Service: Golf 2004

Service
Repair Manual
Golf 2004 ➤
Heating, Ventilation and Air Conditioning
BUB CBR BGP BGQ CBT
Engine ID
CBU BPY CBF CCT
A A A A A
Edition 04.2015
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Service Department. Technical Information
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Service
List of Workshop Manual Repair Groups
Repair Group
80 - Heating, Ventilation
87 - Air Conditioning
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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.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg D3E8001F467

Golf 2004 ➤
Heating, Ventilation and Air Conditioning - Edition 04.2015
Contents
80 - Heating, Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Heater Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Passenger Compartment Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Heat and Fresh Air Control Multi-Pin Connector Assignments . . . . . . . . . . . . . . . . . . . . . . 3
2 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Ventilation, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Air Distribution Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Air Distribution Door Adjusting Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Air Grille . . . . . . . . . . . . . . . . . . . . . . . . . . n. A.G. ..V.ol.ks. w. a.g.en. A. G
.......................... 8
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3.4 Dust and Pollen Filter . . . . . . . . . V. o. l . . . . . . . . . . . . . . . . . . . o.e.s .no.t .g. . . . . . . . . . . . . . . . . . .
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3.6 Fresh Air Blower V2 . . . a.ut.ho. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .e o. r .a . . . . . . . . . . . . 11
3.7 Fresh Air Blower Series Resistor ss with Fuse N24 . . . . . . . . . . . . . . . . . . . . c. . . . . . . . . . . . 11
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3.8 Fresh/Recirculating Air Door Motor V154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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3.9 Heat and Fresh Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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3.10 Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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3.11 Heater Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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3.12 Heating Unit Partition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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3.13 Temperature Door Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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3.14 Temperature Door Release Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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3.15 Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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4.1 Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
87 - Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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1.1 A/C System, Repairing and Handling Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . tion in 26

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1.2 A/C Compressor, Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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1.3 Climatronic A/C System with Automatic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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1.4 Odors in Vehicles with A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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1.5 Refrigerant Circuit, Specialized Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.1 Air Quality Sensor G238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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2.2 Climatic A/C System with Manual Control Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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2.3 Climatic Heating and A/C Controls, Multi-pin Harness Connectors . . . . . . . . . . . . . . . . . . 34

2.4 Climatronic A/C Display Control Head Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.5 Climatronic Control Module, Multi-pin Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . 36
2.6 Climatronic A/C System with Automatic Control Overview . . . . . . . . . . . . . . . . . . . . . . . . 38
2.7 Evaporator Housing Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.8 Refrigerant Circuit Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.9 Ribbed Belt Pulley, Denso A/C Compressor Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.1 Refrigerant R134a Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.2 Refrigerant Oil Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.3 Oil Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.1 Condensation Water Drain Hose on Heating and A/C Unit, Checking . . . . . . . . . . . . . . . . 48
4.2 Climatronic, Checking and Adjusting Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.3 Pressure Relieve Valve on A/C Compressor, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Contents i
Golf 2004 ➤
5 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

5.1 Air Quality Sensor G238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.2 A/C Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.3 Climatic A/C Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.4 Climatic A/C System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.5 Climatronic A/C Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.6 Climatronic Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.7 Climatronic Door Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.8 Climatronic Indirect Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.9 Fresh Air Blower Control Module J126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.10 Sunlight Photo Sensor G107 / Sunlight Photo Sensor G134 . . . . . . . . . . . . . . . . . . . . . . 81
5.11 Heating and A/C Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.12 Ribbed Belt Pulley, Denso A/C Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.13 Refrigerant Circuit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.14 A/C Compressor Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.15 A/C Compressor Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.16 A/C Compressor Sub-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6.1 Climatic Heating and A/C Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6.2 Climatronic Heating and A/C Unit . . . . . . . . . . . . . . . . . . . . . . A.G. . .V.ol.ks.w.a.g.en. . . . . . . . . . . . . 104
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ii Contents
Golf 2004 ➤
80 – Heating, Ventilation
1 Description and Operation
(Edition 04.2015)
⇒ “1.1 Heater Overview”, page 1
⇒ “1.2 Passenger Compartment Heating”, page 2
⇒ “1.3 Heat and Fresh Air Control Multi-Pin Connector Assign‐
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2 - Bracket
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3 - Cover
4 - Fresh/Recirculating Air
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Door Motor - V154-
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and Information System
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⇒ “4.2 Climatronic,
Checking and Adjusting
Components”,
page 48 .
5 - Housing For Air Entry
❑ With recirculating air
door.
6 - Heater Unit
7 - Fresh Air Blower - V2-
ling. Refer to ⇒ “3.6 Fresh Air Blower V2 ”, page 11 .
8 - Fresh Air Blower Series Resistor With Fuse - N24-
❑ Removing and installing. Refer to ⇒ “3.7 Fresh Air Blower Series Resistor with Fuse N24 ”, page 11 .
9 - Dust and Pollen Filter
❑ Removing and installing. Refer to ⇒ “3.4 Dust and Pollen Filter”, page 9 .
10 - Cover
❑ For dust and pollen filter.
1. Description and Operation 1

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11 - Heater Core
❑ Removing and installing. Refer to ⇒ “3.10 Heater Core”, page 13 .
12 - Heater Core Trim
13 - Auxiliary Heater Heating Element - Z35-
❑ Only installed on vehicles with Diesel engine.
14 - Air Distribution Housing
15 - Adjusting Unit For Air Distribution Doors
❑ Removing and installing. Refer to ⇒ “3.2 Air Distribution Door Adjusting Unit”, page 7 .
1.2 Passenger Compartment Heating

Disconnect the battery before removing the components marked
with **. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; gRemoval
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4 - Right Vent
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Vent”, page 23 .
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5 - Fresh Air and Heated Air

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Adjuster - E94- and

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Air Controls”,
page 12 .
6 - Fresh/Recirculating Air
Door Motor - V154-
❑ Removing. Refer to
⇒ “3.8 Fresh/Recircu‐
lating Air Door Motor
V154 ”, page 11 .
7 - Right Footwell Vent
❑ Removing and installing. Refer to ⇒ “3.15.6 Right Footwell Vent”, page 23 .
❑ Removing. Refer to ⇒ “3.6 Fresh Air Blower V2 ”, page 11 .
2 Rep. Gr.80 - Heating, Ventilation

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9- Fresh Air
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10 - Heating Unit Partition
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❑ Removing. Refer to ⇒ “3.12 Heating Unit Partition”, page 19 .
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❑ Only in vehicles without air guide to vent installed in center console at rear.
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❑ With activated charcoal filter.
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13 - Connection
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❑ For the center console air guide to the rear vents.

❑ The center console must be removed to remove it. Refer to ⇒ Body Iinterior; Rep. Gr. 68 ; Removal and
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14 - Rear Channel For Right Footwell
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❑ Removing and installing. Refer to ⇒ “3.15.3 Rear Footwell Channel”, page 22 .
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15 - Rear Channel For Left Footwell

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17 - Adapter For Controls
❑ Removing and installing. Refer to ⇒ “3.9 Heat and Fresh Air Controls”, page 12 .
19 - Heater Core
❑ After replacing heater core, coolant must be replaced completely.
20 - Left Footwell Vent
❑ Removing and installing. Refer to ⇒ “3.15.2 Left Footwell Vent”, page 22 .
21 - Bowden Cable For Temperature Door
❑ Removing and installing. Refer to ⇒ “3.14 Temperature Door Release Cable”, page 20 .
22 - Flexible Shaft For Air Distribution
❑ Removing and installing. Refer to ⇒ “3.5 Flexible Air Distribution Shaft”, page 10 .
23 - Heater Unit
❑ Removing and installing. Refer to ⇒ “3.11 Heater Unit”, page 16 .
❑ Disassembling and assembling. Refer to ⇒ “4.1 Heater”, page 24 .
24 - Left Side Vent
1.3 Heat and Fresh Air Control Multi-Pin

Connector Assignments
Special tools and workshop equipment required
♦ Test Box - VAG1598/42-
♦ Test Adapter - VAG1598/47-
♦ Template - 1598/47-2-

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2 - 2nd blower speed
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3 - 1st blower speed
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4 - 4th blower speed
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Auxiliary Heater Operation Relay - J485-
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20-pin Harness Connector, (T20c)
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3 - Fresh/Recirculating Air Door Motor - V154-

6 - Fresh/Recirculating Air Door Motor - V154-
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7 - Auxiliary Air Heater Control Module - J604-
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8 - Rear window
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11 - Heated Driver Seat Control Module - J131- thi

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15 - Heated Front Passenger Seat Control Module - J132-

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16 - Terminal 75 seat heater (optional)
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18 - Terminal 30 rig ht
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19 - Terminal 15 Prote
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20 - Terminal 31

Golf 2004 ➤
AG. Volkswagen AHeating, Ventilation and Air Conditioning - Edition 04.2015
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2 Diagnosis and Testing
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⇒ “2.1 Ventilation, Checking”, page 5
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♦ The stale air escapes through the vent openings in the luggage
es, in part or in w
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compartment trim.
♦ If the ventilation is to function properly, the ventilation open‐
ings must not be covered.
rrectness of i
♦ The ventilation frames are located in the rear side panels, be‐
l purpos
hind the bumper.
nf
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Checking
orm
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– Remove rear bumper. Refer to ⇒ Body Exterior; Rep. Gr. 63 ;
om
Removal and Installation .
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– The sealing lips -1- in the ventilation frame on both sides of

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vehicle must be free to move and close automatically.
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– Observe installed position.

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2. Diagnosis and Testing 5

Golf 2004 ➤
3 Removal and Installation

⇒ “3.1 Air Distribution Housing”, page 6
⇒ “3.2 Air Distribution Door Adjusting Unit”, page 7
⇒ “3.3 Air Grille”, page 8
⇒ “3.4 Dust and Pollen Filter”, page 9
⇒ “3.5 Flexible Air Distribution Shaft”, page 10
⇒ “3.6 Fresh Air Blower V2 ”, page 11
⇒ “3.7 Fresh Air Blower Series Resistor with Fuse N24 ”,
page 11
⇒ “3.8 Fresh/Recirculating Air Door Motor V154 ”, page 11
⇒ “3.9 Heat and Fresh Air Controls”, page 12
⇒ “3.10 Heater Core”, page 13
⇒ “3.11 Heater Unit”, page 16
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⇒ “3.12 Heating Unit Partition”, page 19 olksw
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⇒ “3.13 Temperature Door Adjuster”, page 19 orise nte
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⇒ “3.14 Temperature Door Release Cable”, page 20 ss a c
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⇒ “3.15 Vents”, page 21
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3.1 Air Distribution Housing
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Golf 2004 ➤
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– Remove the heater. Refer to

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⇒ “3.11 Heater Unit”, page 16 .

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– Disconnect any existing connectors on the air distribution
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– Remove the heater core along with the coolant pipes. Refer to
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⇒ “3.10 Heater Core”, page 13 . Prote AG.
– Remove the bolts -arrows- 1.4 Nm.

– Remove the air distribution housing -1- from the heater -2-.
Installing
Install in reverse order of removal.
3.2 Air Distribution Door Adjusting Unit

Removing
– Remove the instrument panel. Refer to ⇒ Body Interior; Rep.
Gr. 70 ; Removal and Installation .
3. Removal and Installation 7

Golf 2004 ➤
– Unclip flexible shaft from adapter for controls. Refer to

⇒ “3.5 Flexible Air Distribution Shaft”, page 10 .
– Unscrew bolts -1- and remove adjusting unit for air distribution
doors.
Installing
– The arrows on the gears must align.
– Position adjusting unit for air distribution doors and tighten
bolts -1-.
Note
After installing, function of air distribution doors must be checked.

Refer to ⇒ “3.5 Flexible Air Distribution Shaft”, page 10 .
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– Remove the plenum chamber cover. Refer to ⇒ Body Exterior; s
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– Remove the cover -1- from the plenum chamber.

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♦ From 11.05.08 with Climatronic, a bracket with an Air Quality

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Sensor - G238- is installed on the intake air grille.

♦ Air quality sensor function, refer to
⇒ “2.1 Air Quality Sensor G238 ”, page 30 .
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– Disconnect the connector from the air quality sensor and re‐
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move the air quality sensor by rotating it to the right until it

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Golf 2004 ➤
– Remove the flange nutsge-arrows-

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The seal must fit correctly in the air grille.
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Assembly sequence:
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– Align the air grille on the flange.
– Hold the air grille and install the side flange nuts (2.5 +/- 0.4
Nm) and then the center flange nut.
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3.4 Dust and Pollen Filter
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Removing
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– Remove the plastic screws -2- and the partition-1-.
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– Release cover -1- in direction of arrow.

– Remove dust and pollen filter downward out of heater.
Installing
Note
Note installation position of dust and pollen filter.

Golf 2004 ➤
3.5 Flexible Air Distribution Shaft

Removing
– Remove the radio. Refer to ⇒ Communication; Rep. Gr. 91 ;
– If the vehicle does not have a radio, remove the trim from the
center of the instrument panel. Refer to ⇒ Body Interior; Rep.
– Remove the glove compartment. Refer to ⇒ Body Interior;
– Move the flexible shaft in to the following position:
– Turn the switch for the air distribution control -B- until the lock‐
ing mechanism on the shaft -2- is visible in step-up gearing
-3-.
– Remove controls for hot air and fresh air. Refer to

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⇒ “3.9 Heat and Fresh Air
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– Reach into the centered console and push the tab -1- in direction
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– Pull flexible sshaft out of adapter -2-.
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When installing flexible shaft, adapter and rotary switches on

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controls for hot air and fresh air must have a specific position to
hole
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each other, otherwise it will malfunction. Refer to ⇒ page 10 .

es, in part or in w
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Checking
Flexible shaft for adjusting unit of air distribution doors:
rrectness of i
– Let fresh air blower run on highest speed. The flexible shaft is
l purpos
installed correctly if air flows out of the defroster vents in the

“Defrost function” position, but not out of the footwell vents. If
this is not the case, remove flexible shaft from adapter. Place
nform
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controls for hot air and fresh air onto adapter and rotate rotary
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knob for air distribution 1/2 rotation (180°). Then re-connect

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flexible shaft. Repeat test.

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Golf 2004 ➤
3.6 Fresh Air Blower - V2-

Removing
Fresh Air Blower is accessible from footwell on front passenger
side.
– Remove the partition from the heater. Refer to
⇒ “3.12 Heating Unit Partition”, page 19 .
– Disconnect harness connector -A- from Fresh
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3.7 Fresh Air Blower Series Resistor with
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Fuse - N24-
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Removing
WARNING
rrectness of i
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Contact with a hot exhaust system can cause severe burns.

Fresh Air Blower Series Resistor With Fuse may be hot.
nform
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Let Fresh Air Blower Series Resistor With Fuse cool off before
m
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– Remove the partition from the heater. Refer to

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⇒ “3.12 Heating Unit Partition”, page 19 .

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– Disconnect harness connector -1- from fresh air blower series
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– Push the retainer in direction of -arrow- and remove the fresh
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Installing
3.8 Fresh/Recirculating Air Door Motor -

V154-
Removing
Note
Position of recirculating air door must not be changed.

Golf 2004 ➤

– Remove the cover -1-.
– Disconnect the connector from the fresh/recirculation air door
motor -2-.
– Remove the fresh/recirculation air door motor -2-.
Installing
Note
After installing the fresh/recirculation air door motor, the function

of the recirculating air door must be checked.
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System - VAS5051B-ris.ed ran
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– Replacing, perform
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sis, Testing and Information System - VAS5051B- . Refer to
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⇒ “4.2 Climatronic, Checking and Adjusting Components”,
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3.9 Heat and Fresh Air Controls

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Note
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♦ The controls consist of two separable housings. Before re‐

moving controls, bring rotary buttons into the following posi‐
tions:
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♦ Heater control to “cold”

inform
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♦ Blower to “0”
atio
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♦ Air flow direction to “footwell”

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– If the vehicle does not have a radio, remove the trim from the . Cop py
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Gr. 68 ; Removal and Installation . cop Vo
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– Remove the screws -2- (4.2 x 45) and -3- (4.2 x 16) and the
AG.
controls -1- from the center console.

Golf 2004 ➤
Tightening specification for the screws -2- and -3-: 1.5 +/- 0.2 Nm.
– Release the connector -A- by pulling it in direction of arrow
-1-.
– Press connector release -B- toward the connector -arrow 2-
and disconnect the connector -C-.
– Disconnect the connector -D-.
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Illustration shows “Climatic” version. The ir se procedure for releasing
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Installation is performed in reverse order of removal, make sure
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3.10 Heater Core
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♦ Drip Tray For Shop Crane - VAS6208-
rrectne
♦ Hose Clamps Up To Diameter 40 mm - VAS3093-
♦ Compressed air gun, commercially available
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Removing
inform
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– Place -VAG1306- under the engine.
atio
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WARNING
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Contact with hot engine coolant can cause severe scalding. cum
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Coolant temperature can be above 100 °C with a warm engine.
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If necessary, reduce pressure and temperature before repairs.
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– Clamp the coolant hoses -1- using the Hose Clamps Up To

Diameter 40 mm - VAS3093- and remove the coolant hoses
from the heater core.
– Connect a section of hose -A- to the upper connection on the
heater core.
– Hold a container -B- under the lower connection -C-.
– Using a compressed air gun, carefully clear out any coolant
still inside the heater core into the container -B-.

Golf 2004 ➤
Depending on the engine, additional parts may need to be re‐

moved such as the charge air pipe.
– Loosen the bolt -1- slightly from the connection flange between
the heater core connections.
Note
♦ Loosen but do not remove the bolt -1-.

♦ By loosening the screw -1-, the coolant pipes are loosened
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– Remove driver side footwell trim. Refer
thoris to ⇒ Body Interior; nte
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Rep. Gr. 68 ; Removal and Installation
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– Remove the left footwell vent. Refer to
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⇒ “3.15.2 Left Footwell Vent”, page 22 .
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– Remove the bolts -A- and the cover -B-.
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Note
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♦ There are different versions of cover -B-.
♦ The illustration shows the version with Auxiliary Air Heater
rrectness of i
Heating Element - Z35- .
l purpos
♦ If the temperature door lever -C- is in a position that hinders

access to the upper screw -A-, change the position of the tem‐
perature door using the hot and fresh air controls; on vehicles
nform
ercia
with Climatronic (for example “Hi” setting).

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– Cover the carpet the in area under the heater core with wa‐
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terproof foil and water absorbing paper.

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– Open the clamps -A- and remove the coolant pipes from the
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Installation is carried out in the reverse order while noting the fol‐
lowing:
– Check the seals -A- and -B- on the heater core for damage.
Note
♦ An incorrectly glued seal can roll up into heater unit when slid‐
ing in the heater core.
♦ Cold air may flow past heater core if seal is damaged or not
properly fitted.

Golf 2004 ➤
– Check the heater unit (while the heater core is removed)

through the opening -A- for the heater core, for dirt.
– Remove any dirt or coolant which has leaked out of the heater
unit (for example, after removing a leaking heater core).
– Install the heater core into the heater unit.
– Coat sealing rings-1- with coolant before installing.

– Install the seals -1- into the connection in the heater core.
Note
♦ Ensure sealing rings are installed on the proper side, as shown

in the illustration.
♦ If pipe clamps are deformed, replace them.
– Attach the coolant pipes to the heater core.

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– Pipe clamps -A- must be able Vol to be twisted slightly whenot in‐
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– Pipe clamps -A-ss must
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– Tighten the pipe clamps -A- to 2 Nm.

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– Make sure the clamps -A- are tight after tightening the screws.
They must completely enclose the flange on the heater core
nform
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and coolant pipe and must not come in contact with other
components.
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– Tighten the connection flange bolt -1- between the heater core
n in
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connections to 2 Nm.
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Golf 2004 ➤
– Make sure the grommet -C- fits correctly inside the plenum
chamber bulkhead.
– Seal flange for coolant pipes to heater core -A- and for expan‐
sion valve (to evaporator, only in vehicles with A/C system)
-B- at pass-through of grommet -C- with silicon adhesive seal‐
ant if necessary to prevent water from penetrating.
Note
♦ The seals must be replaced.

