Heating Air Conditioning PDF

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Workshop Manual
Golf 2004
Heating, air conditioning
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Edition 02.2008
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Service Department. Technical Information
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Service
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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AG.
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Copyright 2010 Volkswagen AG, Wolfsburg
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All rights reserved.

No reproduction without prior agreement from publisher.
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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.
K0058991220
Golf 2004
Heating, air conditioning - Edition 02.2008
Contents
80 - Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . .
AG. Volkswagen AG dair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connectors on controls
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Removing and installing
flexible
shaft
for
air
distribution
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d
ntflap
iseinstalling Bowden cable for temperature
r
Removing and
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Removing
and
installing
fresh
air
and
air
recirculation
flap
control
motor V154 . . . . . . . .
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.13
1.14
1.15
1.16
2
2.1
2.2
2.3
2.4
2.5
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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
1
1
3
3
4
4
7
8
9
10
11
12
15
16
18
18
19
23
23
24
25
26
26
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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2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
3
3.1
3.2
3.3
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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1
2
2.1
2.2
2.3
Contents
28
29
29
31
33
33
35
36
36
36
38
39
39
41
42
43
44
45
47
50
52
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54
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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
ii
Contents
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4.2
4.3
4.4
4.5
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3.23
3.24
3.25
3.26
4
4.1
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3.17
3.18
3.19
3.20
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3.12
3.13
3.14
3.15
3.16
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.10
3.11
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a Removing
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54
55
55
56
57
58
59
59
59
60
60
61
62
63
64
65
66
67
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69
71
73
75
77
79
82
83
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88
92
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94
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106
109
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109
Heating,
AG. Volkswagen AG d
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Repairing heater
1.1
Passenger compartment heating
Disconnect battery before removing components marked **

Rep. Gr. 27 .
1 - Dash panel**
2 - Centre vents
Removing vent
page 5 .
3 - Right side vent
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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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4 - Right vent
Removing vent
page 5 .
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80
Golf 2004
air conditioning - Edition 02.2008
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6 - Fresh air and air recircula

tion flap control motor -V154 Removing page 11
7 - Right footwell vent
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
1. Repairing heater
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13 For centre console air duct (to rear vents)

To remove, centre console must be removed Rep. Gr. 68 .
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14 - Air duct for right rear footwell

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02.2008
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Connecting piece
15 - Air duct for left rear footwell

16 - Securing bolt
Qty. 8
Various lengths.
17 - Adapter for controls

22 - Flexible shaft for air distribution

23 - Heater unit
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
AG.
21 - Bowden cable for temperature flap

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20 - Left footwell vent

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19 - Heat exchanger
After renewing heat exchanger, renew coolant completely
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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.
Golf 2004
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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prevent
water from entering vehicle interior, installationc posi
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1.2
Removing fresh air blower -V2-
1.2.1
Removing
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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).
Removing and installing fresh air blower

series resistor with overheating fuse N24agen
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Release catch -2-, turn fresh air blower -V2- in direction of

-arrow- and remove.
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To
tion must be observed.
Removing
WARNING
Danger of burn injuries.

The fresh air blower series resistor with overheating fuse -N24can be hot.
Before removing fresh air blower series resistor with overheat
ing fuse -N24- , let it cool off.
First carry out the following work:
1. Repairing heater
Golf 2004
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.
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Install in reverse order.
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Installing
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Removing and installing dust and pollen

filter
1.4.1
Removing
rrectness of i
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spec
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1.4
Remove footwell trim -1- on front passenger side.

Remove baffle plate -2- from heater unit page 2 .
Release cover -3- in direction of arrow.
Prote
cted
by
Observe installation position of dust and pollen filter.
1.5
Removing vents
Note
Removal and installation of rear vents (in arm rest) is described

in ELSA under General body repairs, interior; Rep. Gr. 68 ;
Removing and installing centre console (Highline version).
AG.
Note
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Remove dust and pollen filter from heater unit downwards.
Golf 2004
Heating, Aair
conditioning
Edition
02.2008
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1.5.1
Removing centre vents
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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 bolt -1-.
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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 cover -2- (only in vehicles with Climatronic).

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For vehicles with a storage compartment in dash panel, bolts are

beneath a trim mat.
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Remove central vents -2- upwards -arrow-.
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Remove compartment from dash panel.
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Remove securing bolts -1-.
Separate connectors from central vents.
1.5.2
Installing
1.5.3
Removing right or left vent
Note
The procedure for removal of vents is identical on both sides.
To avoid damage to dash panel, use a pad when levering out
components.
1. Repairing heater
Golf 2004
1.5.4
Removing
Using an appropriate tool, lever out vent -1-.

Separate connector from vent.
1.5.5
Installing
1.5.6
Removing and installing right and left

rear footwell air ducts
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The procedure for removal of footwell air ducts is identical on both

sides.
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atio
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wit
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.
Prote
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by
AG.
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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1.5.7

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1.5.8
Removing right footwell vent
rrectness of i
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spec
atio
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wit
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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Note
If vehicle has glove box cooling, ensure that refrigerant hose is

properly seated.
1.5.10
AG.
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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
Installing
1.6
Removing and installing controls for

heated and fresh air
1.6.1
Removing
Note
The control consists of two separable housings. Before re
moving controls, set rotary knobs to the following positions:
Heater control to cold

Blower to 0
Vent direction to footwell
Remove radio Rep. Gr. 91 .
1. Repairing heater
Golf 2004
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.
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1.7
Connectors on controls for heated and

fresh air
1.7.1
Pin assignment for multi-pin connectors

on back of controls for heated and fresh
air
Special tools and workshop equipment required

Test box -V.A.G 1598/42-
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Template -1598/47-2-
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Adapter cable -V.A.G 1598/47-
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Installation is performed in the reverse order. Ensure that rotary

knobs are in the same positions as when removed.
Golf 2004
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
Removing and installing flexible shaft for

air distribution
1.8.1
Removing

For vehicles without radio, remove centre dash panel trim
Rep. Gr. 68 .
Move flexible shaft to following position:
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Turn rotary switch for air distribution -1- until catch in shaft
-2- is visible in gears -3-.
rrectne
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1.8
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1. Repairing heater
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Remove controls for fresh and heated air page 7 .
Pull flexible shaft out of adapter -2-.

Note
When flexible shaft is installed, the adapter and the rotary knobs
of the controls for heated and fresh air must be aligned in a spe
cific position to one another or the system will malfunction
page 10 .
1.8.2
Checking
Flexible shaft for air distribution flap actuator:

Run fresh air blower at highest speed. If air flows out of de
froster jet in the defrost position and no air flows out of
footwell vent, then the flexible shaft is correctly installed. Oth
erwise, remove flexible shaft from adapter. Position controls
for heated and fresh air on adapter and turn rotary knob for air
distribution 1/2 turn (180). Then reconnect flexible shaft. Re
peat check.
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Removing and installing Bowden cable

for temperature flap
1.9.1
Removing
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1.9
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
rrectness of i
t to the co
nform
spec
at
i
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in t
his
Reach into centre console and release locking lug -1- by

pressing in direction of arrow.
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Golf 2004 ho
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Heating, air
conditioning - Edition 02.2008
c
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Golf 2004
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-.
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Removing and installing fresh air and air

recirculation flap control motor -V154-
1.10.1
Note
Removing
The position of the air recirculation flap must not be changed.

Remove cover -1-.
Remove fresh air and air recirculation flap control motor V154- -2- from mountings.
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1.10.2
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Separate connector from fresh air and air recirculation flap

control motor -V154- -2-.
rrectne
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Check whether temperature knob can be easily turned from

cold to warm.
Installing
1. Repairing heater
11
Golf 2004
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.
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Renewing: initiate basic setting using
d b vehicle diagnosis, test
se
i5051r
ing and information system -VAS
or successor models
tho
page 42 .
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Removing and installing heat exchanger
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1.11
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Drip tray -V.A.G 1306-
AG.
Removing
Place drip tray -V.A.G 1306- beneath engine.

WARNING
Danger of scalding injuries.

When the engine is warm, the coolant temperature may be
above 100 C. The cooling system is pressurised.
If necessary, release pressure before carrying out repairs.
12
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1.11.1
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Compressed air gun, commercially available
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Hose clamps up to 40 mm -VAS 3093-
Golf 2004
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-.
un
le
Note
Loosening the bolt -1- loosens the coolant pipe which eases the
removal of the heat exchanger.
Remove left footwell vent page 7 .
Remove bolts -A- and remove cover -B-.
There are two different versions of cover -B-.

The figure shows the version with auxiliary air heater element
ht
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-Z35- .
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Note
rrectness of i
t to the co
nform
spec
a
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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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Depending on the
ut engine type, some parts must be removed ador a
a
c
s
s
ditionally, e.g. the
charge air pipe.
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).
AG.
Cover carpet in area under heat exchanger with waterproof foil

and water absorbing paper.
Open pipe clamps -A- and pull coolant pipes out of heat ex
changer.
Remove heat exchanger from heater unit.
1. Repairing heater
13
Golf 2004
1.11.2
Installing
Installation is carried out in the reverse order. When installing,

note the following:
Check seals attached to heat exchanger -A- and -B-. Install
heat exchanger only with undamaged seals.
Note
An improperly bonded seal can roll up when heat exchanger
is pushed into heater unit.
If seal is damaged or improperly attached, cold air can flow
past heat exchanger.
Check heater unit for cleanliness through shaft -A- for heat
exchanger while heat exchanger is removed.
If necessary, remove dirt or residue of leaked coolant from
heater unit, e.g. after removing a leaking heat exchanger.
Push heat exchanger into heater unit.
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Moisten seals -1- with coolant before installing.

