1-. Separate connector from vent.
1.5.5 1.5.6
Installing Removing and installing right and left rear footwell air ducts
Note
Remove driver or front passenger seat Rep. Gr. 72 . Remove centre console Rep. Gr. 68 . Raise floor covering, unclip rear footwell air duct from under body and pull off heater unit.
The procedure for removal of footwell air ducts is identical on both sides.

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1.5.7
Installing
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When installing rear footwell air duct, ensure that duct is first pushed onto heater unit -arrow- and then clipped to underbody.
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Note
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1.5.8
Removing right footwell vent
Remove glove compartment Rep. Gr. 68 . Remove securing bolt -2- (1.5 0.2 Nm) and remove right footwell vent -1-.
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Heating, air conditioning - Edition 02.2008
1.5.9
Installing
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Install in reverse order. Note
1.5.10
Removing left footwell vent
Remove driver side footwell cover Rep. Gr. 68 . Remove securing bolt -2- (1.5 0.2 Nm) and remove left foot well vent -1-.
1.5.11 1.6
Installing Removing and installing controls for heated and fresh air Removing
1.6.1
Note
The control consists of two separable housings. Before re Heater control to cold Blower to 0 Vent direction to footwell Remove radio Rep. Gr. 91 .
moving controls, set rotary knobs to the following positions:
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If vehicle has glove box cooling, ensure that refrigerant hose is properly seated.
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1. Repairing heater
Golf 2004 Heating, air conditioning - Edition 02.2008 For vehicles without radio, remove centre dash panel trim Rep. Gr. 68 . Remove bolts -2- (4.2 x 45) and -3- (4.2 x 16) and remove the controls -1- from centre console.
Specified torque for bolts -2- and -3- (1.5 0.2 Nm). Release connector catch -A- by pulling in direction of arrow -1-. Push connector catch -B- to connector -arrow 2- and remove connector -C-. Release connector catch -D- and remove connector -D-. Note
Figure shows Climatic version. The procedure for releasing con nector is the same. n AG. Volkswagen AG do e wage
1.6.2
Installing
Installation is performed in the reverse order. Ensure that rotary knobs are in the same positions as when removed.
1.7
Connectors on controls for heated and fresh air Pin assignment for multi-pin connectors on back of controls for heated and fresh air
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1.7.1
Special tools and workshop equipment required Test box -V.A.G 1598/42 Adapter cable -V.A.G 1598/47-
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Template -1598/47-2-
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Golf 2004 Heating, air conditioning - Edition 02.2008 The 16-pin connector is vacant. 5-pin connector, T5 in current flow diagram 1 - 3rd blower speed 2 - 2nd blower speed 3 - 1st blower speed 4 - 4th blower speed 5 - X terminal
20-pin connector, T20c in current flow diagram 3 - Fresh air and air recirculation flap control motor -V1546 - Fresh air and air recirculation flap control motor -V1547 - With auxiliary air heater control unit -J6048 - Rear window 11 - Heated driver seat control unit -J13115 - Heated front passenger seat control unit -J13216 - Terminal 75, seat heating (optional) 18 - Terminal 30 19 - Terminal 15 20 - Terminal 31
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1.8
1.8.1
Removing
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Removing and installing flexible shaft for air distribution
Remove radio Rep. Gr. 91 . For vehicles without radio, remove centre dash panel trim Rep. Gr. 68 . Remove glove compartment Rep. Gr. 68 . Move flexible shaft to following position: Turn rotary switch for air distribution -1- until catch in shaft -2- is visible in gears -3-.
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1. Repairing heater
Remove controls for fresh and heated air page 7 . Reach into centre console and release locking lug -1- by pressing in direction of arrow. Pull flexible shaft out of adapter -2-. Note
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When flexible shaft is installed, the adapter and the rotary knobs of the controls for heated and fresh air must be aligned in a spe cific position to one another or the system will malfunction page 10 .
1.8.2
Checking
Flexible shaft for air distribution flap actuator: Run fresh air blower at highest speed. If air flows out of de froster jet in the defrost position and no air flows out of footwell vent, then the flexible shaft is correctly installed. Oth erwise, remove flexible shaft from adapter. Position controls for heated and fresh air on adapter and turn rotary knob for air distribution 1/2 turn (180). Then reconnect flexible shaft. Re peat check.
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1.9
Removing and installing Bowden cable for temperature flap Removing
1.9.1
Remove controls for fresh and heated air page 7 . Reach into centre console and release catch -1- of Bowden cable sheath -2- and remove Bowden cable sheath from sup port. Release ball on Bowden cable -3- from operating lever -4-.
10
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Golf 2004 Heating, air conditioning - Edition 02.2008 Remove driver side footwell trim Rep. Gr. 68 . Unclip Bowden cable from control unit for temperature flap -A- and heater unit -B-.
1.9.2
Installing
Install in reverse order. Ensure that Bowden cable lies under hook -arrow-. Check whether temperature knob can be easily turned from cold to warm.
1.10
Removing and installing fresh air and air recirculation flap control motor -V154-
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1.10.1
Note
Removing
The position of the air recirculation flap must not be changed.

Remove glove compartment Rep. Gr. 68 . Remove cover -1-.
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Separate connector from fresh air and air recirculation flap control motor -V154- -2-.
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Remove fresh air and air recirculation flap control motor V154- -2- from mountings.
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1.10.2
Installing
1. Repairing heater
11
Golf 2004 Heating, air conditioning - Edition 02.2008 Note
After installing fresh air and air recirculation flap control motor V154- , check operation of air recirculation flap.
Checking: vehicle diagnosis, testing and information system AG. Volkswagen AG d VAS 5051- or successor models. agen o
V Renewing: initiate basic setting using yvehicle diagnosis, test db se ing and information system -VASri5051- or successor models tho page 42 . au
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Special tools and workshop equipment required

Drip tray -V.A.G 1306-
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1.11
Removing and installing heat exchanger

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Hose clamps up to 40 mm -VAS 3093-
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Compressed air gun, commercially available
1.11.1
Removing
WARNING
Place drip tray -V.A.G 1306- beneath engine.
Danger of scalding injuries. When the engine is warm, the coolant temperature may be above 100 C. The cooling system is pressurised. If necessary, release pressure before carrying out repairs.
12
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Golf 2004 Heating, air conditioning - Edition 02.2008 Clamp off coolant hoses -1- using hose clamps up to 40 mm -VAS 3093- and disconnect coolant hoses to heat exchanger. Push a piece of hose -A- onto upper connection of heat ex changer. Hold a container -B- under lower connection -C-. Using a compressed air pistol, carefully blow coolant out of heat exchanger into container -B-.
n AG. Volkswagen AG do es n wage ot g olks V ua by ran ed is tee or th Depending on the engine type, some parts must be removed ador a au c ss ditionally, e.g. the charge air pipe.
Loosen bolt (6 mm hexagon socket head) -1- on flange be tween heat exchanger connections, but do not remove com pletely.
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Note
Loosening the bolt -1- loosens the coolant pipe which eases the removal of the heat exchanger.
Remove driver side footwell trim Rep. Gr. 68 . Remove left footwell vent page 7 . Remove bolts -A- and remove cover -B-.
Note
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There are two different versions of cover -B-.
-Z35- .
If the lever -C- to temperature flap is positioned so the the up

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per bolt -A- is not accessible. Change the position of the temperature flap at the heater and fresh air controls. On vehi cles with Climatronic, at the control and display unit (e.g. the setting Hi).
Cover carpet in area under heat exchanger with waterproof foil and water absorbing paper. Open pipe clamps -A- and pull coolant pipes out of heat ex changer. Remove heat exchanger from heater unit.
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The figure shows the version with auxiliary air heater element
1. Repairing heater
13
1.11.2
Installing
Installation is carried out in the reverse order. When installing, note the following: Check seals attached to heat exchanger -A- and -B-. Install heat exchanger only with undamaged seals. Note An improperly bonded seal can roll up when heat exchanger
is pushed into heater unit. past heat exchanger.
If seal is damaged or improperly attached, cold air can flow
Check heater unit for cleanliness through shaft -A- for heat exchanger while heat exchanger is removed. If necessary, remove dirt or residue of leaked coolant from heater unit, e.g. after removing a leaking heat exchanger. Push heat exchanger into heater unit.
Set seals -1- in connection of heat exchanger. Note
Moisten seals -1- with coolant before installing.
Ensure that seals are installed in the proper direction as shown
in figure.
Renew deformed pipe clamps.
Connect coolant pipes to heat exchanger.
During assembly, pipe clamps -A- must turn easily on coolant pipes. Pipe clamps -A- must be installed as shown in figure. Tighten pipe clamps -A- to 2 Nm.
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14
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Check seating of both clamps -A- after tightening bolts. They must fully enclose the flange on the heat exchanger and the coolant pipe and the must not contact other components.
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Golf 2004 air conditioning - Edition 02.2008
Tighten bolt -1- on connecting flange between heat exchanger connections to 2 Nm.
Check that grommet -C- in bulkhead is properly seated.
If necessary, seal flanges for coolant pipes to heat exchanger -A- and for expansion valve to evaporator (only in vehicles with air conditioning) -B- at apertures in grommet -C- with silicone adhesive sealant against moisture intrusion.
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Note
After renewing heat exchanger, renew coolant completely
Rep. Gr. 19 .
Check coolant circuit for leaks. Examine in particular connec
tions between coolant pipes and heat exchanger.
1.12
Removing and installing auxiliary air heater element -Z35- on vehicles up to 1K-7P015628 and 1K-7B084800
Note
Installed only in vehicles with diesel engines without supple
mentary heater.
Checking: with vehicle diagnosis, testing and information sys
tem -VAS 5051- (or later model), under Heating, ventilation, air conditioning; Systems capable of self-diagnosis; Auxiliary heating; Electrical components.
1.12.1
Removing
Remove driver side footwell trim Rep. Gr. 68 . Remove left footwell vent page 7 . Note
If the lever -C- to temperature flap is positioned so the the upper bolt -A- is not accessible. Change the position of the temperature flap at the heater and fresh air controls. On vehicles with Clima tronic, at the control and display unit (e.g. the setting Hi).
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Always renew seals.
AG.
1. Repairing heater
15
Golf 2004 Heating, air conditioning - Edition 02.2008 Disconnect the battery Rep. Gr. 27 . Remove bolts -1- from cover -2-. Caution
Danger of short circuit. Disconnect battery before performing repair work.

Remove securing nut for voltage supply -3- and earth con nection -4- (6 1 Nm). Pull connectors -5- off auxiliary air heater element -Z35- . WARNING
Danger of burn injuries. The auxiliary air heater element -Z35- may be hot. Before removing auxiliary air heater element -Z35- , allow it to cool off.
Pull auxiliary air heater element -Z35- out of heater unit.
1.12.2 1.13
Installing
AG. V agen Removing and installing auxiliary air ksw Vol heater element -Z35- on vehicles fromised by r 1K-7P015629 und 1K-7B084801 autho
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1.13.1
Checking auxiliary air heater element Z35- with peripherals
ss
Auxiliary air heater element -Z35- peripherals (load signal for al ternator terminal DF, low heat output relay -J359- , high heat output relay -J360- , intake manifold temperature sender -G72- , coolant temperature sender -G62- ) can be read via the engine control unit self-diagnosis.
1.13.2
Checking auxiliary air heater element Z35-
Vehicle diagnostic, testing and information system -VAS 5051B- with 100 A pick-up clamp -VAS 5051B/7-
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16
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1.13.3

Test conditions
Intake temperature less than 19 C Coolant temperature less than 80 C Passenger compartment temperature about 20 C Battery voltage greater than 11 V Alternator load not greater than 50% (terminal DF) Engine speed greater than 450 rpm Turn rotary knob for interior temperature to end position for maximum temperature.
1.13.4
t au
s no olks Remove leftVfootwell vent page 7 . t gu by ara ed ris centre console trim from left footwell. ntee Remove o h
Test procedure age G. Volksw

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c ss Measure current consumption on earth wire -arrow- using ve hicle diagnostic, testing and information system -VAS 5051Band 100 A pick-up clamp -VAS 5051B/7- .
or a
Low heating output: approx. 30 amps Medium heating output: approx. 60 amps High heating output: approx. 80 amps
1.13.5
Removing
Removing and installing
Remove driver side footwell trim Rep. Gr. 68 . Remove left footwell vent page 7 .
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Note
If the lever -C- to temperature flap is positioned so the the upper bolt -A- is not accessible. Change the position of the temperature flap at the heater and fresh air controls. On vehicles with Clima tronic, at the control and display unit (e.g. the setting Hi).
Disconnect the battery Rep. Gr. 27 . Remove bolts -A- from cover -B-. Caution
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AG.
Danger of short circuit. Disconnect battery before performing repair work.
1. Repairing heater
17
Golf 2004 Heating, air conditioning - Edition 02.2008 Unscrew nut -1- (9 1 Nm). Release connector strip catch -arrow-. WARNING
Danger of burn injuries. The auxiliary air heater element -Z35- may be hot. Before removing auxiliary air heater element -Z35- , allow it to cool off.
Remove screw -2- (1.4 Nm) and pull out auxiliary air heater element -Z35- from blower box. Installing Note
Ensure that the earth wire is in proper position.