♦ After replacing heater core, coolant must be replaced com‐
pletely. Refer to ⇒ Engine Mechanical, Fuel InjectionAand
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♦ Check coolant circuit for leaks, pay particular
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connection between coolant hoses and
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3.11 Heater Unit
an
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Removing
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Note
To improve accessibility, additional components must be re‐
nform
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moved, such as the engine cover (depending on engine version).

Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition; Rep.
m
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Gr. 10 ; Removal and Installation . tion in

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Gr. 70 ; Removal and Installation

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– Remove the rear channels from the right and left footwells.
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Refer to ⇒ “3.15.3 Rear Footwell Channel”, page 22 .
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– Mark the coolant hoses -1-.
WARNING
Contact with hot engine coolant can cause severe scalding.


Golf 2004 ➤
– Clamp the coolant hoses -1- using the -VAS3093- and remove
the coolant hoses from the heater core.
– Connect a section of hose -A- to the upper connection on the
heater core.
– Using a compressed air gun, carefully blow residual coolant
out of heater core at heater core connection.
– Cover the carpet inside the passenger compartment with wa‐
Note
When removing the bolts, make note of the lengths and allocation.
1 - Screw
❑ 4.5 +/- 0.7 Nm
❑ On the lower right, on n AG. Volkswagen AG do
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the heater cablebybracket
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2 - Screws
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❑ 4.5 +/- 0.7 Nm

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3 - Cable Bracket
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4 - Heater Unit
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Removing
spec
– Disconnect the connec‐

t to the co
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Note
s
All cable ties opened or cut during

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removal must be reinstalled at the

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– Remove the two nuts

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Module - J393- and

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Rep. Gr. 97 ; Removal cop Vo
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and Installation .
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– Remove the bolts -6-

and the holder -5-.
– Remove the screws -8-

and -10-, and the cover -9- and -11-.
– Remove the bolts -12- and -14- and bracket -13-.
– Remove the bolts -2- and -1- from the cable bracket -3-.

Golf 2004 ➤
Note
♦ To be able to reach the bolt -1-,

heater on driver side must be
pulled out slightly from facing
AG. Volkswagen AG d
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♦ When removing
d b heater unit, ua
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make sure ut
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plenum chamber or noise insu‐
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lation pan.
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♦ Observe wiring harness, individ‐
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may get damaged when pulling
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– Remove the heater unit.
Installing
rrectne
Installation is carried out in the reverse order while noting the following:
ss o
Tighten the bolts -8- on the subframe first when installing the supports -9 and 11-.
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Note
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A second technician is necessary to
thi
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install the heater unit.

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– When inserting heater unit, have the second technician guide both coolant pipes to heater core through
en
ng
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the seal (from engine compartment). Refer to ⇒ page 19 .
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– Fill with coolant. Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition; Rep. Gr. 19 ; General
p by
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Information . Prote
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agen
5 - Bracket
6 - Screws
❑ 8 +/- 1 Nm
7 - Subframe
8 - Screws
❑ 9 +/- 1.3 Nm
9 - Right Support
10 - Screws
❑ 20 +/- 3 Nm
11 - Left Support
12 - Screws
❑ 9 +/- 1.3 Nm
13 - Bracket
14 - Screws
❑ 9 +/- 1.3 Nm

AG. Volkswagen AG d
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Golf 2004 ➤
d
Heating,
rise Ventilation and Air Conditioning - Edition
nte 04.2015
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Seal Between Heater and Engine Compartment
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Note
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Make sure the seal -A- is installed correctly.
h re
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rrectness of i
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3.12 Heating Unit Partition
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Removing
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– Remove the plastic screws -2- and the partition-1-.
on
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– First insert seal into bulkhead between heater and engine
his
ate
compartment -A-, then place on heater core.
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Installation Position of Seal for Heater and Engine Compartment
Note
To prevent water from entering vehicle interior, note the installa‐

tion position.
Installing
3.13 Temperature Door Adjuster

Removing
– Remove driver side footwell trim. Refer to ⇒ Body Interior;

Golf 2004 ➤

– Unclip cable at adjusting unit for temperature door -2-.
– Disengage locking mechanism -1- and press adjusting unit for
temperature door in direction of -arrow- until it reaches stop.
– Remove adjusting unit for temperature door.
Installing
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Temperature knobs on hot air and fresh air controls must be able
s a c
to moved easily and without catching from “cold” position to
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un
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“warm” position.
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3.14 Temperature Door Release Cable
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Removing
spec
– Remove controls for hot air and fresh air. Refer to
t to the co
⇒ “3.9 Heat and Fresh Air Controls”, page 12 .
– Reach in the center console and loosen the retainer -1- on the
rrectne
cable grommet -2- and then remove the grommet from the
mount. ss
– Loosen the ball on the cable -3- from the lever -4-.
o
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– Unclip Bowden cable at adjusting unit of temperature doors
-A- and unclip heater -B-.
Installing

Golf 2004 ➤
Install in reverse order of removal. When doing this, make sure

that Bowden cable lies under the hook -arrow-.
– Check whether the temperature control can be moved easily
from “cold” to “warm”.
3.15 Vents
⇒ “3.15.1 Center Vent”, page 21 wage
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⇒ “3.15.2 Left Footwell Vent”, pageed22 by ua
ran
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⇒ “3.15.3 Rear Footwell Channel”,
auth page 22 or
ac
ss
⇒ “3.15.4 Rear Vents in Armrest”, page 22
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⇒ “3.15.5 Right or Left Vent”, page 23

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⇒ “3.15.6 Right Footwell Vent”, page 23
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3.15.1 Center Vent
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Removing
es, in part or in w
t to the co
– In vehicles with a storage compartment in the center console,
remove the rubber mat to reach the bolt -1-.
rrectness of i
– On vehicles with Climatronic, remove the Sunlight Photo Sen‐
sor - G107- or Sunlight Photo Sensor 2 - G134- first. Refer to
l purpos
⇒ “5.10 Sunlight Photo Sensor G107 / Sunlight Photo Sensor

G134 ”, page 81 .
nform
ercia
– Remove the bolt -1-.

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– If the vehicle has Climatronic, remove the cover -2-.
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– Remove nuts -1-.
Note
On vehicles with storage compartment in instrument panel,

screws are under a lining mat.
– Remove storage compartment from instrument panel.

– Remove the center vent -2- upward in direction of -arrow-.
– Disconnect the connectors from the center vents.
Installing

Golf 2004 ➤
3.15.2 Left Footwell Vent

agen
AG. Volkswagen AG d
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– Remove the driver eside d b footwell cover. Refer to ⇒ BodyuInte‐
yV tg
ara
rior; Rep. Gr. 68hor;isRemoval and Installation . nte
e
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au ac
– Remove the sbolts
s -2- (1.5 +/- 0.2 Nm) and remove left footwell
vent -1-.
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Installing
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3.15.3 Rear Footwell Channel
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Note
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The procedure for removing rear channels is identical for both

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sides.
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– Remove driver or front passenger seat. Refer to ⇒ Body In‐ do

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terior; Rep. Gr. 72 ; Removal and Installation .

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– Remove the center instrument panel. Refer to ⇒ Body Interior; Cop py
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Rep. Gr. 68 ; Removal and Installation . opyri
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– Lift floor carpet, unclip rear channel from floor and pull off from
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AG.
Installing
Note
When installing the rear channel, ensure the rear channel is first
slid onto heater -arrow- and then clipped in to floor.
3.15.4 Rear Vents in Armrest
Note
Removing and installing the rear vents in the armrest is described

in ⇒ Body Interior; Rep. Gr. 68 ; Removal and Installation .

Golf 2004 ➤
Heating,
en AGVentilation
. Volkswagen and
AG Air Conditioning - Edition 04.2015
ag does
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Note
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♦ The procedure for removing the vent is identical for both sides.
rm
ab
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♦ To prevent damage to instrument panel, use a pad when pry‐ ot
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ing out.
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Removing
t to the co
– Pry out vent -1- using an appropriate tool.
– Disconnect the connector from the vent.
rrectness of i
Installing
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3.15.6 Right Footwell Vent
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– Remove bolts -2- (1.5 +/- 0.2 Nm) and remove right footwell
vent -1-.
Installing
Note
If the vehicle has glove compartment cooling, check the cold air
hose to make sure it is installed correctly.

Golf 2004 ➤
4 Disassembly and Assembly

⇒ “4.1 Heater”, page 24
4.1 Heater
Disassembling
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– Remove the heater. Refer to ⇒ “3.11 Heater Unit”, page 16 .

t to the co
– Removing the air distribution housing. Refer to

⇒ “3.1 Air Distribution Housing”, page 6 .
rrectness of i
– Loosen the clips -2- and the bolts -arrows- from the heater unit.
l purpos
– Remove the heater unit.

nf
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Assembling
orm
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atio
Assemble in reverse order.

om
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Rep. Gr.80 - Heating, Ventilation Prote AG.
Golf 2004 ➤
5 Special Tools
AG. Volkswagen AG d
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♦ Template - 1598/47-2-
rrectness of i
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5. Special Tools 25
Golf 2004 ➤
87 – Air Conditioning
1 General Information
⇒ “1.1 A/C System, Repairing and Handling Refrigerant”,
page 26
⇒ “1.2 A/C Compressor, Installation Information”, page 26
⇒ “1.3 Climatronic A/C System with Automatic Controls ”,
page 28
⇒ “1.4 Odors in Vehicles with A/C”, page 28
⇒ “1.5 Refrigerant Circuit, Specialized Repairs”, page 29
1.1 A/C System, Repairing and Handling

Refrigerant
♦ Information regarding repair work on vehicles with A/C and
handling refrigerant. Refer to ⇒ Refrigerant R134a Servicing;
Rep. Gr. 00 .
♦ Information regarding testing equipment and tools for repairs
done on vehicles with A/C. Refer to ⇒ Refrigerant R134a
Servicing; Rep. Gr. 00 .
♦ Information regarding work using the A/C Service Station on
vehicles with A/C. Refer to ⇒ Refrigerant R134a Servicing;
Rep. Gr. 00 .
♦ Conditions and procedures for flushing with refrigerant R134a.
Refer to ⇒ Refrigerant R134a Servicing; Rep. Gr. 00 .
AG. Volkswagen AG d
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Caution Volksw
oes
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Do not bend or kink A/C lines excessively. ut
hor eo
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There is a foil inside the refrigerant lines that can be destroyed. s
ce
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un
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Refrigerant lines must not be bent beyond a radius less than
an
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R = 100 mm.
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Further information:
ole,
spec
♦ Refer to ⇒ Wiring diagrams, Troubleshooting & Component

locations. t to the co
1.2 A/C Compressor, Installation Informa‐

rrectne
tion
– Start the engine only after assembling the refrigerant circuit.
ss o
cial p
– After installing a new A/C compressor or fresh refrigerant oil

inform
has been filled into compressor (for example, after blowing

mer
through the A/C system), turn ribbed belt pulley of A/C com‐
atio
m
pressor 10 rotations by hand before starting the engine. This

o
n
c
prevents damage to the A/C compressor.

i
or
n thi
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– Only start the engine when the refrigerant circuit is filled.

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26 Rep. Gr.87 - Air Conditioning

Golf 2004 ➤
Note
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♦ The A/C compressor is always driven byethe d by ribbed belt pulley ua
ran
(no A/C clutch). thoris tee
u or
a ac
♦ If the A/C compressor is blocked,ssthe compressor shaft over‐
load protection is activated. The blockage is mostly recog‐
ce
e
nl
pt
du
nized by deformations/bumps on the ribbed belt pulley. In
an
itte
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addition, the blockage can be recognized by the abraded rub‐
erm
ab
ber in the area of the ribbed belt pulley.
ility
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♦ The A/C compressor is equipped with a protected oil supply,
h re
this prevents A/C compressor damage in the event that the
hole
spec
system is empty. This means that approximately 40 to 50
es, in part or in w
cm3 of refrigerant oil remains in the A/C compressor.
t to the co
♦ The engine may only be started when the refrigerant circuit is
installed correctly. For example; if the refrigerant lines are not
rrectness of i
connected to A/C compressor, when the engine is running the
A/C compressor may heat up (via internal heat generation) so
l purpos
much that the A/C compressor will be damaged.

♦ A/C Compressor Regulator Valve - N280- is not activated
nf
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o
when the refrigerant circuit is empty and the A/C compressor
rm
m
idles with the engine.
atio
om
n in
c
♦ If it is necessary to start the engine with a discharged refrig‐

or
thi
erant circuit:
te
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♦ Refrigerant circuit must be fully assembled.
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♦ At least 1/4 of the prescribed refrigerant oil must be in the A/
yi Co
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C compressor.
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♦ Do not rev engine higher than 2000 rpm.
cop Vo
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♦ The engine should only run as long as is absolutely necessary,
maximum 10 minutes.
Note
Pay attention to the following when starting the engine for the first
time after filling the refrigerant circuit:
– Start engine with A/C compressor switched off (“ECON”

mode) and wait until the idling speed stabilizes.
– Open the instrument panel vents.
– Select the temperature setting “Lo” on the Front A/C Display
Control Head - E87- .
– Turn on the A/C compressor (“AUTO”) and let the engine run
for 5 minutes at idling speed.
1. General Information 27
Golf 2004 ➤
1.3 Climatronic A/C System with Automatic

Controls
Note
♦ Switching from °C to °F and back. Hold down the AUTO button

and then press the ECON or AC buttons.
♦ Pressing the button AUTO will reverse all settings which devi‐
ate from the automatic operation.
♦ Deviations from automatic operation, refer to respective oper‐
ating instructions.
AG. Volkswagen AG d
agen oes
♦ For vehicles through 21/07: If the ECON button is on, ythe
Vol A/C
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gu
compressor is set to almost 0 delivery. Depending ris
edon the ve‐
b ara
nte
hicle equipment level, the Auxiliary Air HeateruHeating
tho Ele‐ eo
ment - Z35- or the auxiliary heater (being used
ss aas an additional ra
c
heater) is switched off . The auxiliary heating remains switched
ce
le
un
on if it is activated manually. The specific ambient conditions
pt
an
d
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or activation signals must be present. The heating and venti‐
y li
rm
ab
lation operation continues to be controlled electronically.
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♦ When the ECON button is off, the A/C compressor turns on.
wit
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Depending on the vehicle equipment level, the Auxiliary Air
hole
Heater Heating Element - Z35- or the auxiliary heater (being
spec
es, in part or in w
used as an additional heater) is switched on. The auxiliary
t to the co
heating remains switched on if it is activated manually. The
specific ambient conditions or activation signals must be
present. The heating and ventilation operation continues to be
rrectness of i
controlled electronically.
l purpos
♦ When the ON/OFF button is on, the Climatronic works.

♦ When the ON/OFF button is off, the Climatronic does not work.
nform
ercia
There is no heating or ventilation.

m
a
♦ Vehicles from May 28 2007 do not have an ECON button. The
com
tion in
AC button replaces it. The ON/OFF button is no longer there.
r
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The OFF button replaces it.
s
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♦ When the AC button is on, the A/C compressor turns on. De‐
um
fo
en
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pending on the vehicle equipment level, the Auxiliary Air Heat‐

n
t.
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er Heating Element - Z35- or the auxiliary heater (being used Cop py
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as an additional heater) is switched on. The auxiliary heating yri
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remains switched on if it is activated manually. The specific cop Vo
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ambient conditions or activation signals must be present. The cted agen
Prote AG.
heating and ventilation operation continues to be controlled
electronically.
♦ If the AC button is off, the A/C compressor is set to almost 0
delivery. Depending on the vehicle equipment level, the Aux‐
iliary Air Heater Heating Element - Z35- or the auxiliary heater
(being used as an additional heater) remains switched on. The
auxiliary heating remains switched on if it is activated man‐
ually. The specific ambient conditions or activation signals
must be present. The heating and ventilation operation con‐
tinues to be controlled electronically.
♦ OFF button is on. Climatronic is switched off. There is no heat‐
ing or ventilation.
♦ OFF button is off. Climatronic is switched on.
1.4 Odors in Vehicles with A/C

♦ If there are unpleasant odors coming from the evaporator,
clean the evaporator.

Golf 2004 ➤
♦ For cleaning the evaporator, Volkswagen has tested and ap‐

proved the Ultrasound A/C Cleaner - VAS6189B- as well as
the Suction Feed Spray Gun - VAG1538- with a suitable spray
nozzle.
♦ Instructions for cleaning the evaporator are provided with the
tools.
♦ As soon as Volkswagen approves new procedures, the rele‐
vant notes can be found in the repair manual. Refer to ⇒
Refrigerant R134a Servicing; Rep. Gr. 00 .
1.5 Refrigerant Circuit, Specialized Repairs

In some countries, other qualifications are required when opening
the refrigerant circuit.
Further Information
♦ Information regarding repair work on vehicles with A/C and
handling refrigerant.wRefer
agen to ⇒ Refrigerant
AG. Volkswagen AG d R134a Servicing;
oes
Rep. Gr. 00 . y Volks not
gu b ara
ed
♦ Informationho regarding testing equipment and tools for erepairs
ris nte
done on
s aut vehicles with A/C. Refer to ⇒ Refrigerant R134aor
ac
s
ce
e
nl
pt
du
♦ Information regarding work using the A/C Service Station on

an
itte
vehicles with A/C. Refer to ⇒ Refrigerant R134a Servicing; y li

erm
Rep. Gr. 00 . ab
ility
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♦ Conditions and procedures for flushing with refrigerant R134a. h re

hole
spec
es, in part or in w
t to the co
rrectness of i
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1. General Information 29
Golf 2004 ➤
2 Description and Operation

⇒ “2.1 Air Quality Sensor G238 ”, page 30
⇒ “2.2 Climatic A/C System with Manual Control Overview”, page
31
⇒ “2.3 Climatic Heating and A/C Controls, Multi-pin Harness Con‐
nectors”, page 34
⇒ “2.4 Climatronic A/C Display Control Head Function”,
page 35 n AG. Volkswagen AG do
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⇒ “2.5 Climatronic Control Module, Multi-pin Harness
ed
by V Connec‐ ua
ran
tors”, page 36 horis tee
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au ac
⇒ “2.6 Climatronic A/C System with Automatic
ss Control Overview”,
page 38
ce
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nl
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⇒ “2.7 Evaporator Housing Overview”, page 42
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erm
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⇒ “2.8 Refrigerant Circuit Components Overview”, page 42
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⇒ “2.9 Ribbed Belt Pulley, Denso A/C Compressor Overview”,
h re
hole
page 45
spec
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2.1 Air Quality Sensor - G238-
t to the co
♦ The air quality sensor detects pollutants in the ambient air
(mostly gasoline and/or diesel fumes).
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♦ Climatronic Control Module - J255- evaluates the signal from
l purpos
the air quality sensor. The A/C system is activated depending

on the strength and type of heavily polluted air.
nform
ercia
At an outside temperature greater than approximately + 2° C (35.6

m
°F), recirculation mode is switched on when there is only a slight
at
om
io
increase in pollutants in the ambient air.
n
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At an outside temperature between approximately + 2° C (35.6 °

at
do
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F) and approximately -5° C (23 °F), the switch to recirculation

p
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mode only occurs at a sharp increase in the pollutant level. The
for
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A/C compressor is switched on at the same time.