Set seals -1- in connection of heat exchanger.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Note
Ensure that seals are installed in the proper direction as shown
in figure.
Renew deformed pipe clamps.
Connect coolant pipes to heat exchanger.
During assembly, pipe clamps -A- must turn easily on coolant

pipes.
Pipe clamps -A- must be installed as shown in figure.
Tighten pipe clamps -A- to 2 Nm.
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AG. Volkswagen AG d
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h
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Golf 2004
air conditioning - Edition 02.2008
un
le
Tighten bolt -1- on connecting flange between heat exchanger

connections to 2 Nm.
Check that grommet -C- in bulkhead is properly seated.
rrectness of i
t to the co
nform
spec
a
t
i
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o
n in
wit
thi
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Always renew seals.
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Note
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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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After renewing heat exchanger, renew coolant completely
Rep. Gr. 19 .
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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.
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

Note
If the lever -C- to temperature flap is positioned so the the upper

bolt -A- is not accessible. Change the position of the temperature
flap at the heater and fresh air controls. On vehicles with Clima
tronic, at the control and display unit (e.g. the setting Hi).
1. Repairing heater
15
Golf 2004
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

The auxiliary air heater element -Z35- may be hot.
Before removing auxiliary air heater element -Z35- , allow it to
cool off.
Pull auxiliary air heater element -Z35- out of heater unit.
1.12.2
Installing
1.13
n AG. V
Removing and installing auxiliary air
wage
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heater element -Z35- on vehicles fromised by
r
1K-7P015629 und 1K-7B084801 autho
olkswagen AG
does
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1.13.1
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spec
atio
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wit
Checking auxiliary air heater element Z35- with peripherals
Auxiliary air heater element -Z35- peripherals (load signal for al

ternator terminal DF, low heat output relay -J359- , high heat
output relay -J360- , intake manifold temperature sender -G72- ,
coolant temperature sender -G62- ) can be read via the engine
control unit self-diagnosis.
1.13.2
Checking auxiliary air heater element Z35-
Vehicle diagnostic, testing and information system -VAS

5051B- with 100 A pick-up clamp -VAS 5051B/7-
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16
Golf 2004
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
Test procedure
G. Volkswage
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Remove left
footwell
vent page 7 .
t gu
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Remove
centre
console
trim
from
left
footwell.
o
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au
or
a
Low heating output: approx. 30 amps

High heating output: approx. 80 amps
1.13.5
Removing
ht
rig
py
Co
t.
Note
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Medium heating output: approx. 60 amps
thi
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hole
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f
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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- .
Prote
cted
by
c
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rig
ht
.
C
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yi
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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Disconnect the battery Rep. Gr. 27 .

Remove bolts -A- from cover -B-.
Caution
Danger of short circuit.

Disconnect battery before performing repair work.
1. Repairing heater
17
Golf 2004
Unscrew nut -1- (9 1 Nm).
Release connector strip catch -arrow-.
WARNING

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
Checking ventilation
Note
The stale air escapes via ventilation openings
compartment trim.
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l purpos
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ings must not be covered.
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If the ventilation is to function properly, the ventilation open
The ventilation frames are located in the rear side panels be
1.14.1
Checking
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
hind the bumper.
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.
c
o
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.
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yi
Remove plenum chamber cover Rep. Gr. 64 .
18
Prote
cted
by
Removing
AG.
1.15.1
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Removing and installing air intake

screen
thi
sd
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1.15
ht
rig
py
Co
t.
Note installation position.
Golf 2004
Remove cover -1- from plenum chamber.
Note
On vehicles with Climatronic from week 45/2007, a retainer
with an air quality sensor -G238- is fitted on the air intake grille.
Function of air quality sensor -G238- page 56 .
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Prote
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by
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Installing
c
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1.15.2
ht
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Co
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fo
ng
Unscrew collar nuts -arrows- (2.5 0.4 Nm) and remove air
intake grille upwards.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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en
ole,
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is n
mer
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or
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a
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p
un
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Release air quality sensor

retainer.
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-G238- -1d and turn to right out of
ran
ir se
tee
o
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or
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ac
a
ss
Note
Seal must seat properly on air intake screen.

Assembly sequence:
Adjust air intake grille on metal collar.
Hold air intake grille and first tighten lateral collar nuts
(2.5 0.4 Nm), then tighten middle collar nut.
1.16
Removing and installing heater unit
1. Repairing heater
19
Golf 2004
AG. Volkswagen AG d
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1.16.1
Removing
Note
To improve access, depending on engine version, additional com

ponents must be removed e.g. engine cover Rep. Gr. 10 .
Remove dash panel Rep. Gr. 70 .
Remove right and left rear footwell air ducts page 6 .
Prote
cted
by
20
AG.

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WARNING
ht
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Co
t.
Mark coolant hoses -1-
r
fo
ng
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
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p
ility
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un
le
Golf 2004
-VAS 3093- and disconnect coolant hoses
to heat
olkswexchanger.
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Push a piece of hose -A- onto bupper
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changer.
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Hold a container -B- under
lower connection -C-.
ss
Cover carpet in vehicle interior with waterproof foil and ab

sorbent paper.
Note
During removal, note lengths and locations of bolts for later installation.
AG.
Removing:
agen
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4 - Heater unit
Prote
cted
by c
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3 - Cable retainer
ht
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py
Co
t.
2 - Bolts
4,5 0.7 Nm
r
fo
ng
1 - Bolt
4,5 0.7 Nm
Lower right on cable re
tainer to heater unit,
near bulkhead
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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c
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Carefully blow remaining coolant out of heat exchanger using

a compressed air pistol at heat exchanger connection.
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-.

-10- and remove sup
ports -9- and -11-.

-14- and remove retain
er -13-.
Remove bolts -2- and

-1- from cable retainer
-3-.
Note
Remove heater unit.

1. Repairing heater
21
Golf 2004
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
Fill with coolant Rep. Gr. 19 .
5 - Bracket
un
le
pe
rm
itte
d
Seal between heater unit and engine compartment

Note
Observe position of seal -A- during installation.
22
do
c
um
en
14 - Bolts
9 1.3 Nm
r
te o
iva
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fo
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n
13 - Bracket
Prote
cted
by
12 - Bolts
9 1.3 Nm
AG.
11 - Left support
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10 - Bolts
20 3 Nm
rrectness of i
t to the co
nform
spec
a
t
i
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o
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wit
thi
s
9 - Right support
es, in part or in w
l purpos
hole
ercia
, is n
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com
7 - Mounting plate
8 - Bolts
9 1.3 Nm
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6 - Bolts
8 1 Nm
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Have second mechanic guide both coolant pipes to heat exchanger through seal during installation of
heater unit page 22 .
ht
rig
py
Co
t.
Golf 2004
Dismantling and assembling heater

unit
2.1
Assembly overview heater unit
1 - Temperature flap actuator

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)
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
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- Fresh air blower
ir se-V2tee
o
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or
u and installing
ac
a
Removing
ss
6 - Heater unit
7
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
8 - Fresh air blower series re

sistor with overheating fuse N24 Removing and installing
page 3
10 - Cover
For dust and pollen filter.
11 - Heat exchanger
12 - Heat exchanger trim
13 - Auxiliary air heater element -Z35Vehicles up to 1K-7P015628 and 1K-7B084800
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
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erm
o
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t
a
itte
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ility
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page 3
With auxiliary air heater control unit -J604- .

components.
2. Dismantling and assembling heater unit
23
ht
rig
py
Co
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Prote
cted
by
c
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.
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Golf 2004
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.
14 - Air distribution housing
15 - Air distribution flap actuator
2.2
Removing and installing air distribution

housing
2.2.1
Removing
AG.
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Prote
cted
by
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rig
ht
.
C
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24
ht
rig
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Co
t.
Separate all available connectors from air distribution housing.
do
c
um
en
Remove heater unit page 19 .
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
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AG. Volkswagen AG d
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Golf 2004
AG. Volkswagen AG d
genconditioning
aair
oes 02.2008
Heating,
Edition
w
s
n
lk
ility
ab
y li
an
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ce
Remove air distribution housing -1- from heater unit -2-.
Installing
Dismantling and assembling heater unit
2.3.1
Dismantling
r
fo
ng
2.3
ht
rig
py
Co
t.
2.2.2
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
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p
Remove bolts -arrows- (1.4 Nm).
un
le
Remove heat exchanger together with coolant

page 12 .
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Prote
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by c
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C
op
yi
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.