1.14
Note
Checking ventilation
AG. Volkswagen AG d agen oes not lksw Vo gu by ara d nte in therise luggage o eo th u ra a c ss
The stale air escapes via ventilation openings
compartment trim.
ings must not be covered. hind the bumper.
The ventilation frames are located in the rear side panels be
If the ventilation is to function properly, the ventilation open
1.14.1
Checking
Remove rear bumper Rep. Gr. 63 .
Sealing lips -1- in ventilation frames on both sides of vehicle must be free to move and close by themselves. Note installation position.
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1.15.1
Removing
Remove plenum chamber cover Rep. Gr. 64 .
18
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Prote cted by
1.15
Removing and installing air intake screen
Golf 2004 Heating, air conditioning - Edition 02.2008 Remove cover -1- from plenum chamber. Note On vehicles with Climatronic from week 45/2007, a retainer Function of air quality sensor -G238- page 56 .
with an air quality sensor -G238- is fitted on the air intake grille.
Release air quality sensor retainer.
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Unscrew collar nuts -arrows- (2.5 0.4 Nm) and remove air intake grille upwards.
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Seal must seat properly on air intake screen.

Assembly sequence: Adjust air intake grille on metal collar. Hold air intake grille and first tighten lateral collar nuts (2.5 0.4 Nm), then tighten middle collar nut.
1.16
Removing and installing heater unit
AG.
Prote cted by
1.15.2
Installing
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1. Repairing heater
19
Golf 2004 Heating, air conditioning - Edition 02.2008 Drip tray -V.A.G 1306-
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1.16.1
Note
Removing
To improve access, depending on engine version, additional com ponents must be removed e.g. engine cover Rep. Gr. 10 .
Remove dash panel Rep. Gr. 70 . Remove right and left rear footwell air ducts page 6 . Place drip tray -V.A.G 1306- beneath engine. Mark coolant hoses -1WARNING
r fo ng
Danger of scalding injuries.
If necessary, release pressure before carrying out repairs.
20
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When the engine is warm, the coolant temperature may be above 100 C. The cooling system is pressurised.
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Golf 2004 Heating, air conditioning - Edition 02.2008 Clamp off coolant hoses -1- using hose clamps up to 40 mm -VAS 3093- and disconnect coolant hosesAG. heat wagen AG to Volks exchanger. en Push a piece of hose -A- onto by Vol connection of heat ex upper ed changer. ris
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Cover carpet in vehicle interior with waterproof foil and ab sorbent paper.
Carefully blow remaining coolant out of heat exchanger using a compressed air pistol at heat exchanger connection.
Note
During removal, note lengths and locations of bolts for later installation.
1 - Bolt 4,5 0.7 Nm Lower right on cable re tainer to heater unit, near bulkhead
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2 - Bolts 4,5 0.7 Nm 3 - Cable retainer 4 - Heater unit Removing:
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Separate connectors from heater unit. Note
Remove both securing nuts from convenience system central control unit -J393- and hang central control unit to side Rep. Gr. 97 . Unscrew bolts -6- and remove bracket -5-. Unscrew bolts -8- and -10- and remove sup ports -9- and -11-. Unscrew bolts -12- and -14- and remove retain er -13-. Remove bolts -2- and -1- from cable retainer -3-. Note
Remove heater unit.

1. Repairing heater
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21
Golf 2004 Heating, air conditioning - Edition 02.2008 Installing: Installation is carried out in the reverse order. When installing, note the following: First tighten bolts -8- when installing supports -9- and -11-. Note Have second mechanic guide both coolant pipes to heat exchanger through seal during installation of heater unit page 22 . Fill with coolant Rep. Gr. 19 .
5 - Bracket
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6 - Bolts 8 1 Nm 7 - Mounting plate 8 - Bolts 9 1.3 Nm 9 - Right support 10 - Bolts 20 3 Nm 11 - Left support 12 - Bolts 9 1.3 Nm 13 - Bracket 14 - Bolts 9 1.3 Nm
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Seal between heater unit and engine compartment Note
Observe position of seal -A- during installation.
22
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Prote cted by
Dismantling and assembling heater unit

Assembly overview heater unit
2.1
1 - Temperature flap actuator Removing and installing page 26 2 - Bracket 3 - Cover 4 - Fresh air and air recircula tion flap control motor -V154 Checking: vehicle diag nosis, testing and infor mation system -VAS 5051- (or later model) Removing and installing page 11 Renewing: initiate basic settings using vehicle diagnosis, testing and information system VAS 5051- or successor model page 42 5 - Air intake housing With air recirculation flap 6 - Heater unit 7
8 - Fresh air blower series re sistor with overheating fuse N24 Removing and installing page 3 9 - Dust and pollen filter Removing and installing page 4 10 - Cover For dust and pollen filter. 11 - Heat exchanger Removing and installing page 12 12 - Heat exchanger trim 13 - Auxiliary air heater element -Z35Vehicles up to 1K-7P015628 and 1K-7B084800
AG. Volkswagen AG d agen oes not lksw Vo gu by ara d nte - Fresh air blower e-V2is or eo th u and installing ra a Removing c ss
page 3
With auxiliary air heater control unit -J604- . Checking: with vehicle diagnostic, testing and information system -VAS 5051- (or later model), under Heating, ventilation, air conditioning; Systems capable of self-diagnosis; Auxiliary heating; Electrical components. Removing and installing page 15
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2. Dismantling and assembling heater unit
23
Golf 2004 Heating, air conditioning - Edition 02.2008 Vehicles from 1K-7P015629 and 1K-7B084801 A three-level auxiliary air heater element -Z35- is fitted here; it is controlled by the respective engine control unit via relays. Installed only in vehicles with diesel engines without supplementary heater. Removing and installing page 16 14 - Air distribution housing 15 - Air distribution flap actuator Removing and installing page 26
2.2
Removing and installing air distribution housing Removing
2.2.1

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Remove heater unit page 19 . Separate all available connectors from air distribution housing.
24
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Remove heat exchanger together with coolant page 12 .

Remove bolts -arrows- (1.4 Nm).
Remove air distribution housing -1- from heater unit -2-.
2.2.2 2.3 2.3.1
Installing
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Dismantling and assembling heater unit Dismantling
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Remove heater unit page 19 . Remove air distribution housing page 24 . Remove clip -2- and bolts -arrows- from heater unit. Unfold heater unit.
2.3.2
Assembling
Assemble in reverse order.

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25
2.4 2.4.1
n AG. Volkswagen AG do es n wage ot g olks yV ua db ran Golf 2004 e tee ris ho - Edition 02.2008 Heating, air conditioning t or ac au ss
Removing and installing air distribution flap actuator Removing
Remove dash panel Rep. Gr. 70 . Unclip flexible shaft from adapter for controls page 9 . Remove bolts -1- and remove air distribution flap actuator.
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Note
After installation, check operation of air distribution flap page 9 .
2.5
Removing and installing temperature flap actuator Removing
2.5.1
Remove driver side footwell trim Rep. Gr. 68 . Remove left footwell vent page 7 . Unclip cable on temperature flap actuator -2-. Release catch -1- and press temperature flap actuator in -direction of arrow- to stop. Pull off temperature flap actuator.
2.5.2
Installing
26
AG.
Position air distribution flap actuator and tighten bolts -1-.
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Arrows on gears must align.
2.4.2
Installing
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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.

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Prote cted by
27
Notes on repair work to vehicles with air conditioning and on handling re frigerant
Note
87
Air conditioning system
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Notes on repair work to vehicles with air conditioning and on
handling refrigerant can be found in ELSA under Heating, ventilation, air conditioning system; Air conditioning system with refrigerant R134a Rep. Gr. 00 ; Technical data.
Notes on testing equipment and tools for repair work to vehi
cles with air conditioning can be found in ELSA under Heating, ventilation, air conditioning system; Air conditioning system with refrigerant R134a Rep. Gr. 00 ; Technical data.
r fo ng
Caution
There is a film in the refrigerant lines which can be destroyed. Refrigerant lines must not be bent to a radius less than r = 100 mm.
Additional information:
Current flow diagrams, Electrical fault finding and Fitting lo cations
28
Rep. Gr.87 - Air conditioning system
AG.
Do not kink or severely bend refrigerant lines.
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Air conditioning system with manual controls Climatic

Air conditioning and heating - passenger compartment
Note
2.1
Disconnect battery before removing components marked **
Rep. Gr. 27 .
does wag A label on the lock carrier indicates the type and quantity no of olks
olkswagen AG en AG. V
refrigerant used.
2 - Centre vents Removing and installing page 5 3 - Right side vent 4 - Right vent Removing and installing page 5 5 - Climatic heating and air conditioning controls with air conditioning system control unit -J301 With dash panel tem perature sensor -G56 With fresh air and air re circulation flap switch E159- . With heated rear win dow button -E230- . With fresh air blower switch -E9 With air conditioning system control unit J301- . With heated driver seat regulator -E94- and heated front passenger seat regulator -E95 For vehicles with sup plementary heating hav ing instant heating but ton -E537- . Removing and installing page 33
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1 - Dash panel**
V by ed ris ho ut sa s
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6 - Air recirculation flap control motor -V113 Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model) Removing and installing page 60 Renewing: initiate basic settings using vehicle diagnosis, testing and information system -VAS 5051- or successor model page 42
2. Air conditioning system with manual controls Climatic
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Prote cted by
29
Golf 2004 Heating, air conditioning - Edition 02.2008 7 - Right footwell vent Removing and installing page 7 8 - Fresh air blower -V2 Removing and installing page 3
w 9 - Fresh air blower series resistor with overheatinglkfuse -N24o s yV db Removing and installing page 3 rise
AG. Volkswagen AG d agen oes
11 - Evaporator temperature sensor -G308- or evaporator output temperature sender -G263 Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model) Note
10 - Baffle plate for heater unit Removing page 2
ho ut sa s
not gu ara nte eo ra c

Removing and installing page 55 12 - Sealing cap Fitted only in vehicles without air duct to vent in rear centre console. 13 - Dust and pollen filter With activated charcoal filter Removing and installing page 4 14 - Connecting piece For centre console air duct. To remove, centre console must be removed Rep. Gr. 68 .
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17 - Securing bolt Qty. 8 18 - Adapter for controls
19 - Auxiliary air heater element -Z35 Installed only in vehicles with diesel engines without supplementary heater. Removing and installing page 15 Vehicles up to 1K-7P015628 and 1K-7B084800 With auxiliary air heater control unit -J604- . Checking: with vehicle diagnostic, testing and information system -VAS 5051- (or later model), under Heating, ventilation, air conditioning; Systems capable of self-diagnosis; Auxiliary heating; Electrical components. Vehicles from 1K-7P015629 and 1K-7B084801 A three-level auxiliary air heater element -Z35- is fitted here; it is controlled by the respective engine control unit via relays. 20 - Heat exchanger Removing and installing page 12 21 - Left footwell vent Removing and installing page 7 22 - Temperature flap control motor -V68 Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model) Removing and installing page 36
30
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AG.
Prote cted by
16 - Air duct for left rear footwell Removing and installing page 6
15 - Air duct for right rear footwell Removing and installing page 6
Golf 2004 Heating, air conditioning - Edition 02.2008 Renewing: initiate basic settings using vehicle diagnosis, testing and information system -VAS 5051- or successor model page 42 olkswagen AG en AG. V
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Vol 23 - Flexible shaft by ed ris Removing and installing opage 9 h
25 - Heater and air conditioning unit Removing and installing page 84 Dismantling and assembling page 31 26 - Left side vent 27 - Centre vent temperature sender -G191 Removing and installing page 39
ss 24 - Footwell vent temperature sender -G192 Removing and installing page 38
t au
does not gu ara nte eo ra c
2.2
Dismantling and assembling heater and air conditioner unit Climatic
2 - Bracket 3 - Bolts Bolts must be removed to separate air distribu tion housing from evap orator housing. 4 - Cover 5 - Air recirculation flap control motor -V113 Checking: vehicle diag nostic, testing and infor mation system -VAS 5051- (or later model) Removing and installing page 36 Renewing: initiate basic settings using vehicle diagnosis, testing and information system VAS 5051- or successor model page 42 6 - Air intake housing With air recirculation flap
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1 - Temperature flap control motor -V68 Checking: vehicle diag nostic, testing and infor mation system -VAS 5051- (or later model) Removing and installing page 36 Renewing: initiate basic settings using vehicle diagnosis, testing and information system VAS 5051- or successor model page 42
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31
Golf 2004 Heating, air conditioning - Edition 02.2008 7 - Upper part of evaporator housing Dismantling and assembling evaporator housing page 52 8 - Lower part of evaporator housing n Dismantling and assembling evaporator housing pageg52AG. Volkswagen AG doe wa e 9 - Evaporator Removing and installing page 103
olks yV db e ris ho ut a ss
Note
10 - Evaporator temperature sensor -G308- or evaporator output temperature sender -G263 Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
Removing and installing page 55
11 - Connections for glove box cooling To dismantle, remove glove compartment Rep. Gr. 68 Installation position of connections for glove compartment cooling page 32 12 - Refrigerant hose for glove compartment cooling To dismantle, remove glove compartment Rep. Gr. 68 13 - Fresh air blower series resistor with overheating fuse -N24 Removing and installing page 3 14 - Fresh air blower -V2 Removing and installing page 3 15 - Dust and pollen filter With activated charcoal filter Removing and installing page 4 16 - Cover For dust and pollen filter. 17 - Heat exchanger Removing and installing page 12 18 - Heat exchanger trim
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19 - Auxiliary air heater element -Z35 Only in vehicles with diesel engines without supplementary heater. Checking: with vehicle diagnostic, testing and information system -VAS 5051- (or later model), under Heating, ventilation, air conditioning; Systems capable of self-diagnosis; Auxiliary heating; Electrical components. Removing and installing page 15 20 - Air distribution housing Installation position of connections for glove compartment cooling 1 - Connecting piece 2 - Valve
32
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Prote cted by
2.3
Removing and installing heating and air conditioning controls, Climatic with air conditioning system control unit -J301Removing
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2.3.1
Note
The control consists of two separable housings. Before re Heater control to cold Blower to 0
moving controls, set rotary knobs to the following positions:
Vent direction to footwell
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Specified torque for bolts -2- and -3-: 1.5 0.2 Nm. Release connector catch -A- by pulling in direction of arrow -1-. Push connector catch -B- to connector -arrow 2- and remove connector -C-. Release connector catch -D- and remove connector -D-.
2.3.2 2.4
Installing Connectors on controls for heating and air conditioning Climatic Pin assignment for multi-pin connectors on back of controls for heating and air conditioning Climatic
Installation is performed in the reverse order. Ensure that rotary knobs are in the same positions as when removed.
2.4.1
AG.
Remove bolts -2- (4.2 x 45) and -3- (4.2 x 16) and remove the controls -1- from centre console.
Prote cted by
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For vehicles without radio, remove centre dash panel trim. Rep. Gr. 68 .
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Remove radio Rep. Gr. 91 .
33
Golf 2004 Heating, air conditioning - Edition 02.2008 Test box -V.A.G 1598/42 Adapter cable -V.A.G 1598/47-
Template -1598/47-220-pin connector, T20c in current flow diagram 3 - Centre vent temperature sender -G1915 - High-pressure sender -G657 - CAN, low 8 - CAN, high 12 - Right seat heating (optional) 13 - Left seat heating (optional) 15 - Terminal 75, seat heating agen AG. Volkswagen AG doe (optional) w
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by 16 - Air conditioning system compressor regulating valve guara -N280ed
s no t
t 19 - Terminal 30Ah au
is or
20 - Terminal 31 16-pin connector, T16e in current flow diagram 1 - Temperature flap control motor -V68- , warm
ss
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2 - Evaporator temperature sensor -G308- or evaporator output temperature sender -G2634 - Footwell vent temperature sender -G1925 - Temperature flap control motor potentiometer -G927 - + 5 V for temperature flap control motor potentiometer -G928 - Earth for potentiometer for temperature flap control motor G92- , centre vent temperature sender -G191- , footwell vent temperature sender -G192- and evaporator temperature sensor -G308- or evaporator output temperature sender -G2639 - Air recirculation flap control motor -V113- , open 10 - Air recirculation flap control motor -V113- , closed 11 - Temperature flap control motor -V68- , cold
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Golf 2004 Heating, air conditioning - Edition 02.2008 5-pin connector, T5 in current flow diagram 1 - 3rd blower speed 2 - 2nd blower speed 3 - 1st blower speed 4 - 4th blower speed 5 - X terminal
2.5
Removing and installing flexible shaft for air distribution Removing