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p by
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is a significant increase in the level of pollutants. However, it only Prote
cted AG.
agen
switches on for approximately 15 seconds and the A/C compres‐
sor does not switch on. If the concentration decreases, the air
conditioner switches to the fresh air mode.
♦ “Automatic recirculating air mode” can be switched off at any
time. If the function is active, the A/C compressor is switched
on with a request for “automatic recirculating air mode”, in‐
cluding when the outside air temperature is below 2° C (35.6
°F). If the temperature is less than approximately -5° C (23 °
F), it is not possible to use the A/C compressor.
♦ In the case of vehicles with “automatic recirculation mode”, the
A/C compressor can be switched on at a temperature of up to
approximately -5° C (23 °F) even if recirculation mode is acti‐
vated manually.
♦ To ensure that the A/C does not operate constantly in the re‐
circulating air mode in areas with a consistently higher pollu‐
tion, the sensor is self learning (it adjusts its sensitivity to the
environmental conditions).
♦ If outside air pollution load remains high for longer period of
time, the sensor starts to adapt itself to the changing environ‐
mental condition through an adaptation program (learning
program), the air recirculation request in evenly polluted am‐
bient air is therefore generally shorter than 12 minutes. If a
succession of peaks in the polluted air is detected, the air con‐

Golf 2004 ➤
ditioning system can operate over a longer period of time in

recirculated air mode.
♦ A certain amount of time is required for repositioning of the air
conditioning system doors. In the event that a sudden increase
in pollutants is encountered (for example, when driving
through a diesel exhaust cloud) gaseous pollutants can be
taken in with the fresh air into the passenger compartment until
the door can be closed. For this reason, a dust and pollen filter
is installed with a charcoal layer. A filter that is saturated with
pollutants is no longer effective and needs to be replaced .
♦ In order to avoid frequent shifting of the recirculated air/fresh
air door, a slight increase of pollutants in the ambient air will
not allow for immediate shifting (the sensor does not send a
request to the Climatronic Control Module - J255- ). The filter‐
ing of the charcoal insert in the dust and pollen filter will be
sufficient .
♦ In order to avoid frequent shifting of the recirculating air/fresh
air door, the requirement from the sensor for “Automatic air
recirculation” mode remains for at least 25 seconds (minimum
duration period), even if the pollutant concentration is so far
reduced that recirculating air mode is no longer necessary.
♦ If the A/C compressor is switched off, then the Climatronic
control module limits the “automatic recirculating air mode” to
a maximum of approximately 15 seconds to prevent the win‐
dows from fogging up.
♦ So that fogged windows are cleared as quickly as possible,
the Climatronic Controln AGModule
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en AG not permit recirculated
wage does
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♦ After hthe
ris ignition is switched on, the air quality sensor
nte
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ut o
approximately 30 seconds to be operational (warm-up r a time).
a c
During
ss this time there is no requirement from the sensor to
ce
le
Climatronic Control Module for “Automatic recirculated air”

un
pt
an
mode.
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♦ The air quality sensor contains a highly sensitive electronic

pe
ility
component which can be damaged if it comes in direct contact

ot
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with solvents, fuels or chemicals. For this reason, do not install

h re
sensors that may have come into contact with these substan‐
hole
spec
ces.
es, in part or in w
t to the co
2.2 Climatic A/C System with Manual Con‐

trol Overview
rrectness of i
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Note
nform
ercia
♦ Disconnect the battery before removing the components

marked with **. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ;
m
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ion in
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♦ A data plate on the lock carrier indicates the refrigerant used

thi
s
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and capacity.
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Golf 2004 ➤
1 - Dash Panel **
2 - Center Vents
ling. Refer to
⇒ “3.15.1 Center Vent”, n AG. Volkswagen AG do
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page 21 . olks es n
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byV ua
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3 - Right Side Vent ir se tee
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4 - Right Vent ss
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e
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pt
du
an
ling. Refer to
itte
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⇒ “3.15.5 Right or Left
erm
ab
Vent”, page 23 .
ility
ot p
wit
, is n
5 - “Climatic” Heating and A/C
h re
hole
Controls With A/C Control
spec
Module - J301-
es, in part or in w
t to the co
❑ With Instrument Panel
Interior Temperature
Sensor - G56- .
rrectness of i
❑ With Fresh Air/Recircu‐
lating Door Switch -
l purpos
E159- .
❑ With Rear Window De‐
nf
ercia
o
fogger Switch - E230- .
rm
m
atio
❑ With Fresh Air Blower
om
Switch - E9- .
n in
or c
thi
e
❑ With A/C Control Mod‐

t
sd
iva
ule - J301- .
o
r
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cu
o
m
❑ With Heated Driver Seat
f
en
ng
t.
yi
Adjuster - E94- and
Co
op py
Heated Front Passen‐ t. C rig
gh ht
ger Seat Adjuster - yri
p by
o Vo
E95- .
c by lksw
cted agen
Prote AG.
ling. Refer to
⇒ “5.3 Climatic A/C Con‐
trols”, page 53 .
6 - Recirculation Door Motor - V113-
❑ Checking. Refer to Vehicle Diagnosis, Testing and Information System - VAS5051B- .
❑ Removing and installing. Refer to
⇒ “5.7.8 Recirculation Door Motor V113 , Removing and Installing”, page 72 .
❑ Replacing, initiate Basic Setting function with Vehicle Diagnosis, Testing and Information System -
VAS5051B- . Refer to ⇒ “4.2 Climatronic, Checking and Adjusting Components”, page 48 .
❑ Removing and installing. Refer to ⇒ “3.6 Fresh Air Blower V2 ”, page 11 .
11 - Evaporator Temperature Sensor - G308- or Evaporator Vent Temperature Sensor - G263-

Golf 2004 ➤
Note
One or both of the component des‐

ignations will appear, depending on
software. The tasks are the same.
❑ Removing and installing. Refer to gen AG
. Volkswagen AG
does
swa
⇒ “5.6.3 Evaporator Temperature Sensor y V G308 or Evaporator Vent Temperature
olk not
gu Sensor G263 ”, page
61 . ris
edb ara
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tho or
12 - Cap au ac
ss
❑ Only in vehicles without air guide to vent installed in center console at rear.
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pt
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ility
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wit
, is n
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hole
14 - Connection
spec
es, in part or in w
❑ For center console air guide.
t to the co
❑ The center console must be removed to remove it. Refer to ⇒ Body Interior; Rep. Gr. 68 ; Removal and
Installation .
rrectness of i
l purpos

nf
ercia
orm
m
atio
17 - Screw
om
n in
c
❑ Quantity: 8
or
thi
te
sd
a
18 - Adapter For Controls

iv
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cu
o
m
f
en
ng
t.
yi Co
❑ Only installed on vehicles with Diesel engine. Cop py
t. rig
gh ht
yri
20 - Heater Core p by
o Vo
by c lksw
cted
agen
Prote AG.

22 - Temperature Regulator Door Motor - V68-
⇒ “5.4.6 Temperature Control Door Motor V68 , Removing and Installing”, page 57 .
23 - Flexible Shaft
❑ Removing and installing. Refer to ⇒ “3.5 Flexible Air Distribution Shaft”, page 10 .
24 - Footwell Outlet Temperature Sensor - G192-
❑ Removing and installing. Refer to ⇒ “5.4.3 Footwell Outlet Temperature Sensor G192 ”, page 55 .
25 - Heating and A/C Unit
❑ Removing and installing. Refer to ⇒ “5.11 Heating and A/C Unit”, page 81 .
❑ Disassembling and assembling. Refer to ⇒ “6.1 Climatic Heating and A/C Unit ”, page 102 .
26 - Left Side Vent
27 - Center Outlet Temperature Sensor - G191-
❑ Removing and installing. Refer to ⇒ “5.4.1 Center Vent Temperature Sensor G191 ”, page 54 .

Golf 2004 ➤
2.3 Climatic Heating and A/C Controls, Mul‐

ti-pin Harness Connectors
♦ Template - 1598/47-2-
20-pin Harness Connector, (T20c)
wage es n
3 - Center Outlet Temperature Sensor - G191- yV
olks ot g
ua
d b ran
5 - High Pressure Sensor - G65- ir se tee
tho
u or
a ac
7 - CAN Low ss
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pt
8 - CAN High
du
an
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12 - Right seat heater (optional)
erm
ab
ility
ot p
13 - Left seat heater (optional)
wit
, is n
h re
15 - Terminal 75 seat heater (optional)
hole
spec
es, in part or in w
16 - A/C Compressor Regulator Valve - N280-
t to the co
18 - Center Outlet Temperature Sensor - G191- ground
19 - Terminal 30A
rrectness of i
20 - Terminal 31
l purpos
16-pin Harness Connector, (T16e)
nf
ercia
or
1 - Temperature Regulator Door Motor - V68- , warm
m
m
atio
m
2 - Evaporator Temperature Sensor - G308- or Evaporator Vent

o
n in
or c
Temperature Sensor - G263-
thi
te
sd
iva
4 - Footwell Outlet Temperature Sensor - G192-
o
r
rp
cu
o
m
f
en
ng
5 - Temperature Regulator Door Motor Position Sensor - G92- yi

t.
Co
op py
7 - + 5 volt for Temperature Regulator Door Motor Position Sensor
t. C rig
gh ht
yri
- G92- p by
co Vo
by lksw
cted agen
8 - Ground for Temperature Regulator Door Motor Position Sen‐ Prote AG.
sor - G92- , Center Outlet Temperature Sensor - G191- , Footwell
Outlet Temperature Sensor - G192- and Evaporator Temperature
Sensor - G308- or Evaporator Vent Temperature Sensor - G263-
9 - Recirculation Door Motor - V113- , open
10 - Recirculation Door Motor - V113- , close
11 - Temperature Regulator Door Motor - V68- , cold
5-pin Harness Connector, (T5)

1 - 3rd blower speed
2 - 2nd blower speed
3 - 1st blower speed
4 - 4th blower speed
5 - Terminal X and depending on the vehicle equipment level
Auxiliary Heater Operation Relay - J485-

AG. Volkswagen AG d
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ed
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aut
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ra Golf 2004 ➤
s c
s Heating, Ventilation and Air Conditioning - Edition 04.2015
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d
2.4 Climatronic A/C Display Control Head Function
itte
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1 - Display Of Selected Interior
h re
Temperature, Left Side
hole
spec
es, in part or in w
Switching from °C to °F and
t to the co
back. Hold down the AUTO but‐
ton and then press the ECON or
AC buttons.
rrectness of i
l purpos
2 - Recirculating Air Mode But‐

ton
❑ Press button for recircu‐
nform
ercia
lating air function to pre‐

m
vent polluted air from
a
com
tio
entering interior.
n in
r
te o
thi
3 - Button - Center Air Distri‐
s
iva
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bution
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cum
fo
4 - Button - Lower Air Distribu‐
en
ng
t.
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tion . Cop py
rig
ht ht
rig
5 - Button - Upper Air Distribu‐ py by
co Vo
tion
by lksw
cted agen
Prote AG.
6 - Display Of Selected Interior
Temperature, Right Side
Switching from °C to °F and
back. Hold down the AUTO but‐
ton and then press the ECON or
AC buttons.
7 - Recirculating Air Mode Or

Automatic Recirculating Air
Mode Button
❑ Press button for recircu‐
lating air function to pre‐
vent polluted air from
entering interior.
❑ Vehicles through
05/2007. Pressing the
recirculation button again activates the automatic recirculation function.
Note
♦ Only for vehicles with an Air

Quality Sensor - G238- .
♦ Air quality sensor function. Refer
to
⇒ “2.1 Air Quality Sensor G238
”, page 30 .
♦ Removing and installing. Refer
to
⇒ “5.1 Air Quality Sensor G238
”, page 50 .

Golf 2004 ➤
AG. Volkswagen AG d
agen oes
8 - Windshield Defroster Button olksw not
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9 - Push Button For Rear Window Defroster
thori
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au ra
10 - Interior Temperature Regulator,
ss Left c
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pt
11 - Blower Regulator
du
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12 - Dual Button or Immediate Heating Button - E537- erm
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❑ If the indicator light in the button comes on, different temperatures can be set for left and right.
wit
, is n
h re
❑ When the Dual button is pressed (the indicator lamp turns off), then the temperature setting for the driver
hole
spec
seat will also apply to the front passenger seat.
es, in part or in w
t to the co
Note
♦ On vehicles with auxiliary heater
rrectness of i
(parking heater function), the Im‐
mediate Heating Button - E537-
l purpos
is in this location.
nf
ercia
♦ In order to switch on the dual
or
function on vehicles with auxili‐
m
m
atio
ary heating, press the AUTO but‐
om
n in
ton for 3 seconds.
or c
thi
te
sd
iva
13 - Instrument Panel Interior Temperature Sensor - G56-
o
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cu
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m
f
14 - A/C Pressure Switch OFF or ON/OFF
en
ng
t.
yi Co
op py
15 - AUTO Button
t. C rig
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pyri by
❑ By pressing the AUTO button, Climatronic maintains the selected vehicle interior temperature completely
co Vo
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cted agen
automatically. With this setting the vent air temperature, the blower speed and the air distribution are Prote AG.
controlled automatically.
16 - AC Button
❑ For information regarding vehicles through 05/20/2007 and from 05/27/2007. Refer to
⇒ “1.3 Climatronic A/C System with Automatic Controls ”, page 28 .
❑ By switching the AC button off, the compressor is set to almost zero delivery. The heating and ventilation
operation continues to be controlled electronically.
17 - ECON Button
❑ For information regarding vehicles through 05/20/2007 and from 05/27/2007. Refer to
⇒ “1.3 Climatronic A/C System with Automatic Controls ”, page 28 .
❑ By pressing the ECON button, A/C compressor is set to almost zero delivery. The heating and ventilation
operation continues to be controlled electronically. The auxiliary heater (optional) is also switched off.
18 - Interior Temperature Regulator, Right
2.5 Climatronic Control Module, Multi-pin

Harness Connectors
♦ Template - 1598/47-2-

Golf 2004 ➤
20-pin Harness Connector, (T20c) -A-

1 - Sunlight Photo Sensor 2 - G134- or Sunlight Photo Sensor -
G107- , signal
2 - High Pressure Sensor - G65-
3 - Sunlight Photo Sensor 2 - G134- or Sunlight Photo Sensor -
G107- , signal
4 - From 11.05/2007 Air Quality Sensor - G238- , signal
5 - CAN High
6 - CAN Low
9 - + 5 volt for Sunlight Photo Sensor 2 - G134- or Sunlight Photo
Sensor - G107-
10 - Heated Driver Seat Control Module - J131- (optional)
11 - Heated Front Passenger Seat Control Module - J132- (op‐
tional)
12 - Terminal 75 (optional)
13 - Left Vent Temperature Sensor - G150-
Volkswagen AG
14 - Right Vent Temperature Sensor
swa
-geG151-
n AG. does
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y V g
16 - Positive connection (15a) ed bor on vehicles with auxiliary heateruara
nte
is
and Air Quality Sensor -thG238-
or positive connection (30a) eo
au ra
c
17 - Sensor signal ground
ss
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pt
du
18 - A/C Compressor Regulator Valve - N280-

an
itte
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erm
19 - Terminal 31 ab
ility
ot p
20 - Positive connection (15a) or in vehicles with auxiliary heater

wit
, is n
h re
positive connection (30a)
hole
spec
es, in part or in w
16-pin Harness Connector, (T16c) -B-

t to the co
1 - + 5 volt for control motors

2 - Left Temperature Door Potentiometer/Actuator - G220-
rrectness of i
3 - Right Temperature Door Potentiometer/Actuator - G221-

l purpos
4 - Defroster Door Motor Position Sensor - G135-

nf
ercia
5 - Central Door Motor Position Sensor - G112-

rm
m
atio
m
6 - Vehicles through 04/2007 Recirculation Door Motor Position

o
n in
c
Sensor - G143- . Vehicles from 05/2007 Recirculation Door Motor

or
thi
Position Sensor - G143- discontinued

te
sd
iva
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rp
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7 - Vehicles through 04/2007 Back Pressure Door Motor Position

o
m
f
Sensor - G113- . Vehicles from 05/2007 Fresh Air/Recirculating

en
ng
t.
yi
Air/Back Pressure Door Motor Position Sensor - G644-
Co
Cop py
t. rig
gh
8 - Left Footwell Vent Temperature Sensor - G261-
ht
pyri by
Vo
o
by c lksw
cted
9 - Right Footwell Vent Temperature Sensor - G262-
agen
Prote AG.
10 - Fresh Air Intake Duct Temperature Sensor - G89- only in‐

stalled through 12/2005
11 - Evaporator Temperature Sensor - G308- or Evaporator Vent
Temperature Sensor - G263-
14 - Signal Ground (GND) potentiometer

Golf 2004 ➤
16-pin Harness Connector, (T16d) -C-

1 - Left Temperature Door Motor - V158- , cold
2 - Left Temperature Door Motor - V158- , warm
3 - Defroster Door Motor - V107- , closed
4 - Defroster Door Motor - V107- , open
5 - Central Air Door Motor - V70- , upper body outlet
6 - Central Air Door Motor - V70- , footwell
7 - Vehicles through 04/27/2007 Air Recirculation Door Motor -
V113- , recirculating air mode activation. From 05/2007, Recircu‐
lation Door Motor - V113- discontinued
8 - Vehicles through 04/2007 Recirculation Door Motor - V113- ,
fresh air activation. From 05/2007, Recirculation Door Motor -
V113- discontinued
9 - Through 04/2007 Air Flow Door Motor - V71- , open. From
04/29/2007, Fresh Air/Recirculating Air/Back Pressure Door Mo‐
tor - V425- (recirculation mode/partial recirculation)
10 - Through 04/2007 Air Flow Door Motor - V71- , closed. From
05/2007 Fresh Air/Recirculating Air/Back Pressure Door Motor -
V425- (recirculation mode/back pressure)
11 - Right Temperature Door Motor - V159- , cold
12 - Right Temperature Door Motor - V159- , warm
15 - Fresh Air Blower - V2- (PWM activation)
16 - Fresh Air Blower - V2- , return message signal
2.6 Climatronic A/C System with Automatic

Control Overview
Note AG. Volkswagen AG d

agen oes
olksw not
♦ Disconnect the battery before removing the components ed by V gu
ara
marked with **. Refer to ⇒ Electrical Equipment; Rep. Gr.horis27 ; nte
eo
Removal and Installation . s aut ra
c
s
♦ A data plate indicates the refrigerant used and capacity.
ce
e
nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
by
38
copy Vo
by lksw
Rep. Gr.87 - Air Conditioning cted agen
Prote AG.
Golf 2004 ➤
1 - Dash Panel **
ling. Refer to ⇒ Body
Interior; Rep. Gr. 70 ;
Removal and Installa‐
tion . agen
AG. Volkswagen AG d
oes
olksw not
V gu
2 - Sunlight Photo Sensor - d by ara
G107- or Sunlight Photo Sen‐ rise nte
tho eo
sor 2 - G134- s au ra
c
s
❑ Checking. Refer to Ve‐
ce
e
nl
pt
du
an
itte
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erm
ab
- VAS5051B- .
ility
ot p
❑ Tasks: Controls temper‐
wit
, is n
ature door and fresh air
h re
hole
blow depending on light
spec
intensity.
es, in part or in w
t to the co
❑ Emergency running in
the event of failure: the
Climatronic Control
rrectness of i
Module - J255- utilizes a
fixed value.
l purpos

ling. Refer to
nform
ercia
⇒ “5.10 Sunlight Photo

Sensor G107 / Sunlight
m
at
om
Photo Sensor G134 ”,
ion
c
page 81 .
in t
or
his
ate
3 - Indirect Ventilation
do
priv
cum
or

f
en
g
ling. Refer to
n
t.
yi Co
op
⇒ “5.8 Climatronic Indi‐ C py
t. rig
rect Ventilation”,
gh ht
pyri by
page 78 .
co Vo
by lksw
cted agen
Prote AG.
4 - Center Vents
ling. Refer to ⇒ “3.15.1 Center Vent”, page 21 .
5 - Right Side Vent
6 - Air Outlet
❑ Removing and installing. Refer to ⇒ “3.15.5 Right or Left Vent”, page 23 .
7 - Right Vent Temperature Sensor - G151-
⇒ “5.6.2 Left Vent Temperature Sensor G151 / Right Vent Temperature Sensor G150 ”, page 61 .
8 - Climatronic Control Module - J255-
❑ The Climatronic Control Module and the Front A/C Display Control Head - E87- are one component that
cannot be disassembled.
❑ Removing and installing. Refer to ⇒ “5.5 Climatronic A/C Controls”, page 59 .
❑ Replacing, initiate Basic Setting function with Vehicle Diagnosis, Testing and Information SystemB -
VAS5051- . Refer to ⇒ “4.2 Climatronic, Checking and Adjusting Components”, page 48 .
9 - Vehicles Through 04/2007 Air Flow Door Motor - V71- ; From 05/2007 Fresh Air/Recirculating Air/Back
Pressure Door Motor Position Sensor - V425-
⇒ “5.7.1 Airflow Door Motor V71 , Removing and Installing, on Vehicles through 04/30/2007”,
page 63 on vehicles through 04/2007.