25
Removing and installing air distribution

flap actuator
2.4.1
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
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g
n
2.4
ility
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AG. Volkswagen AG d
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Golf 2004
e
nte
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ut - Edition 02.2008
ra
a
c
s
s
Removing

Unclip flexible shaft from adapter for controls page 9 .
Remove bolts -1- and remove air distribution flap actuator.
Position air distribution flap actuator and tighten bolts -1-.
AG.
Note
After installation, check operation of air distribution flap

page 9 .
2.5
Removing and installing temperature

flap actuator
2.5.1
Removing

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
agen
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Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Arrows on gears must align.
ht
rig
py
Co
t.
Installing
do
c
um
en
2.4.2
Golf 2004
Note
After installation, check operation of temperature flap. Tempera

ture knob of control for heated and fresh air must move freely and
without jerking from cold position to warm position.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
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erm
o
e
t
a
itte
riv
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or
nl
f
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g
n
ility
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do
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ht
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27
AG.
Prote
cted
by
c
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un
le
Notes on repair work to vehicles with

air conditioning and on handling re
frigerant
Note
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
Air conditioning system
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
AG.
Do not kink or severely bend refrigerant lines.
There is a film in the refrigerant lines which can be destroyed.
agen
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by
Prote
cted
by c
o
p
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gh
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C
op
yi
Caution
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
ht
rig
py
Co
t.
r
fo
ng
cles with air conditioning can be found in ELSA under Heating,

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
87
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
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not
l
o
V
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Golf 2004
by
ara
d
e
nte
s
i
r
Heating, air conditioningtho- Edition 02.2008
eo
u
ra
a
c
s
s
Golf 2004
Air conditioning system with manual

controls Climatic
2.1
Air conditioning and heating - passenger

compartment
Note
Rep. Gr. 27 .
olkswagen AG
en AG. V
does
wag the type and quantity
A label on the lock carrier indicates
nof
o
olks
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2 - Centre vents
page 5
3 - Right side vent
4 - Right vent
page 5
r
fo
ng
ht
rig
py
Co
t.
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- .
page 33
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
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i
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p
ility
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1 - Dash panel**
un
le
refrigerant used.
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AG.
Prote
cted
by
c
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p
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C
op
yi
6 - Air recirculation flap control motor -V113 Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
Renewing: initiate basic settings using vehicle diagnosis, testing and information system -VAS 5051- or
successor model page 42
2. Air conditioning system with manual controls Climatic
29
Golf 2004
8 - Fresh air blower -V2 Removing and installing page 3
AG. Volkswagen AG d
agen
oes
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9 - Fresh air blower series resistor with overheating
Vol fuse -N24by
d
Removing and installing page 3 rise
tho
au
s
s
11 - Evaporator temperature sensor -G308- or evaporator output temperature sender -G263 Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
Note

12 - Sealing cap
AG.
Prote
cted
by
17 - Securing bolt
Qty. 8
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ht
rig
py
Co
t.

do
c
um
en
14 - Connecting piece
For centre console air duct.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
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or
nl
f
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ility
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Removing page 2
not
gu
ara
nte
eo
ra
c
18 - Adapter for controls

19 - Auxiliary air heater element -Z35 Installed only in vehicles with diesel engines without supplementary heater.
Vehicles up to 1K-7P015628 and 1K-7B084800
With auxiliary air heater control unit -J604- .
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
22 - Temperature flap control motor -V68 Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
30
Golf 2004
olkswagen AG
en AG. V
ag
ksw
does
not
gu
ara
nte
eo
ra
c
ol
23 - Flexible shaft
yV
db
e
ris
Removing and installing hopage
9
t
au
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
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ce
ss sender -G19224 - Footwell vent temperature

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
25 - Heater and air conditioning unit

26 - Left side vent
27 - Centre vent temperature sender -G191 Removing and installing page 39
Dismantling and assembling heater and air conditioner unit Climatic
do
c
um
en
agen
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Vo
by
AG.
1 - Temperature flap control

motor -V68 Checking: vehicle diag
nostic, testing and infor
mation system -VAS
page 36
model page 42
ht
rig
py
Co
t.
2.2
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
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
mation system -VAS
page 36
model page 42
With air recirculation flap
31
Golf 2004
7 - Upper part of evaporator housing
Dismantling and assembling evaporator housing page 52
8 - Lower part of evaporator housing
Dismantling and assembling evaporator housing page
52
e
wage
9 - Evaporator
s no
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rrectness of i
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at
i
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in t
his
Note
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
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
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16 - Cover
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17 - Heat exchanger
19 - Auxiliary air heater element -Z35 Only in vehicles with diesel engines without supplementary heater.
components.
Installation position of connections for glove compartment cooling
2 - Valve
32
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Removing and installing heating and air

conditioning controls, Climatic with air
conditioning system control unit -J301-
2.3.1
Removing
rrectness of i
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nf
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spec
atio
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wit
2.3
Note
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or Golf 2004
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Heating, air conditioning - Edition
02.2008
ss
The control consists of two separable housings. Before re
moving controls, set rotary knobs to the following positions:
Heater control to cold

Blower to 0
AG.
Remove bolts -2- (4.2 x 45) and -3- (4.2 x 16) and remove the
controls -1- from centre console.
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For vehicles without radio, remove centre dash panel trim.

Rep. Gr. 68 .
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Vent direction to footwell
Prote
cted
by
Specified torque for bolts -2- and -3-: 1.5 0.2 Nm.
Release connector catch -A- by pulling in direction of arrow
-1-.
Push connector catch -B- to connector -arrow 2- and remove
connector -C-.
Release connector catch -D- and remove connector -D-.
2.3.2
Installing
Installation is performed in the reverse order. Ensure that rotary

knobs are in the same positions as when removed.
2.4
Connectors on controls for heating and

air conditioning Climatic
2.4.1

on back of controls for heating and air
conditioning Climatic
33
Golf 2004
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)
. Volkswagen AG
15 - Terminal 75, seat heatingwa(optional)
gen AG
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16 - Air conditioning system
compressor regulating valve g-N280ra
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19 - Terminal 30A
au
ss
16-pin connector, T16e in current flow diagram

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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34
rrectness of i
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1 - Temperature flap control motor -V68- , warm
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20 - Terminal 31
Golf 2004
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
2.5.1
Removing
Remove radio Rep. Gr.
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For vehicles without radio,

Rep. Gr. 68 .
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remove
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Turn rotary switch for air distribution -1- until catch in shaft
-2- is visible in gears -3-.
Remove heating and air conditioning controls, Climatic
page 33 .
Carefully pull out adapter for controls.
Press in locking lug -arrow- of flexible shaft and pull out flexible
shaft.
r
fo
ng
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.
AG.
Prote
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Checking
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2.5.2
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Note
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Move flexible shaft to following position:
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.
35
Golf 2004
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.
Removing and installing air recirculation

flap control motor -V113-
2.7.1
Removing
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

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-.
Installing
Prote
cted
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Note
After installation, check operation of air recirculation flap.

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

page 42 .
2.8
Removing and installing temperature

2.8.1
Removing

Remove left footwell trim Rep. Gr. 68 .
36
ht
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2.7.2
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2.7
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Golf 2004
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.
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-.
Note
Installing
Optimised control motors are marked with an X.

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To ease assembly, use an approx. 2 mm shorter oval-head screw

-N 103 254 01- .
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2.8.2
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atio
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wit
Mark connector -C- to control motor (danger of interchanging

with other connectors of same construction).
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37
Prote
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Golf 2004
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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.


page 42 .
2.9.1
Removing
r
fo
ng
Removing and installing footwell vent

temperature sender -G192-
Prote
cted
by

Remove bolts -1- and -3- (9 1.3 Nm).
38
AG.

97 .
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2.9
rrectne
s
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form
spec
atio
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Cut off bracket -1- from old temperature flap control motor V68- , e.g. using side cutting pliers.
Golf 2004
Remove bracket -2-.
Pull connector off footwell vent temperature sender -G192-1-.
Turn footwell vent temperature sender -G192- 90 and remove
it from housing.
2.9.2
Installing
2.10
Removing and installing centre vent

2.10.1
Removing
Remove left dash panel cover Rep. Gr. 70 .

Pull connector off centre vent temperature sender -G191-1-.
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2.10.2
rrectness of i
t to the co
nform
spec
a
t
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wit
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Turn centre vent temperature sender -G191- -2- 90 in

-direction of arrow- and remove from dash panel.
Installing
2.11
2.11.1
Ambient temperature sensor -G17Removing
Pull centre grille out of fasteners in front bumper cover Rep.

Gr. 63 .
do
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Unclip ambient temperature sensor -G17- -1- from retainer

and separate electrical connector.
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Golf 2004
2.11.2
Installing
Installation is carried out in the reverse order. When installing,

note the following:
Note
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40
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rrectness of i
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nform
spec
a
t
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Ensure proper seating of electrical connection to prevent intrusion

of splashed water.
Golf 2004
Volkswaautomat
gen AG
AG.with
Air conditioning system
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Switch from C to F and vice versa. Press and hold AUTO
rrectness of i
t to the co
nform
spec
a
t
i
h re
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wit
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button and then press ECON or AC button.
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Note
ri
ho
ut
a
ss
Pressing the AUTO button will cancel all settings which deviate
from automatic operation.
Deviations from automatic operation appropriate operating
instructions.
Vehicles up to calendar week 21/2007: if ECON button is acti
ECON button deactivated, air conditioner compressor switched

ht
rig
py
Co
t.
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.
do
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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.
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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.
AC button deactivated, air conditioner compressor will be
switched to almost zero delivery. Depending on vehicle equip

ment, the auxiliary air heater element -Z35- or the auxiliary
heater (in supplementary heater function) will remain on. If the
auxiliary heater is activated by the driver, it will remain on. The
respective surrounding conditions have to be fulfilled or the
activation signals must have been delivered. The heating and
ventilation operations continue to be controlled electronically.
OFF button is activated. Climatronic is out of operation. There
is no heating and ventilation.
OFF button is deactivated. Climatronic is in operation.
3. Air conditioning system with automatic regulation Climatronic
41
Golf 2004
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.
Checking cooling output.
AG.
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42
do
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a
t
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Read data block.
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Basic settings
Golf 2004
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.
es, in part or in w
l purpos
hole
ercia
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2 - Air recirculation button