AG. Volkswagen AG d agen oes not lksw Vo 91 . gu by ara d nte ise or eo remove centre dash panel trim th u ra a c ss
2.5.1
Remove radio Rep. Gr. For vehicles without radio, Rep. Gr. 68 .
Turn rotary switch for air distribution -1- until catch in shaft -2- is visible in gears -3-. Remove heating and air conditioning controls, Climatic page 33 . Carefully pull out adapter for controls.
Move flexible shaft to following position:
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Press in locking lug -arrow- of flexible shaft and pull out flexible shaft. Note
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Flexible shaft for air distribution flap actuator: Run fresh air blower at highest speed. If air flows out of de froster jet in the defrost position, and no air flows out of footwell vent, then the flexible shaft is correctly installed. Oth erwise, remove flexible shaft from adapter. Position controls for Climatic heating and air conditioning on adapter and turn rotary knob for air distribution 1/2 turn (180). Then reconnect flexible shaft. Repeat check.
AG.
2.5.2
Checking
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When the flexible shaft is installed, the adapter and the rotary knob of the Climatic heating and air conditioning controls must be aligned in a specific position to one another or the system will malfunction.
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2.6
Checking condensation water drainage hose on heater and air conditioner unit
Remove footwell trim on front passenger side. Note It must be possible to push condensation drain hose -1- onto
heater and air conditioner unit connection without tension.
The condensation drain hose must be fitted securely to the
connection for condensation drainage of the heater and air conditioner unit.
2.7
2.7.1
Removing and installing air recirculation flap control motor -V113-
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Removing
Remove glove compartment Rep. Gr. 68 . Remove cover -1- for control motor. Separate connector from recirculated air flap control motor V113- -2-. Pull off air recirculation flap control motor -V113- -2-.
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2.7.2
Installing
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After installation, check operation of air recirculation flap. Initiate basic settings function using vehicle diagnosis, test
ing and information system -VAS 5051- or successor model page 42 .
2.8
Removing and installing temperature flap control motor -V68Removing
2.8.1
Remove left footwell vent page 7 . Remove left footwell trim Rep. Gr. 68 .
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Golf 2004 Heating, air conditioning - Edition 02.2008 Remove data bus diagnostic interface -J533- from Rep. Gr. 97 . Remove bolts -3- (9 Nm 1.3 Nm). Do not remove bolts -1-. Do not remove bracket -2-.
Press bracket -1- in direction of brake pedal -arrow- and se cure it on brake pedal with a cable tie.
Mark connector -C- to control motor (danger of interchanging with other connectors of same construction). Separate connector -C- on temperature flap control motor V68- . Remove cover -A-. Remove securing bolts -D- (1.4 Nm) and remove temperature flap control motor -V68- -B-. Remove lever -E- of control motor from connecting rod -F-.
2.8.2
Note
Installing
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Optimised control motors are marked with an X.

To ease assembly, use an approx. 2 mm shorter oval-head screw -N 103 254 01- .
AG.
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Golf 2004 Heating, air conditioning - Edition 02.2008 Cut off bracket -1- from old temperature flap control motor V68- , e.g. using side cutting pliers.
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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
2.9
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Removing and installing footwell vent temperature sender -G192agen lksw Vo by
Remove data bus diagnostic interface -J533- from Rep. Gr. 97 . Remove left footwell vent page 7 . Remove bolts -1- and -3- (9 1.3 Nm).
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AG.
Remove dash panel Rep. Gr. 70 .
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2.9.1
Removing
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Golf 2004 Heating, air conditioning - Edition 02.2008 Remove bracket -2-. Pull connector off footwell vent temperature sender -G192-1-. Turn footwell vent temperature sender -G192- 90 and remove it from housing.
2.9.2 2.10
Installing Removing and installing centre vent temperature sender -G191Removing
2.10.1
Remove left dash panel cover Rep. Gr. 70 . Pull connector off centre vent temperature sender -G191-1-. Turn centre vent temperature sender -G191- -2- 90 in -direction of arrow- and remove from dash panel.
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2.10.2 2.11
Installing Ambient temperature sensor -G17Removing
2.11.1
Pull centre grille out of fasteners in front bumper cover Rep. Gr. 63 . Unclip ambient temperature sensor -G17- -1- from retainer and separate electrical connector.
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2.11.2
Installing
Installation is carried out in the reverse order. When installing, note the following: Note
Ensure proper seating of electrical connection to prevent intrusion of splashed water.
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3
Note
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Switch from C to F and vice versa. Press and hold AUTO

button and then press ECON or AC button.
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Pressing the AUTO button will cancel all settings which deviate
from automatic operation. instructions.
Deviations from automatic operation appropriate operating Vehicles up to calendar week 21/2007: if ECON button is acti
ECON button deactivated, air conditioner compressor switched

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vated, the air conditioner compressor will be switched to al most zero delivery. Depending on vehicle equipment, the auxiliary air heater element -Z35- or the auxiliary heater (in supplementary heater function) will be switched off. If the aux iliary heater is activated by the driver, it will remain on. The respective surrounding conditions have to be fulfilled or the activation signals must have been delivered. The heating and ventilation operations continue to be controlled electronically. on. Depending on vehicle equipment, the auxiliary air heater element -Z35- or the auxiliary heater (in supplementary heater function) will be switched on. If the auxiliary heater is activated by the driver, it will remain on. The respective surrounding conditions have to be fulfilled or the activation signals must have been delivered. The heating and ventilation operations continue to be controlled electronically.
AG.
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ON/OFF button activated, Climatronic in operation. ON/OFF button deactivated, Climatronic out of operation.
There is no heating and ventilation.
Vehicles from calendar week 22/2007: the ECON button was
discontinued. Replaced by AC button. ON/OFF button was discontinued. Replaced by OFF button.
AC button activated, air conditioner compressor switched on.
Depending on vehicle equipment, the auxiliary air heater ele ment -Z35- or the auxiliary heater (in supplementary heater function) will be switched on. If the auxiliary heater is activated by the driver, it will remain on. The respective surrounding conditions have to be fulfilled or the activation signals must have been delivered. The heating and ventilation operations continue to be controlled electronically. switched to almost zero delivery. Depending on vehicle equip ment, the auxiliary air heater element -Z35- or the auxiliary heater (in supplementary heater function) will remain on. If the auxiliary heater is activated by the driver, it will remain on. The respective surrounding conditions have to be fulfilled or the activation signals must have been delivered. The heating and ventilation operations continue to be controlled electronically. is no heating and ventilation.
AC button deactivated, air conditioner compressor will be
OFF button is activated. Climatronic is out of operation. There OFF button is deactivated. Climatronic is in operation.
3. Air conditioning system with automatic regulation Climatronic
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41
3.1
Procedure for checking and adjusting components
Select guided fault finding function in the vehicle diagnostic, testing and information system -VAS 5051- (or later model). After all control units have been read: Press GoTo button. Select Function/component selection. Select Body. Heating, ventilation, air conditioning (Repair group 01; 80 87). Select 01-On Board Diagnostic (OBD) capable systems. Select Climatronic or Climatic. Select Functions. Basic settings Checking cooling output. Read data block.
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3.2
Function of operating and display unit for Climatronic air conditioning sys tem -E87-
1 - Display for selected left in terior temperature Switch from C to F and vice versa. Press and hold AUTO button and then press ECON or AC button. 2 - Air recirculation button Pressing air recircula tion button prevents pol luted air from entering interior. 3 - Centre air distribution but ton
4 - Lower air distribution button 5 - Upper air distribution button
6 - Display for selected right in terior temperature Switch from C to F and vice versa. Press and hold AUTO button and then press ECON or AC button.
Note 8 - Windscreen defroster button 9 - Rear window heating button 10 - Rotary regulator for interior temperature, left 11 - Rotary blower regulator Turn to change blower speed. 12 - Dual button or instant heating button -E537 If the lamp in the button is on, the left and right temperatures may be adjusted independently. If the Dual button is pressed, the warning lamp goes out and the passenger side will assume the tem perature setting for the driver side. Note
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7 - Button for air recirculation mode or button for automatic recirculation mode Pressing the air recircu lation button switches to the air recirculation mode and prevents pol luted air from entering the interior. Vehicles from calendar week 22/2007. Pressing the air recirculation but ton again activates the automatic recirculation mode.
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Golf 2004 Heating, air conditioning - Edition 02.2008 13 - Dash panel temperature sensor -G5614 - Button for air conditioning system OFF or ON/OFF 15 - AUTO button Pressing AUTO button causes the Climatronic to maintain the selected interior temperature completely automatically. With this setting, the vent air temperature, the blower speed and the air distribution are controlled automatically. 16 - AC button Observe notes on vehicles up to calendar week 21/2007 and from calendar week 22/2007 page 41 . Deactivating the AC button sets the compressor to near-zero delivery. The heating and ventilation op erations continue to be controlled electronically. 17 - ECON button Observe notes on vehicles up to calendar week 21/2007 and from calendar week 22/2007 page 41 . Pressing the ECON button sets the air conditioner compressor to near-zero delivery. The heating and ventilation operations continue to be controlled electronically. The optional supplementary heater will likewise be switched off. 18 - Rotary regulator for interior temperature, right
3.3
Removing and installing operating and display unit for Climatronic air condition ing system -E87- with Climatronic con AG. Volkswagen AG d trol unit -J255agen oes n lksw
Note
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The Climatronic control unit -J255- and the operating and display unit for Climatronic air conditioning system -E87- are a single component which cannot be dismantled.
3.3.1
Removing
Remove centre dash panel trim Rep. Gr. 68 . Remove bolts -2- (1.5 0.2 Nm) and remove operating and display unit for Climatronic air conditioning system -E87- -1from dash panel. Separate connectors on operating and display unit for Clima tronic air conditioning system -E87- .
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3.3.2
Installing
3.4
Connectors on Climatronic control unit J255Pin assignment for multi-pin connectors A, B and C on back of Climatronic con trol unit -J255-
3.4.1
Special tools and workshop equipment required Test box -V.A.G 1598/42 Adapter cable -V.A.G 1598/47-
Template -1598/47-220-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 -G653 - Sunlight penetration photosensor 2 -G134- or sunlight pene tration photosensor -G107- , signal 5 - CAN, high 6 - CAN, low
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4 - From calendar week 45/2007: air quality sensor -G238- , signal
9 - + 5 V for sunlight penetration photosensor 2 -G134- or sunlight penetration photosensor -G10710 - Heated driver seat control unit -J131- (optional)
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11 - Heated front passenger seat control unit -J132- (optional) 13 - Left vent temperature sender -G150agen lksw Vo by
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12 - Terminal 75 (optional) 14 - Right vent temperature sender -G151AG.