Golf 2004 ➤
⇒ “5.7.4 Fresh Air/Recirculating Air/Back Pressure Door Motor V425 , Removing and Installing, Vehicles
from 04/30/2007”, page 66 on vehicles from 05/2007.
❑ Replacing, initiate Basic Setting function with the Vehicle Diagnosis, Testing and Information System -
10 - Vehicles Through 04/2007 Recirculation Door Motor - V113- , From 05/2007 the Recirculation Door Motor
- V113- is Discontinued.
11 - Fresh Air Intake Duct Temperature Sensor - G89-
❑ Only installed on vehicles through 12/2005.
❑ Task: Temperature sensor controls temperature door and fresh air blower depending on temperature.
❑ To disassemble, remove the instrument panel. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Removal and
Installation .
13 - Fresh Air Blower - V2- with Fresh Air Blower Control Module - J126-
❑ On vehicles from 11/2005, Fresh Air Blower Control Module can be replaced separately.
❑ Fresh Air Blower, removing and installing. Refer to ⇒ “3.6 Fresh Air Blower V2 ”, page 11 .
❑ Fresh Air Blower Control Module, removing and installing. Refer to
⇒ “5.9 Fresh Air Blower Control Module J126 ”, page 80 .
14 - Connector
16 - Cap AG. Volkswagen AG d
agen oes
❑ Only in vehicles without
Volkswair guide to vent installed noin
t g center console at rear.
by ua
ed ra
17 - Dust and Pollen riFilter
s nte
utho eo
❑ With activated
ss a charcoal filter. ra
c
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e
nl
pt
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an
itte
18 - Center Console Air Duct Connection (Optional)

y li
erm
ab
❑ The center console must be removed to remove it. Refer to ⇒ Body Interior; Rep. Gr. 68 ; Removal and
ility
ot p
Installation .
wit
, is n
h re

hole
spec

es, in part or in w
t to the co

rrectness of i

l purpos

nf
ercia
Note
orm
m
atio

om
n in

or c
thi

te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
40
cop Vo
by lksw
Rep. Gr.87 - Air Conditioning Prote
cted AG.
agen
Golf 2004 ➤
⇒ “5.6.3 Evaporator Temperature Sensor G308 or Evaporator Vent Temperature Sensor G263 ”, page
61 .
22 - Right Temperature Door Motor - V159-
⇒ “5.7.7 Right Temperature Control Door Motor V159 , Removing and Installing”, page 71 .
❑ Replacing, initiate Basic Setting using the Vehicle Diagnosis, Testing and Information System -
24 - Heater Core
25 - Central Air Door Motor - V70-
⇒ “5.7.2 Central Air Door Motor V70 , Removing and Installing”, page 64 .
27 - Left Temperature Door Motor - V158-
⇒ “5.7.6 Left Temperature Control Door Motor V158 , Removing and Installing”, page 69 .
VAS5051- . Refer to ⇒ “4.2 Climatronic,
agen
Checking
AG. Volkswagand Adjusting
en AG
do Components”, page 48 .
w es n
olks o
28 - Left Footwell Vent Temperature d b Sensor - G261-
yV t gu
ara
ir se nte
❑ Checking. Refer to Vehicle
utho Diagnosis, Testing and Information System e o - VAS5051- .
a ra
❑ Removing. Refer to ⇒ ss “5.6.1 Left Footwell Vent Temperature Sensor G261 c ”, page 60 .
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e
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pt
29 - Defroster Door Motor - V107-

du
an
itte
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❑ Checking. Refer to Vehicle Diagnosis, Testing and Information System - VAS5051- .

erm
ab
ility

ot p
wit
⇒ “5.7.3 Defroster Door Motor V107 , Removing and Installing”, page 65 .

, is n
h re
hole
spec

es, in part or in w
t to the co
30 - Heating and A/C unit

❑ Removing and installing. Refer to ⇒ “5.11 Heating and A/C Unit”, page 81 .
rrectness of i
❑ Disassembling and assembling. Refer to ⇒ “6.2 Climatronic Heating and A/C Unit”, page 104 .
l purpos
31 - Right Footwell Vent Temperature Sensor - G262-

nform
ercia
❑ Removing. Refer to ⇒ “5.6.5 Right Footwell Vent Temperature Sensor G262 ”, page 62 .
m
at
32 - Left Side Vent

om
ion
c
in t
r
33 - Left Vent Temperature Sensor - G150-

o
his
ate

do
priv
cum
or

f
en
g
⇒ “5.6.2 Left Vent Temperature Sensor G151 / Right Vent Temperature Sensor G150 ”, page 61 .
n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004 ➤
2.7 Evaporator Housing Overview

– Remove the heating and A/C unit. Refer to
⇒ “5.11 Heating and A/C Unit”, page 81 .
– Remove the air distribution housing/evaporator housing from
the heater and A/C unit. Refer to
⇒ “3.1 Air Distribution Housing”, page 6 .
1 - Evaporator Housing Lower

Section
❑ Disassembling and as‐
sembling. Refer to
⇒ “4.1 Heater”,
page 24 .
2 - Evaporator
❑ Check insulation, it must
be completely present.
ling. Refer to
⇒ “5.13.3 Evaporator”,
page 89 .
3 - Clip
4 - Evaporator Housing Upper AG. Volkswagen AG d
Section agen oes
olksw not
V gu
by
❑ Disassembling and as‐ rised ara
nte
sembling. Refer to ut
ho eo
ra
⇒ “4.1 Heater”, ss a c
page 24 .
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pt
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an
5 - Screw
itte
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erm
ab
6 - Seal / Insulation
ility
ot p
wit
❑ Heat insulation for ex‐

, is n
h re
pansion valve.
hole
spec

es, in part or in w
ling. Refer to
t to the co
page 89 .
rrectness of i
7 - Bracket
l purpos

ling. Refer to
nform
ercia
page 89 .
m
at
om
ion
c
in t
or
2.8 Refrigerant Circuit Components Over‐

his
ate
do
riv
view
p
cum
for
en
ng
t.
yi
Co
Cop py
t. rig
gh
♦ Torque Wrench - VAG1331/- (5 to 50 Nm)
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Hose Clamps Up To Diameter 40 mm - 3093-

♦ A/C Service Station with Rinsing Device For Refrigerant Cir‐
cuits - VAS6337/1A-

Golf 2004 ➤
Note
♦ Refrigerant must be extracted before hand using A/C Service

Station .
♦ The previously used service stations can still be used. Refer
to VAG workshop equipment catalog.
♦ To prevent the entry of dampness all components of the re‐
frigerant circuit which have been opened must be sealed agwith
en AG. V
olkswagen AG
does
suitable plugs. yV
olksw not
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♦ The color coding of refrigerant circuit O-rings
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been discontinued. Colored and black O-rings
sa
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ac
s
♦ Under certain conditions, fluid reservoir with dryer is no longer
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to be replaced after each time the refrigerant circuit is opened.
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♦ Information for repairing vehicles with air conditioning and
wit
, is n
working with refrigerant can be found in ⇒ Refrigerant R134a
h re
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spec
es, in part or in w
t to the co
WARNING
rrectness of i
There is a danger of ice-up.
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Refrigerant leaks out if refrigerant circuit is not discharged.

Refrigerant must be extracted before opening the refrigerant
nf
ercia
circuit. If refrigerant circuit is not opened within 10 minutes of
or
extraction, pressure may form in refrigerant circuit due to evap‐
m
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atio
oration. Extract refrigerant once more.
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Golf 2004 ➤
1 - Fluid Reservoir With Drier
Note
Under certain conditions, fluid res‐

ervoir with dryer is no longer to be
replaced after each time the refrig‐
erant circuit is opened. Refer to ⇒
Refrigerant R134a Servicing; Rep.
Gr. 00 .
ling. Refer to
⇒ “5.13.5 Fluid Reser‐
voir with Dryer”, AG. Volkswagen AG d
page 92 . lksw
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2 - A/C Compressor rised ara
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❑ Denso manufacturer aut
h
ra
identification: ss c
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le
7SEU17C.
un
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❑ Pay attention to notes

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erm
for installing A/C com‐
ab
ility
pressor. Refer to
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⇒ “1.2 A/C Compressor,
is n
h re
Installation Information”,
ole,
spec
page 26
t to the co
ling. Refer to
⇒ “5.2 A/C Compres‐
sor”, page 51 .
rrectne
3 - Condenser
ss
o
cial p
f
ling. Refer to
inform
⇒ “5.13.1 Condenser”,
mer
page 86 .
atio
om
n
4 - High Pressure Sensor -
c
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G65-
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Removing and installing, refer to ⇒ “5.13.7 High Pressure Sensor G65 ”, page 95 .
p
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5 - Nuts
Co
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❑ 6 Nm
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6 - Bracket
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❑ Nuts (6 Nm)
7 - Evacuating and Charging Valve
❑ High pressure side.
❑ Environmentally hazardous draining of refrigerant is an offense punishable by law.
⇒ “5.13.2 Evacuating and Charging Valve, Low and High Pressure Sides”, page 89 .
❑ Capacities. Refer to ⇒ “3.1 Refrigerant R134a Capacities”, page 47 .
8 - Screw
❑ 3.5 Nm
9 - Retainer
10 - Evacuating and Charging Valve
❑ Low pressure side.
❑ Environmentally hazardous draining of refrigerant is an offense punishable by law.
⇒ “5.13.2 Evacuating and Charging Valve, Low and High Pressure Sides”, page 89 .

Golf 2004 ➤
❑ Capacities. Refer to ⇒ “3.1 Refrigerant R134a Capacities”, page 47 .
11 - Expansion Valve agen
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❑ Function and removal. Refer
db
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gu
ar 90 .
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12 - Bracket utho or
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13 - Hex Head Nut
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un
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❑ 20 Nm
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14 - Retainer
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15 - Screw
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❑ 3.5 Nm
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t to the co
2.9 Ribbed Belt Pulley, Denso A/C Com‐
pressor Overview
rrectness of i
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Note
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♦ This type of ribbed belt pulley is installed on “7SEU17C” A/C

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♦ Different versions of the ribbed belt pulley may be installed,

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depending on A/C compressor construction type and engine
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version. Refer to Parts Catalog.
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♦ Ribbed belt pulley, removing and installing. Refer to

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⇒ “5.12 Ribbed Belt Pulley, Denso A/C Compressor”, C py
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page 85 .
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Golf 2004ri➤ se
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Heating,au Ventilation and Air Conditioning - Edition 04.2015
th or
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1 - Cap un
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2 - Circlip
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❑ Remove carefully using
ility
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a small screwdriver or
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needle-nose pliers (pay
hole
special attention to rib‐
spec
bed belt pulley when do‐
es, in part or in w
t to the co
ing this).
3 - Guide Cage
rrectness of i
4 - Circlip
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❑ Always replace.
❑ Install on correct side
(flat side toward A/C
nform
ercia
compressor).
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5 - Spacer
on in
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6 - Ribbed Belt Pulley
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❑ The ribbed belt pulley is
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sensitive to impact, be
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especially careful when
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❑ Different versions. Re‐ Prote
cted AG.
agen
fer to Parts Catalog.
7 - A/C Compressor
❑ Depending on engine
and market version, dif‐
ferent versions can be
installed. Refer to Parts
Catalog.
❑ Clean A/C compressor
flange before sliding on
ribbed belt pulley.
8 - Rubber Element
❑ Quantity: 6
❑ Decouples ribbed belt pulley from A/C compressor input shaft, dampens vibration and noise.
❑ For installation, lightly coat rubber elements, for example, with tire mounting paste or a soap solution (as
a lubricant).

Golf 2004 ➤
3 Specifications
⇒ “3.1 Refrigerant R134a
genCapacities”,
AG. Volkswagenpage
AG d 47
wa oes
olks not
⇒ “3.2 Refrigerant
d b Oil Capacities”, page 47
yV gu
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⇒ “3.3 OiluthDistribution”,
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3.1 Refrigerant R134a Capacities
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Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03
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3.2 Refrigerant Oil Capacities
ot
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Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03
hole
spec
3.3 Oil Distribution
es, in part or in w
t to the co
The oil, which is located in the A/C compressor oil pan before the
initial switching on of the A/C system, is distributed through the
rrectness of i
refrigerant circuit as follows:
l purpos
♦ A/C compressor approximately 50%

♦ Condenser approximately 10%
nform
ercia
♦ Suction hose approximately 10%

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♦ Evaporator approximately 20% n in
r
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♦ Receiver/dryer approximately 10%

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3. Specifications 47
Golf 2004 ➤ AG. Volkswagen AG d
Heating, Ventilation and Air Conditioning agen
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4 Diagnosis and Testing
ss
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⇒ “4.1 Condensation Water Drain Hose on Heating and A/C Unit,
pt
an
d
Checking”, page 48
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page 48
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⇒ “4.3 Pressure Relieve Valve on A/C Compressor, Checking”,
hole
spec
page 48
es, in part or in w
t to the co
4.1 Condensation Water Drain Hose on
Heating and A/C Unit, Checking
rrectness of i
– Remove the footwell cover on the front passenger side.
l purpos
Note
nform
mercia
a
♦ The condensation water hose -1- must be able to be connec‐
com
tion in
ted to connection of heating and A/C unit without pre-tension.
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♦ Condensation water hose must sit securely on connection for
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condensation water hose on heating and A/C unit.
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4.2 Climatronic, Checking and Adjusting
Prote AG.
Components
♦ Vehicle Diagnosis, Testing and Information System -
VAS5051B-
Select “Guided Fault Finding” on -VAS5051B- .
After all control modules have been interrogated:
– Press “Go to” button.
– Select “Function/component selection”.
– Select “Body”.
– “Heating, ventilation, air conditioning (Repair Group 01; 80 to
87)”.
– Select “01 - On Board Diagnostic (OBD) capable systems”.
– Select “Climatronic” or “Climatic”.
– Select “Functions”
– “Basic setting”.
– “Checking the cooling output”.
– “Read measured value block”.
4.3 Pressure Relieve Valve on A/C Com‐

pressor, Checking
♦ Function: protects refrigerant circuit against excessive pres‐
sure.

AG. Volkswagen AG d
agen oes
olksw not
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ra Golf 2004 ➤
a
ss Heating, Ventilation and c Air Conditioning - Edition 04.2015
ce
le
un
pt
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WARNING
erm
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ility
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wit
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ole,
Pressure relief valve will drain refrigerant with engine running
spec
and high pressure in refrigerant circuit.
t to the co
Turn engine off.
rrectne
Checking Check Valve on A/C Compressor (Denso)
s
♦ The pressure relief valve -arrow- has operated when refriger‐
s o
ant oil is found in the close vicinity.
cial p
f inform
♦ In this case, vehicle must be taken to an A/C specialist work‐
mer
atio
shop. Refer to
om
⇒ “1.5 Refrigerant Circuit, Specialized Repairs”, page 29 .
n
c
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or
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Cop py
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4. Diagnosis and Testing 49

Golf 2004 ➤
5 Removal and Installation olksw

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AG. Volkswagen AG d
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⇒ “5.1 Air Quality Sensor G238 ”, page 50 rised
nte
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⇒ “5.2 A/C Compressor”, page 51 ss a ra
c
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⇒ “5.3 Climatic A/C Controls”, page 53
nl
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⇒ “5.4 Climatic A/C System Components”, page 54
erm
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ility
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⇒ “5.5 Climatronic A/C Controls”, page 59
wit
, is n
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⇒ “5.6 Climatronic Temperature Sensors”, page 60 hole
spec
⇒ “5.7 Climatronic Door Motors”, page 63
es, in part or in w
t to the co
⇒ “5.8 Climatronic Indirect Ventilation”, page 78
⇒ “5.9 Fresh Air Blower Control Module J126 ”, page 80
rrectness of i
⇒ “5.10 Sunlight Photo Sensor G107 / Sunlight Photo Sensor
l purpos
G134 ”, page 81
⇒ “5.11 Heating and A/C Unit”, page 81
nform
ercia
⇒ “5.12 Ribbed Belt Pulley, Denso A/C Compressor”, page 85

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⇒ “5.13 Refrigerant Circuit Components”, page 86
n
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Engine Codes BUB and CBRA

at
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⇒ “5.14 A/C Compressor Sub-Assembly”, page 96

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Engine Codes BGP, BGQ, CBTA and CBUA
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⇒ “5.15 A/C Compressor Sub-Assembly”, page 97 . Cop py
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Engine Codes BPY, CBFA and CCTA py by
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⇒ “5.16 A/C Compressor Sub-assembly”, page 99
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5.1 Air Quality Sensor - G238-
Note
♦ The air quality sensor is installed at the right front on the intake
air grille in the plenum chamber.
♦ The air quality sensor contains a highly sensitive electronic
component which can be damaged if it comes in direct contact
with solvents, fuels or chemicals.
♦ Do not install a sensor that has been kept, for example, in a
tool box.
♦ Do not store removed sensors in areas where they can come
into contact with solvents, fuels and certain chemical compo‐
sitions (fluids or vapors).
Removing
– Remove the plenum chamber cover. Refer to ⇒ Body Exterior;

Golf 2004 ➤
– Remove the cover -1- from the plenum chamber.
– Disconnect the connector from the air quality sensor.

– Remove the air quality sensor -1- from the bracket on the air
grille.
Installing
– Install in reverse order of removal.
5.2 A/C Compressor

Removing
AG. Volkswagen AG d
Note lksw
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Zexel A/C compressors have been replaced hbyoriseDenso A/C com‐ nte
eo
pressors. See TPL 2011410. s aut ra
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♦ A/C Service Station

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hole
spec
Note
es, in part or in w
t to the co
♦ Flush the refrigerant circuit with R134a refrigerant under the

following conditions:
rrectness of i
♦ In the event of dirt or other contamination in the refrigerant

l purpos
circuit.
♦ If vacuum reading is not maintained on evacuating a leak-free
nf
ercia
refrigerant circuit (pressure build-up due to moisture in refrig‐

or
erant circuit).
m
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atio
om
♦ If refrigerant circuit has been left open for longer than normal
n in
or c
(for example, following an accident).

thi
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♦ If pressure and temperature measurements in the refrigerant

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circuit indicate the likelihood of moisture

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♦ In the event of doubt about the amount of refrigerant oil in the Cop py
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♦ The A/C compressor had to be replaced on account of internal
by
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damage (for example, noise or no output).
AG.

AG. Volkswagen AG d
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Golf 2004 ➤ d by ara
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Heating, Ventilation and Air Conditioning ut - Edition 04.2015
ho eo
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s
The procedure for flushing with R134a refrigerant is described in
ce
e
nl
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⇒ Refrigerant R134a Servicing; Rep. Gr. 00 ; General Informa‐
an
itte
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tion (Refrigerant Circuit and Components).
erm
ab
ility
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Information for repairing vehicles with air conditioning and work‐
wit
, is n
ing with refrigerant can be found in ⇒ Refrigerant R134a Servic‐
h re
ing; Rep. Gr. 00 ; General Information .
hole
spec
es, in part or in w
Information for special tools and equipment when repairing vehi‐
t to the co
cles with air conditioning can be found in ⇒ Refrigerant R134a
Servicing; Rep. Gr. 00 ; Special Tools .
– Extract the refrigerant using the A/C Service Station , only then
rrectness of i
open the refrigerant circuit. See the instructions. Refer to
l purpos
⇒ “2.8 Refrigerant Circuit Components Overview”, page 42 .
nf
ercia
orm
m
atio
om
n in
or c
thi
te
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Cop py
t. rig
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Prote AG.
– Remove the noise insulation under the engine. Refer to ⇒

Body Exterior; Rep. Gr. 50 ; Description and Operation .
– Remove the wheel housing liner, front, right ⇒ Body Exterior;

Golf 2004 ➤
Note
Remove fan ring (vehicle-specific) for MKB BWA. Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition;
– Remove the ribbed belt. Refer to ⇒ Engine Mechanical, Fuel

Injection and Ignition; Rep. Gr. 13 ; Removal and Installation .
WARNING

– Remove the bolts (22 Nm ± 1 Nm) -1- from the A/C compressor
and then disconnect the refrigerant pipes from the A/C com‐
pressor.
– Remove the hex bolts (25 Nm) -2- and the A/C compressor.
Installing
Note
♦ Make sure alignment bushings -3- are seated correctly.

n AG. Volkswagen A
♦ Pay attention to notes for installing A/Colcompressor.
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age Refer to G does no
⇒ “1.2 A/C Compressor, Installationd bInformation”,
yV page 26 . t gu
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5.3 Climatic A/C Controls au ra
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nl
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Removing
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erm
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Note
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hole
♦ The controls consist of two separable housings. Before re‐

spec
moving controls, bring rotary buttons into the following posi‐

es, in part or in w
t to the co
tion:
♦ Heater control to “cold”
rrectness of i
♦ Blower to “0”
l purpos
♦ Air flow direction to “footwell”

nform
ercia

m
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ion
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ate
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Prote AG.

Golf 2004 ➤
Volkswagen AG
– If the vehicle does not have a radio, remove the trim fromsthe agen
AG. does
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center of the instrument panel. Refer to ⇒ Body Interior;
by
V Rep.
ol not
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ara
Gr. 68 ; Removal and Installation . ris
ed nte
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– Remove the screws -2- (4.2 x 45) and -3- (4.2
ss
aux 16) and the ra
c
controls -1- from the center console.
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erm
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es, in part or in w
t to the co
Tightening specification for the screws -2- and -3-: 1.5 +/- 0.2 Nm.
rrectness of i
– Release the connector -A- by pulling it in direction of arrow
-1-.
l purpos
– Press connector release -B- toward the connector -arrow 2-

and disconnect the connector -C-.
nform
ercia
– Disconnect the connector -D-.

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Installing
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Installation is performed in reverse order of removal, make sure

at
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when doing so that the rotary buttons have the same position as
p
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when removing.
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5.4 Climatic A/C System Components
rig
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⇒ “5.4.1 Center Vent Temperature Sensor G191 ”, page 54
cted agen
Prote AG.
⇒ “5.4.2 Flexible Air Distribution Shaft”, page 55

⇒ “5.4.3 Footwell Outlet Temperature Sensor G192 ”,
page 55
⇒ “5.4.4 Outside Air Temperature Sensor G17 ”, page 56
⇒ “5.4.5 Recirculation Door Motor V113 , Removing and Instal‐
ling”, page 56
⇒ “5.4.6 Temperature Control Door Motor V68 , Removing and
Installing”, page 57
5.4.1 Center Vent Temperature Sensor -

G191-
Removing
– Remove the instrument panel cover. Refer to ⇒ Body Interior;
– Disconnect connector at center vent temperature sensor -1-.
– Rotate center vent temperature sensor -2-, rotate 90° in di‐
rection of -arrow- and remove from instrument panel.
Installing

Golf 2004 ➤
5.4.2 Flexible Air Distribution Shaft

Removing
– If the vehicle does not have a radio, remove the trim from the
– Move the flexible shaft in to the following position:
– Turn the switch for the air distribution control -1- until the lock‐
ing mechanism on the shaft -2- is visible in step-up gearing
-3-.
– Remove controls for heating and A/C system. Refer to
⇒ “5.3 Climatic A/C Controls”, page 53 .
– Carefully pull out adapter for controls.
– Press in retaining tab -arrow- for flexible shaft and remove

flexible shaft. wage
e ks s no
Vol t gu
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Note utho eo
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When installing flexible shaft, adapter and rotary switch on con‐
e
nl
pt
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trols for heating and A/C system must have a specific position to
an
itte
y li
each other, otherwise it will malfunction .
erm
ab
ility
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Checking
, is n
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hole
Flexible shaft for adjusting unit of air distribution doors:
spec
es, in part or in w
– Let fresh air blower run on highest speed. If air flows out of
t to the co
defroster vents in the “Defrost” position and no air flows out of
footwell vents, installation of flexible shaft is correct. If this is
not the case, remove flexible shaft from adapter. Place con‐
rrectness of i
trols for heating and A/C system onto adapter and rotate rotary
l purpos
knob for air distribution 1/2 rotation (180°). Then re-connect

flexible shaft. Repeat test
nf
ercia
or
5.4.3 Footwell Outlet Temperature Sensor -
m
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atio
m
G192-
o
n in
or c
thi
e
Removing
t
sd
iva
o
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cu
– Remove the Data bus on board diagnostic interface - J533- .

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Refer to ⇒ Electrical Equipment; Rep. Gr. 97 ; Removal and

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Installation . C py
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– Remove the driver footwell vent. Refer to cop Vo
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⇒ “3.15.2 Left Footwell Vent”, page 22 . cted agen
Prote AG.
– Disconnect connector at Footwell Outlet Temperature Sensor

-1-.
– Rotate Footwell Outlet Temperature Sensor 90° and remove
from housing.
Installing

Golf 2004 ➤
5.4.4 Outside Air Temperature Sensor - G17-

Removing
– Pull the center air grille out of the catches on the front bumper
cover. Refer to ⇒ Body Exterior; Rep. Gr. 63 ; Removal and
Installation .
– Unclip the outside air temperature sensor -1- from the bracket
and disconnect the connector.
Installing
Installation is carried out in the reverse order while noting the fol‐
lowing:
Note
Ensure electrical connector is seated correctly (water entry).
5.4.5 Recirculation Door Motor - V113- , Re‐

moving and Installing
♦ Vehicle Diagnostic Tester
Note
AG. Volkswagen AG d
agen oes
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♦ The motors were changed starting from 11/04/2013. d by See the
V gu
ara
general information and Parts Catalog. ise nte
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aut ra
♦ The color-coded connecting elements on the
ss actuator have c
been discontinued as a running change as of 11/04/2013 for
ce
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pt
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those connecting elements installed by the manufacturer and

an
itte
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delivered as a replacement part. Additionally the connecting
erm
elements are no longer preinstalled on actuators that are de‐ ab

ility
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livered as a replacement part. wit

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♦ The actuators and the associated connecting elements differ.
hole
spec
In some cases, however, the differences are so small that they

es, in part or in w
are not always easy to detect at first glance. If a different ver‐

t to the co
sion of the actuator or a connecting element is installed than

the designated version, it usually leads to problems when per‐
forming the final basic setting.
rrectness of i
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Removing
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Golf 2004 ➤
– Remove the adjustment motor cover -1-.

– Disconnect the connector from the Recirculation Door Motor -
V113- -2-.
– Remove the Recirculation Door Motor - V113- -2-.
Installing
Note
♦ Incorrectly installed actuators or connecting elements cause

malfunctions in the heating or A/C system.
♦ Label the connectors to the actuators.
♦ Install the correct connecting elements on the actuators.
Note
♦ After installing, the recirculation door function must be

checked.
♦ Initiate the “Basic Setting” function using the Vehicle Diagnos‐
tic Tester . Refer to
page 48 .
5.4.6 Temperature Control Door Motor -

V68- , Removing and Installing
G. Volkswage
Special tools and workshop
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equipment
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♦ The color-coded connecting elements on the actuator have

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es, in part or in w

t to the co
elements are no longer preinstalled on actuators that are de‐

livered as a replacement part.
rrectness of i

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Heating, Ventilation and Air Conditioning - Edition 04.2015 ss c
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– If necessary, remove the Data Bus on Board Diagnostic Inter‐
itte
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face - J533- with the bracket. Refer to ⇒ Electrical Equipment;
erm
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– Remove the bolts -3- (9 ± 1.3 Nm).
h re
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spec
t to the co
Note
♦ The bolts -1- are not to be removed.
rrectne
♦ Do not remove the bracket -2-.
ss o
cial p
f inform
– Push the bracket -1- toward the brake pedal -arrow- and se‐
mer
cure it there with a cable tie.
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om
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– Mark the connector -C- for the motor (danger of confusing it

with other connectors that may look the same).
– Disconnect the connector -C- on the Temperature Control
Door Motor - V68- .
– Remove the cover -A-.
– Remove the screws -D- 1.4 Nm and the Temperature Control
Door Motor - V68- -B-.
– Disconnect the lever -E- from the connecting rod -F-.
Installing
Note

Note
Optimal adjustment motors are marked with an “X”.
For better assembly a Raised Head Screw - N 106 115 02- can
be used.

n AG. Volkswagen AG do Golf 2004 ➤
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ran
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– Disconnect the mount from the old Temperatureau Control Door
t or
ac
Motor - V68- using for example a diagonal cutter -1-. ss
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– Attach the new Temperature Control Door Motor - V68- that is
marked with an “X” to the mount -3- on the blower case using
the new raised head screw -2- and the removed mount -1-.
nform
ercia
– Route the wiring harness so that it cannot come in contact with

m
at
om
any moving parts (for example, the adjustment motor lever).
ion
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♦ After installing, the function of the left temperature door must
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♦ Initiate the “basic setting” using the Vehicle Diagnostic Tester . cop Vo
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page 48 .
5.5 Climatronic A/C Controls
Note
The Climatronic Control Module - J255- and the Front A/C Display
Control Head - E87- are one component that cannot be disas‐
sembled.
Removing
– Remove the trim panel, center instrument panel. Refer to ⇒
Body Interior; Rep. Gr. 68 ; Removal and Installation .
– Remove the screws -arrows- (1.5 ± 0.2 Nm) and take the Front
A/C display control head -1- from the instrument panel.
– Disconnect the connectors from the Front A/C display control
head.
Installing

Golf 2004 ➤
5.6 Climatronic Temperature Sensors

⇒ “5.6.1 Left Footwell Vent Temperature Sensor G261 ”,
page 60 gen AG
. Volkswagen AG
d wa oes
olks no
⇒ “5.6.2 Left Vent Temperature by Sensor G151 / Right Vent Tem‐
V t gu
ara
ed
perature Sensor G150 ”, opage
ris 61 nte
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ut or
⇒ “5.6.3 Evaporator sTemperature
sa Sensor G308 or Evaporator ac
Vent Temperature Sensor G263 ”, page 61
ce
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nl
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⇒ “5.6.4 Outside Air Temperature Sensor G17 ”, page 61
itte
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⇒ “5.6.5 Right Footwell Vent Temperature Sensor G262 ”,
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page 62
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h re
5.6.1 Left Footwell Vent Temperature Sensor
hole
spec
es, in part or in w
- G261-
t to the co
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nf
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or
– Remove the Data Bus On Board Diagnostic Interface - J533- .
m
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♦ Do not remove the bolts -1-. op Vo
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AG.
– Push the bracket -1- toward the brake pedal -arrow- and then
tie it there with a cable tie.
– Disconnect connector at Left footwell vent temperature sensor

-1-.
– Turn the left footwell vent temperature sensor -2- 90° and re‐
move it from the housing.
Installing

Golf 2004 ➤
5.6.2 Left Vent Temperature Sensor - G151- /

Right Vent Temperature Sensor - G150-
Note
Removal of sensors on both sides is identical, only the sides are

reversed.
– Remove the right or left instrument panel cover. Refer to ⇒

Body Interior; Rep. Gr. 70 ; Removal and Installation .
– Disconnect the connector -1- fromenthe
AG.left
Volkvent
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sensor -2-. olks
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ris sensor -2-, rotate 90° in direction of ntee
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-arrow- and removethofrom instrument panel. or
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5.6.3 Evaporator Temperature Sensor -
es, in part or in w
G308- or Evaporator Vent Temperature
t to the co
Sensor - G263-
rrectness of i
Removing
l purpos
– Remove the right trim in the footwell. Refer to -1-.

nf
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orm
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– Remove connector on Evaporator Temperature Sensor or

Evaporator Vent Temperature Sensor -1-.
– Rotate Evaporator Temperature Sensor or Evaporator Vent
Temperature Sensor in direction of -arrow- and remove.
Installing
5.6.4 Outside Air Temperature Sensor - G17-

Removing
– Pull the center air grille out of the catches on the front bumper
cover. Refer to ⇒ Body Exterior; Rep. Gr. 63 ; Removal and
Installation .

Golf 2004 ➤
– Unclip the outside air temperature sensor from the bracket and
disconnect the connector.
Installing
Note
Ensure electrical connector is seated correctly (water entry).
5.6.5 Right Footwell Vent Temperature Sen‐

sor - G262-
Removing
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For the sake of illustration, the right footwell vent temperature
ss
a ac
sensor is depicted with instrument panel removed. Instrument
ce
le
un
pt
panel must not be removed for installation.
an
d
itte
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ility
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– Disconnect the connector from the right footwell vent temper‐
spec
ature sensor -1-.
t to the co
– Turn the right footwell vent temperature sensor -1- 90° and
remove it from the housing.
rrectne
Installing
ss o
cial p
f inform
mer
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Golf 2004 ➤
5.7 Climatronic Door Motors

⇒ “5.7.1 Airflow Door Motor V71 , Removing and Installing, on
Vehicles through 04/30/2007”, page 63
⇒ “5.7.2 Central Air Door Motor V70 , Removing and Installing”,
page 64
⇒ “5.7.3 Defroster Door Motor V107 , Removing and Installing”,
page 65
⇒ “5.7.4 Fresh Air/Recirculating Air/Back Pressure Door Motor
V425 , Removing and Installing, Vehicles from 04/30/2007”, page
66
⇒ “5.7.5 Fresh Air/Recirculating Air/Back Pressure Door Adjust‐
er”, page 68
⇒ “5.7.6 Left Temperature Control Door Motor V158 , Removing
and Installing”, page 69
⇒ “5.7.7 Right Temperature Control Door Motor V159 , Removing
and Installing”, page 71
⇒ “5.7.8 Recirculation Door Motor V113 , Removing and Instal‐
ling”, page 72
⇒ “5.7.9 Actuator Information”, page 73
⇒ “5.7.10 Connecting Element, Inserting in Actuator Shaft”, page
75
⇒ “5.7.11 Actuator, Activating using Adapter Cable”, page 77
⇒ “5.7.12 Adapter Cable for Activating Actuators”,
en AG. V
page
olkswagen AG
78
ag does
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Vol
5.7.1 Airflow Door Motor - V71- , Removing
ed
by gu
ara
nte
ris
and Installing, on Vehicles through
au
tho eo
ra
04/30/2007
ss c
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general information and Parts Catalog.
rrectness of i

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Removing
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– Remove the glove compartment. Refer to ⇒ Body Interior; Prote
cted AG.
agen

Golf 2004 ➤
Note
Position of air flow door must not be changed.
– Remove the cover -1-.

– Remove the Recirculation Door Motor - V113- . Refer to
n AG. Volkswagen AG
⇒ “5.7.8 Recirculation Door lMotor
kswage V113 , Removingdoand
es n In‐
stalling”, page 72 . d byV
o ot g
ua
e ran
ris tee
– Disconnect the connector
ut
ho from the Airflow Door Motor - V71- or
-2-. ss
a ac
ce
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nl
– Remove the Airflow Door Motor - V71- -2-.
pt
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Installing
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ility
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Note
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spec
es, in part or in w
t to the co
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atio
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♦ After installing, function of air flow door must be checked.

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page 48 . t. C rig
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5.7.2 Central Air Door Motor - V70- , Remov‐
AG.
ing and Installing

Note


Golf 2004 ➤
Removing
– Disconnect the connector on the Central Air Door Motor -
V70- .
– Remove the screws -1- (1.4 Nm) and remove the Central Air
Door Motor - V70- .
Installing
Note

Note
n AG. Volkswagen A
♦ After installing, the function of the
olks
central
wage air door mustGbe
does
no
checked. db
yV t gu
ara
s e nte
ri
♦ Initiate the “Basic Setting”
utho
function using the Vehicle Diagnos‐ eo
ra
tic Tester . Refer to ss a c
ce
e
nl
pt
page 48 .
du
an
itte
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ility
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5.7.3 Defroster Door Motor - V107- , Remov‐

wit
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ing and Installing

hole
spec
es, in part or in w

t to the co

rrectness of i
Note
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♦ The actuators and the associated connecting elements differ. C py
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Removing
– Remove the driver side storage compartment. Refer to ⇒
Body Interior; Rep. Gr. 68 ; Removal and Installation

Golf 2004 ➤

– Remove the Data Bus On Board Diagnostic Interface - J533- .
Installation .
– Remove the bolts -1- and -3- (9 ± 1.3 Nm).

– Disconnect the connector -C- from the Defroster Door Motor -
V107- . n AG. Volkswagen AG age does
ksw not
– Remove the screws -A- (1.4 Nm) and remove the y VDefroster
ol gu
Door Motor - V107- -B-. edb ara
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– Disconnect the lever -E- from the connecting
ss
au rod -D-. ra
c
ce
le
Installing
un
pt
an
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itte
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erm
ab
ility
Note
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ole,
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t to the co
rrectne
ss o
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Note
form
mer
atio
m
♦ After installing, the function of the defroster door must be

o
n
c
checked.
i
or
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page 48 .
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5.7.4 Fresh Air/Recirculating Air/Back Pres‐
cted agen
Prote AG.
sure Door Motor - V425- , Removing and

Installing, Vehicles from 04/30/2007

lkswage es n
o ot g
byV ua
d ranGolf 2004 ➤
ir se tee
o
Heating,
auth Ventilation and Air Conditioning - Edition or 04.2015
ac
ss
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un
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an
d
itte
Note
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ility
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es, in part or in w
t to the co
rrectness of i
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ercia

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a
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te o
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Removing
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– Remove the screws -1- (1.4 Nm).
gh ht
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– Turn the Fresh Air/Recirculating Air/Back Pressure Door Mo‐ cted agen
Prote AG.
tor - V425- -2- approximately 15° in direction of the-arrow- and
then pull it off of the air intake housing.
– Disconnect the connector -1- from the Fresh Air/Recirculating

Air/Back Pressure Door Motor - V425- .
Note
Position of air flow door must not be changed.
Installing
Note

Install in reverse order of removal. Note the following:

Golf 2004 ➤
The Fresh Air/Recirculating Air/Back Pressure Door Motor -

V425- fits in only one position on the curved washer.
Note
♦ After installing, check the function of the back pressure and

recirculation door.
page 48 .
5.7.5 Fresh Air/Recirculating Air/Back Pres‐

sure Door Adjuster
VAS5051B-
Perform the following work first:
– Turn off all electric consumers. n AG. Volkswagen AG do
lkswage es n
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– Switch off the ignition. d byV ua
ran
ir se tee
– Remove the key. utho
or
a ac
ss
Removing
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un
pt
an
– Remove Fresh Air/Recirculating Air/Back Pressure Door Mo‐
d
itte
y li
tor - V425- . Refer to
rm
ab
pe
⇒ “5.7.4 Fresh Air/Recirculating Air/Back Pressure Door Mo‐
ility
ot
tor V425 , Removing and Installing, Vehicles from

wit
, is n
04/30/2007”, page 66
h re
hole
– Open the retainers -arrows- on the adjusting lever -1-. spec

es, in part or in w
t to the co
– Remove the adjusting lever from the curved washer.
– Remove the curved washer -2- from the air intake housing.
rrectness of i
Installing
l purpos
Note
nform
mercia
When installing the curved washer, make sure the guide pin for
a
com
tio
the air flow door adjusting lever is seated in the groove.

n in
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do
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– Install the curved washer -1- on the air intake housing.

um
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Make sure the guide pin for the recirculation air door adjusting Prote AG.
lever is seated in the curved washer groove.
– Mount and latch the recirculation air door adjusting lever.