Pressing air recircula
tion button prevents pol
luted air from entering
interior.
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spec
atio
h re
n in
wit
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.
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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.
Prote
cted
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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
43
Golf 2004
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
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spec
at
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in t
his
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- .
AG.
44
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Installing
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3.3.2
do
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l purpos
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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.
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Golf 2004
3.4
Connectors on Climatronic control unit J255-
3.4.1

A, B and C on back of Climatronic con
trol unit -J255-

Test box -V.A.G 1598/42-
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Adapter cable -V.A.G 1598/47-
ole,
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Template -1598/47-220-pin connector, T20c in current flow diagram -A-
2 - High-pressure sender -G65-
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
1 - Sunlight penetration photosensor 2 -G134- or sunlight pene

tration photosensor -G107- , signal
3 - Sunlight penetration photosensor 2 -G134- or sunlight pene
tration photosensor -G107- , signal
4 - From calendar week 45/2007: air quality sensor -G238- , signal

5 - CAN, high
6 - CAN, low
9 - + 5 V for sunlight penetration photosensor 2 -G134- or sunlight

penetration photosensor -G10710 - Heated driver seat control unit -J131- (optional)
11 - Heated front passenger seat control unit -J132- (optional)

r
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13 - Left vent temperature sender -G15014 - Right vent temperature sender -G151-
ht
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12 - Terminal 75 (optional)
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Prote
cted
by
16 - Positive connection (15a) or positive connection (30a) for

vehicles with supplementary heating and air quality sensor G238AG.
17 - 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
Golf 2004
un
le
ility
ab
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es n
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16-pin connector, T16c in current flow diagram -ByV
ua
b
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ran
ir se
tee
o
1 - + 5V for control motor
h
t
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ac
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s
s
2 - Potentiometer for left temperature flap control motor -G220pe
rm
itte
d
3 - Potentiometer for right temperature flap control motor -G221es, in part or in w

l purpos
hole
ercia
, is n
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ot
com
4 - Potentiometer for defroster flap control motor -G135-
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
5 - 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 -G262r
te o
iva
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fo
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n
3 - Defroster flap control motor -V107- , closed

4 - Defroster flap control motor -V107- , open
5 - Central flap control motor -V70- , chest
6 - Central flap control motor -V70- , footwell
7 - Vehicles up to calendar week 17/2007: air recirculation flap
control motor -V113- , recirculation actuated. From calendar week
18/2007: air recirculation flap control motor -V113- was discon
tinued.
8 - Vehicles up to calendar week 17/2007: air recirculation flap
control motor -V113- , fresh air actuated. From calendar week
18/2007: air recirculation flap control motor -V113- was discon
tinued.
9 - Vehicles up to calendar week 17/2007: air flow flap control
motor -V71- open. From calendar week 18/2007: control motor
for fresh air and air recirculation flap and air flow flap -V425- (air
recirculation/partial air recirculation)
10 - Vehicles up to calendar week 17/2007: air flow flap control
motor -V71- closed. From calendar week 18/2007: control motor
for fresh air and air recirculation flap and air flow flap -V425- (air
recirculation/increased flow)
11 - Right temperature flap control motor -V159- , cold
12 - Right temperature flap control motor -V159- , warm
15 - Fresh air blower -V2- (PWM actuated)
16 - Fresh air blower -V2- , feedback signal
46
Prote
cted
by
2 - Left temperature flap control motor -V158- , warm
AG.
1 - Left temperature flap control motor -V158- , cold
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16-pin connector, T16d in current flow diagram -C-
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14 - Signal earth, potentiometer
ht
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11 - Evaporator temperature sensor -G308- or evaporator output

do
c
um
en
10 - Fresh air intake duct temperature sensor -G89- only installed

up to December 2005
Golf 2004
3.5
Climatronic - passenger compartment

Note
Rep. Gr. 27 .
A label indicates the type and quantity of refrigerant used.

1 - Dash panel**
AG. Volkswagen AG d
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Rep. Gr.
70
k
no
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t to the co
nf
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spec
atio
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wit
es, in part or in w
l purpos
hole
ercia
, is n
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2 - Sunlight
ise penetration photo
or
h
t
sensorau-G107- or sunlight pen
etration
ss photosensor 2 -G134 Checking: vehicle diag
mation system -VAS
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
page 59
4 - Right side vent
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6 - Right vent temperature

sender -G151 Checking: vehicle diag
mation system -VAS
page 58
ht
rig
py
Co
t.
5 - Vent
page 5
thi
sd
o
cu
m
en
3 - Centre vents
page 5
Prote
cted
by
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)
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
47
Golf 2004
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
10 - Fresh air intake duct temperature sensor -G89 Only installed in vehicles up to 12.05
Function: temperature sensor controls temperature flap and fresh air blower, depending on temperature
To dismantle, remove dash panel Rep. Gr. 70
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
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gen AG
page 3 n AG does n
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Removing and installing fresh air
ed blower control unit -J126- page 53ra
13 - Connector
es, in part or in w
l purpos
hole
ercia
, is n
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ot p
o
c
erm
or
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t
a
itte
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f
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ng
rrectness of i
t to the co
nf
o
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m
spec
atio
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n in
wit
15 - Sealing cap
ility
ab
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Removing page 2
nte
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tho
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ss

17 - Connection for centre console air duct (optional)
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Note
thi
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Prote
cted
by
21 - Right temperature flap control motor -V159 Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
AG.
22 - Auxiliary air heater element -Z35 Installed only in vehicles with diesel engines without auxiliary coolant heater.
48
ility
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ce
es, in part or in w
l purpos
hole
ercia
, is n
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erm
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a
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Golf 2004
AG. Volkswagen AG d
agen
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Heating,
air
conditioning
Edition
02.2008
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ris with vehicle diagnostic, testing and information
Checking:
system -VAS 5051- (or later model), under
eo
ho
ut ventilation, air conditioning; Systems capable
r aof self-diagnosis; Auxiliary heating; Electrical
Heating,
a
c
s
s
components.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
23 - Heat exchanger
24 - Central flap control motor -V70 Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
do
c
um
en
26 - Left temperature flap control motor -V158 Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
27 - Left footwell vent temperature sender -G261 Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
Removing page 54
ht
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py
Co
t.
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Prote
cted
by
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rig
ht
.
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28 - Defroster flap control motor -V107 Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
AG.
29 - Heater and air conditioning unit

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)
49
Golf 2004
3.6
Dismantling and assembling heater and air conditioner unit Climatronic
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
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d
p
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fo
ng
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
2 - Left temperature flap con

trol motor -V158 Checking: vehicle diag
mation system -VAS
page 64
model page 42
ht
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Co
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ility
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1 - Central flap control motor V70 Checking: vehicle diag

AG. Volkswagen AG d
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b
ara
mation system -VAS
d
e
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ris
5051- (or laterhomodel)
eo
t
u
ra
c
Removing sand
s a installing
page 66
model page 42
c
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p
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C
op
yi
3 - Defroster flap control motor

-V107 Checking: vehicle diag
mation system -VAS
page 63
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AG.
Prote
cted
by
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
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)
50
Golf 2004
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
n AGand
n AG. Volkswageflap
Function: temperature sensor controls
does fresh air blower, depending on temperature
agetemperature
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To dismantle, remove dash dpanel
Rep. Gr. 70
b
ar
e
ris
un
le
pe
rm
itte
d
12 - Lower part of evaporator housing

Dismantling and assembling evaporator housing page 52
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
13 - Evaporator
an
tee
or
ac
ility
ab
y li
an
pt
ce
ho
11 - Upper part of evaporatoruthousing
a
s
s
Dismantling and assembling
evaporator housing page 52
Note

15 - Connections for glove box cooling
r
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fo
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um
en
16 - Refrigerant hose for glove compartment cooling

Installation position of connections for glove compartment cooling page 52
17 - Fresh air blower -V2- with fresh air blower control unit -J126 Vehicles as of 11.05; fresh air blower control unit -J126- can be renew individually
Removing and installing fresh air blower -V2- page 3
Removing and installing fresh air blower control unit -J126- page 53
ht
rig
py
Co
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AG.
Prote
cted
by c
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19 - Cover
20 - Heat exchanger
21 - Right temperature flap control motor -V159 Checking: vehicle diagnostic, testing and information system -VAS 5051- (or later model)
23 - Auxiliary air heater element -Z35 Installed only in vehicles with diesel engines with no supplementary heater
51
Golf 2004
components.
Removing and installing page 15 .
Installation position of connections for glove compartment cooling
2 - Valve
Remove heating and air conditioning unit page 84 .
AG.
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Prote
cted
by
c
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rig
ht
.
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52
ht
rig
py
Co
t.
r
fo
ng
Separate air distribution housing/evaporator housing from

heater and air conditioning unit page 24 .
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
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o
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erm
or
e
t
a
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v
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p
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le
Assembly overview - evaporator hous

ing
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3.7
AG. Volkswagen AG d
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is
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h
ut
ra
a
c
s
s
Golf 2004
1 - Lower part of evaporator
housing
Dismantling and assem
bling page 25
2 - Evaporator
Check insulation. It
must be complete.
page 103
3 - Clip
AG. Volkswagen AG d
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l purpos
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f
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agen
4 - Upper part of evaporator
ksw
Vol
housing
y
b
ed
ris
Dismantling and assem
o
h
t
au
bling page 25
ss
5 - Bolt
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
6 - Sealing and insulation

Heat insulation for ex
pansion valve.
page 103
7 - Bracket
page 103
Removing
agen
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3.8.1
ht
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py
Co
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control unit -J126-
thi
sd
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en
3.8
AG.
Prote
cted
by
Remove fresh air blower -V2- page 3 .