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16 - Positive connection (15a) or positive connection (30a) for vehicles with supplementary heating and air quality sensor G23817 - Signal earth of senders 18 - Air conditioning system compressor regulating valve -N28019 - Terminal 31 20 - Positive connection (15a) or positive connection (30a) for vehicles with supplementary heating.
45
4 - Potentiometer for defroster flap control motor -G1355 - Potentiometer for centre flap control motor -G1126 - Vehicles up to calendar week 17/2007: potentiometer for air recirculation flap control motor -G143- . Vehicles from calendar week 18/2007: potentiometer for air recirculation flap control mo tor -G143- was discontinued. 7 - Vehicles up to calendar week 17/2007: potentiometer for air flow flap control motor -G113- . Vehicles from calendar week 18/2007: potentiometer for control motor for fresh air and air re circulation flap and air flow flap -G644- . 8 - Left footwell vent temperature sender -G2619 - Right footwell vent temperature sender -G262or ate riv p or gf n
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3 - Potentiometer for right temperature flap control motor -G221-
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AG. Volkswagen AG d agen oes not lksw Vo 16-pin connector, T16c in current flow diagram -Bgu by ara d nte ise or 1 - + 5V for control motor eo th u ra a c ss-G2202 - Potentiometer for left temperature flap control motor
10 - Fresh air intake duct temperature sensor -G89- only installed up to December 2005
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14 - Signal earth, potentiometer 16-pin connector, T16d in current flow diagram -C1 - Left temperature flap control motor -V158- , cold 2 - Left temperature flap control motor -V158- , warm 3 - Defroster flap control motor -V107- , closed 4 - Defroster flap control motor -V107- , open 5 - Central flap control motor -V70- , chest 6 - Central flap control motor -V70- , footwell
7 - Vehicles up to calendar week 17/2007: air recirculation flap control motor -V113- , recirculation actuated. From calendar week 18/2007: air recirculation flap control motor -V113- was discon tinued. 8 - Vehicles up to calendar week 17/2007: air recirculation flap control motor -V113- , fresh air actuated. From calendar week 18/2007: air recirculation flap control motor -V113- was discon tinued. 9 - Vehicles up to calendar week 17/2007: air flow flap control motor -V71- open. From calendar week 18/2007: control motor for fresh air and air recirculation flap and air flow flap -V425- (air recirculation/partial air recirculation) 10 - Vehicles up to calendar week 17/2007: air flow flap control motor -V71- closed. From calendar week 18/2007: control motor for fresh air and air recirculation flap and air flow flap -V425- (air recirculation/increased flow) 11 - Right temperature flap control motor -V159- , cold 12 - Right temperature flap control motor -V159- , warm 15 - Fresh air blower -V2- (PWM actuated) 16 - Fresh air blower -V2- , feedback signal
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11 - Evaporator temperature sensor -G308- or evaporator output temperature sender -G263-
3.5
Note
Climatronic - passenger compartment
Disconnect battery before removing components marked **
Rep. Gr. 27 .
A label indicates the type and quantity of refrigerant used. 1 - Dash panel** Removing and installingkswagen AG ol en AG. V does Rep. Gr. swag no lk 70 o 2 - Sunlighted ris penetration photo tho sensoru-G107- or sunlight pen a etration photosensor 2 -G134ss Checking: vehicle diag nostic, testing and infor mation system -VAS 5051- (or later model) Function: controls tem perature flap and fresh air blower depending on light intensity Emergency running in event of failure: Clima tronic control unit -J255assumes fixed value Removing and installing page 59 3 - Centre vents Removing and installing page 5 4 - Right side vent
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V by

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7 - Climatronic control unit -J255 The Climatronic control unit -J255- and the operating and display unit for Climatronic air conditioning system -E87- are a single component which cannot be dismantled. Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model) Removing and installing page 44 Renewing: initiate basic settings using vehicle diagnosis, testing and information system -VAS 5051- or successor model page 42 8 - Vehicles up to calendar week 17/2007: air flow flap control motor -V71- ; from calendar week 18/2007: control motor for fresh air and air recirculation flap and air flow flap -V425 Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model) Removing and installing page 60 for vehicles up to calendar week 17/2007
AG.
6 - Right vent temperature sender -G151 Checking: vehicle diag nostic, testing and infor mation system -VAS 5051- (or later model) Removing and installing page 58
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5 - Vent Removing and installing page 5

47
Golf 2004 Heating, air conditioning - Edition 02.2008 Removing and installing page 61 for vehicles up to calendar week 18/2007 Renewing: initiate basic settings using vehicle diagnosis, testing and information system -VAS 5051- or successor model page 42 9 - Vehicles up to calendar week 17/2007: air recirculation flap control motor -V113- ; from calendar week 18/2007: air recirculation flap control motor -V113- was discontinued Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model) Removing and installing page 60 Renewing: initiate basic settings using vehicle diagnosis, testing and information system -VAS 5051- or successor model page 42 10 - Fresh air intake duct temperature sensor -G89 Only installed in vehicles up to 12.05 Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model) Function: temperature sensor controls temperature flap and fresh air blower, depending on temperature To dismantle, remove dash panel Rep. Gr. 70 11 - Right footwell vent Removing and installing page 7 12 - Fresh air blower -V2- with fresh air blower control unit -J126 Vehicles as of 11.05; fresh air blower control unit -J126- can be renew individually Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model) . Volkswage gen A Removing and installing fresh air blowera-V2- G page 3 n AG does n lksw ot o yV ua Removing and installing fresh airbblower control unit -J126- pageg53a r ed 13 - Connector 14 - Baffle plate for heater unit Removing page 2
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15 - Sealing cap Fitted only in vehicles without air duct to vent in rear centre console. 16 - Dust and pollen filter With activated charcoal filter Removing and installing page 4 17 - Connection for centre console air duct (optional) To remove, centre console must be removed Rep. Gr. 68 . 18 - Air duct for right rear footwell Removing and installing page 6 19 - Air duct for left rear footwell Removing and installing page 6
20 - Evaporator temperature sensor -G308- or evaporator output temperature sender -G263 Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
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Note
21 - Right temperature flap control motor -V159 Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model) Removing and installing page 65 Renewing: initiate basic settings using vehicle diagnosis, testing and information system -VAS 5051- or successor model page 42 22 - Auxiliary air heater element -Z35 Installed only in vehicles with diesel engines without auxiliary coolant heater.
AG.
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Prote cted by
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Golf 2004 n AG. Volkswagen AG do es n wage Heating, air conditioning - Edition 02.2008 ot g olks V ua by ran ed tee ris with vehicle diagnostic, testing and information system -VAS 5051- (or later model), under Checking: o th ventilation, air conditioning; Systems capabler of self-diagnosis; Auxiliary heating; Electrical o Heating, ac au ss components.
23 - Heat exchanger Removing and installing page 12
24 - Central flap control motor -V70 Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model) Removing and installing page 66 Renewing: initiate basic settings using vehicle diagnosis, testing and information system -VAS 5051- or successor model page 42 25 - Left footwell vent Removing and installing page 7
26 - Left temperature flap control motor -V158 Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model) Removing and installing page 64 Renewing: initiate basic settings using vehicle diagnosis, testing and information system -VAS 5051- or successor model page 42 27 - Left footwell vent temperature sender -G261 Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model) Removing page 54 28 - Defroster flap control motor -V107 Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model) Removing and installing page 63 Renewing: initiate basic settings using vehicle diagnosis, testing and information system -VAS 5051- or successor model page 42 29 - Heater and air conditioning unit Removing and installing page 84 Dismantling and assembling page 50 30 - Right footwell vent temperature sender -G262 Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model) Removing page 54 31 - Left side vent 32 - Left vent temperature sender -G150 Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model) Removing and installing page 58
AG.
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3.6
Dismantling and assembling heater and air conditioner unit Climatronic
1 - Central flap control motor V70 Checking: vehicle diag . Volkswagen AG gen AG does nostic, testing and infor swa not olk gu yV ara mation system -VAS db e nte 5051- (or laterhoris model) eo ut ra c Removing ss a installing and page 66 Renewing: initiate basic settings using vehicle diagnosis, testing and information system VAS 5051- or successor model page 42
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3 - Defroster flap control motor -V107 Checking: vehicle diag nostic, testing and infor mation system -VAS 5051- (or later model) Removing and installing page 63 Renewing: initiate basic settings using vehicle diagnosis, testing and information system -VAS 5051- or successor model page 42 4 - Bracket 5 - Bolts Bolts must be removed to separate air distribution housing from evaporator housing. 6 - Cover 7 - Vehicles up to calendar week 17/2007: air recirculation flap control motor -V113- ; from calendar week 18/2007: air recirculation flap control motor -V113- was discontinued Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model) Removing and installing page 60 Renewing: initiate basic settings using vehicle diagnosis, testing and information system -VAS 5051- or successor model page 42 8 - Vehicles up to calendar week 17/2007: air flow flap control motor -V71- ; from calendar week 18/2007: control motor for fresh air and air recirculation flap and air flow flap -V425 Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model) Removing and installing page 60 for vehicles up to calendar week 17/2007 Removing and installing page 61 for vehicles up to calendar week 18/2007
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2 - Left temperature flap con trol motor -V158 Checking: vehicle diag nostic, testing and infor mation system -VAS 5051- (or later model) Removing and installing page 64 Renewing: initiate basic settings using vehicle diagnosis, testing and information system VAS 5051- or successor model page 42
Golf 2004 Heating, air conditioning - Edition 02.2008 Renewing: initiate basic settings using vehicle diagnosis, testing and information system -VAS 5051- or successor model page 42 9 - Air intake housing With air recirculation flap With air flow flap (Climatronic). 10 - Fresh air intake duct temperature sensor -G89 Only installed in vehicles up to 12.05 Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model) n AG. Volkswag flap do Function: temperature sensor controlsetemperature en AGand fresh air blower, depending on temperature es n wag ot g olks V ua To dismantle, remove dash dpanel Rep. Gr. 70 by r
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ho 11 - Upper part of evaporator thousing u sa s Dismantling and assembling evaporator housing page 52
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13 - Evaporator Removing and installing page 103
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12 - Lower part of evaporator housing Dismantling and assembling evaporator housing page 52
14 - Evaporator temperature sensor -G308- or evaporator output temperature sender -G263 Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model) Note
Removing and installing page 55 15 - Connections for glove box cooling To dismantle, remove glove compartment Rep. Gr. 68
16 - Refrigerant hose for glove compartment cooling To dismantle, remove glove compartment Rep. Gr. 68 Installation position of connections for glove compartment cooling page 52
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17 - Fresh air blower -V2- with fresh air blower control unit -J126 Vehicles as of 11.05; fresh air blower control unit -J126- can be renew individually Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model) Removing and installing fresh air blower -V2- page 3 Removing and installing fresh air blower control unit -J126- page 53 18 - Dust and pollen filter With activated charcoal filter Removing and installing page 4 19 - Cover For dust and pollen filter. 20 - Heat exchanger Removing and installing page 12 21 - Right temperature flap control motor -V159 Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model) Removing and installing page 65 Renewing: initiate basic settings using vehicle diagnosis, testing and information system -VAS 5051- or successor model page 42 22 - Heat exchanger trim 23 - Auxiliary air heater element -Z35 Installed only in vehicles with diesel engines with no supplementary heater
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51
Golf 2004 Heating, air conditioning - Edition 02.2008 Checking: with vehicle diagnostic, testing and information system -VAS 5051- (or later model), under Heating, ventilation, air conditioning; Systems capable of self-diagnosis; Auxiliary heating; Electrical components. Removing and installing page 15 . 24 - Air distribution housing Installation position of connections for glove compartment cooling 1 - Connecting piece 2 - Valve
Remove heating and air conditioning unit page 84 . Separate air distribution housing/evaporator housing from heater and air conditioning unit page 24 .
3.7
Assembly overview - evaporator hous ing

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Golf 2004 Heating, air conditioning - Edition 02.2008 1 - Lower part of evaporator housing Dismantling and assem bling page 25 2 - Evaporator Check insulation. It must be complete. Removing and installing page 103 3 - Clip
n 4 - Upper part of evaporator wage olks housing yV b ed ris Dismantling and assem ho t au bling page 25 ss 5 - Bolt
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6 - Sealing and insulation Heat insulation for ex pansion valve. Removing and installing page 103 7 - Bracket Removing and installing page 103