Golf 2004 ➤
5.7.6 Left Temperature Control

agen
AG. VolkswDoor
agen AG Motor -
does
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V158- , Removing
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and Installing not
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ut
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⇒ “3.15.2 Left Footwell Vent”, page 22 . t. C rig
gh ht
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– Remove the left footwell center console trim panel.
co Vo
by lksw
cted agen
Prote AG.
– If necessary, remove the Data Bus on Board Diagnostic Inter‐
face - J533- with the bracket. Refer to ⇒ Electrical Equipment;
Note
♦ The bolts -1- are not to be removed.

– Push the bracket toward the brake pedal -arrow- and then tie
it there with a cable tie.

Golf 2004 ➤

– Disconnect the connector -C- on the Left Temperature Control
Door Motor - V158- .
– Remove the cover -A-.
– Remove the screws -D- 1.4 Nm and the Left Temperature
Control Door Motor - V158- -B-.
– Disconnect the lever -E- from the connecting rod -F-.
Installing
Note

Note
Optimal adjustment motors are marked with an “X”.
For better assembly a Raised Head Screw - N 106 115 02- can
be used.
– Remove the mount from the old Left Temperature Control

Door Motor - V158- using a diagonal cutter -1-, for example.
lkswage es n
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– Attach the new Left Temperature Control Door Motor - V158-

h re
hole
that is marked with an “X” to the mount -3- on the blower case
spec
using the new raised head screw -2- and the removed mount
es, in part or in w
t to the co
-1-.
– Route the wiring harness so that it cannot come in contact with
any moving parts (for example, the adjustment motor lever).
rrectness of i
l purpos
Note
nform
ercia
♦ After installing, the function of the left temperature door must

m
be checked.
at
om
ion
c
♦ Initiate the “basic setting” using the Vehicle Diagnostic Tester .

in t
or
his
Refer to
ate
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page 48 .
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Golf 2004 ➤
5.7.7 Right Temperature Control Door Motor -

V159- , Removing and Installing
Note

general information and Parts Catalog .
Removing
AG. Volkswagen AG d
Rep. Gr. 68 ; Removal and Installation lksw
agen oes
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– Remove the right footwell vent. Referisto
ed
b ran
⇒ “3.15.6 Right Footwell Vent”, page
ut
h 23 .
or tee
or
sa ac
– Disconnect the connector on thes Right Temperature Control
ce
le

un
pt
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d
itte
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– Remove the screws -1- (1.4 Nm) and the Right Temperature
rm
Control Door Motor - V159- . ab

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– Unhook the brace -2- from the Right Temperature Control h re

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es, in part or in w
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♦ After installing, the function of the right temperature door must
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be checked.
cop Vo
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Prote AG.
page 48 .

Golf 2004 ➤
5.7.8 Recirculation Door Motor - V113- , Re‐

moving and Installing
Note

Removing
gen AG
. Volkswagen AG
does
Rep. Gr. 68 ; Removal and Installation Volkswa not
y gu
db ara
– Remove the adjustment motor cover.
or
ise nte
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– Label the connector -A- (to prevent
ss
a mix-up). c
ce
le
– Disconnect the connector -A-.

un
pt
an
d
itte
y li
– Loosen the catches -C- and -D- for the bracket -B- on the air
rm
ab
intake shroud, and remove the bracket -B- (toward the rear).
pe
ility
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– Remove the motor -A- from the air intake shroud.

h re
hole
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Installing
es, in part or in w
t to the co
Note
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♦ After installing, the recirculation door function must be C py
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checked.
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by
♦ Initiate the “Basic Setting” function using the Vehicle Diagnos‐ cted agen
Prote AG.
page 48 .

Golf 2004 ➤
5.7.9 Actuator Information
Note

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Golf 2004 ➤
♦ Different actuators are installed on the air distribution box and

the air intake unit for the heater and A/C unit. These actuators
vary in their electrical values (due to their adjusting range,
specified by the different connecting elements), connecting
elements and in part number. Refer to the Parts Catalog.
Therefore mark the actuators before removing it (risk of inter‐
changing).
♦ The actuators gradually change starting from 11/04/2013. The
connecting elements (levers, gears, etc., which are attached
to the various actuators) to the doors in the heater and A/C
unit varied by color up to this point in time. From 11/04/2013
actuators are installed with all connecting elements to the var‐
ious doors for the heater and A/C unit being only one color
(currently black). A color-coded allocation is therefore no lon‐
ger possible. This illustration shows, for example, a Temper‐
ature Control Door Motor - V68- -A- with the related connecting
element (lever) -B-.
♦ Through 11/04/2013, various actuators were sent as a re‐
placement part with a preinstalled color-coded connecting
element (for example, the lever -B- to a Temperature Control
Door Motor - V68- -A-) with different part numbers. As a run‐
ning change from 11/04/2013, an actuator is sent as a re‐
placement part without the connecting element preinstalled
and a set of connecting elements (for example, the lever -B-
for a Temperature Control Door Motor - V68- -A-). Refer to the
Parts Catalog. Select the corresponding connecting element
required from this set (depending on the version of the heater
and A/C unit and on the actuator component location) and in‐
stall it in the actuator shaft. Refer to
⇒ “5.7.10 Connecting Element, Inserting in Actuator Shaft”,
page 75 .
♦ Different actuator versions without the attached connecting
elements -B- were installed or delivered as a replacement part
from 11/04/2013. The actuator version, which is installed as a
Recirculation Door Motor - V113- on a heater or a manual cli‐
mate control system has , for example, no potentiometer (has
stop switches for it). There are different adjustment agranges
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actuators with potentiometer (electrically evaluable olksw adjust‐ s no
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ment range maximum approximately 120° sed or
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the Parts Catalog. Ensure the correct uthversion
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If an actuator with an incorrect adjustment
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it will lead to problems, for example when performing the A/C
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system basic setting and/or when operating the heating and

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A/C system using the Vehicle Diagnostic Tester .

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♦ After installing the actuator, perform the A/C system basic set‐
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♦ Using the “output diagnostic test mode” and “basic setting”

spec
functions, the activation of the electrical components for the A/

C system can be checked (for example, to check for inter‐
t to the co
changing). Use the Vehicle Diagnostic Tester in the “Guided

Fault Finding” function.
rrectne
♦ Check the activation and function of the adjustment motor us‐

ing the display control head.
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Rep. Gr.87 - Air Conditioning
Golf 2004 ➤
5.7.10 Connecting Element, Inserting in Actua‐

tor Shaft
Note
♦ Through 11/04/2013, various actuators were sent as a re‐

placement part with a preinstalled color-coded connecting AG. Volkswagen AG d
element (for example, the lever -B- to a Temperature
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placement part without the connecting
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element preinstalled ra
and with a set of connecting elements
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-B- for a Temperature Control Door Motor - V68- -A-). Refer to
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the Parts Catalog. If necessary, select the corresponding con‐
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necting element required from the set and insert it correctly
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♦ The connecting element (for example, the lever -B-) can only
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be installed and engaged in the shaft -D- of the actuator -A- in
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one position.
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♦ The connecting elements installed in the actuators that were
installed through 11/04/2013 (for example, lever -B-) are
locked in the shaft -D- of the actuator. They can be pried out
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using, for example, two screwdrivers.
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♦ So that the respective connecting element -B- can be inserted

into the shaft -D- of the actuator, it must be located in the po‐
sition illustrated.
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Connecting Element, Inserting
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– Remove the connecting element from the removed actuator

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(by carefully prying it out using, for example, two screwdrivers)
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or select the required connecting element from the set of con‐
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necting elements. Refer to Parts Catalog. en

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♦ If the wrong connecting element is selected or mounted, it may
be possible to install the actuator. Problems may occur how‐
ever when adapting the newly installed actuator.
♦ The connecting elements are to some extent very similar,
therefore make sure it is the correct version.
♦ Only insert a connecting element that exactly matches the
form of the removed connecting element.
♦ The connecting element can be installed with the actuator de‐
spite being incorrectly assigned. Problems may occur howev‐
er when adapting the newly installed actuator.
♦ The various actuators are identical in construction and only
differ in their part number. Therefore make sure it is the correct
version.
♦ Only install actuators that can be explicitly allocated.

Golf 2004 ➤
Note
♦ The connecting elements available in the set are not color-

coded. Refer to the Parts Catalog.
G. Volkswage
♦ The possible adjusting range of an actuator
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the shape of the connecting element -B- and the stop -C- on
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the actuator. The shaft positionor-D-
ise of the actuator is deter‐
ran
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mined by the respective controlau
th module via an installed po‐ or
tentiometer (or via a stop switch).
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– Check the shaft position -D- of the actuator -A-. The shaft -F-
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of the connecting element can only be inserted and engaged
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without pretension when it is in the position illustrated.
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♦ If the shaft -D- of the actuator -A- is not located in the position
illustrated (the connecting element can only be inserted in this
position), activate the removed actuator so that the shaft -D-
rrectness of i
is moved into the correct position. Refer to
⇒ “5.7.11 Actuator, Activating using Adapter Cable”,
l purpos
page 77 .
♦ The connecting element -B- may only be installed in the posi‐
nf
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tion where it can be inserted and engaged without being forced
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in. The mount contour -E- of the actuator shaft -D- is stamped
atio
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on various connecting elements so that the correct installation

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position can be better found. If pretension is needed to insert
thi
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the connecting element, check the actuator shaft -D-. It can be

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rotated 180°. o
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♦ Do not reuse a connecting element that shows signs of wear.

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– Insert and engage the shaft of the removed or selected con‐
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necting element -F- from the delivered set into the shaft of the
AG.
actuator -D-.
– Check the connecting element -B- for a secure fit in the ac‐
tuator -A- .
– Attach the actuator to the heater and A/C unit at the designated
position.

Golf 2004 ➤
5.7.11 Actuator, Activating using Adapter Ca‐

ble
Note
♦ For the connecting element to be able to be inserted into the

shaft -D- for the actuator -A-, the shaft must be in a certain
position. If the shaft -D- is in a different position than the one
illustrated, it can be moved into the correct position by acti‐
vating the actuator.
♦ The actuator shaft -D- does not have a stop. It rotates contin‐
uously on an actuator with an installed potentiometer when
voltage is supplied between contacts 5 and 6 on the actuator
connector. Therefore, if the connecting element -B- is con‐
nected or it cannot be connected, voltage should be applied
only when the actuator has been removed in order to bring the
shaft -D- into the correct position.
♦ If the connecting element -B- cannot be inserted into the ac‐
tuator without pretension, the shaft -D- may be incorrectly
positioned.
Actuator Shaft, Bringing into the Correct Position

– Connect the adapter cable (refer to
⇒ “5.7.12 Adapter Cable for Activating Actuators”,
page 78 ) to the actuatoren-A-.
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Instead of using an adapter cable, the contacts “5” and “6” (in the
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actuator connector -A-) can also be connected to a 12 V battery

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using a lead from the Connector Test Set - VAG1594D- via a 5A

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fuse.
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– Connect one of the two adapter lines via a 5A fuse to the pos‐
h re
ole,
itive terminal, for example, on a 12 V battery.

spec
– Briefly connect the other line of the adapter cable to the neg‐
t to the co
ative terminal on this 12 V battery (for example, using an

adapter cable from the Connector Test Set - VAG594D- ).
rrectne
• Activate the actuator so that the shaft -D- moves to the shortest
adjusting range in the illustrated position.
ss
– Observe the actuator shaft -D- movement (rotation). If the

o
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shaft rotates in the wrong direction, the line polarity is inter‐

inform
changed.
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atio
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– As soon as the actuator shaft -D- is in the correct position, stop

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the activation of the actuator.

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Golf 2004 ➤
5.7.12 Adapter Cable for Activating Actuators

Procedure
– Connect each of the contacts “5” and “6” on the connector
-A- ( Flat Terminal Housing with Auxiliary Terminal Retainer -
6Q0 972 706- ) to a line with a diameter of 0.25 mm2. Refer to
the Parts Catalog .
– Connect the other end of each wire to a commercially available
banana coupling -B-.
Note
The line can be connected to a 12 V power supply (for example,

a 12 V battery) via the banana couplings -B- (using, for example,
leads from the Connector Test Set - VAG1594D- ).
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5.8 Climatronic Indirect Ventilation d b ua
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Special tools and workshop au
equipmentssrequired ac
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♦ Trim Removal Wedge - 3409-

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– Switch off the ignition.
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– Use the Trim Removal Wedge - 3409- to pry the photo sensor
hole
spec
-1-from its mount in indirect ventilation -2-.
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t to the co
– Disconnect the wiring harness from the photo sensor.
– Remove the bolt -3- (1.5 Nm).
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Note
The following figure shows the dismantled components to make it easier to understand.
– Insert two Trim Removal Wedge - 3409- as shown, in the joint

between the indirect ventilation -1- and the vent -2-.
– Press the metal clips-3- and -4- toward the rear using Trim
Removal Wedge - 3409- and pull out the indirect ventilation
upward out of the mounts in the vent -arrow-.

Golf 2004 ➤
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– Remove the bolts -1- (1.5 Nm). C py
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– Loosen the vent -2-, from its mounts in the front area. copy Vo
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– Insert the Trim Removal Wedge - 3409- in the vent's lower joint
AG.
-arrows- pry it out with an upward motion, out of the instrument

panel mounts.
– Activate the corresponding catches and disconnect the wiring
harnesses from the emergency flasher switch and indicator
lamp.

Golf 2004 ➤
AG. Volkswagen AG d
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Installing
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– Install in reverse order of removal.

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5.9 Fresh Air Blower Control Module - J126-

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Removing
hole
spec
– Remove the Fresh Air Blower - V2- . Refer to

es, in part or in w
t to the co
⇒ “3.6 Fresh Air Blower V2 ”, page 11

– Disconnect the connector -1- from the fresh air blower.
rrectness of i
– Remove the bolts -arrows-.

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Golf 2004 ➤
5.10 Sunlight Photo Sensor - G107- / Sun‐

light Photo Sensor - G134-
– Unclip sunlight photo sensor -1- from instrument panel using
an appropriate tool.
– Disconnect harness connector from sunlight photo sensor.
5.11 Heating and A/C Unit

Volkswag
♦ A/C Service Stationswith n AG.
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cuits - VAS6337/1A-
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♦ Drip TraythFor
or Shop Crane - VAS6208- tee
or
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sa
♦ Hose Clamps
s Up To Diameter 40 mm - VAS3093-
ce
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Removing
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Note
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es, in part or in w
To improve accessibility, additional components must be re‐

t to the co
moved, for example, engine cover (depending on engine version).

Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition; Rep.
rrectness of i
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– Extract refrigerant using A/C Service Station , only then open

the refrigerant circuit. See notes, refer to
nform
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on in
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– Remove the rear channels from the right and left footwells.
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Refer to ⇒ “3.15.3 Rear Footwell Channel”, page 22 .

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– Mark the coolant hoses -1-.
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WARNING
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Contact with hot engine coolant can cause severe scalding.


Golf 2004 ➤
– Clamp the coolant hoses -1- using the -VAS3093- and remove
the coolant hoses from the heater core.
– Connect a section of hose -A- to the upper connection.
– Using a compressed air gun, carefully blow residual coolant
out of heater core at heater core connection.
Only for vehicles with a heat shield in front of the expansion valve
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– Remove the nut -1- (6 +/- 0.9 Nm).ho rise nte
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– Remove the clamps -2- and the s heat shield -3-.
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es, in part or in w
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All vehicles
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WARNING
nf
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orm
m
atio
om
Refrigerant leaks out if refrigerant circuit is not discharged. n in

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– From inside the engine compartment, remove the bolts (10 +/- cted agen
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1 Nm), -2- from the refrigerant pipes -2-.
– Remove the refrigerant pipes from the expansion valve -3-.
Note
♦ Seal the open connections.

♦ To seal off all open connections on expansion valve, sealing
caps from a replacement expansion valve can be used (pre‐
venting dirt and moisture from entering the system).
– Cover the carpet inside the passenger compartment with wa‐

Note
When removing the bolts, make note of the lengths and allocation.

Golf 2004 ➤
1 - Screw
❑ 4.5 +/- 0.7 Nm
❑ On the lower right side
on the cable bracket for
the heater and air con‐
ditioner near the plenum
chamber bulkhead.
2 - Screws
❑ 4.5 +/- 0.7 Nm
3 - Cable Bracket
4 - Heating and A/C unit
❑ Removing agen
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– Remove the condensa‐ ed by ara
nte
tion water hose fromhoris
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heater and air condition‐ ra
s c
er. Refer to s
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le
⇒ “4.1 Condensation
un
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an
d
Water Drain Hose on

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Heating and A/C Unit,
rm
ab
pe
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Checking”, page 48 .
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– Disconnect the connec‐
hole
tors from the heater and
spec
es, in part or in w
air conditioner.
t to the co
Note
rrectness of i
♦ All cable ties and other wiring
l purpos
harness fasteners released or

cut open on removing air condi‐
tioner unit are to be re-attached
nform
ercia
in same position on installation.

m
♦ The air conditioning wiring har‐

com
tion in
ness is removed with the heater

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te o
thi
and air conditioner.

s
iva
do
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rp
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– Remove the two nuts from the Comfort System Central Control Module - J393- and hang the comfort
fo
en
g
system central control module to the side. Refer to ⇒ Electrical Equipment; Rep. Gr. 97 ; Removal and
n
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– Remove the bolts -6- and the holder -5-.
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– Remove the screws -8- and -10-, and the cover -9- and -11-.
– Remove the bolts -12- and -14- and bracket -13-.

– Remove the bolts -1- and -2- from the cable bracket -3-.
Note
♦ To be able to reach the bolt -1-,

heating and A/C unit on driver
side must be pulled out slightly
from facing wall.
♦ When removing heat unit, make
sure the two coolant pipes of the
heater core do not get caught
and bent or damaged on plenum
chamber or noise insulation pan.

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Golf 2004
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Heating,
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a
Ventilation and Air Conditioning - Edition 04.2015 ac
ce
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♦ Observe wiring harness, individ‐
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itte
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ual electrical wiring connections
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ab
may get damaged when pulling
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on harness.
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– Remove heating and A/C unit.
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es, in part or in w
t to the co
Installing
Installation is carried out in the reverse order while noting the following:
rrectness of i
Note
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A second technician is necessary to
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ercia
install the heater.

m
at
om
io
– When inserting heater, have the second technician guide both coolant pipes to heater core through the
n
c
in t
r
seal (from engine compartment). Refer to ⇒ page 85 .

o
his
ate
do
riv
– Make sure the condensation water hose fits correctly. Refer to

p
cum
or
⇒ “4.1 Condensation Water Drain Hose on Heating and A/C Unit, Checking”, page 48 .
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– Fill with coolant. Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition; Rep. Gr. 19 ; General
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– Fill with R134a refrigerant and refrigerant oil. Refer to ⇒ “3 Specifications”, page 47 .
Prote AG.
5 - Bracket
6 - Screws
❑ 8 Nm
7 - Subframe
8 - Screws
❑ 9 +/- 1.3 Nm
9 - Right Support
10 - Screws
❑ 20 +/- 3 Nm
11 - Left Support
12 - Screws
❑ 9 +/- 1.3 Nm
13 - Bracket
14 - Screws
❑ 9 +/- 1.3 Nm
Note
Tighten the bolts -8- on the subframe first when installing the sup‐
ports -9- and -11-.

Golf 2004 ➤
Seal for heating and A/C unit / engine compartment
Note
Make sure the seal -A- is installed correctly.
5.12 Ribbed Belt Pulley, Denso A/C Com‐

pressor
Removing
– Carefully remove circlip -A-, for example, with a small screw‐
driver or needle-nose pliers. Be especially careful that the
ribbed belt pulley is not damaged when doing this.
– Hold the A/C compressor input shaft -B- firmly in place using
a standard Allen wrench or a socket wrench from the Shock
Absorber Set - T10001- (depending on the compressor ver‐ agen
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in the direction of the arrow -E- (tightening specification
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– Remove drive plate -C-. ss
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– Remove locking ring -A-.
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– Remove the ribbed belt pulley -B-.
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spec
Installing
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Golf 2004 ➤
Note
♦ Remove locking ring -A-.

♦ Clean A/C compressor flange before sliding on ribbed belt
pulley.
♦ When installing locking ring -A-, note that it cannot be bent
open more than is necessary for installation.
– Install the ribbed belt pulley -B-. n AG. Volkswagen AG do

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– Insert circlip -A- on correct side, the side with beveled insertion
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edge -C- faces away from A/C compressor (install rflat ise side
d ran
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facing A/C compressor). utho
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ss
– Insert rubber elements -D- in belt pulley -B- according to illus‐
ce
le
un
tration.
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Note
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When installing drive plate, coat the rubber element -D- lightly for
spec
example, with tire mounting paste or soap solution (as sliding
compound).
t to the co
– Insert drive plate -C- far enough into rubber elements -D- until
rrectne
it contacts A/C compressor shaft -B-.
s
– Screw drive plate -C- onto compressor shaft -F- by rotating in
s o
direction of arrow -B-.
cial p
f inform
– Install locking ring -A-.
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
5.13 Refrigerant Circuit Components
cop Vo
by lksw
cted agen
Prote AG.
⇒ “5.13.1 Condenser”, page 86
⇒ “5.13.2 Evacuating and Charging Valve, Low and High Pres‐
sure Sides”, page 89
⇒ “5.13.3 Evaporator”, page 89
⇒ “5.13.4 Expansion Valve”, page 90
⇒ “5.13.5 Fluid Reservoir with Dryer”, page 92
⇒ “5.13.6 Fluid Strainer and Dryer Bag”, page 94
⇒ “5.13.7 High Pressure Sensor G65 ”, page 95
5.13.1 Condenser
cuits - VAS6337/1A-

lkswage es n
o ot g
byV ua Golf 2004 ➤
d ran
ir se
tho Heating, Ventilation and Air Conditioning
tee
or - Edition 04.2015
au ac
ss
ce
le
un
pt
an
d
Note
itte
y li
rm
ab
pe
ility
♦ Refrigerant must be extracted before hand using for example,
ot
wit
A/C Service Station .
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ To prevent the ingress of dampness all components of the re‐
frigerant circuit which have been opened must be sealed with
suitable plugs.
rrectness of i
l purpos
Perform the following work first:

– Turn off all electric consumers.
nform
ercia
– Switch off the ignition.

m
a
com
tio
– Remove the key.
n in
r
te o
thi
– Extract refrigerant for example, using A/C Service Station .
s
iva
do
r
rp
cum
fo
en
ng
t.
Note Cop
yi Co
py
t. rig
gh ht
Environmentally hazardous draining of refrigerant is an offense pyri by
Vo
co
punishable by law.
by lksw
cted agen
Prote AG.
– Remove front bumper. Refer to ⇒ Body Exterior; Rep. Gr. 63 ;

– Remove the lock carrier. Refer to ⇒ Body Exterior; Rep. Gr.
50 ; Description and Operation .
– Disconnect connector.
WARNING

– Loosen the bolts -1- and -3- (12 ± 1.8 Nm).
Note
Illustration shows 1.6L engine with 75 Kw. Changes in the refrig‐

erant line arrangement can occur, depending on the vehicle.
– Remove and seal refrigerant lines -2- and -4-.

Golf 2004 ➤
1 - Protective Grate
❑ Only for vehicles with
rough terrain equip‐
ment.
❑ Only in vehicles with
“Showa” condenser.
❑ Position protective grate
from below on the 3rd rib
-arrow-.
2 - Clip
❑ Quantity: 8
3 - Condenser
AG. Volkswagen AG d
❑ Secure to radiator with 4 agen oes
olksw not
bolts. d by V gu
ara
rise nte
4 - Sealing Strips utho eo
ra
a c
❑ Adhere the upper seal‐ ss
ce
le
ing strips from above

un
pt
an
onto the 6th row of fins
d
itte
y li
on the condenser before
rm
ab
pe
installing.
ility
ot
wit
❑ Adhere the lower seal‐
, is n
h re
ing strips from below on‐
hole
spec
to the 1st row of fins on
es, in part or in w
the condenser before in‐
t to the co
stalling.
❑ Before assembly, attach
side sealing strips to
rrectness of i
outer edge of condens‐
l purpos
er.
5 - Spacer
nform
ercia
Note
m
a
com
tion in
Spacer is only installed in vehicles

r
te o
thi
with gasoline engine!

s
iva
do
r
rp
cum
fo
6 - Screw
en
ng
t.
yi Co
❑ 5 +/- 0.5 Nm t. Cop py
rig
gh ht
yri
7 - Radiator p by
co Vo
by lksw
cted agen
8 - Screws Prote AG.
❑ Quantity: 4
❑ 5 +/- 0.5 Nm
Note
On vehicles with a gasoline engine,

first secure bolt -6- before the bolts
-8- are secured.
9 - Fluid Reservoir With Drier

Under certain conditions, fluid reservoir with dryer is no longer to be replaced after each time the refrigerant
circuit is opened. Refer to ⇒ Refrigerant R134a Servicing; Rep. Gr. 00 ; Removal and Installation .
❑ Removing and installing. Refer to ⇒ “5.13.5 Fluid Reservoir with Dryer”, page 92 .

Golf 2004 ➤
5.13.2 Evacuating and Charging Valve, Low

and High Pressure Sides
cuits - VAS6337/1A-
♦ Adapter Set With Service Connection - T10364-
♦ Torque Wrench - VAG1783-
♦ Ratchet Insert 1/4" - VAS6234-
Note
AG. Volkswagen
♦ Environmentally hazardouslkdraining
swa
gen of refrigerant is ean
AG do
s n of‐
fense punishable by law. db
yV
o ot g
ua
ran
ise
r tee
♦ To prevent the entryut
ho of dampness, all components of the re‐ or
frigerant circuitsswhich have been opened must be sealed with
a ac
suitable plugs.
ce
le
un
pt
an
d
itte
y li
– Remove the cap -3-.
erm
ab
ility
ot p
wit
is n
WARNING
h re
ole,
spec
t to the co
Refrigerant and refrigerant oil will leak out if the refrigerant cir‐
cuit has not been evacuated.
Refrigerant must be extracted before opening the refrigerant rrectne
circuit. If the refrigerant circuit is not opened within 10 minutes
after extracting it, pressure may build up in the circuit again.
ss
Extract refrigerant once more.

o
cial p
f inform
mer
atio
– Evacuate the refrigerant circuit using, for example, A/C Serv‐

om
ice Station (or succeeding model), then replace the valve -2-.
c
i
or
n thi
te
– Remove the valve insert -2- (2.4 +/- 0.2 Nm) from the refrig‐
sd
iva
o
r
erant pipe with the proper adapter -4-. Hold the valve mount
p
cum
r
fo
-1- secure with a suitable tool when doing this.

en
ng
t.
yi Co
Cop py
t. rig
5.13.3 Evaporator
gh ht
pyri by
Vo
co lksw
by
cted
– Remove the heating and A/C unit. Refer to
agen
Prote AG.
⇒ “5.11 Heating and A/C Unit”, page 81 .
– Disassemble the heater and A/C unit. Refer to
⇒ “6.2 Climatronic Heating and A/C Unit”, page 104 , vehicles
with Climatic, refer to
⇒ “6.1 Climatic Heating and A/C Unit ”, page 102 .

Golf 2004 ➤
Heating, Ventilation and Air aConditioning
gen AG
. Volkswa-gEdition
en AG 04.2015
do
w es n
olks ot g
yV ua
– Disassemble the evaporator
ris
ed housing. Refer to
b ran
tee
⇒ “2.7 Evaporator Housing
tho Overview”, page 42 . or
au ac
ss
– Remove the evaporator -A- from the evaporator housing lower
ce
section. le
un
pt
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
♦ Before inserting the evaporator, check condensation water
hole
spec
drain and clean drain, if necessary.
es, in part or in w
t to the co
♦ Before inserting evaporator, clean evaporator housing and the
evaporator, if necessary.
rrectness of i
– When inserting evaporator -A- into lower section of evaporator
l purpos
housing, and when assembling both housing halves, make

sure the seal -F- is not damaged.
nform
ercia
– Check seal -F- (it must be glued all around) before inserting
m
evaporator.
a
com
tion in
– Mount the bracket -C- and seal/insulation -B- on the evapora‐
r
te o
thi
tor connecting pipes -D- and -E-.
s
iva
do
r
rp
c
– Insert evaporator -A- into lower section of evaporator housing
um
fo
as shown in the illustration.
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
Note co Vo
by lksw
cted agen
Prote AG.
♦ After assembling both housing halves, check seal / insulation
-B- for correct seating at pass-through for both refrigerant lines
-D- and -E-.
♦ Check seating of bracket -C- on both refrigerant lines -D- and
-E- for correct seating.
♦ If heat protection insulation -B- is missing or not installed cor‐
rectly, it can cause reduced performance of the A/C system
(change of adjusted control characteristics of expansion valve
due to radiant heat).
5.13.4 Expansion Valve

cuits - VAS6337/1A-
Note

♦ To prevent the ingress of dampness all components of the re‐
suitable plugs.

Golf 2004 ➤
Functions
♦ The expansion valve atomizes the streaming refrigerant and
controls the flow quantity so that the vapor is gaseous only at
the evaporator outlet, depending on the heat transmission.
olkswagen AG
en AG. V
Only for vehicles with a heat shield in front of the
olksexpansion valve
wag does
not
V gu
by ara
– Remove the nut -1- (6 +/- 0.9) Nm. rised nte
o h eo
ut
– Remove the clamps -2- and thessheat
a shield -3-. ra
c
ce
le
All vehicles
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
1 - Screws
ss
❑ 10 +/- 1 Nm
o
cial p
f in
❑ Quantity: 2
form
mer
atio
2 - Refrigerant Lines On Ex‐
om
pansion Valve
n
c
i
or
n thi
e
3 - O-ring
t
sd
iva
o
pr
c
❑ 13.7 mm; 2.5 mm
um
r
fo
en
ng
t.
4 - Expansion Valve
yi Co
Cop py
❑ Removing:
t. rig
gh ht
pyri by
Vo
co
– Extract refrigerant for
by lksw
cted agen
Prote
example, using A/C
AG.
Service Station .
WARNING
There is a danger of ice-
up.
Refrigerant leaks out if
refrigerant circuit is not
discharged.
Refrigerant must be ex‐
tracted before opening
the refrigerant circuit. If
refrigerant circuit is not
opened within 10 mi‐
nutes of extraction, pres‐
sure may form in refrig‐
erant circuit due to
evaporation. Extract re‐
frigerant once more.
– Remove the bolts -1-

and the refrigerant pipes
-2- from the expansion
valve.
– Remove the bolts -8- and the expansion valve -4-.

Golf 2004 ➤
5 - O-ring
❑ 14 mm; 1.82 mm
❑ Coat with refrigerant oil when installing.
6 - O-ring
❑ 10.8 mm; 1.82 mm
❑ Coat with refrigerant oil when installing.
7 - O-ring
❑ 9.5 mm; 2.5 mm
8 - Cylindrical Combination Bolt
❑ 5 Nm
5.13.5 Fluid Reservoir with Dryer

AG. Volkswagen AG d
agen oes
olksw not
V gu
by
Note rised ara
nte
ho eo
aut ra
Under certain conditions, fluid reservoir with dryer iss no longer to
s c
be replaced after each time the refrigerant circuit is opened. Refer
ce
le
un
pt
to ⇒ Refrigerant R134a Servicing; Rep. Gr. 00 ; Removal and
an
d
itte
y li
Installation .
erm
ab
ility
ot p
wit
is n
h re
ole,
♦ Torque wrench - VAG1331/- (5 to 50 Nm)
spec
t to the co
cuits - VAS6337/1A-
♦ Workshop Crane - VAS6100-
rrectne
♦ Engine Sling - 2024A-
s
Removing
s o
cial p
f inform
mer
Note
atio
om
n
c
i
or
n
♦ See notes, refer to thi
e

t
sd
iva
o
pr
cum

r
fo
en
ng

t.
yi Co
Cop py
t. rig
gh ht
yri
p by
o Vo
by c lksw
cted agen
Prote AG.

suitable plugs.
– Extract refrigerant for example, using A/C Service Station ,

only then open the refrigerant circuit.

Golf 2004 ➤
– Move the lock carrier into the service position. Refer to ⇒ Body
Exterior; Rep. Gr. 50 ; Description and Operation .
– Remove the radiator mounting bolts (7 Nm) -arrows-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
– Hang cooler on Workshop Crane - VAS6100- and Engine
wit
is n
Sling - 2024 A- using workshop equipment (cable ties or weld‐
h re
ole,
ing wire) and unhook cooler from lock carrier, coolant hoses
spec
and refrigerant lines remain connected.
t to the co
– Unscrew mounting bolt -2- and remove retaining clip.
rrectne
WARNING
s
s o
cial p
f
inform
mer
atio
m

o
n
c
i
or
n thi
e

t
sd
iva
o
pr
cum
r
fo
en
ng
t.
– Remove bolts -1- and pull fluid reservoir with dryer upward and
yi Co
op
out.
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
Note
AG.
Depending on condenser, bolt -1- may also only be installed once.
Installing
Note
♦ First tighten the bolt(s) -1- to 4.2 Nm +/- 0.7 Nm and then
mounting bolt -2-.
♦ When installing cooler, ensure that sealing strips are seated
correctly on cooler.

Golf 2004 ➤
5.13.6 Fluid Strainer and Dryer Bag
Note
♦ See notes, refer to

suitable plugs.
Removing
– Move the lock carrier into the service position. Refer to ⇒ Body
Exterior; Rep. Gr. 50 ; Description and Operation .
– Remove the Safety Warning label on the cap.
– Remove the cap -1- with a 50 TORX® socket.
WARNING

Refrigerant and refrigerant oil will leak out if the refrigerant cir‐
cuit has not been evacuated.
circuit. If the refrigerant circuit is not opened within 10 minutes
after extracting it, pressure may build up in the circuit gagain. AG. Volkswagen AG d
Extract refrigerant once more. a en oes
olksw not
V y gu
db ara
rise nte
tho eo
au ra
c
– Push the cover -1- down slightly andssremove the circlip
ce
le
-arrow-.
un
pt
an
d
itte
y li
– Install the M12 bolt into the cover and carefully pull it out of the
erm
ab
fluid container -2-.

ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Golf 2004 ➤
– Remove the dryer bag using a commercially available pick-up

tool in direction of -arrow- from the fluid container.
– Make a 2 mm welding wire with the following dimensions:

a - 380 mm
b - maximum 7 mm
c - maximum 6 mm
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
Hook the welding wire to the sstrainer
s exactly as illustrated to pre‐
vent damaging the fluid container.
ce
e
nl
pt
du
an
itte
– Carefully remove the filter (strainer) -2- from the fluid container
y li
erm
ab
with the welding wire -1-.
ility
ot p
Installing
wit
, is n
h re
hole
– Install the new strainer in the fluid container.

spec
es, in part or in w
– Insert the dryer bag into the fluid container.

t to the co
Perform remaining installation operations in reverse order of re‐

moval.
rrectness of i
l purpos
5.13.7 High Pressure Sensor - G65-

nform
ercia
Removing
m
at
om
– Remove the engine noise insulation. Refer to ⇒ Body Exterior;

ion
c
Rep. Gr. 50 ; Description and Operation .

in t
or
his
te
– Disconnect the connector from the high pressure sensor -1-.

a
do
priv
cum
or
– Remove the high pressure sensor -1- (8 ± 1 Nm) from the re‐
f
en
ng
t.
frigerant line connection. Cop
yi Co
py
t. rig
gh ht
pyri by
Vo
o
Note
c by lksw
cted agen
Prote AG.
♦ Replace O-ring -2-.

♦ High pressure sensor -1- may also be installed on a different
side in the vicinity of the condenser, depending on the engine
version.
Installing

Golf 2004 ➤
5.14 A/C Compressor Sub-Assembly

♦ Torque Wrench - VAG1331/- (or 5-50 Nm equivalent)
Note
♦ The bracket for A/C compressor and ancillary parts can be

removed and installed without opening the refrigerant circuit.
♦ Removing the ribbed belt. Refer to ⇒ Engine aMechanical,
gen AG
. VolkswFuel
agen AG
does
lksw
Injection and Ignition; Rep. Gr. 13 ; Removal
Vo and Installation . n ot g
by ua
ed ran
♦ Position of ribbed V-belt. Refer thtooris⇒ page 97 . tee
or
au ac
ss
ce
e
nl
pt
du
1 - Ribbed Belt
an
itte
y li
erm
ab
ility
ling. Refer to ⇒ Engine
ot p
wit
Mechanical, Fuel Injec‐
, is n
h re
tion and Ignition; Rep.
hole
Gr. 13 ; Removal and
spec
es, in part or in w
Installation .
t to the co
2 - Ribbed Belt Pulley - Coolant
Pump
rrectness of i
3 - Tensioning Roller
l purpos
4 - Generator and A/C Com‐

pressor Sub-Assembly Brack‐
et
nform
mercia
Removing
at
om
ion
c
in t
– Loosen the A/C com‐
or
his
e
pressor and remove the

at
do
riv
bolts -9-. Remove the A/

p
cum
or
C compressor from the

f
en
ng
sub-assembly bracket
t.
yi Co
op
and then tie it to the
C py
ht. rig
body (for example, with rig ht
py by
Vo
a welding wire). Refer to
co lksw
by
cted agen
⇒ page 97 . Prote AG.
– Remove the bolts from

the subassembly brack‐
et.
Follow the tightening se‐

quence when installing. Refer
to ⇒ page 97
5 - Fitting Bolt
❑ 25 Nm
6 - Generator
7 - Dowel Sleeves
❑ Quantity: 2
❑ Make sure they fit correctly between the auxiliary component bracket and the A/C compressor.
8 - A/C Compressor
❑ Removing and installing. Refer to ⇒ “5.2 A/C Compressor”, page 51 .
9 - Hex Bolts M8×100
❑ 25 Nm

Golf 2004 ➤
AG. Volkswagen AG d
❑ Quantity: 3 agen oes
olksw not
V gu
d by ara
10 - Fitting Bolt orise nte
h eo
❑ 25 Nm aut ra
ss c
ce
e
11 - Idler Rollers
nl
pt
du
an
❑ 40 +/- 4 Nm
itte
y li
erm
ab
ility
ot p
wit
, is n
Securing A/C Compressor to Body
h re
hole
spec
If A/C compressor is removed and refrigerant circuit not opened,
es, in part or in w
A/C compressor must be secure to body using appropriate ma‐
t to the co
terial, a welding wire for example.
Make sure the refrigerant lines on the A/C compressor remain free
rrectness of i
of tension.
l purpos
Note
nf
ercia
orm
♦ When installing the belt ensure it is correctly seated in the rib‐
m
atio
m
bed belt pulley.

o
n in
or c
♦ Last, install ribbed belt over ribbed belt pulley of A/C com‐
thi
te
sd
a
pressor.
iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Sub-assembly Bracket Tightening Sequence t. Cop py
rig
gh ht
pyri by
Vo
o
by c lksw
Note cted agen
Prote AG.
Bolts -1- and -2- are fitting bolts.
– Tighten the bolts hand-tight in the following sequence: 1

through 5.
– Tighten the bolts to 25 Nm in the following sequence: 1 through
5.
Ribbed Belt Routing

1 - Tensioning roller
2 - Ribbed belt pulley - generator
3 - Idler rollers
4 - Ribbed belt
5 - Ribbed belt pulley - A/C compressor
6 - Ribbed belt pulley - crankshaft
7 - Ribbed belt pulley - coolant pump
5.15 A/C Compressor Sub-Assembly


Golf 2004 ➤
♦ Torque Wrench - VAG1331/- (or 5-50 Nm equivalent)
Note

♦ Removing the ribbed belt. Refer to ⇒ Engine Mechanical, Fuel
Injection and Ignition; Rep. Gr. 13 ; Removal and Installation .
♦ Position of ribbed V-belt. Refer to ⇒ page 99 .
1 - Generator and A/C Com‐

pressor Sub-Assembly Brack‐
et
AG. Volkswagen AG d
Removing lksw
agen oes
not
Vo gu
by ara
d
– Loosen the A/C com‐ orise nte
eo
pressor and remove the auth
ra
hex bolts -6-. Remove ss c
ce
the A/C compressor
e
nl
pt
du
from the sub-assembly
an
itte
y li
bracket and then tie it to
erm
ab
the body (for example,
ility
ot p
with a welding wire).
wit
, is n
h re
hole
– Remove the bolts from
spec
the subassembly brack‐
es, in part or in w
et.
t to the co
2 - Multi-Point Socket Head
M8x60
rrectness of i
❑ 25 Nm
l purpos
3 - Multi-point Socket Head

M8X110
nf
ercia
❑ 25 Nm
rm
m
atio
m
4 - Hex Socket Head M8X30

o
n in
or c
❑ 25 Nm
thi
te
sd
iva
❑ Quantity: 4
o
r
rp
cu
o
m
f
5 - A/C Compressor
en
ng
t.
yi Co
op
❑ Removing and instal‐ C py
t. rig
ling. Refer to
gh ht
pyri by
co Vo
by lksw
cted
sor”, page 51 .
agen
Prote AG.
6 - Hex Bolts M8x85

❑ 25 Nm
❑ Quantity: 3
7 - Dowel Sleeves
❑ Quantity: 2
❑ Make sure they fit correctly between the auxiliary component bracket and the A/C compressor.

agen
AG. Volkswagen AG d
oes Golf 2004 ➤
ksw n
by Vol
Heating, Ventilation andotAir
gu Conditioning
ara
- Edition 04.2015
d
rise nte
o eo
Securing A/C Compressorauto
t body
h
ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
of tension.
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Ribbed Belt Routing

1- Idler roller, top
nform
ercia
2- Ribbed belt pulley - generator

m
a
com
t
3- Idler roller, bottom
ion in
r
te o
4- Ribbed belt for generator and coolant pump
thi
s
iva
do
r
5- Ribbed belt pulley - A/C compressor

rp
cum
fo
en
ng
6- Ribbed belt for A/C compressor

t.
yi Co
Cop py
t. rig
7- Ribbed belt pulley - crankshaft opyri
gh by
Vo
ht
c
8- Tensioning roller for ribbed belt - A/C compressor
by lksw
cted agen
Prote AG.
9- Tensioning roller for ribbed belt - generator and coolant
pump
10 - Ribbed belt pulley - coolant pump
5.16 A/C Compressor Sub-assembly

♦ Torque Wrench - VAG1331- (or 5-50 Nm equivalent)
Note

♦ Removing the ribbed belt. Refer to ⇒ Engine Mechanical, Fuel
Injection and Ignition; Rep. Gr. 13 ; Removal and Installation
♦ Position of ribbed V-belt. Refer to ⇒ page 101 .

Golf 2004 ➤
1 - M10x45 Hex Collar Bolt

❑ 2.0L Turbo FSI engine:
40 Nm
❑ Fitting hole
40 Nm
40 Nm
40 Nm
5 - A/C Compressor
ling. Refer to
sor”, page 51
6 - Hex Bolts M8×100
❑ 25 Nm AG. Volkswagen AG d
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❑ Fitting hole
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9 - Dowel Sleeves
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❑ Quantity: 2
❑ Make sure they fit cor‐
rectly between the auxiliary component bracket and the A/C compressor.
rrectness of i
10 - A/C Compressor Sub-Assembly Bracket
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Removing
– Remove the generator. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Removal and Installation . nform
ercia
– Loosen the A/C compressor and remove the hex bolts -6-. Remove the A/C compressor from the sub-
assembly bracket and then tie it to the body (for example, with a welding wire). Refer to ⇒ page 101 .
m
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– Remove the bolts -1- through -4- and -7- and -8- and remove the sub-assembly bracket -10- from the
ion
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cylinder block.
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at
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♦ Always observe tightening sequence of the bolts:

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– Tighten cylinder collar bolt item -1- (fitting hole), -7- (fitting hole), -4-, -8-, -3- and -2- in succession.
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Golf 2004 ➤
Securing A/C Compressor to body

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2- Ribbed belt pulley - generator
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3- Ribbed belt pulley - A/C compressor
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4- Ribbed belt
t to the co
5- Ribbed belt pulley - crankshaft
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♦ When installing the belt ensure it is correctly seated in the rib‐ nform
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bed belt pulley.

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♦ Last, install ribbed belt over ribbed belt pulley of A/C com‐
com
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pressor.
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Golf 2004 ➤
6 Disassembly and Assembly

⇒ “6.1 Climatic Heating and A/C Unit ”, page 102
olkswagen AG
en AG. V
⇒ “6.2 Climatronic Heating
olks and A/C Unit”, page 104s no
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6.1 Climatic Heating and A/C Unit
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1 - Temperature Regulator
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Door Motor - V68-
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❑ Checking, use Vehicle
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Diagnosis, Testing and
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Information System -
h re
VAS5051B- .
hole
spec
es, in part or in w
t to the co
ling. Refer to
⇒ “5.4.6 Temperature
Control Door Motor
V68 , Removing and In‐
rrectness of i
stalling”, page 57 .
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Setting function with Ve‐
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distributor and evapora‐ Prote AG.
tor housing.
4 - Cover
5 - Recirculation Door Motor -
V113-
VAS5051B- .
ling. Refer to
⇒ “5.4.5 Recirculation
Door Motor V113 , Removing and Installing”, page 56 .
❑ With recirculating air door.
7 - Evaporator Housing Upper Section
❑ Disassembling and assembling evaporator housing. Refer to
⇒ “2.7 Evaporator Housing Overview”, page 42 .
8 - Evaporator Housing Lower Section
9 - Evaporator
❑ Removing and installing. Refer to ⇒ “5.13.3 Evaporator”, page 89 .

Golf 2004 ➤

❑ Checking, use Vehicle Diagnosis, Testing and Information System - VAS5051B- .
Note

61 .
11 - Connection For Glove Compartment Cooling
❑ For disassembly, the glove compartment must be removed. Refer to ⇒ Body Interior; Rep. Gr. 68 ;
❑ Installation position of glove compartment cooling connection. Refer to ⇒ page 103 .
12 - Coolant Hose For Glove Compartment Cooling
❑ Removing and Installing. Refer to ⇒ “3.7 Fresh Air Blower Series Resistor with Fuse N24 ”, page 11 .
❑ Removing and Installing. Refer to ⇒ “3.6 Fresh Air Blower V2 ”, page 11 .
❑ Removing and Installing. Refer to ⇒ “3.4 Dust and Pollen Filter”, page 9 .
16 - Cover
17 - Heater Core
❑ Removing and installing.
wage
nRefer
AG. Voto ⇒ag“3.10
lksw en AG Heater Core”, page 13 .
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19 - Auxiliary Heater
au
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❑ Only on vehicles with Diesel engine.
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20 - Junction Box
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Installation position of glove compartment cooling connection

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1 - Connection
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2 - Valve
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103
Prote AG.
6. Disassembly and Assembly
Golf 2004 ➤
6.2 Climatronic Heating and A/C Unit
1 - Central Air Door Motor -

V70-
VAS5051B- .
ling. Refer to
⇒ “5.7.2 Central Air
Door Motor V70 , Re‐
moving and Installing”,
page 64 .
Setting using the Vehi‐
cle Diagnosis, Testing
⇒ “4.2 Climatronic, AG. Volkswagen AG d
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Components”, page 48 . rised
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2 - Left Temperature Door Mo‐ ss a ra
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tor - V158-
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un
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VAS5051B- .
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hole
ling. Refer to
spec
⇒ “5.7.6 Left Tempera‐
es, in part or in w
t to the co
ture Control Door Motor
V158 , Removing and
Installing”, page 69 .
rrectness of i
Setting using the Vehi‐
l purpos
cle Diagnosis, Testing

nform
ercia
m
a
Checking and Adjusting Components”, page 48 .
com
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3 - Defroster Door Motor - V107-

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⇒ “5.7.3 Defroster Door Motor V107 , Removing and Installing”, page 65 .

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VAS5051B- . Refer to ⇒ “4.2 Climatronic, Checking and Adjusting Components”, page 48 . p by
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4 - Bracket Prote AG.
5 - Screws
❑ Bolts must be unscrewed to separate air distributor and evaporator housing.
6 - Cover
7 - Vehicles through 04/2007 Recirculation Door Motor - V113- , from 05/2007 the Recirculation Door Motor -
V113- is Discontinued.

AG. Volkswagen AG d
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ara Golf 2004 ➤
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horis Heating, Ventilation and Air Conditioning
eo - Edition 04.2015
aut ra
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8 - Vehicles through 04/2007 Air Flow Door Motor - V71- ; from 05/2007 Fresh Air/Recirculating Air/Back Pres‐
ce
le
un
sure Door Motor Position Sensor - V425-
pt
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⇒ “5.7.1 Airflow Door Motor V71 , Removing and Installing, on Vehicles through 04/30/2007”, page 63
is n
h re
on vehicles through 04/2007.
ole,
spec
⇒ “5.7.4 Fresh Air/Recirculating Air/Back Pressure Door Motor V425 , Removing and Installing, Vehicles
t to the co
from 04/30/2007”, page 66 on vehicles from 05/2007.
rrectne
ss
❑ With recirculating air door.
o
cial p
f in
❑ With air flow door (Climatronic).
form
mer
10 - Fresh Air Intake Duct Temperature Sensor - G89-
atio
om
n
❑ Only installed on vehicles through 12/2005.
c
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or
n thi
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t
sd
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❑ Task: Temperature sensor controls temperature door and fresh air blower depending on temperature.
um
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❑ To disassemble, remove the instrument panel. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Removal and
t.
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Installation . C py
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11 - Evaporator Housing Upper Section
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12 - Evaporator Housing Lower Section
13 - Evaporator
❑ Removing and installing. Refer to ⇒ “5.13.3 Evaporator”, page 89 .
Note

61 .
15 - Connection For Glove Compartment Cooling
16 - Coolant Hose For Glove Compartment Cooling
❑ Installation position of glove compartment cooling connection. Refer to ⇒ page 106 .
17 - Fresh Air Blower - V2- with Fresh Air Blower Control Module - J126-
❑ On vehicles from 11/2005, Fresh Air Blower Control Module - J126- can be replaced separately.
❑ Fresh Air Blower - V2- , removing and installing. Refer to ⇒ “3.6 Fresh Air Blower V2 ”, page 11 .
❑ Fresh Air Blower Control Module - J126- , removing and installing. Refer to
⇒ “5.9 Fresh Air Blower Control Module J126 ”, page 80 .
6. Disassembly and Assembly 105

Golf 2004 ➤

19 - Cover
20 - Heater Core
21 - Right Temperature Door Motor - V159-
⇒ “5.7.7 Right Temperature Control Door Motor V159 , Removing and Installing”, page 71 .
24 - Air Distribution Housing
AG. Volkswagen AG d
Installation position of glove compartment cooling lconnection
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Golf 2004 ➤
7 Special Tools
cuits - VAS6337/1A-
♦ Engine Sling - 2024 A-
♦ Adapter Set With Service Connection - T10364-

AG. Volkswagen AG d
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7. Special Tools
AG.
Golf 2004 ➤
♦ Torque Wrench - VAG1783- (2…10 Nm) for Adapter Set With

Service Connections - T10364-

AG. Volkswagen AG d
♦ Test Adapter - VAG1598/47- lksw
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♦ Template - 1598/47-2-
rrectness of i
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VAS5051-
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♦ Workshop Crane - VAS6100-
AG.

Golf 2004 ➤
♦ Ratchet Insert 1/4" - VAS6234- for Adapter Set With Service

Connections - T10364-
Edition - K0058991221 - 05/26/2015 - FU - JY
AG. Volkswagen AG d
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7. Special Tools 109

Golf 2004 ➤
AG. Volkswagen AG d
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8 Revision History by ara
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Re Dat Job Type Feedback # Notes Editor
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Cautions & Warnings
Please read these WARNINGS and CAUTIONS before proceeding with maintenance
and repair work. You must answer that you have read and you understand these
WARNINGS and CAUTIONS before you will be allowed to view this information.
•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
wholly or in part by any of the extensive warranties issued by Volkswagen.
Volkswagen AG
AG.terminal
•= Disconnect the battery negative
agen (ground
doesstrap) whenever you work on the fuel system or the electrical
lksw not
system. Do not smoke
by V or work near heaters or other
o gfire
ua hazards. Keep an approved fire extinguisher handy.
ed ran
oris tee
h
•= Volkswagen autis constantly improving its vehicles and sometimes
these changes, both in parts and specifications,
or
ac
s
are mades applicable to earlier models. Therefore, part numbers
listed in this manual are for reference only. Always
ce
le
un
check with your authorized Volkswagen retailer parts department for the latest information.
pt
an
d
itte
y li
rm
ab
•= Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to
pe
ility
reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).
ot
wit
, is n
h re
hole
•= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support
spec
es, in part or in w
a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running. t to the co
•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
rrectness of i
battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
l purpos
become inoperable, even if the correct code is used in a later attempt.
•= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
nform
ercia
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
m
starting the vehicle while you are under it.

com
tion in
r
te o
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•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
s
iva
do
others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
r
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being fully alert.

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•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
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•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
Prote
cted AG.
agen
goggles, gloves and other protective clothing whenever the job requires working with harmful substances.
•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe
injury could result.
•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
new parts where indicated, and any other time it is deemed necessary by inspection.
Page 1 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled
fuel or oil.
•= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
grinding, sanding, or by cleaning with compressed air. AvoidAGbreathing
. Volkswageasbestos
n AG d fibers and asbestos dust.
n
Breathing asbestos can cause serious diseases such wage
olks as asbestosis or cancer,sandno may result in death.
oe
yV t gu
db ara
ise ne
•= Finger rings should be removed so that they r
tho cannot cause electrical shorts, get caught tine orunning machinery, or be
crushed by heavy parts. s au ra
c
s
ce
le
un
pt
•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
an
d
itte
y li
instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
rm
ab
pe
ility
replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
ot
wit
repairs.
, is n
h re
hole
spec
•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
es, in part or in w
might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
t to the co
once, but do not store the oily rags, which can ignite and burn spontaneously.
rrectness of i
•= Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque
l purpos
listed.
nform
ercia
•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
ignited, it will ignite gas trapped in the cells and cause the battery to explode.
m
a
com
tion in
•=
r
Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of
te o
thi
the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
s
iva
do
r
govern the disposal of wastes.

rp
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fo
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ng
i t.
py Co
•= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be t. Co py
rig
serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
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rig by
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trained in related safety precautions, and familiar with regulations governing the discharging and disposal of co Vo
by lksw
cted agen
automotive chemical refrigerants. Prote AG.
•= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
negative terminal (ground strap) and the ABS control module connector.
•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase
system pressure and may cause the system to burst.
•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
components is not separately fused, disconnect the control module connector(s).
•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
should test, disassemble or service the airbag system.
Page 2 of 3
Version 1.0
Cautions & Warnings
•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the
battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.
•= Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained
Volkswagen Service technicians using the VAG 1551 Scan Tool (ST) or an approved equivalent. The airbag unit
must never be electrically tested while it is not installed in the vehicle.
•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been
inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair
area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the
tire from the rim before attempting any repair.
•= When driving or riding in an airbag-equipped

agen
AG. Volkswagen AGvehicle,
do
never hold test equipment in your hands or lap while the
w es n
vehicle is in motion. VObjects
olks between you and the airbag
ot g can increase the risk of injury in an accident.
y ua
db ran
rise tee
tho or
s au ac
s I have read and I understand these Cautions and Warnings.
ce
e
nl
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du
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erm
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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or
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ate
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for
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Prote AG.
Page 3 of 3
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Service: Golf 2004

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3.8 Fresh/Recirculating Air Door Motor V154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.9 Heat and Fresh Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.11 Heater Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.14 Temperature Door Release Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.1 A/C System, Repairing and Handling Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . tion in 26

1.2 A/C Compressor, Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1.3 Climatronic A/C System with Automatic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1.4 Odors in Vehicles with A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.3 Climatic Heating and A/C Controls, Multi-pin Harness Connectors . . . . . . . . . . . . . . . . . . 34

5 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

❑ Removing and instal‐

❑ Checking. Refer to Ve‐

⇒ “3.8 Fresh/Recircu‐ his

lating Air Door Motor

❑ Replacing, initiate Basic

1. Description and Operation 1

1.2 Passenger Compartment Heating

3 - Right Side Vent

5 - Fresh Air and Heated Air

lating Door Switch -

❑ With Heated Driver Seat

Adjuster - E94- and

Heated Front Passen‐

ger Seat Adjuster -

2 Rep. Gr.80 - Heating, Ventilation

12 - Dust and Pollen Filter

❑ For the center console air guide to the rear vents.

14 - Rear Channel For Right Footwell

15 - Rear Channel For Left Footwell

1.3 Heat and Fresh Air Control Multi-Pin

1. Description and Operation 3

The 16-pin harness connector

5 - Terminal X and depending on the vehicle equipment level

3 - Fresh/Recirculating Air Door Motor - V154-

11 - Heated Driver Seat Control Module - J131- thi

15 - Heated Front Passenger Seat Control Module - J132-

4 Rep. Gr.80 - Heating, Ventilation

hind the bumper.

Removal and Installation .

– The sealing lips -1- in the ventilation frame on both sides of

– Observe installed position.

2. Diagnosis and Testing 5

3 Removal and Installation

⇒ “3.15 Vents”, page 21

6 Rep. Gr.80 - Heating, Ventilation

– Remove the heater. Refer to

⇒ “3.11 Heater Unit”, page 16 .

– Remove the bolts -arrows- 1.4 Nm.

3.2 Air Distribution Door Adjusting Unit

3. Removal and Installation 7

– Unclip flexible shaft from adapter for controls. Refer to

After installing, function of air distribution doors must be checked.

Rep. Gr. 64 ; Removal and Installation .

– Remove the cover -1- from the plenum chamber.

♦ From 11.05.08 with Climatronic, a bracket with an Air Quality

Sensor - G238- is installed on the intake air grille.

move the air quality sensor by rotating it to the right until it

comes out of the bracket.

8 Rep. Gr.80 - Heating, Ventilation

– Remove the flange nutsge-arrows-