Disconnect connector -1- to fresh air blower -V2- .
Remove bolts -arrows-.
3.8.2
Installing
53
Golf 2004
3.9
Removing and installing left footwell

vent temperature sender -G261-
3.9.1
Removing

Remove retainer -2-.
Pull connector off left footwell vent temperature sender -G261-1-.

Turn left footwell vent temperature sender -G261- -1- 90 and
remove it from housing.
3.9.2
Installing
AG. Volkswagen AG d
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s
Removing and installing right footwell

vent temperature sender -G262-
ility
ab
y li
an
pt
ce
3.10.1
Removing
For better illustration, right footwell vent temperature sender G262- is shown with dash panel removed. The dash panel need
not be removed.
agen
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by
AG.
Prote
cted
by
c
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ht
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Co
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54
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Note
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
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o
nl
f
e
ng
3.10
Golf 2004
Pull connector off right footwell vent temperature sender G262- -1-.
Turn right footwell vent temperature sender -G262- -1- 90 and
remove it from housing.
3.10.2
Installing

lkswagen AG
n AG. Voevaporator
does
wage
s
k
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ysensor
temperature
-G308or
evapora
b
ara
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e
nte
ris
o
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tor output
h temperature sender -G263t
u
r
a
ss
ac
ility
ab
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an
pt
ce
Removing
Remove right footwell trim -1-.
Pull connector off evaporator temperature sensor -G308- or

evaporator output temperature sender -G263- -1-.
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Prote
cted
by
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3.11.2
ht
rig
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Co
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Turn evaporator temperature sensor -G308- or evaporator

output temperature sender -G263- in -direction of arrow- and
pull it out.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
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um
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ole,
cial p
is n
mer
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o
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erm
or
e
t
a
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v
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p
3.11.1
un
le
3.11
Installing
3.12
Ambient temperature sensor -G17-
3.12.1
Removing
Pull centre grille out of fasteners in front bumper cover Rep.

Gr. 63 .
55
Golf 2004
Unclip ambient temperature sensor -G17- from retainer and
separate electrical connector.
3.12.2
Installing
Note
Ensure proper seating of electrical connection to prevent intrusion

of splashed water.
3.13
Function of air quality sensor -G238-
The air quality sensor detects noxious substances in the am

bient air (primarily petrol and/or diesel fumes).
The Climatronic control unit -J255- evaluates the signal from
the air quality sensor -G238- . The air conditioning system is
actuated depending on the degree and manner of ambient air
pollution.
At an ambient temperature higher than approx. +2 C, air recir
AG. Volkswagen AG d
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culation is actuated even when there is a minimal increase in
ksw
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noxious substances in the ambient air.
ar
db
an
tee
or
ac
e
ris
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.
r
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Prote
cted
by
AG.
56
agen
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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
ht
rig
py
Co
t.
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.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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ole,
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is n
mer
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a
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v
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ho
At an ambient temperature between approx. +2 C andutapprox.
sa
-5 C, air recirculation is not actuated until there is a sstrong
in
crease in noxious substances in the ambient air. The compressor
is also switched on at the same time.
Golf 2004
level of pollution. If a series of pollution peaks occur, the air
conditioning system may.operate
a longer period of time
Volkswageover
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in air recirculation
amode.
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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.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
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.
r
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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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A certainiseamount
of time is required for repositioning
nte of the air
r
o
eo
conditioning
system
flaps.
To
prevent
noxious
substances
h
t
u
ra
a entering the passenger compartment while the flaps
from
are
c
s
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.
c
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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- .
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AG.
Prote
cted
by
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.
3.14
Removing and installing air quality sen

sor -G238Note
The air quality sensor -G238- is installed on the air intake grille
in the front right (from the driver's perspective) of the plenum

chamber.
The air quality sensor -G238- is a highly sensitive electronic
component which direct contact with solvents, fuels and cer

tain chemical compositions could damage beyond repair.
Do not install a sensor that has been kept, for example, in a
tool box.
Do not place a removed sensor in an area where it can come
into contact with solvents, fuels and certain chemical com

pounds (fluids or vapours).
3.14.1
Removing
Remove plenum chamber cover Rep. Gr. 64 .
57
Golf 2004
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Separate connector on air quality sensor -G238- .
Removing left vent temperature sender

-G150- and right vent temperature send
er -G151Prote
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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
AG.
3.15
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Installing
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3.14.2
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Release air quality sensor -G238- -1- and turn out of retainer
on air intake grille.
rrectne
s
s
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i
t to the co
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form
spec
atio
h re
n
wit
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Remove cover -1- from plenum chamber.
Golf 2004
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.
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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.

r
fo
ng
Renewing control motors for air condi

tioning regulation
AG.
Vehicle diagnosis, testing and information system -VAS 5051or successor models.
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3.18
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3.17
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Pull connector off sunlight penetration photosensor.

Switch off all electrical consumers.
Switch off ignition.
Pull out ignition key.
59
Golf 2004
Heating, air conditioning - Edition 02.2008 AG. Volkswagen
AG do
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3.19.1
Removing
pe
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Removing and installing air recirculation

ility
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3.19
es n
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or
ac
rrectness of i
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a
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com

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).
AG.
Prote
cted
by

Note
After installation, check operation of air recirculation flap.

page 42 .
3.20
Removing and installing air flow flap

control motor -V71- for vehicles up to
calendar week 17/2007
3.20.1
Removing

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

Remove cover -1-.
60
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Installing
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3.19.2
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Remove control motor -A- from intake duct.
Golf 2004
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.

es, in part or in w
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hole
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com
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
3.21.1
Removing

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.
do
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Remove bolts -1- (1.4 Nm).
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

page 42 .
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61
Prote
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by c
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Golf 2004
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 .
Removing and installing setting unit for

fresh air and air recirculation flap and air
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Removing
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3.22.1
un
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3.22
pe
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d
Remove control motor for fresh air and air recirculation flap
and air flow flap -V425- page 61 .
rrectness of i
t to the co
nform
spec
a
t
i
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wit
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Release catches -arrows- from adjusting lever -1-.

Remove adjusting levers from cable cam.
AG.
62
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.
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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.
do
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Note
Installing
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3.22.2
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Pull off cable cam -2- from air intake housing.
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Note
rrectness of i
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spec
atio
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wit
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Push cable cam -1- onto air intake housing.
Golf 2004
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.
Removing and installing defroster flap

control motor -V107-
3.23.1
Removing
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3.23
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Prote
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Remove bracket -2-.

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

Note
After installation, check operation of defroster flap.

page 42 .
63
Golf 2004
3.24
Removing and installing left tempera

ture flap control motor -V158-
3.24.1
Removing

Remove centre console trim from left footwell.
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.
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or
(danger ofau interchanging
ac
ss
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Mark connector -C- to control motor

es, in part or in w
l purpos
hole
ercia
, is n
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com
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Remove cover -A-.
pe
rm
itte
d
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-.
3.24.2
Note
Installing
AG.
Prote
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64
ht
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To ease assembly, use an approx. 2 mm shorter oval-head screw

-N 103 254 01- .
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Optimised control motors are marked with an X.
Golf 2004
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.

page 42 .
3.25
Removing and installing right tempera

ture flap control motor -V159-
3.25.1
Removing
Remove glove compartment Rep.
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Gr.s a68 .
c
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Remove right footwell vent page 7 .
Separate connector on right temperature flap control motor V159- .
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
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- .
Installing
After installation, check operation of right temperature flap.

c
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page 42 .
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Note
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3.25.2
AG.
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65
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AG. Volkswagen AG d
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Golf 2004
nte
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Heating, air conditioning - aEdition
02.2008
ut
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Removing and installing central flap

control motor -V70Removing

Separate connector on central flap control motor -V70- .
Prote
cted
by
After installation, check operation of central flap.


page 42 .
66
AG.
Note
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Installing
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3.26.2
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Unscrew securing bolts -1- (1.4 Nm) and remove central flap
control motor -V70- .
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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3.26.1
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3.26
Golf 2004
Removing and installing ancillary

bracket for air conditioner compres
sor
4.1
Engine codes: AZV, BDK, BJB, BKC,

BKD, BLS, BMM, BMN, BRM, BRU,
BVB, BXE, BXF and BXJ

Torque wrench -V.A.G 1331/- (550 Nm)
es, in part or in w
l purpos
hole
ercia
, is n
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erm
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rrectness of i
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spec
at
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Note
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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
67
Golf 2004
1 - Hexagon bolt M1065
45 Nm
45 Nm
45 Nm
4 - Hexagon bolt M10x45
45 Nm
45 Nm
45 Nm
Qty. 3
25 Nm
8 - Ancillary bracket for alter
nator and air conditioner com
pressor
Number on ancillary unit
bracket -03G 903 143 A-
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Tighten bolts (positions -1--6-) one after the other
rrectness of i
t to the co
nform
spec
a
t
i
h re
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n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
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com
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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:
10 - Dowel sleeves
Qty. 2
Ensure proper seating between ancillary unit bracket and engine block.
AG.
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68
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11 - Air conditioner compressor

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9 - Dowel sleeves
Qty. 2
Ensure proper seating between ancillary unit bracket and air conditioner compressor
Golf 2004
Securing air conditioner compressor to body
If compressor is removed without opening refrigerant circuit, it
should be secured to body using suitable material, for example,
welding wire.
When doing this, ensure refrigerant hoses on air conditioner com
pressor are not stressed.
Note
When installing poly V-belt, ensure that it is correctly seated
on poly V-belt pulley.
Finally, place poly V-belt over pulley of air conditioner com
pressor.
Poly V-belt routing

1 - Tensioning roller
2 - Poly V-belt pulley for alternator
3 - Poly V-belt pulley for air conditioner compressor
4 - Poly V-belt
Engine codes: BCA, BUD
Prote
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by c
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AG.
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Note
r
fo
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rrectne
s
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i
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form
spec
atio
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wit
i
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4.2
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5 - Poly V-belt pulley for crankshaft
69
Golf 2004
50 Nm
Qty. 2
pressor
Removing

compressor and re
wire) page 70 .