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3.8.1
Removing
Remove fresh air blower -V2- page 3 . Disconnect connector -1- to fresh air blower -V2- . Remove bolts -arrows-.
3.8.2
Installing
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3.8
AG.
Removing and installing fresh air blower control unit -J126Prote cted by
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53
3.9
Removing and installing left footwell vent temperature sender -G261Removing
3.9.1
Remove dash panel Rep. Gr. 70 . Remove bolts -1- and -3- (9 1.3 Nm). Remove retainer -2-.
Pull connector off left footwell vent temperature sender -G261-1-. Turn left footwell vent temperature sender -G261- -1- 90 and remove it from housing.
3.9.2 3.10
Installing Removing and installing right footwell vent temperature sender -G262Removing
3.10.1
Note
For better illustration, right footwell vent temperature sender G262- is shown with dash panel removed. The dash panel need not be removed.
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AG.
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54
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Golf 2004 Heating, air conditioning - Edition 02.2008 Remove glove compartment Rep. Gr. 68 . Pull connector off right footwell vent temperature sender G262- -1-. Turn right footwell vent temperature sender -G262- -1- 90 and remove it from housing.
3.10.2 3.11
Installing
AG. V lkswagen AG d Removing and installingoevaporator agen oes not lksw Vo gu temperaturebysensor -G308- or evaporaara d nte ise or temperature sender -G263eo tor output h ut r
Remove right footwell trim -1-.
3.11.1
Removing
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Pull connector off evaporator temperature sensor -G308- or evaporator output temperature sender -G263- -1-. Turn evaporator temperature sensor -G308- or evaporator output temperature sender -G263- in -direction of arrow- and pull it out.
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3.11.2 3.12 3.12.1
Installing Ambient temperature sensor -G17Removing
Pull centre grille out of fasteners in front bumper cover Rep. Gr. 63 .
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AG.
55
Golf 2004 Heating, air conditioning - Edition 02.2008 Unclip ambient temperature sensor -G17- from retainer and separate electrical connector.
3.12.2
Note
Installing
Ensure proper seating of electrical connection to prevent intrusion of splashed water.
3.13
Function of air quality sensor -G238-
The air quality sensor detects noxious substances in the am bient air (primarily petrol and/or diesel fumes). The Climatronic control unit -J255- evaluates the signal from the air quality sensor -G238- . The air conditioning system is actuated depending on the degree and manner of ambient air pollution. At an ambient temperature higher than approx. +2 C, air recir n AG. Volkswagen AG do culation is actuated even when there is a minimal increase in es n wage ot g olks yV noxious substances in the ambient air. ua db r
ho At an ambient temperature between approx. +2 C andutapprox. -5 C, air recirculation is not actuated until there is a ss a strong in crease in noxious substances in the ambient air. The compressor is also switched on at the same time.
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At an ambient temperature less than approx. -5 C, air recircula tion is not actuated until there is a strong increase in noxious substances in the outside air, but only for approx. 15 seconds, and the compressor is not started. When the concentration de creases, the air conditioning system is switched back to fresh air mode. The automatic air recirculation function can be switched off at any time. If the function is active, the compressor will be switched on even at an ambient temperature below +2 C when automatic air recirculation is required. However, even with this function, it is not possible to operate the compressor at temperatures below -5 C. On vehicles with automatic air recirculation, the air condi tioner compressor can also be switched on at temperatures down to approx. -5 C even if the recirculated air function has been activated manually. So that the air conditioning system does not operate continu ally in air recirculation mode in areas with consistently high levels of pollutants, the "intelligent" sensor adapts its sensitiv ity to the prevailing environmental pollution.
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If the level of noxious substances in the ambient air remains relatively high over a long period of time, the intelligent sensor starts to adapt to the change in environmental conditions so that, generally, the demand for recirculated air lasts less than 12 minutes in areas where the ambient air exhibits a constant
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ara db A certain eamount of time is required for repositioning of the air nte ris eo conditioning system flaps. To prevent noxious substances ho ut ra from entering the passenger compartment while the flaps are c sa s closing (e.g. when driving through a cloud of diesel smoke), a dust and pollen filter with an activated charcoal layer is instal led. A saturated filter cannot perform this task and should be renewed.
To prevent too frequent operation of the recirculation/fresh air flap, the flap is not actuated immediately if there is a minimal increase in noxious substances in the ambient air (the sensor does not send a request to the Climatronic control unit -J255- ). The effect of the activated charcoal filter in the dust and pollen filter is adequate for this. To prevent the air recirculation/fresh air flap from switching too frequently, the sensor's request for automatic air recircula tion continues for at least 25 seconds (minimum waiting pe riod) even if the air pollutants decrease to a level that no longer requires air recirculation.
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If the air conditioner compressor is switched off (e.g. in ECON mode), the maximum period of automatic air recirculation is limited to approx. 15 seconds by the Climatronic control unit J255- so that condensation does not develop on the windows. To clear condensation from windows as quickly as possible, the Climatronic control unit -J255- does not permit air recircu lation in the defrost mode.
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The air quality sensor -G238- requires approx. 30 seconds to become operational once the ignition has been switched on (warm-up time). During this time, the sensor can send no re quest for automatic air recirculation to the Climatronic control unit -J255- . The air quality sensor -G238- is a highly sensitive electronic component which direct contact with solvents, fuels and cer tain chemical compositions could damage beyond repair. For this reason, do not install sensors that may have come into contact with these substances.
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3.14
The air quality sensor -G238- is installed on the air intake grille
in the front right (from the driver's perspective) of the plenum chamber. component which direct contact with solvents, fuels and cer tain chemical compositions could damage beyond repair. tool box.
The air quality sensor -G238- is a highly sensitive electronic Do not install a sensor that has been kept, for example, in a
Do not place a removed sensor in an area where it can come
into contact with solvents, fuels and certain chemical com pounds (fluids or vapours).
3.14.1
Remove plenum chamber cover Rep. Gr. 64 .
Removing and installing air quality sen sor -G238Note
Removing
57
Golf 2004 Heating, air conditioning - Edition 02.2008 Remove cover -1- from plenum chamber.
Separate connector on air quality sensor -G238- . Release air quality sensor -G238- -1- and turn out of retainer on air intake grille.
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3.14.2 3.15
Installing
Note
Removal of senders on both sides is identical, but one is a mirror image of the other.
Remove left or right dash panel cover Rep. Gr. 70 . Pull connector -1- off vent temperature sender -2-. Turn vent temperature sender -2- 90 in -direction of arrowand remove from dash panel.
58
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Removing left vent temperature sender -G150- and right vent temperature send er -G151AG.
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3.16
Removing sunlight penetration photo sensor -G107- or sunlight penetration photosensor 2 -G134-
Unclip sunlight penetration photosensor -1- out of dash panel using an appropriate tool. Pull connector off sunlight penetration photosensor.
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3.17
Checking condensation water drainage hose on air conditioner unit
Remove footwell trim on front passenger side. Note
It must be possible to push condensation water drainage hose
-1- onto air conditioner unit connection without tension.
The condensation drain hose must be fitted securely to con
densation drain connection on heater and air conditioning unit.
First carry out the following work: Switch off all electrical consumers. Switch off ignition. Pull out ignition key.
AG.
Vehicle diagnosis, testing and information system -VAS 5051or successor models.
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3.18
Renewing control motors for air condi tioning regulation

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3.19
Removing and installing air recirculation flap control motor -V113Removing

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3.19.1
Remove glove compartment Rep. Gr. 68 . Remove cover for control motors. If necessary, mark connector -A- (to prevent interchanging if several connectors are separated at the same time.) Separate connector -A-. Release catches -C- and -D- for retainer -B- on intake duct and remove retainer -B- (to rear). Remove control motor -A- from intake duct.
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Install in reverse order. Note After installation, check operation of air recirculation flap.
Initiate basic settings function using vehicle diagnosis, test
3.20
Removing and installing air flow flap control motor -V71- for vehicles up to calendar week 17/2007 Removing
3.20.1
Remove glove compartment Rep. Gr. 68 . Note
The position of the air flow flap must not be changed.

Remove cover -1-.
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3.19.2
Installing
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Golf 2004 Heating, air conditioning - Edition 02.2008 Remove air recirculation flap control motor -V113 page 60 . Separate connector from air flow flap control motor -V71- -2-. Pull off air flow flap control motor -V71- -2-.
3.20.2
Installing

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After installation, check operation of air flow flap. Initiate basic settings function using vehicle diagnosis, test
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3.21
Removing and installing control motor for fresh air and air recirculation flap and air flow flap -V425- for vehicles from cal endar week 18/2007 Removing
3.21.1
Remove glove compartment Rep. Gr. 68 . Turn control motor for fresh air and air recirculation flap and air flow flap -V425- -2- approx. 15 in direction of -arrow- and then pull off air intake housing.
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Remove bolts -1- (1.4 Nm).
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Golf 2004 Heating, air conditioning - Edition 02.2008 Disconnect connector -1- from control motor for fresh air and air recirculation flap and air flow flap -V425- . Note
The position of the air flow flap must not be changed.
3.21.2
Installing
Install in reverse order, noting the following: The control motor for fresh air and air recirculation flap and air flow flap -V425- fits on the cable cam in one position only. Note After installation, check operation of air flow flap and air recir
culation flap.
Initiate basic setting function using vehicle diagnostic, testing
and information system -VAS 5051- (or later model) page 42 .
3.22
Removing and installing setting unit for fresh air and air recirculation flap and airG. Volkswagen AG A does agen ksw not flow flap Vol gu y
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3.22.1
Removing
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Release catches -arrows- from adjusting lever -1-. Remove adjusting levers from cable cam. Pull off cable cam -2- from air intake housing.
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Remove control motor for fresh air and air recirculation flap and air flow flap -V425- page 61 .
3.22.2
Note
Installing
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When fitting the cable cam, ensure that the guide pin of the ad justing lever for the air flow flap sits in the groove.
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Push cable cam -1- onto air intake housing. Note
When doing this, also ensure that the guide pin of the adjusting lever for the air flow flap sits in the groove.
Fit adjusting lever for air recirculation flap and lock.
3.23
Removing and installing defroster flap control motor -V107Removing

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3.23.1
Remove dash panel Rep. Gr. 70 . Remove bolts -1- and -3- (9 1.3 Nm).
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Remove bracket -2-. Mark connector -C- to control motor (danger of interchanging with other connectors of same construction). Separate connector -C- on defroster flap control motor V107- . Unscrew securing bolts -A- (1.4 Nm) and remove defroster flap control motor -V107- -B-. Remove lever -E- of control motor from connecting rod -D-.
3.23.2
Installing
Install in reverse order. Note After installation, check operation of defroster flap. Initiate basic settings function using vehicle diagnosis, test
AG.
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3.24
Removing and installing left tempera ture flap control motor -V158Removing
3.24.1
Remove left footwell vent page 7 . Remove centre console trim from left footwell. Remove data bus diagnostic interface -J533- from Rep. Gr. 97 . Remove bolts -3- (9 Nm 1.3 Nm). Do not remove bolts -1-. Do not remove bracket -2-.
Press bracket in direction of brake pedal -arrow- and secure it on brake pedal with cable tie.
Remove cover -A-.
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Separate connector -C- on left temperature flap control motor -V158- . Unscrew securing bolts -D- (1.4 Nm) and remove left temper ature flap control motor -V158- -B-. Remove lever -E- of control motor from connecting rod -F-.
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Mark connector -C- to control motor with other connectors of same construction).
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3.24.2
Note
Installing
Optimised control motors are marked with an X.

To ease assembly, use an approx. 2 mm shorter oval-head screw -N 103 254 01- .
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Golf 2004 Heating, air conditioning - Edition 02.2008 Cut off bracket -1- from old left temperature flap control motor -V158- , e.g. using side cutting pliers.
Position new left temperature flap control motor -V158marked 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
3.25
Removing and installing right tempera ture flap control motor -V159Removing
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3.25.1
Remove glove compartment Rep.
Separate connector on right temperature flap control motor V159- . Unscrew securing bolts -1- (1.4. Nm) and remove right tem perature flap control motor -V159- . Unhook lever -2- from right temperature flap control motor V159- .
Remove right footwell vent page 7 .
3.25.2
Installing
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Initiate basic settings function using vehicle diagnosis, test

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After installation, check operation of right temperature flap.

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3.26
Removing and installing central flap control motor -V70Removing
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3.26.1
Remove dash panel Rep. Gr. 70 . Separate connector on central flap control motor -V70- . Unscrew securing bolts -1- (1.4 Nm) and remove central flap control motor -V70- .
Note
After installation, check operation of central flap. Initiate basic settings function using vehicle diagnosis, test
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3.26.2
Installing
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Removing and installing ancillary bracket for air conditioner compres sor
Engine codes: AZV, BDK, BJB, BKC, BKD, BLS, BMM, BMN, BRM, BRU, BVB, BXE, BXF and BXJ
4.1
Special tools and workshop equipment required Torque wrench -V.A.G 1331/- (550 Nm)
Note
The ancillary bracket for air conditioner compressor and rela
ted components can be removed and installed without the refrigerant circuit being opened.
To remove poly V-belt Rep. Gr. 13 . Poly V-belt routing page 69
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4. Removing and installing ancillary bracket for air conditioner compressor
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Golf 2004 Heating, air conditioning - Edition 02.2008 1 - Hexagon bolt M1065 45 Nm 2 - Hexagon bolt M1045 45 Nm 3 - Hexagon bolt M1045 45 Nm 4 - Hexagon bolt M10x45 45 Nm 5 - Hexagon bolt M1065 45 Nm 6 - Hexagon bolt M1065 45 Nm 7 - Hexagon bolt M8x100 Qty. 3 25 Nm 8 - Ancillary bracket for alter nator and air conditioner com pressor Number on ancillary unit bracket -03G 903 143 Ape rm itte d
Removing Remove alternator Rep. Gr. 27 . Loosen air conditioner compressor and re move hexagon bolt -7-. Remove air conditioner compressor from ancil lary bracket and secure to body with suitable material (e.g.welding wire) page 69 . Remove bolts -1- through -6- and remove ancillary bracket from cylinder block. Strictly observe tightening sequence of securing bolts:
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Tighten bolts (positions -1--6-) one after the other
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11 - Air conditioner compressor Removing and installing page 94
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10 - Dowel sleeves Qty. 2 Ensure proper seating between ancillary unit bracket and engine block.
9 - Dowel sleeves Qty. 2 Ensure proper seating between ancillary unit bracket and air conditioner compressor
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Golf 2004 Heating, air conditioning - Edition 02.2008 Securing air conditioner compressor to body If compressor is removed without opening refrigerant circuit, it should be secured to body using suitable material, for example, welding wire. When doing this, ensure refrigerant hoses on air conditioner com pressor are not stressed. Note When installing poly V-belt, ensure that it is correctly seated
on poly V-belt pulley. pressor.
Finally, place poly V-belt over pulley of air conditioner com
Poly V-belt routing 1 - Tensioning roller 2 - Poly V-belt pulley for alternator 3 - Poly V-belt pulley for air conditioner compressor 4 - Poly V-belt 5 - Poly V-belt pulley for crankshaft
4.2
Engine codes: BCA, BUD
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Note

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69
Golf 2004 Heating, air conditioning - Edition 02.2008 1 - Hexagon bolt M1055 50 Nm Qty. 2 2 - Ancillary bracket for alter nator and air conditioner com pressor Number on ancillary unit bracket -036 260 885Removing Remove alternator Rep. Gr. 27 .
Loosen air conditioner compressor and re move hexagon bolt -4-. Remove air conditioner compressor from ancil lary bracket and secure to body with suitable material (e.g.welding wire) page 70 .
Remove bolts -1- and -3- and remove ancillary bracket from cylinder block.
3 - Hexagon bolt M1045 50 Nm Qty. 2 4 - Hexagon bolt M8x100 25 Nm
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6 - Dowel sleeves Qty. 2 Ensure proper seating between ancillary unit bracket and air conditioner compressor Securing air conditioner compressor to body If compressor is removed without opening refrigerant circuit, it should be secured to body using suitable material, for example, welding wire. When doing this, ensure refrigerant hoses on air conditioner com pressor are not stressed. Note When installing poly V-belt, ensure that it is correctly seated
70
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5 - Air conditioner compressor Removing and installing page 94
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Golf 2004 Heating, air conditioning - Edition 02.2008 Poly V-belt routing 1 - Poly V-belt pulley for crankshaft 2 - Tensioning roller 3 - Poly V-belt pulley for alternator 4 - Poly V-belt 5 - Poly V-belt pulley for air conditioner compressor
4.3
Engine codes: BLG, BMY
Note The ancillary bracket for air conditioner compressor and rela To remove poly V-belt Rep. Gr. 13 . Poly V-belt routing page 73
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ted components can be removed and installed without the AG. Volkswagen AG d agen oes not lksw refrigerant circuit being opened. Vo g
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Golf 2004 Heating, air conditioning - Edition 02.2008 1 - Air conditioner compressor Removing and installing page 94 2 - Hexagon bolt M8x100 25 Nm 3 - Hexagon bolt M1045 50 Nm 4 - Ancillary bracket for alter nator and air conditioner com pressor Number on ancillary unit bracket -03C 903 143 ARemoving
Remove alternator Rep. Gr. 27 .
Loosen air conditioner compressor and re move hexagon bolt -2-. Remove air conditioner compressor from ancil lary bracket and secure to body with suitable material (e.g.welding wire) page 72 . Remove bolts -3- and remove ancillary brack et from cylinder block.
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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
72
AG.
Securing air conditioner compressor to body
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5 - Dowel sleeves Qty. 2 Ensure proper seating between ancillary unit bracket and air condi tioner compressor
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Golf 2004 Heating, air conditioning - Edition 02.2008 Poly V-belt routing 1 - Poly V-belt pulley for cooling system pump 2 - Poly V-belt pulley for crankshaft 3 - Lower tensioning roller 4 - Upper tensioning roller 5 - Poly V-belt pulley for alternator 6 - Poly V-belt pulley for air conditioner compressor 7 - Poly V-belt
4.4
Engine codes: BAG, BKG, BLF, BLN, BLP and CAX
Note
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Golf 2004 Heating, air conditioning - Edition 02.2008 1 - Hexagon bolt M845 Qty. 3 25 Nm 2 - Hexagon bolt M8x100 Qty. 3 25 Nm 3 - Air conditioner compressor Removing and installing page 94 4 - Dowel sleeves Qty. 2 Ensure proper seating between ancillary unit bracket and air condi tioner compressor 5 - Ancillary bracket for air con ditioner compressor Number on ancillary unit bracket -1K0 260.885 BRemoving Loosen air conditioner compressor and re move hexagon bolt -2-. Remove air conditioner compressor from ancil lary bracket and secure to body with suitable material (e.g.welding wire) page 74 . Remove bolts -1- and remove ancillary brack et -5- from cylinder block.
Securing air conditioner compressor to body If compressor is removed without opening refrigerant circuit, it should be secured to body using suitable material, for example, welding wire. When doing this, ensure refrigerant hoses on air conditioner com pressor are not stressed.
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74
AG.
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When installing poly V-belt, ensure that it is correctly seated
Note
Golf 2004 Heating, air conditioning - Edition 02.2008 Poly V-belt routing 1234567Poly V-belt pulley for cooling system pump Poly V-belt pulley for crankshaft Lower tensioning roller Upper tensioning roller
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Poly V-belt pulley for alternator Poly V-belt pulley for air conditioner compressor
Poly V-belt
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4.5
Engine codes: AXW, AXX, BGU, BHY, BLR, BLX, BLY, BPY, BSE, BSF, BVX, BVY, BVZ, BWA, BYD, CAWB, CBFA and CCTA
Special tools and workshop equipment required Torque wrench -V.A.G 1331- (550 Nm)
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Note The ancillary bracket for air conditioner compressor and rela
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75
Golf 2004 Heating, air conditioning - Edition 02.2008 1 - Socket head flange bolt n AG. Volkswagen AG do es n wage M1045 ot g olks yV ua db Dowel hole ran se tee ri ho t or Observe different tor ac au ques: ss 1.6 l injection engine and 2.0 l FSI engine: 52 Nm 2.0 l turbo FSI engine: 40 Nm
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2 - Socket head flange bolt M1045 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 M1045 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
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4 - Socket head flange bolt M1045 Observe different tor ques: 1.6 l injection engine and 2.0 l FSI engine: 52 Nm 2.0 l turbo FSI engine: 40 Nm 5 - Air conditioner compressor Removing and installing page 94 6 - Hexagon bolt M8x100 Qty. 3 25 Nm
7 - Socket head flange bolt M1045 Dowel hole Observe different torques: 1.6 l injection engine and 2.0 l FSI engine: 52 Nm 2.0 l turbo FSI engine: 40 Nm 8 - Socket head flange bolt M1045 Observe different torques: 1.6 l injection engine and 2.0 l FSI engine: 52 Nm 2.0 l turbo FSI engine: 40 Nm 9 - Dowel sleeves Qty. 2 Ensure proper seating between ancillary bracket and air conditioner compressor.
76
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Golf 2004 Heating, air conditioning - Edition 02.2008 10 - Ancillary bracket for air conditioner compressor Number on ancillary unit bracket -06F 903 143 E/FRemoving Remove alternator Rep. Gr. 27 . Loosen air conditioner compressor and remove hexagon bolt -6-. Remove air conditioner compressor from ancillary bracket and secure to body with suitable material (e.g.welding wire) page 77 . Remove bolts -1- through -4-, -7- and -8- and remove ancillary bracket -10- from cylinder block. Installing Strictly observe tightening sequence of securing bolts: Tighten socket head flange bolts, positions -1- (dowel hole), -7- (dowel hole), -4-, -8-, -3- and -2- one after the other.
Securing air conditioner compressor to body If compressor is removed without opening refrigerant circuit, it should be secured to body using suitable material, for example, welding wire. When doing this, ensure refrigerant hoses on air conditioner com pressor are not stressed.
Poly 123urposes, in part or in wh ole, cial p is n mer ot com
45-
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n AG. Volkswagen AG do es n wage ot g olks y V-belt routing V ua db ran se tee ri ho Tensioning roller t or ac au ss
Poly V-belt pulley for alternator Poly V-belt
Poly V-belt pulley for air conditioner compressor Poly V-belt pulley for crankshaft Note
4.6
Engine codes: BGP, BGQ, BTK, CBTA and CBUA

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77
Golf 2004 Heating, air conditioning - Edition 02.2008 Torque wrench -V.A.G 1331/- (550 Nm)
Note
To remove poly V-belt Rep. Gr. 13 . Poly V-belt routing page 79 1 - Ancillary bracket for alter nator and air conditioner com pressor Number on ancillary unit bracket -07K 903 143 BRemoving Loosen air conditioner compressor and re move hexagon bolt -6-. Remove air conditioner compressor from ancil lary bracket and secure to body with suitable material (e.g.welding wire) page 79 . Remove bolts from an cillary bracket.
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2 - Multi-point socket head bolt M8X60 25 Nm 3 - Multi-point socket head bolt M8X110 25 Nm 4 - Hexagon socket head bolt M8X30 25 Nm Qty. 4 5 - Air conditioner compressor Removing and installing page 94 6 - Hexagon bolts M885 Qty. 3
78
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n AG. Volkswagen AG do Heating, air conditioning es n wage ot g olks yV ua db ran e 25 Nm tee ris ho t or ac au - Dowel sleevesss
Golf 2004 - Edition 02.2008
Qty. 2 Ensure proper seating between ancillary unit bracket and air conditioner compressor
Securing air conditioner compressor to body If compressor is removed without opening refrigerant circuit, it should be secured to body using suitable material, for example, welding wire. When doing this, ensure that refrigerant hoses on air conditioner compressor are not strained.
Poly V-belt routing

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Upper idler pulley Lower idler pulley

Poly V-belt pulley for alternator
Poly V-belt for alternator and air conditioner compressor Poly V-belt pulley for air conditioner compressor Poly V-belt for air conditioner compressor Poly V-belt pulley for crankshaft
AG.
Tensioning roller for poly V-belt for air conditioner compres sor Tensioning roller for poly V-belt for alternator and cooling system pump
10 - Poly V-belt pulley for cooling system pump
4.7
Engine codes: BUB, CBRA
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79
Poly V-belt routing page 81

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To remove poly V-belt Rep. Gr. 13 .
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n AG. Volkswagen AG do es n wage ot g olks V ua by The ancillary bracket for air conditioner compressor and rela ran ed is tee ted components can be removed and installed without the or th or ac au refrigerant circuit being opened. ss
1 - Poly V-belt Removing and installing Rep. Gr. 13 2 - Poly V-belt pulley for cool ing system pump 3 - Tensioning roller 4 - Ancillary bracket for alter nator and air conditioner com pressor
Number on ancillary unit bracket -038 903 143 AF Removing Loosen air conditioner compressor and re move hexagon bolt -9-. Remove air conditioner compressor from ancil lary bracket and secure to body with suitable material (e.g.welding wire) page 81 . Remove bolts from an cillary bracket.
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Note tightening sequence when installing page 81 . 5 - Fit bolt 25 Nm 6 - Alternator 7 - Dowel sleeves Qty. 2 Ensure proper seating between ancillary unit bracket and air conditioner compressor 8 - Air conditioner compressor Removing and installing page 94 9 - Hexagon bolt M8x100 Qty. 3 25 Nm 10 - Fitted bolt 25 Nm
80
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Golf 2004 Heating, air conditioning - Edition 02.2008 Securing air conditioner compressor to body
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wa If compressor is removed without opening refrigerant circuit, oes not g it olks yV ua should be secured to body usingb suitable material, for example, d ran se tee ri welding wire. ho t o
Note
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When doing this, ensuress refrigerant hoses on air conditioner com pressor are not stressed.
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Tightening sequence for ancillary bracket Note
Bolts -1- and -2- are fit bolts.

First tighten bolts in sequence 1...5 by hand. Then tighten bolts in sequence 1...5 to 25 Nm.
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Poly V-belt routing 1 - Tensioning roller 2 - Poly V-belt pulley for alternator 3 - Idler rollers 4 - Poly V-belt 5 - Poly V-belt pulley for air conditioner compressor 6 - Poly V-belt pulley for crankshaft 7 - Poly V-belt pulley for cooling system pump
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81
Repair work on refrigerant circuit which may be performed only in ap propriate workshops by specially trained mechanics
Note
handling refrigerant can be found in ELSA under Heating, ventilation, air conditioning system; Air conditioning system with refrigerant R134a Rep. Gr. 00 ; Technical data.
Notes on testing equipment and tools for repair work to vehi
cles with air conditioning can be found in ELSA under Heating, ventilation, air conditioning system; Air conditioning system with refrigerant R134a Rep. Gr. 00 ; Technical data.
WARNING
Danger of freezing injuries. If refrigerant circuit has not been evacuated, refrigerant will escape. Extract refrigerant before opening refrigerant circuit. If the re frigerant circuit is not opened within 10 minutes after it has been evacuated, pressure may develop n AG. Volkswacircuit due in coolant gen AG does age to re-evaporation. Extract refrigerantwagain. not lks Vo
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The refrigerant circuit must be purged with refrigerant R134a

under the following circumstances:
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Note
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If dirt or other contamination is in the circuit. If during the evacuation of a leak-tight refrigerant circuit the
vacuum is not maintained at the gauge (there is moisture in the refrigerant circuit and this generates vapour pressure). mally required for repairs (e.g. following an accident).
If the refrigerant circuit has been left open for longer than nor When pressure and temperature measurements in the refrig
erant circuit indicate that there is moisture in the refrigerant circuit. erant circuit.
There is doubt about the amount of refrigerant oil in the refrig The air conditioner compressor has to be exchanged because
of internal damage (e.g. noisy or lack of power).