-3- and remove ancillary
bracket from cylinder
block.
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page 94
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

25 Nm
6 - Dowel sleeves
Qty. 2
welding wire.
Note
pressor.
70
do
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50 Nm
Qty. 2
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hole
ercia
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Remove alternator
Rep. Gr. 27 .
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bracket -036 260 885-
Golf 2004
Poly V-belt routing
4 - Poly V-belt
4.3
Engine codes: BLG, BMY

Note

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at
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71
Golf 2004
page 94
25 Nm
50 Nm
pressor

compressor and re
wire) page 72 .

remove ancillary brack
et from cylinder block.
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Remove alternator
Rep. Gr. 27 .
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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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welding wire.
Note
pressor.
72
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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Removing
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bracket -03C 903 143 A-
Golf 2004
Poly V-belt routing
1 - Poly V-belt pulley for cooling system pump
3 - Lower tensioning roller
4 - Upper tensioning roller
7 - Poly V-belt
4.4
Engine codes: BAG, BKG, BLF, BLN,

BLP and CAX

un
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73
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Golf 2004
Qty. 3
25 Nm
Qty. 3
25 Nm
page 94
4 - Dowel sleeves
Qty. 2
between ancillary unit
bracket and air condi
tioner compressor
5 - Ancillary bracket for air con
ditioner compressor
bracket -1K0 260.885 BRemoving

remove ancillary brack
et -5- from cylinder
block.
rrectness of i
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nform
spec
at
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compressor and re
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welding wire.
pressor.
74
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Note
Golf 2004
Poly V-belt routing
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
pe
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1-
Engine codes: AXW, AXX, BGU, BHY,

BLR, BLX, BLY, BPY, BSE, BSF, BVX,
BVY, BVZ, BWA, BYD, CAWB, CBFA
and CCTA
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Torque wrench -V.A.G 1331- (550 Nm)
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Note


75
Golf 2004
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
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M1045
ques:
52 Nm
2.0 l turbo FSI engine: 40 Nm
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M1045
ques:
52 Nm
40 Nm
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tor
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ques:
s
52 Nm
40 Nm

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
8 - Socket head flange bolt M1045
Observe different torques:
1.6 l injection engine and 2.0 l FSI engine: 52 Nm
9 - Dowel sleeves
Qty. 2
Ensure proper seating between ancillary bracket and air conditioner compressor.
76
Golf 2004
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.

welding wire.
Poly
1-
un
le
pe
rm
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d
35-
es, in part or in w
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hole
ercia
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com
Poly V-belt
Note
pressor.
Engine codes: BGP, BGQ, BTK, CBTA

and CBUA
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4.6
rrectness of i
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AG. Volkswagen AG d
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Tensioning
roller
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77
AG.
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Golf 2004
es, in part or in w
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bracket -07K 903 143 BRemoving
compressor and re
wire) page 79 .
Remove bolts from an

cillary bracket.
2 - Multi-point socket head bolt

M8X60
25 Nm
3 - Multi-point socket head bolt
M8X110
25 Nm
4 - Hexagon socket head bolt
M8X30
25 Nm
Qty. 4
page 94
6 - Hexagon bolts M885
Qty. 3
78
do
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AG.

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rrectness of i
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AG. Volkswagen AG d
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- Dowel sleevesss
c
Golf 2004
- Edition 02.2008

welding wire.
When doing this, ensure that refrigerant hoses on air conditioner
compressor are not strained.
Poly V-belt routing

Upper idler pulley
2-
3-
Lower idler pulley
4-
Poly V-belt for alternator and air conditioner compressor
5-
6-
Poly V-belt for air conditioner compressor
7-
8-
Tensioning roller for poly V-belt for air conditioner compres

sor
9-
Tensioning roller for poly V-belt for alternator and cooling

system pump
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AG.
4.7
Engine codes: BUB, CBRA

79
Golf 2004
Note
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AG. Volkswagen AG d
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The ancillary bracket for air conditioner
compressor
and
rela
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e
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is
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ted components can be removed
and
installed
without
the
o
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1 - Poly V-belt
Rep. Gr. 13
2 - Poly V-belt pulley for cool
ing system pump
pressor
Remove bolts from an

cillary bracket.
AG.
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compressor and re
wire) page 81 .
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Note tightening sequence

when installing page 81 .
5 - Fit bolt
25 Nm
6 - Alternator
7 - Dowel sleeves
Qty. 2
between ancillary unit bracket and air conditioner compressor
Qty. 3
25 Nm
10 - Fitted bolt
25 Nm
80
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Removing
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bracket -038 903 143 AF -
Golf 2004
. Volkswagen AG
gen AG
d
a
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If compressor is removed without opening
refrigerant circuit, oites not g
Vol
y
ua
should be secured to body using
d b suitable material, for example,
ran
se
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r
welding wire.
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a
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Note
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When doing this, ensuressrefrigerant hoses on air conditioner com

pressor.
Tightening sequence for ancillary bracket

Note
First tighten bolts in sequence 1...5 by hand.

Then tighten bolts in sequence 1...5 to 25 Nm.
do
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Bolts -1- and -2- are fit bolts.
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Poly V-belt routing

3 - Idler rollers
4 - Poly V-belt
81
Golf 2004
Repair work on refrigerant circuit

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

Notes on testing equipment and tools for repair work to vehi
cles with air conditioning can be found in ELSA under Heating,

WARNING
Danger of freezing injuries.

If refrigerant circuit has not been evacuated, refrigerant will
escape.
gu
ara
nte
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c
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rm
itte
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by
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ris
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th
au
ss
The refrigerant circuit must be purged with refrigerant R134a

es, in part or in w
l purpos
hole
ercia
, is n
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ot
com
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
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s
under the following circumstances:
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Note
un
le
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
inAGcoolant
gen AG due
. Volkswacircuit
does
agen
wagain.
s
to re-evaporation. Extract refrigerant
k
not
l
Vo
If dirt or other contamination is in the circuit.

If during the evacuation of a leak-tight refrigerant circuit the
vacuum is not maintained at the gauge (there is moisture in

the refrigerant circuit and this generates vapour pressure).
If the refrigerant circuit has been left open for longer than nor
mally required for repairs (e.g. following an accident).
When pressure and temperature measurements in the refrig
erant circuit indicate that there is moisture in the refrigerant

circuit.
There is doubt about the amount of refrigerant oil in the refrig

The air conditioner compressor has to be exchanged because
of internal damage (e.g. noisy or lack of power).
agen
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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.
AG.
82
ht
rig
py
Co
t.
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.
do
c
um
en
r
te o
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fo
g
n
erant circuit.
Golf 2004
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

Volkswagen AG
does
k
not
l
o
V
gu
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ara
d b-VAS 6007A- (or later mod
air conditioner service station
e
nte
is
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a
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.
gen AG
swa
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rrectness of i
t to the co
nform
spec
at
i
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in t
his
es, in part or in w
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hole
ercia
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E.g.
el)
Adapter set for service connections -T10364-
do
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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
83
Golf 2004
Ratchet insert tool 1/4" -VAS 6234- for adapter set for service
connections -T10364-
5.2
Removing and installing heater and air

conditioning unit
r
fo
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ole,
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is n
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m
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a
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p
AG.
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84
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.
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o
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atio
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AG. Volkswagen AG d
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un
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Air conditioner service station -VAS 6007A- or later model.
Golf 2004
5.2.1
Removing
Note
To improve access, additional components must be removed de

pending on engine version e.g. engine cover Rep. Gr. 10 .
Extract refrigerant, e.g. with air conditioner service station VAS 6007A- before opening refrigerant circuit. Observe notes
page 88 .
Remove dash panel Rep. Gr. 70
Remove right and left rear footwell air ducts page 6 .
Mark coolant hoses -1WARNING

-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
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Note
un
le
d
Applies only to vehicles with a protective plate before rthe
ise expan
o
h
sion valve.
ut
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Unscrew nut -1- (6 0.9 Nm).
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
On right-hand drive vehicles, lock washers are installed instead

of a clip and a nut.
do
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Release clips -2- and remove protective plate -3-.
agen
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85
Golf 2004
Continuation for all vehicles
WARNING

escape.
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-.
. Volkswagen AG
gen AG
does
not
gu
ara
nte
eo
ra
c
a
ksw valve -3-.
Remove refrigerant lines from expansion
Vol
ss
pe
rm
itte
d
Seal open connections for lines.

To seal open connections of expansion valve, use, for exam
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
ple, sealing cap of a spare expansion valve.
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Note
by
ed
ris
o
th
au
Cover carpet in vehicle interior with waterproof foil and ab

sorbent paper.
Note
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rig
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.
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86
do
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During removal, note lengths and locations of bolts for later installation.
Golf 2004
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 .

remove bracket -5-.

-10- and remove sup
ports -9- and -11-.
Unscrew bolts
Remove bolts -1- and -2- from cable retainer -3-.

Note
Remove heater and air conditioner unit.
Installing:
Installation is carried out in the reverse order. When installing, note the following:
Note
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
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or
nl
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ility
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AG. Volkswagen AG d
agen
oes
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b
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s
i
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-12- andho-14- and remove retainer -13-.
eo
ut
ra
a
c
s
s
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 .
do
c
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.
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87
AG.
Golf 2004
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
Renewing components of refrigerant cir

cuit
pe
rm
itte
d
un
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ab
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5.3
es n
wage
s
k
l
ot g
installation. y Vo
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
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88
do
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Golf 2004
Drip tray for workshop hoist -VAS 6208-
Hose clamps up to 40 mm -3093-
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Air conditioner
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service
station
-VAS
6007Aor
later
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89
Golf 2004
Note
The refrigerant must be extracted beforehand, e.g. with air
conditioner service station -VAS 6007A- .
The previously used service stations can still be used Volks
wagen Workshop Equipment catalogue.
All of the refrigerant circuit's components that have been
opened must be sealed with suitable plugs to prevent the in

gress of moisture.
The colour coding of O-rings for R134a refrigerant circuits has
been discontinued. Coloured and black O-rings are used.
Under certain conditions, it is not necessary to renew the re
wagen AG
. Volkscircuit
ceiver with dryer every time that the
is doe
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warefrigerant
s
k
l
opened. Refer to ELSA underbyHeating,
ventilation, air condis not gu
Vo
ara
ed system with refrigerant R134a
tioning system; Air conditioning
nte
ris
eo
ho data; Renewing components.
Rep. Gr. 00 ; Technical
t
u
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sa
un
le
rrectness of i
t to the co
nform
spec
a
t
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o
n in
wit
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es, in part or in w
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Notes on repair works to vehicles with air conditioning and on

WARNING

escape.
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Golf 2004
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1 - Receiver with dryer
rrectness of i
t to the co
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spec
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Note

page 92
AG.
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page 92
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4 - High-pressure sender G65-
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3 - Condenser
page 103
do
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Manufacturer: Denso,
designation 7SEU17C
Observe remarks on in
stallation of air condi
tioner compressor
page 106 .
page 94
5 - Bracket
Nuts, 6 Nm
6 - Evacuating and charging
valve
High-pressure side
Releasing refrigerant in
to the environment is a
punishable offence.
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.
Capacities page 109
9 - Expansion valve
Function and removal page 100 .
10 - Hexagon nut
20 Nm
11 - Bracket
91
Golf 2004
5.4
Removing and installing high-pressure

sender -G65-
5.4.1
Removing
Remove noise insulation tray from engine Rep. Gr. 50 .

Separate connector from high-pressure sender -1-.
ility
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Renew O-ring -2-.
es, in part or in w
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hole
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Note
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Unscrew high-pressure sender

connection.
AG. Volkswagen AG d
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by refrigerant line
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rrectness of i
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spec
a
t
i
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wit
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s
Depending on engine version, the high-pressure sender -G65-
-1- may be installed in another location near the condenser.
5.4.2
Installing
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.
agen
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Note
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Removing and installing receiver with

dryer
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5.5
Golf 2004
5.5.1
Removing
Note
Observe notes page 88 .
AG. Volkswagen AG d
The previously used service stations can still be used wVolks
agen
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All of the refrigerant circuit's components that
ho have been
t
opened must be sealed with suitable plugs
au to prevent the
ss
gress of moisture.
Extract refrigerant, e.g. with air conditioner service station VAS 6007A- before opening refrigerant circuit.
rrectness of i
t to the co
nf
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m
spec
atio
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n in
wit
Move lock carrier to service position Rep. Gr. 50 .

Remove radiator securing bolts -arrows- (7 Nm).
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93
Golf 2004
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

escape.
Extract refrigerant before opening refrigerant circuit. If the reAG. Volkswagen A
G do
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frigerant circuit is not opened within 10 minutes after
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been evacuated, pressure may develop in coolant
circuit
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to re-evaporation. Extract refrigerant again. oris
tee
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hole
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Remove bolts -1- and pull out receiver with dryer upwards.
rrectness of i
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nform
spec
at
i
h re
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in t
his
Note
or
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Depending on condenser, only one bolt -1- may be present.
5.5.2
Installing

Note
First tighten bolt(s) -1- to 4.2 Nm 0.7 Nm and then tighten
securing bolt -2-.
When installing radiator, ensure that sealing strips on radiator
Removing
Prote
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Note
Zexel air conditioner compressors have to be replaced by
Denso air conditioner compressors. Refer to technical solution

(TPL) 2011410.
A software update of the engine control unit is only required
for the 1.6 l 75 kW engine with engine code BSE. These soft
ware versions are only available online via SVM (Software
Versions Management) and can be flashed with the code for
the repair measure.
94
AG.
5.6.1
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Removing and installing air conditioner

compressor
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5.6
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are properly seated.
Golf 2004
Note
The refrigerant circuit must be
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purgedsswith
refrigerant R134a
c
If dirt or other contamination is in the circuit.

If during the evacuation of a leak-tight refrigerant circuit the
vacuum is not maintained at the gauge (there is moisture in

the refrigerant circuit and this generates vapour pressure).
If the refrigerant circuit has been left open for longer than nor
mally required for repairs (e.g. following an accident).
When pressure and temperature measurements in the refrig
erant circuit indicate that there is moisture in the refrigerant

circuit.
There is doubt about the amount of refrigerant oil in the refrig
erant circuit.
The air conditioner compressor has to be exchanged because
of internal damage (e.g. noisy or lack of power).
r
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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.
ht
rig
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Co
t.
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.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
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thi
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under the following circumstances:
Prote
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95
Golf 2004
Extract refrigerant, e.g. with air conditioner service station VAS 6007A- before opening refrigerant circuit. Observe notes
page 88 .
rrectness of i
t to the co
nf
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m
spec
atio
h re
n in
wit
es, in part or in w
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hole
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Remove poly V-belt Rep. Gr. 13 .

WARNING

escape.
Remove bolts (22 Nm 1 Nm) -1- from air conditioner com
pressor and separate refrigerant lines from air conditioner
compressor.
96
ht
rig
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t.
Remove front right wheel housing liner Rep. Gr. 66 .
thi
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Remove noise insulation under engine Rep. Gr. 50 .
Golf 2004
Remove hexagon bolts (25 Nm) -2- and remove air conditioner
compressor.
Volkswa
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Installing
s
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does
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Ensure that dowel sleeves -3- are properly seated.
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5.6.2
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page 106 .
5.7
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s
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form
spec
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n
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thi
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Observe remarks on installation of air conditioner compressor
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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97
Golf 2004
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)

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
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
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thi
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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
un
le
5 - Shim
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98
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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.
Golf 2004
5.8
Removing and installing poly V-belt pul

ley (air conditioner compressor from
Denso)
5.8.1
Removing
Carefully remove circlip -Ausing a small screwdriver or longAG. Volkswagen AG d

agen attention not
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ua
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Remove drive plate -C-.
Remove circlip -A-.
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Installing
AG.
Note
agen
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5.8.2
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Pull off belt poly V-belt pulley -B-.
rrectne
s
s
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f
i
t to the co
n
form
spec
atio
h re
n
wit
i
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thi
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Counterhold
drive shaft of air conditioner compressoree-Bor us
ut
aopen-jaw
ing an
spanner or socket from Shock absorberacset 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).
Renew circlip -A-.