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Notes on repair work to vehicles with air conditioning and on han dling refrigerant can be found in ELSA under Heating, ventilation, air conditioning system; Air conditioning system with refrigerant R134a Rep. Gr. 00 ; Technical data.
82
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The procedure for purging with refrigerant R134a is described in ELSA under Heating, ventilation, air conditioning system; Air con ditioning system with refrigerant R134a Rep. Gr. 00 Technical data; Clearing refrigerant circuit of contaminants.
AG.
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Golf 2004 Heating, air conditioning - Edition 02.2008 Notes on testing equipment and tools for repair work to vehicles with air conditioning can be found in ELSA under Heating, venti lation, air conditioning system; Air conditioning system with re frigerant R134a Rep. Gr. 00 ; Technical data.
5.1
Testing equipment and tools
Notes on testing equipment and tools for repair work to vehicles with air conditioning can be found in ELSA under Heating, venti lation, air conditioning system; Air conditioning system with re frigerant R134a Rep. Gr. 00 ; Technical data.
gen Special tools and workshop equipment required AG. swa
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Volkswagen AG does not olk gu yV ara air conditioner service stationb-VAS 6007A- (or later mod ed nte ris eo ho t ra au c s s
Adapter set for service connections -T10364-
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Torque wrench -V.A.G 1783- (210 Nm) for adapter set for service connections -T10364AG.
5. Repair work on refrigerant circuit which may be performed only in appropriate workshops by specially trained mechanics
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83
Golf 2004 Heating, air conditioning - Edition 02.2008 Ratchet insert tool 1/4" -VAS 6234- for adapter set for service connections -T10364-
5.2
Removing and installing heater and air conditioning unit
Special tools and workshop equipment required Air conditioner service station -VAS 6007A- or later model.
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Drip tray -V.A.G 1306-
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84
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5.2.1
Note
Removing
To improve access, additional components must be removed de pending on engine version e.g. engine cover Rep. Gr. 10 .
Extract refrigerant, e.g. with air conditioner service station VAS 6007A- before opening refrigerant circuit. Observe notes page 88 . Remove dash panel Rep. Gr. 70 Remove right and left rear footwell air ducts page 6 . Place drip tray -V.A.G 1306- beneath engine. Mark coolant hoses -1WARNING
Danger of scalding injuries. When the engine is warm, the coolant temperature may be above 100 C. The cooling system is pressurised. If necessary, release pressure before carrying out repairs.
Clamp off coolant hoses -1- using hose clamps up to 40 mm -VAS 3093- and disconnect coolant hoses to heat exchanger. Push a piece of hose -A- onto upper connection. Hold a container -B- under lower connection -C-. Carefully blow remaining coolant out of heat exchanger using AG. Volkswagen AG d oes a compressed air pistol at heat exchanger connection. lkswagen no
d Applies only to vehicles with a protective plate before rthe expan ise ho sion valve. ut
Vo by
On right-hand drive vehicles, lock washers are installed instead of a clip and a nut.
Unscrew nut -1- (6 0.9 Nm).
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Note
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a ss
Release clips -2- and remove protective plate -3-.
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85
Golf 2004 Heating, air conditioning - Edition 02.2008 Continuation for all vehicles WARNING
Danger of freezing injuries. If refrigerant circuit has not been evacuated, refrigerant will escape. Extract refrigerant before opening refrigerant circuit. If the re frigerant circuit is not opened within 10 minutes after it has been evacuated, pressure may develop in coolant circuit due to re-evaporation. Extract refrigerant again.
With access from engine compartment, remove bolts (10 1 Nm) -1- for refrigerant lines -2-.
a ksw Remove refrigerant lines from expansion valve -3-. Vol
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Note
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Seal open connections for lines. To seal open connections of expansion valve, use, for exam
ple, sealing cap of a spare expansion valve.
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Cover carpet in vehicle interior with waterproof foil and ab sorbent paper. Note
During removal, note lengths and locations of bolts for later installation.
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86
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AG.
Golf 2004 Heating, air conditioning - Edition 02.2008 1 - Bolt 4,5 0.7 Nm Lower right on cable re tainer to heater and air conditioning unit, near bulkhead 2 - Bolts 4,5 0.7 Nm 3 - Cable retainer 4 - Heater and air conditioning unit Removing: Remove condensation water drain hose from air conditioner unit page 59 . Separate connectors on air conditioner unit. Note Remove both securing nuts from convenience system central control unit -J393- and hang central control unit to side Rep. Gr. 97 . Unscrew bolts -6- and remove bracket -5-. Unscrew bolts -8- and -10- and remove sup ports -9- and -11-. Unscrew bolts
n AG. Volkswagen AG do es n wage ot g olks V ua by ran ed tee ris -12- and o-14- and remove retainer -13-. th or ac au ss
Note
Remove bolts -1- and -2- from cable retainer -3-.
Remove heater and air conditioner unit.
Installing:
Installation is carried out in the reverse order. When installing, note the following: Note
Have second mechanic guide both coolant pipes to heat exchanger through seal during installation of heater unit page 88 . During installation, ensure proper seating of condensation drain hose page 59 . Fill with coolant Rep. Gr. 19 . Refilling with refrigerant R134a and refrigerant oil page 109 .
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87
AG.
Golf 2004 Heating, air conditioning - Edition 02.2008 5 - Bracket 6 - Bolts 8 Nm 7 - Mounting plate 8 - Bolts 9 1.3 Nm 9 - Right support 10 - Bolts 20 3 Nm 11 - Left support 12 - Bolts 9 1.3 Nm 13 - Bracket 14 - Bolts 9 1.3 Nm
Note
First tighten bolts -8- when installing supports -9- and -11-.
Heater and air conditioner unit/engine compartment seal Note
Observe position of seal -A- during
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5.3
Renewing components of refrigerant cir cuit
AG. Volkswagen AG d agen oes not lksw installation. y Vo gu b ara d nte ise or eo th u ra a c ss
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88
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AG.
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Golf 2004 Heating, air conditioning - Edition 02.2008 Drip tray for workshop hoist -VAS 6208-
Hose clamps up to 40 mm -3093-
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Air conditioner
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89
Golf 2004 Heating, air conditioning - Edition 02.2008 Note The refrigerant must be extracted beforehand, e.g. with air
conditioner service station -VAS 6007A- . wagen Workshop Equipment catalogue.
The previously used service stations can still be used Volks All of the refrigerant circuit's components that have been
opened must be sealed with suitable plugs to prevent the in gress of moisture. been discontinued. Coloured and black O-rings are used.
The colour coding of O-rings for R134a refrigerant circuits has Under certain conditions, it is not necessary to renew the re
pe rm itte d
handling refrigerant can be found in ELSA under Heating, ventilation, air conditioning system; Air conditioning system with refrigerant R134a Rep. Gr. 00 ; Technical data. handling refrigerant can be found in ELSA under Heating, ventilation, air conditioning system; Air conditioning system with refrigerant R134a Rep. Gr. 00 ; Technical data.
WARNING
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Notes on repair works to vehicles with air conditioning and on
ceiver with dryer every time that the agen AG. Volkswagen AG does refrigerant circuit is ksw opened. Refer to ELSA under yHeating, ventilation, air condinot gu Vol b ara ed tioning system; Air conditioning system with refrigerant R134a nte ris eo Rep. Gr. 00 ; Technical data; Renewing components. tho u r
sa
ac
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.
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90
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1 - Receiver with dryer

Note
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Removing and installing page 92 2 - Air conditioner compressor Manufacturer: Denso, designation 7SEU17C Observe remarks on in stallation of air condi tioner compressor page 106 . Removing and installing page 94 3 - Condenser Removing and installing page 103
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4 - High-pressure sender G65Removing and installing page 92 5 - Bracket Nuts, 6 Nm
6 - Evacuating and charging valve High-pressure side Releasing refrigerant in to the environment is a punishable offence. Removing and installing page 107 Capacities page 109 7 - Retainer Bolt 3.5 Nm 8 - Evacuating and charging valve Low-pressure side Releasing refrigerant into the environment is a punishable offence. Removing and installing page 107 Capacities page 109 9 - Expansion valve Function and removal page 100 . 10 - Hexagon nut 20 Nm 11 - Bracket
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91
5.4
Removing and installing high-pressure sender -G65Removing

n AG. Volkswagen AG do es n wage ot g olks -G65- -1- fromVrefrigerant line y ua db ran e tee ris ho t or ac au ss
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5.4.1
Remove noise insulation tray from engine Rep. Gr. 50 . Separate connector from high-pressure sender -1-. Unscrew high-pressure sender connection. Note Renew O-ring -2-.
Depending on engine version, the high-pressure sender -G65-
pe rm itte d
-1- may be installed in another location near the condenser.
5.4.2 5.5
Installing
Removing and installing receiver with dryer

Note
Torque wrench -V.A.G 1331/- (550 Nm)
92
AG.
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Under certain conditions, it is not necessary to renew the receiver with dryer every time that the refrigerant circuit is opened. Refer to ELSA under Heating, ventilation, air conditioning system; Air conditioning system with refrigerant R134a Rep. Gr. 00 ; Technical data; Renewing components.
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Golf 2004 Heating, air conditioning - Edition 02.2008 Air conditioner service station -VAS 6007A- or later model.
5.5.1
Note
Removing
Observe notes page 88 . The refrigerant must be extracted beforehand, e.g. with air
AG The previously used service stations can still be used wVolks . Volkswagen AG doe agen
Extract refrigerant, e.g. with air conditioner service station VAS 6007A- before opening refrigerant circuit. Move lock carrier to service position Rep. Gr. 50 . Remove radiator securing bolts -arrows- (7 Nm).
olks yV db e r All of the refrigerant circuit's components thatishave been tho opened must be sealed with suitable plugs to prevent the au ss gress of moisture.
in

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93
Golf 2004 Heating, air conditioning - Edition 02.2008 Hang radiator on workshop hoist -V.A.G 1202/A- and lifting tackle -VAS 2024A- using workshop material (cable ties or uncoated wire) and unhook radiator from lock carrier. Coolant hoses and refrigerant lines remain connected. Remove securing bolt -2- and remove retaining clip. WARNING
Danger of freezing injuries. If refrigerant circuit has not been evacuated, refrigerant will escape. Extract refrigerant before opening refrigerant circuit. If the re G. Volkswagen A A G do es n frigerant circuit is not opened within 10 minutes afterswagen k it has ot g Vol been evacuated, pressure may develop in coolanty circuit due ua db ran e to re-evaporation. Extract refrigerant again. oris tee
Remove bolts -1- and pull out receiver with dryer upwards. Note
h ut sa s
or ac
Depending on condenser, only one bolt -1- may be present.
5.5.2
Installing
First tighten bolt(s) -1- to 4.2 Nm 0.7 Nm and then tighten
securing bolt -2-.
When installing radiator, ensure that sealing strips on radiator
are properly seated.
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5.6.1
Note
Removing
Zexel air conditioner compressors have to be replaced by
Denso air conditioner compressors. Refer to technical solution (TPL) 2011410. for the 1.6 l 75 kW engine with engine code BSE. These soft ware versions are only available online via SVM (Software Versions Management) and can be flashed with the code for the repair measure.
A software update of the engine control unit is only required
94
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AG.
5.6
Removing and installing air conditioner compressor
Air conditioner service station -VAS 6007A- or later model.
Note The refrigerant circuit must be
If dirt or other contamination is in the circuit. If during the evacuation of a leak-tight refrigerant circuit the
vacuum is not maintained at the gauge (there is moisture in the refrigerant circuit and this generates vapour pressure). mally required for repairs (e.g. following an accident).
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under the following circumstances:
n AG. Volkswagen AG do es n wage ot g olks yV ua db ran se tee ri ho t or ac au purged swith refrigerant R134a s
If the refrigerant circuit has been left open for longer than nor When pressure and temperature measurements in the refrig
erant circuit indicate that there is moisture in the refrigerant circuit. erant circuit.
There is doubt about the amount of refrigerant oil in the refrig The air conditioner compressor has to be exchanged because
of internal damage (e.g. noisy or lack of power).
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.
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AG.
Notes on repair work to vehicles with air conditioning and on han dling refrigerant can be found in ELSA under Heating, ventilation, air conditioning system; Air conditioning system with refrigerant R134a Rep. Gr. 00 ; Technical data.
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The procedure for purging with refrigerant R134a is described in ELSA under Heating, ventilation, air conditioning system; Air con ditioning system with refrigerant R134a Rep. Gr. 00 Technical data; Clearing refrigerant circuit of contaminants.
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95
Golf 2004 Heating, air conditioning - Edition 02.2008 Extract refrigerant, e.g. with air conditioner service station VAS 6007A- before opening refrigerant circuit. Observe notes page 88 .

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Remove noise insulation under engine Rep. Gr. 50 . Remove front right wheel housing liner Rep. Gr. 66 . Remove poly V-belt Rep. Gr. 13 . WARNING
Remove bolts (22 Nm 1 Nm) -1- from air conditioner com pressor and separate refrigerant lines from air conditioner compressor.
96
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AG.
Golf 2004 Heating, air conditioning - Edition 02.2008 Remove hexagon bolts (25 Nm) -2- and remove air conditioner compressor. Volkswa
5.6.2
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Installing
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Ensure that dowel sleeves -3- are properly seated.
Observe remarks on installation of air conditioner compressor
page 106 .
5.7
Assembly overview - poly V-belt pulley (air conditioner compressor from Den so)
Note
This type of poly V-belt pulley is installed on 7SEU17C air
conditioner compressors.
Various types of poly V-belt pulley are installed depending on
design of air conditioner compressor and type of engine Parts catalogue .

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Removing and installing poly V-belt pulley page 99 .
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AG.
97
Golf 2004 Heating, air conditioning - Edition 02.2008 1 - Cover 2 - Retaining ring Remove carefully using a small screwdriver or long-nose pliers (be es pecially careful with the poly V-belt pulley) 3 - Guide cage 4 - Retaining ring Always renew Install correctly (flat side faces air conditioner compressor) 5 - Shim 6 - Poly V-belt pulley The poly V-belt pulley is constructed in plastic and is especially sensi tive to impact, be espe cially careful when han dling the poly V-belt pulley Various versions Parts catalogue 7 - Air conditioner compressor Various types of poly Vbelt pulley are installed depending on type of engine and country ver sion Parts catalogue Clean air conditioner compressor flange be fore fitting poly V-belt pulley
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8 - Rubber element Qty. 6 Flexible coupling between poly V-belt pulley and air compressor drive shaft, dampens vibrations and noise Lightly moisten rubber elements with, for example, tyre assembly paste or soapy solution (used as a lubricant) when installing.
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98
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5.8
Removing and installing poly V-belt pul ley (air conditioner compressor from Denso) Removing
5.8.1
Carefully remove circlip -A-.using agsmall screwdriver or longa n AG Volksw en A nose pliers (pay particular attention not G does n to damage the poly Vwage ot g olks belt pulley). d by V ua
e ho Counterhold drive shaft of air conditioner compressore-B- us or ut a ing anaopen-jaw spanner or socket from Shock absorber cset s s T10001- (depending on design of air conditioner compressor) and turn drive disc -C- along with poly V-belt pulley -D- in di rection of arrow -E- (specified torque 35 Nm).
e ris
ran t
Remove drive plate -C-.
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Remove circlip -A-. Pull off belt poly V-belt pulley -B-.
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5.8.2
Installing
Renew circlip -A-. Clean air conditioner compressor flange before fitting poly V-
belt pulley. possible.
When installing, ensure the circlip -A- is deformed as little as Install belt poly V-belt pulley -B-. Install circlip -A- correctly, chamfer -C- faces away from air conditioner compressor (flat side towards air conditioner com pressor). Insert rubber elements -D- into poly V-belt pulley -B-, as shown in figure. Note
When installing rubber elements -D- moisten lightly with, for ex ample, tyre assembly paste or soapy solution (used as a lubri cant)
AG.
Note
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99
Golf 2004 Heating, air conditioning - Edition 02.2008 Insert drive plate -C- into rubber elements -D- until it contacts drive shaft of air conditioner compressor -B-. Screw drive plate -C- onto compressor shaft -B- by turning in direction of arrow -F-. Install circlip -A-.
5.9
Removing and installing poly V-belt pul ley, Sanden air conditioner compres sor Removing Installing
5.9.1 5.9.2 5.10
Checking high-pressure safety valve on air conditioner compressor