Clean air conditioner compressor flange before fitting poly V-
belt pulley.
When installing, ensure the circlip -A- is deformed as little as
possible.
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)
99
Golf 2004
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-.
5.9.1
Removing
5.9.2
Installing
5.10
Checking high-pressure safety valve on

air conditioner compressor
Function: protects refrigerant circuit against excessive pres

sure.
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.
The high-pressure safety valve releases refrigerant when the

engine is running and the pressure in the refrigerant circuit is
too high.
agen
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Prote
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.
C
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WARNING
thi
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en
Removing and installing poly V-belt pul

ley, Sanden air conditioner compres
sor
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
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erm
or
e
t
a
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5.9
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Install circlip -A-.
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Golf 2004
rrectness of i
t to the co
nf
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m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
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or
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Note
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AG. Volkswagen AG d
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gress of moisture.
Connecting pipe from charge air cooler must be removed on
some vehicles Rep. Gr. 21
Applies only to vehicles with a protective plate before the expan

sion valve.
ht
rig
py
Co
t.
On right-hand drive vehicles, lock washers are installed instead

of a clip and a nut.
thi
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Note
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101
Golf 2004
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
AG. Volkswagen AG d
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refrigerant,s ae.g.
c
s
4 - Expansion valve
Removing:
ility
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Extract
with air conditioner serv
ice station -VAS
6007A- .
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
un
le
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
WARNING
Danger of freezing inju

ries.
If refrigerant circuit has
not been evacuated, re
frigerant will escape.
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iva
r
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n
Prote
cted
by
c
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py
rig
ht
.
C
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pull refrigerant lines -2out of expansion valve.
Remove screws -8- and remove expansion valve -4-.
102
AG.
6 - O-ring
10.8 mm; 1.82 mm
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5 - O-ring
14 mm; 1.82 mm
Moisten with refrigerant oil when installing.
ht
rig
py
Co
t.
do
c
um
en
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.
Golf 2004
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,
check
water drain and
olksw
agen Acondensed
G
en AG. V
wag
clean if necessary.
olks
housing and, if
does
not
gu
ara
nte
necessary, evaporator,
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l purpos
hole
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or
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Clean
isevaporator
r
o
thinserting.
fore
au
s
s
When inserting evaporator -A- in lower part of evaporator

housing and assembling the two parts of housing, ensure that
seal -F- is not damaged.
rrectness of i
t to the co
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spec
atio
h re
n in
wit
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

thi
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en
seating of combined seal and insulation -B- at opening for both

refrigerant lines -D- and -E-.
Check seating of retainer -C- on both refrigerant lines -D- and
-E- for proper seating.
If heat insulation -B- is missing or improperly installed, it may

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lead to reduced performance of the air conditioning system

(due to changes in the set mapped values of the expansion
valve through heat radiation).
agen
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Prote
cted
by
5.13
Removing and installing condenser
103
Golf 2004
Note
The refrigerant must be extracted beforehand, e.g.
es, in part or in w
l purpos
hole
ercia
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his

gress of moisture.

Switch off all electrical consumers.
Switch off ignition.
Pull out ignition key.
Extract refrigerant, e.g. with air conditioner service station VAS 6007A- .
Prote
cted
by
AG.
104
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Remove lock carrier Rep. Gr. 50 .
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Remove front bumper Rep. Gr. 63 .
do
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Releasing refrigerant into the environment is a punishable of

fence.
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Note
Golf 2004
WARNING

escape.
Remove refrigerant lines on condenser and seal.
es, in part or in w
l purpos
hole
ercia
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2 - Securing clip
Qty. 8
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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 -arrow-
3 - Condenser
Secured with 4 bolts to
radiator
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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
Note
6 - Bolt
5 0.5 Nm
7 - Radiator
8 - Bolts
Qty. 4
5 0.5 Nm
Note
105
Golf 2004
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.
5.14
Notes on installing air conditioner com

pressor
5.14.1
Installing
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.
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.
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.
The engine may be started only when the refrigerant circuit is
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.
Air conditioning system compressor regulating valve -N280- is
not activated when the refrigerant circuit is empty and the air
conditioner compressor idles with the engine.
c
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The refrigerant circuit must be fully assembled.
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If it is necessary to start engine with an empty refrigerant cir
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At least of the quantity of refrigerant oil specified for this

Prote
cted
by
refrigerant circuit must be in the air conditioner compressor.

AG.
The engine speed must not exceed 2000 rpm.

Run engine only as long as absolutely necessary, max.
10 min.
106
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
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i
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thi
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cial p
is n
mer
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or
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a
itte
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p
If an air conditioner compressor seizes, the overload protec
ility
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le
AG. Volkswagen AG d
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Note
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The air conditioner
compressor
is
driven
permanently
by
the
ra
a
c
s
s pulley (not fitted with a magnetic clutch).
poly V-belt
Golf 2004
Note
es, in part or in w
l purpos
hole
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Note the following when starting

refrigerant circuit:
AG. Volkswagen AG d
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engine
a for first time after filling
c
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Start engine with air conditioner compressor switched off

(Econ mode) and wait until the idling speed stabilizes.
rrectness of i
t to the co
nf
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m
spec
atio
h re
n in
wit
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.
5.14.2
Removing evacuating and charging

valve, low-pressure side and high-pres
sure side
thi
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en
E.g. air conditioner service station -VAS 6007A- (or later mod
el)
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Prote
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Adapter set for service connections -T10364-
Torque wrench -V.A.G 1783-
107
olkswagen AG
en AG. V
does
not
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ara
nte
eo
ra
c
6234-
wag
Golf 2004
olks
yV
b
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- Edition 02.2008
se
Note
Releasing refrigerant into the environment is a punishable of
fence.
All components of the refrigerant circuit which have been
AG.
WARNING
agen
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Prote
cted
by
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rig
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Remove cap -3-.

If refrigerant circuit has not been evacuated, refrigerant and
refrigerant oil will escape.
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
ht
rig
py
Co
t.
r
fo
ng
opened must be sealed with suitable plugs to prevent moisture

intrusion.
rrectne
s
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f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
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o
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um
en
ole,
cial p
is n
mer
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or
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a
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le
-VAS
ility
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Ratchet insert
ri
ho
ut
a
tool
ss 1/4"
Golf 2004
Capacities
6.1
Refrigerant R134a
Air conditioner com

pressor
Manufacturer
Total capacity
7SEU16C
7SEU17C
PXE16
DSC17E
Denso
Denso
Sanden
Zexel
52525 grammes
52525 grammes
52525 grammes
52525 grammes
6.2
Refrigerant oil
Note
olkswagen AG
en AG. V
does
not
V
gu
y
bthe refrigerant/ma
R134a only) can no longer be obtained on
ara
d
nte
ise
r
chine oil market.
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c
s
Refrigerant oils from containers which
have
been
open
for
a
s
wag
The special refrigerant oil (for use with refrigerant
olks circuits
G 052 300 A2
G 052 300 A2
G 052 154 A2
G 052 154 A2
Total capacity1)
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
from 07.03
140 cm3 10 cm3
from 07.03
110 cm3 10 cm3
from 06.2005
110 cm3 10 cm3
from 07.03
120 cm3 + 15 cm3
From 11.2006
180 cm3 10 cm3
c
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1) This quantity of refrigerant oil is contained in a replacement air conditioner

compressor and corresponds to the total capacity.
Prote
cted
by
Important information:
AG.
Production period
agen
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by
Type
ht
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Co
t.
Denso 7SEU16C
Denso 7SEU17C
Sanden PXE16
Zexel / Valeo DSC17E
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Refrigerant oil can be obtained using following part No. for
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
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erm
o
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t
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itte
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nl
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longer period of time are unusable.
ility
ab
y li
an
pt
ce
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:
6. Capacities
109
Golf 2004
Air conditioner compressor approx. 50%
Condenser approx. 10%
Suction hose approx. 10%
Evaporator approx. 20%
Receiver approx. 10%
ht
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py
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Prote
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by
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thi
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en
110
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
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nl
f
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ility
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an
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ce
AG. Volkswagen AG d
agen
oes
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not
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ara
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ise
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o
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s

Heating Air Conditioning PDF

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Heating Air Conditioning PDF

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AG.

Heating, air conditioning

Service Department. Technical Information

Copyright 2010 Volkswagen AG, Wolfsburg

All rights reserved.

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

and installing right footwell

Passenger compartment heating

Disconnect battery before removing components marked **

5 - Controls for fresh and heat

6 - Fresh air and air recircula

13 For centre console air duct (to rear vents)

14 - Air duct for right rear footwell

15 - Air duct for left rear footwell

17 - Adapter for controls

22 - Flexible shaft for air distribution

Rep. Gr.80 - Heating

21 - Bowden cable for temperature flap

20 - Left footwell vent

Removing fresh air blower -V2-

Fresh air blower -V2- is accessible from footwell on front passen

Removing and installing fresh air blower

Release catch -2-, turn fresh air blower -V2- in direction of

Danger of burn injuries.

Install in reverse order.

Removing and installing dust and pollen

Remove footwell trim -1- on front passenger side.

Observe installation position of dust and pollen filter.

Removal and installation of rear vents (in arm rest) is described

Rep. Gr.80 - Heating

Install in reverse order.

Remove dust and pollen filter from heater unit downwards.

Removing centre vents

On vehicles with a storage compartment in

Remove bolt -1-.

On vehicles with Climatronic, first remove the sunlight pene

Remove cover -2- (only in vehicles with Climatronic).

For vehicles with a storage compartment in dash panel, bolts are

Remove central vents -2- upwards -arrow-.

Remove compartment from dash panel.

Remove securing bolts -1-.

Separate connectors from central vents.

Install in reverse order.

Removing right or left vent

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

Install in reverse order.

Removing and installing right and left

The procedure for removal of footwell air ducts is identical on both

Remove driver or front passenger seat Rep. Gr. 72 .

Rep. Gr.80 - Heating

Install in reverse order.

Removing right footwell vent

Remove glove compartment Rep. Gr. 68 .

If vehicle has glove box cooling, ensure that refrigerant hose is

Install in reverse order.

Removing left footwell vent

Remove driver side footwell cover Rep. Gr. 68 .

Install in reverse order.

Removing and installing controls for

moving controls, set rotary knobs to the following positions:

Heater control to cold

Figure shows Climatic version. The procedure for releasing con

Connectors on controls for heated and