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Function: protects refrigerant circuit against excessive pres sure. WARNING
The high-pressure safety valve releases refrigerant when the engine is running and the pressure in the refrigerant circuit is too high. Switch off engine.
Checking high-pressure safety valve on air conditioner compres sor (manufacturer Denso) The high-pressure safety valve -arrow- has operated when refrigerant oil is found in the immediate vicinity. In this case, hand over vehicle to a suitable workshop page 82 .
5.11
Expansion valve, function and removing
100
AG.
Danger of freezing injuries.
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Note
The refrigerant must be extracted beforehand, e.g. with air
The previously used service stations can still be used Volks All of the refrigerant circuit's components that have been
opened must be sealed with suitable plugs to prevent the in gress of moisture. some vehicles Rep. Gr. 21
Connecting pipe from charge air cooler must be removed on Applies only to vehicles with a protective plate before the expan sion valve. Note
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AG.
On right-hand drive vehicles, lock washers are installed instead of a clip and a nut.
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101
Golf 2004 Heating, air conditioning - Edition 02.2008 Unscrew nut -1- (6 0.9 Nm). Release clips -2- and remove protective plate -3-. Continuation for all vehicles
1 - Bolts 10 1 Nm Qty. 2 2 - Refrigerant lines on expan sion valve 3 - O-ring 13.7 mm; 2.5 mm 4 - Expansion valve Removing:
WARNING
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Extract with air conditioner serv ice station -VAS 6007A- .

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n AG. Volkswagen AG do es n wage ot g olks V ua by ran ed is tee or th or u refrigerant, ae.g. ac ss
Danger of freezing inju ries. If refrigerant circuit has not been evacuated, re frigerant will escape. Extract refrigerant be fore opening refrigerant circuit. If the refrigerant circuit is not opened within 10 minutes after it has been evacuated, pressure may develop in coolant circuit due to reevaporation. Extract re frigerant again.
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Remove screws -8- and remove expansion valve -4-.
5 - O-ring 14 mm; 1.82 mm Moisten with refrigerant oil when installing. 6 - O-ring 10.8 mm; 1.82 mm
102
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AG.
Remove bolts -1- and pull refrigerant lines -2out of expansion valve.
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Golf 2004 Heating, air conditioning - Edition 02.2008 Moisten with refrigerant oil when installing. 7 - O-ring 9.5 mm; 2.5 mm 8 - Socket head combi-bolt 5 Nm
5.11.1
Function
The expansion valve atomises incoming refrigerant and reg ulates the flow so that, depending on the heat transport, the vapour does not become a gas until it reaches the outlet of the evaporator.
5.12
Removing and installing evaporator
Remove heater and air conditioning unit page 84 . Dismantle heater and air conditioning unit: vehicles with Cli matronic page 50 , vehicles with Climatic page 31 . Dismantle evaporator housing page 52 . Pull evaporator -A- out from lower part of evaporator housing. Note Before inserting evaporator, wagen Acondensed water drain and olks check G en AG. V
wag clean if necessary. olks
V by ed Cleanisevaporator r o forehinserting. ut sa s
housing and, if
does not gu ara nte necessary, evaporator, eo ra c
be
When inserting evaporator -A- in lower part of evaporator housing and assembling the two parts of housing, ensure that seal -F- is not damaged.
Before inserting evaporator, examine seal -F- (it must be bon ded all around).
Set bracket -C- and combined seal and insulation -B- on con nection pipes of evaporator -D- and -E-. Insert evaporator -A- in lower part of evaporator housing as shown in figure. Note
After assembling parts of evaporator housing, check for proper

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seating of combined seal and insulation -B- at opening for both refrigerant lines -D- and -E-. -E- for proper seating.
Check seating of retainer -C- on both refrigerant lines -D- and If heat insulation -B- is missing or improperly installed, it may
lead to reduced performance of the air conditioning system (due to changes in the set mapped values of the expansion valve through heat radiation).
5.13
Removing and installing condenser
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Prote cted by
103
Note The refrigerant must be extracted beforehand, e.g.
The previously used service stations can still be used Volks
wagen Workshop Equipment catalogue.
All of the refrigerant circuit's components that have been
conditioner service station -VAS 6007A- .
AG. Volkswagen AG d agen oes not lksw Vo gu by ara d nte ise or eo th u air ra with a c ss
opened must be sealed with suitable plugs to prevent the in gress of moisture.
First carry out the following work: Switch off all electrical consumers. Switch off ignition. Pull out ignition key.
Extract refrigerant, e.g. with air conditioner service station VAS 6007A- . Note
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104
AG.
Prote cted by
Remove lock carrier Rep. Gr. 50 .
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Remove front bumper Rep. Gr. 63 .
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Releasing refrigerant into the environment is a punishable of fence.
Golf 2004 Heating, air conditioning - Edition 02.2008 WARNING
Remove refrigerant lines on condenser and seal. 1 - Protective screen Only on vehicles with heavy-duty equipment. Only in vehicles with condensers from manu facturer Showa. Position protective screen on 3rd rib from the bottom -arrow2 - Securing clip Qty. 8
3 - Condenser Secured with 4 bolts to radiator
Note 6 - Bolt 5 0.5 Nm 7 - Radiator 8 - Bolts Qty. 4 5 0.5 Nm Note
AG.
5 - Spacer
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4 - Sealing strip Glue top sealing strip to 6th fin row from top of condenser before instal ling Glue bottom sealing strip to 1st fin row from bottom of condenser be fore installing Glue side sealing strips to outer edge of con denser before installing
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105
Golf 2004 Heating, air conditioning - Edition 02.2008 9 - Receiver with dryer Under certain conditions, it is not necessary to renew the receiver with dryer every time that the refrigerant circuit is opened. Refer to ELSA under Heating, ventilation, air conditioning system; Air conditioning system with refrigerant R134a Rep. Gr. 00 ; Technical data; Renewing components. Removing and installing page 92
5.14
Notes on installing air conditioner com pressor Installing
5.14.1
Do not start engine until after reconnecting refrigerant circuit. After installing a new air conditioner compressor or filling with fresh refrigerant oil (e.g. after blowing out refrigerant circuit), turn compressor pulley 10 revolutions by hand before starting engine. This will prevent damage to the air conditioner com pressor. If possible, start engine only with refrigerant circuit charged.
n AG. Volkswagen AG do es n wage ot g olks Note yV ua db ran se tee ri ho t or The air conditioner compressor is driven permanently by thea au c ss poly V-belt pulley (not fitted with a magnetic clutch).
If an air conditioner compressor seizes, the overload protec
tion separates from the air conditioner compressor shaft. The seizure can normally be detected by the bulges in the poly Vbelt pulley. Another indication of a seizure is abraded rubber material around the poly V-belt pulley.
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The air conditioner compressor has an internal oil circuit to
ensure that the air conditioner compressor is not damaged when the refrigerant circuit is empty. This means that about 40 to 50 cm3 refrigerant oil remain in the air conditioner com pressor. properly assembled. If, for example, the refrigerant lines are not connected to the air conditioner compressor and the en gine is running, the compressor may heat up so much through internal warming that it will be destroyed. not activated when the refrigerant circuit is empty and the air conditioner compressor idles with the engine.
The engine may be started only when the refrigerant circuit is
Air conditioning system compressor regulating valve -N280- is If it is necessary to start engine with an empty refrigerant cir The refrigerant circuit must be fully assembled.
AG.
Prote cted by
At least of the quantity of refrigerant oil specified for this The engine speed must not exceed 2000 rpm. Run engine only as long as absolutely necessary, max.
refrigerant circuit must be in the air conditioner compressor.
10 min.
106
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cuit:
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n AG. Volkswagen AG do es n wage ot g olks yV ua db ran se tee ri ho t or engine for first time after filling ac au ss
Start engine with air conditioner compressor switched off (Econ mode) and wait until the idling speed stabilizes. Open dash panel vents. Set temperature to Lo on the operating and display unit for Climatronic air conditioning system -E87- . Now switch air conditioner compressor on (Auto mode) and allow engine to run for at least 5 minutes at idling speed.
Note the following when starting refrigerant circuit:
5.14.2
Removing evacuating and charging valve, low-pressure side and high-pres sure side
Special tools and workshop equipment required E.g. air conditioner service station -VAS 6007A- (or later mod el)
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Adapter set for service connections -T10364-
Torque wrench -V.A.G 1783-
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AG.
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107
ag Golf 2004 ksw Vol by d Heating, air conditioning - Edition 02.2008 se
Ratchet insert
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ri tho au 1/4" tool ss
-VAS
olkswagen AG en AG. V does not gu ara nte eo ra c 6234-
Note
Releasing refrigerant into the environment is a punishable of
fence.
All components of the refrigerant circuit which have been

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WARNING
Danger of freezing injuries. If refrigerant circuit has not been evacuated, refrigerant and refrigerant oil 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.
Evacuate refrigerant circuit, e.g. with air conditioner service station -VAS 6007A- (or later model) before renewing valve -2-. Unscrew valve core -2- (2.4 0.2 Nm) out of refrigerant line using suitable adapter -4-. When doing this, carefully hold valve support -1- with a suitable tool.
108
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Remove cap -3-.
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opened must be sealed with suitable plugs to prevent moisture intrusion.
AG.
6
6.1
Capacities
Refrigerant R134a
Manufacturer Denso Denso Sanden Zexel Total capacity 52525 grammes 52525 grammes 52525 grammes 52525 grammes
Air conditioner com pressor 7SEU16C 7SEU17C PXE16 DSC17E
6.2
Note
Refrigerant oil
w g The special refrigerant oil (for use with refrigerantacircuits olks
Refrigerant oil can be obtained using following part No. for Denso 7SEU16C Denso 7SEU17C Sanden PXE16 Zexel / Valeo DSC17E Type Denso 1K0 820 803 E Sanden 1K0 820 803 G Sanden 1K0 820 859 G Zexel / Valeo 1K0 820 803 H Denso 1K0 820 803 F G 052 300 A2 G 052 300 A2 G 052 154 A2 G 052 154 A2 Total capacity1) 140 cm3 10 cm3 110 cm3 10 cm3 110 cm3 10 cm3 120 cm3 + 15 cm3
olkswagen AG en AG. V does not gu y V refrigerant/ma R134a only) can no longer be obtained on bthe ara d e nte ris chine oil market. eo ho ut ra c sa Refrigerant oils from containers which have been open for a s
longer period of time are unusable.
Production period from 07.03 from 07.03
from 06.2005 from 07.03
do cu m en
Important information:
Because refrigerant oil is very hygroscopic, opened containers must be immediately closed airtight after use to stop intrusion of moisture. Because of its chemical properties, refrigerant oil must not be disposed of together with engine or gear oil.
6.2.1
Oil distribution
The oil, which is located in the sump of the air conditioner com pressor before the air conditioner system is switched on for the first time, distributes itself through the refrigerant circuit as follows:
AG.
1) This quantity of refrigerant oil is contained in a replacement air conditioner compressor and corresponds to the total capacity.
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From 11.2006
180 cm3 10 cm3
6. Capacities
109
Golf 2004 Heating, air conditioning - Edition 02.2008 Air conditioner compressor approx. 50% Condenser approx. 10% Suction hose approx. 10% Evaporator approx. 20% Receiver approx. 10%

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Service

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Heating, air conditioning

Service Department. Technical Information

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Copyright 2010 Volkswagen AG, Wolfsburg

All rights reserved. No reproduction without prior agreement from publisher.

Golf 2004 Heating, air conditioning - Edition 02.2008

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87 - Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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3.4 3.5 3.6 3.7 3.8 3.9

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ran tee or ac vent temperature

54 55 55 56 57 58 59 59 59 60 60 61 62 63 64 65 66 67 67 69 71 73 75 77 79 82 83 84 88 92 92 94 97 99 100 100 100 103 103 106 109 109 109

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Heating, n AG. Volkswagen AG do es n wage ot g olks V ua by ran ed tee ris o th or ac au ss

Golf 2004 air conditioning - Edition 02.2008

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17 - Adapter for controls Removing and installing page 7

Rep. Gr.80 - Heating

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To tion must be observed.

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Removing fresh air blower -V2Removing

Install in reverse order.

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Removing and installing dust and pollen filter Removing

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Observe installation position of dust and pollen filter.

Rep. Gr.80 - Heating

Install in reverse order.

Removing centre vents

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Golf 2004 Heating, AG. conditioning - Edition 02.2008 air Volkswagen

rrectness of i t to the co nform spec a tion h re wit in t his

Installing Removing right or left vent

Install in reverse order.

Remove compartment from dash panel.

Golf 2004 Heating, air conditioning - Edition 02.2008

Install in reverse order.

urposes, in part or in wh ole, cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng

AG. Volkswagen AG d agen oes not lksw Vo gu by ara d nte ise or eo th u ra a c ss

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Rep. Gr.80 - Heating

Install in reverse order.

Removing right footwell vent

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Heating, air conditioning - Edition 02.2008

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Install in reverse order. Note

Removing left footwell vent

Install in reverse order.

moving controls, set rotary knobs to the following positions: