Service: Golf 2015 Golf Variant 2015

Service
Repair Manual
Golf 2015 ➤
Golf Variant 2015 ➤
Heating, Ventilation and Air Conditioning
Edition 12.2015 agen
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
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00 - General, Technical Data
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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 © 2016 Volkswagen AG, Wolfsburg D4B804111B6

Golf 2015 ➤ , Golf Variant 2015 ➤
Heating, Ventilation and Air Conditioning - Edition 12.2015
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Heater and A/C Unit Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Odors in Vehicles with A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Vehicles with Start/Stop System General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Repairing Vehicles Equipped with A/C and Handling Refrigerants
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2.4 Type Label . . . . . . . . . . . . . . . . . . . . . . . . y. V.o.lk.sw. . . . . . . . . . . . . . . . . . .es. n.o.t g. . . . . . . . . . . . 4
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3 Safety Precautions . . . . . . . . . . . . . . o.ris.e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .an. te.e. . . . . . . 5
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .o.r a.c . . . . 5
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3.2 Start/Stop System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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4 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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4.1 Refrigerant Circuit, Specialized Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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5 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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5.1 Refrigerant R134a Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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5.2 Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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5.3 Oil Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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80 - Heating, Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1 Component Location Overview - Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Component Location Overview - Components Outside of Passenger Compartment . . . . 9
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1.2 Component Location Overview - Components Inside Front Passenger Compartment . . . . 10
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2 Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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2.1 Component Location Overview - Front Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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2.2 Temperature Regulator Door Motor V68 with Temperature Regulator Door Motor Position
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Sensor G92 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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2.3 Recirculation Door Motor V113 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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2.4 Air Distribution Door Motor V428 with Position Sensor Air Distribution Door Motor Position
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3 Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.1 Overview - Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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3.2 Fresh Air Blower V2 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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3.3 Fresh Air Blower Control Module J126 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 19
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3.4 Dust and Pollen Filter, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.5 Heater, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.6 Heater, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.7 Auxiliary Heater Heating Element Z35 with Auxiliary Air Heater Control Module J604 ,
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.9 Heater Core, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.10 Partition, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4 Air Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1 Overview - Air Routing and Air Distribution in Passenger Compartment . . . . . . . . . . . . . . 21
4.2 Driver Side Footwell Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.3 Front Passenger Side Footwell Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 21
4.4 Rear Footwell Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.5 Fresh Air Intake, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.6 Fresh Air Intake Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.7 Air Intake Duct, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.8 Passenger Compartment Forced Air Extraction, Checking . . . . . . . . . . . . . . . . . . . . . . . . 22
4.9 Passenger Compartment Forced Air Extraction, Removing and Installing . . . . . . . . . . . . 22
4.10 Air Guide for the Defrost Air Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 22
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4.11 Air Guide for Center Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5 Display and Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.1 Overview - Display and Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2 Display and Control Head, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6 Additional Components for Control and Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.1 Outside Air Temperature Sensor G17 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 25
87 - Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1 Component Location Overview - A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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2.2 Overview - Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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2.3 Refrigerant Circuit Pressure Sensor G805 , Removing and Installing . . . . . . . . . . . . . . . . 36

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2.4 Expansion Valve, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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2.5 Condenser, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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2.6 Dryer Bag, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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2.7 Refrigerant Lines with Inner Heat Exchanger, Removing and Installing . . . . . . . . . . . . . . 52
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2.8 Low Pressure Side Refrigerant Line Balance Weight, Removing and Installing . . . . . . . . 54
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2.9 Evacuating and Charging Valve, Removing and Installing, Low and High Pressure Side . . 55
3 A/C Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
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3.1 Overview - A/C Compressor Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.2 Overview - Belt Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
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3.3 A/C Compressor, Removing and Installing on Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

3.4 A/C Compressor, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
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3.5 Pressure Relieve Valve on A/C Compressor, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 67

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3.6 Belt Pulley, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
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4 Front Heater and A/C Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

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4.1 Overview - Heater and A/C Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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4.2 Overview - Attachments for Heater and A/C Unit and Air Intake Housing . . . . . . . . . . . . . . um 77
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4.3 Overview - Evaporator Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

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4.4 Overview - Air Distribution Housing Doors and Partitions . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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4.5 Heater and A/C Unit, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
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4.6 Heater and A/C Unit, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . cted
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4.7 Air Distribution Housing, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.8 Heater and A/C Unit Bracket, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.9 Evaporator, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.10 Fresh Air Blower Control Module J126 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 91
4.11 Dust and Pollen Filter, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.12 Fresh Air Blower V2 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.15 Heater Core, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.16 Heater Core Coolant Pipes, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.17 Evaporator Temperature Sensor G308 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 108
4.18 Condensation Water Drain, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.19 Condensation Water Drain, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.20 Partition, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
5 Air Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.1 Overview - Air Routing and Air Distribution in Passenger Compartment . . . . . . . . . . . . . . 113
5.2 Fresh Air Intake, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5.3 Fresh Air Intake Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
ii Contents
5.4 Air Intake Duct, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

5.5 Driver Side Footwell Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.6 Front Passenger Side Footwell Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 117
5.7 Rear Footwell Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.8 Rear Center Console Vent Air Guide Channel, Removing and Installing . . . . . . . . . . . . . . 118
5.9 Passenger Compartment Forced Air Extraction, Checking . . . . . . . . . . . . . . . . . . . . . . . . 119
5.10 Passenger Compartment Forced Air Extraction, Removing and Installing . . . . . . . . . . . . 119
5.11 Air Guide for Defrost Air Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5.12 Air Guide for Center Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
6 Display and Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
6.1 Component Location Overview - Display and Control Head . . . . . . . . . . . . . . . . . . . . . . . . 122
6.2 Display and Control Head, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
7 Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
7.1 Component Location Overview - Front Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
7.2 Temperature Regulator Door Motor V68 with Temperature Regulator Door Motor Position
7.3 Defroster Door Motor V107 with Defroster Door Motor Position Sensor G135 , Removing and
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
7.4 Recirculation Door Motor V113 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 134
7.5 Left Temperature Door Motor V158 with Left Temperature Door Potentiometer/Actuator
G220 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
7.6 Right Temperature Door Motor V159 with Right Temperature Door Potentiometer/Actuator
7.7 Fresh Air/Recirculating Air/Back Pressure Door Motor V425 with Fresh Air/Recirculating Air/
Back Pressure Door Motor Position Sensor G644 , Removing and Installing . . . . . . . . . . 140
7.8 Front Air Distribution Door Motor V426 with Air Distribution Door Motor Position Sensor
7.9 Air Distribution Door Motor V428 with Position Sensor Air Distribution Door Motor Position
7.10 Air Distribution Door Adjuster, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
8 Additional Components for Control and Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
8.1 Sunlight Photo Sensor
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8.2 Air Quality
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8.3 Function
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8.4 s auOutside Air Temperature Sensor G17 , Removing
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8.5 A/C Humidity Sensor G260 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
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8.6 Left Vent Temperature Sensor G150 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 153
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8.7 Right Vent Temperature Sensor G151 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 154
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8.8 Footwell Vent Temperature Sensor G192 , Removing and Installing . . . . . . . . . . . . . . . . 155
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9 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

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10 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

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AG.
Contents
n AG. Volkswagen AG do
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iv Contents
00 – General, Technical Data

1 Identification
(Edition 12.2015)
⇒ “1.1 Heater and A/C Unit Identification”, page 1
1.1 Heater and A/C Unit Identification

⇒ “1.1.1 Heater and A/C Unit Identification, Valeo”, page 1
⇒ “1.1.2 Heater and A/C Unit Identification, Denso”, page 1
1.1.1 Heater and A/C Unit Identification, Va‐

leo
Note
Correct allocation must be observed when replacing components.

Interchanging components from different manufacturers is not
permitted. Refer to the Parts Catalog.
– Remove the left footwell center console trim. Refer to ⇒ Body

Interior; Rep. Gr. 68 ; Center Console; Overview - Center
Console .
If the layout of the coolant pipe on the heater core looks like the
one shown in the illustration, then the heater and Air Conditioning
(A/C) unit is from the manufacturer Valeo.
AG. Volkswagen AG d
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1.1.2 Heater and A/C Unit Identification, Den‐

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Note
Correct allocation must be observed when replacing components.

rrectne
Interchanging components from different manufacturers is not

permitted. Refer to the Parts Catalog.
ss o
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f in

form
mer
Console .
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1. Identification 1
Heating, Ventilation and Air Conditioning - oEdition
AG. V lkswagen12.2015
A
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Volks ot g
If the layout of the coolant pipe onedthe by heater core looks like the ua
ran
one shown in the illustration, thenhoristhe heater and Air Conditioning tee
(A/C) unit is from the manufacturer
aut
Denso. or
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2 Rep. Gr.00 - General, Technical Data

2 General Information
⇒ “2.1 Odors in Vehicles with A/C System”, page 3
⇒ “2.2 Vehicles with Start/Stop System General Information”,
page 3
⇒ “2.3 Repairing Vehicles Equipped with A/C and Handling Re‐
frigerants”, page 4
⇒ “2.4 Type Label”, page 4
2.1 Odors in Vehicles with A/C System
Note
♦ Numerous procedures varying in their application and effect

are available on the market for cleaning the evaporator.
♦ Currently, Volkswagen approves using Ultrasound A/C Clean‐
er - VAS6189A- or Suction Feed Spray Gun - VAG1538- and
a spray nozzle to clean the evaporator.
♦ Should Volkswagen test and approve other methods, the in‐
formation will be published in the ⇒ Refrigerant R134a Serv‐
icing; Rep. Gr. 00 ; A/C System, General Information .
2.2 Vehicles with Start/Stop System Gener‐

al Information
AG. Volkswagen AG d
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Read Safety Precautions
ss a
When Working on Vehicles With Start/ c
Stop System. Refer to
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un
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⇒ “3.2 Start/Stop System Safety Precautions”, page 5 .

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If the vehicle has a start-stop system, perform the following ter‐

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mination conditions to deactivate the start-stop function:

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♦ Use the Start/Stop button to switch off the Start/Stop System.

hole
spec
es, in part or in w
♦ The battery state of charge does not make it possible to start

t to the co
the engine again (start voltage prediction).

♦ The defrost function is active.
rrectness of i
♦ The heated front windshield is active.

l purpos
♦ The selected temperature deviates more than 8 °C (46 °F)

from the actual temperature inside the vehicle.
nform
ercia
♦ The engine RPM exceeds 1,200 RPM.

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com
ti
♦ The Generator - C- is faulty, for example, the ribbed belt is torn.

on in
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♦ The coolant temperature is not in the specified range of 25 °C

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to 100 °C (77 to 212 °F).

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♦ Increasing the blower speed by more than four steps.

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2. General Information 3
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Golf 2015 ➤ , Golf Variant 2015 ➤ ksw
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2.3 Repairing Vehicles Equipped with A/C ss
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and Handling Refrigerants
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Note
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♦ ELSA contains all the information regarding performing repairs
spec
on vehicles with air conditioning and working with refrigerant.
Refer to ⇒ Refrigerant R134a Servicing; Rep. Gr. 00 ; A/C
t to the co
System, General Information .
♦ Information on tools for repairs in vehicles with climate control
rrectne
system can be found in ELSA. Refer to ⇒ Refrigerant R134a
Servicing; Rep. Gr. 00 ; A/C System, General Information .
ss
♦ ELSA contains usage information for the A/C service station
o
cial p
f i
when working on vehicles with an A/C system. Refer to ⇒
nform
Refrigerant R134a Servicing; Rep. Gr. 00 ; A/C System, Gen‐
mer
eral Information .
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Caution
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Do not bend or kink refrigerant lines excessively.

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There is a foil inside the refrigerant lines that can be destroyed.
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Refrigerant lines must not be bent beyond a radius less than r
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= 100 mm.
Prote AG.
WARNING
Danger due to refrigerant coming out under pressure.

Danger of frost bite to skin and other parts of the body.
• Extract the refrigerant and immediately open the refriger‐
ant circuit after that.
• If the refrigerant was extracted more than 10 minutes in
the past and the refrigerant circuit was not opened, extract
the refrigerant again. Pressure in the refrigerant circuit is
caused by evaporation.
2.4 Type Label

Type Label for the Refrigerant R134a and Refrigerant Oil Ca‐
pacities
1- Refrigerant name
2- Refrigerant capacity
3- Refrigerant oil name
Note
♦ In deviation from the type label, a filling tolerance of 500 ± 15

grams is permitted.
♦ Refrigerant R134a and refrigerant oil capacities. Refer to
⇒ “5 Technical Data”, page 8 .

3 Safety Precautions
⇒ “3.1 Handling Refrigerant Safety Precautions”, page 5
⇒ “3.2 Start/Stop System Safety Precautions”, page 5
3.1 Handling Refrigerant Safety Precau‐

tions
Note
♦ ELSA contains all safety precautions regarding performing re‐

pairs on vehicles with air conditioning and working with refrig‐
erant. Refer to ⇒ Refrigerant R134a Servicing; Rep. Gr. 00 ;
A/C System, General Information .
♦ If there are unpleasant odors coming from the evaporator,
clean it with the Ultrasound A/C Cleaner - VAS6189B- or with
a Suction Feed Spray Gun - VAG1538- . The operating in‐
structions are provided with the tools.
Caution
Do not bend or kink refrigerant lines excessively.

There is a foil inside the refrigerant lines that can be destroyed.
Refrigerant lines must not be bent beyond a radius less than r
= 100 mm.
AG. Volkswagen AG d
Additional Information lksw
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♦ Refer to ⇒ Wiring diagrams, Troubleshooting
rise
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& Component ara
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locations utho eo
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3.2 Start/Stop System Safety Precautions
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On vehicles with the Start/Stop System, the engine could start

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automatically and cause serious personal injury.

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♦ If the Start/Stop System is activated (recognizable by a

t to the co
message in the instrument cluster), it is possible to start

the engine automatically.
rrectness of i
♦ Make sure the Start/Stop System is deactivated is deac‐

tivated (ignition switched off) whenever working on the
l purpos
vehicle.
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AG.
3. Safety Precautions
4 Repair Information
⇒ “4.1 Refrigerant Circuit, Specialized Repairs”, page 6
4.1 Refrigerant Circuit, Specialized Repairs
Note
♦ ELSA contains all information regarding performing repairs on

vehicles with air conditioning and working with refrigerant. Re‐
fer to ⇒ Refrigerant R134a Servicing; Rep. Gr. 00 ; A/C
System, General Information .
Servicing; Rep. Gr. 00 ; Special Tools .
♦ ELSA contains usage information for the Air Conditioning (A/
C) service station when working on vehicles with an A/C sys‐
tem. Refer to ⇒ Refrigerant R134a Servicing;
agen
AG. VoRep.
lkswagGr.
en AG00 ;
does
A/C System, General Information
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♦ Under certain conditions,hthe
or dryer bag should no longer be
is tee
replaced each time thes arefrigerant
ut circuit is opened. Refer to or
ac
⇒ Refrigerant R134a Servicing; Rep. Gr. 00 ; A/C System,
s
ce
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General Information in ELSA.

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♦ The procedure for flushing with refrigerant R134a is described
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in ELSA. Refer to ⇒ Refrigerant R134a Servicing; Rep. Gr.
pe
ility
00 ; A/C System, General Information .
ot
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Note
♦ Flush the refrigerant circuit with R134a refrigerant under the

following conditions:
♦ In the event of dirt or other contamination in the refrigerant
circuit.
♦ If vacuum reading is not maintained on evacuating a leak-free
G. Volkswage
refrigerant circuit (pressure build-up
ksw
agen due to moisture
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♦ If the refrigerant circuit
tho has been left open for longer than nor‐ e o
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mal (for example,
ss following an accident).
a u r ac
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♦ In the event of doubt about the amount of refrigerant oil in the
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♦ The A/C compressor must be replaced on account of internal
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damage (for example, noise or no output).
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4. Repair Information 7
5 Technical Data
⇒ “5.1 Refrigerant R134a Capacities”, page 8
⇒ “5.2 Refrigerant Oil”, page 8
⇒ “5.3 Oil Distribution”, page 8
5.1 Refrigerant R134a Capacities

Complete R134a refrigerant capacity. Refer to Fluid Capacity
book.
5.2 Refrigerant Oil

Important Information
Refrigerant oil is hygroscopic (attracts moisture). Close any
opened containers immediately after use to prevent moisture from
entering.
Note
♦ The special refrigerant oil (for use with refrigerant circuits

R134a only) is no longer obtainable on the refrigerant/machine
oil market.
♦ Do not use refrigerant oil that was stored for long periods of
time in open containers.
Refrigerant Oil Can be Obtained Using Following Part Number;

For:
6SES14C; Denso G 052 300 A2
11PXE14; Sanden G 052 154 A2
G. Volkswagen AG d
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6CVC140; Delphi ol G
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Complete R134a refrigerant
au
th capacity. Refer to Fluid Capacity or
ac
book. ss
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5.3 Oil Distribution

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The oil, which is located in the sump of the Air Conditioning (A/C)
ility
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compressor before initially switching on the air conditioner sys‐

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tem, is distributed through the refrigerant circuit as follows:

h re
ole,
spec
♦ A/C compressor approximately 50%

t to the co
♦ Condenser approximately 10%

♦ Suction hose approximately 10%
rrectne
♦ Evaporator approximately 20%

♦ Receiver/dryer approximately 10%
ss o
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80 – Heating, Ventilation
1 Component Location Overview -
Heating
⇒ “1.1 Component Location Overview - Components Outside of
Passenger Compartment”, page 9
⇒ “1.2 Component Location Overview - Components Inside Front
1.1 Component Location Overview - Components Outside of Passenger Com‐

partment
1 - Vehicle Interior Forced Air

Extraction
❑ Check using the Vehicle
Diagnostic Tester . Re‐
fer to
⇒ “5.9 Passenger Com‐
partment Forced Air Ex‐
traction, Checking”,
page 119 .
AG. Volkswagen AG d
❑ Removing and instal‐ agen oes
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ling. Refer to ed byV gu
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⇒ “5.10 Passenger horis nte
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Compartment Forced aut ra
c
Air Extraction, Remov‐ ss
ce
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ing and Installing”, page

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119 .
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2 - Outside Air Temperature
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Sensor - G17-
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❑ Removing and instal‐
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ling. Refer to
⇒ “8.4 Outside Air Tem‐ spec
es, in part or in w
t to the co
perature Sensor G17 ,
Removing and Instal‐
ling”, page 153 .
rrectness of i
3 - Fresh Air Intake Cover

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ling. Refer to
⇒ “5.3 Fresh Air Intake
nform
ercia
Cover, Removing and

m
Installing”, page 115 .

at
om
ion
c
4 - Fresh Air Intake

in t
or
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te

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do
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ling. Refer to
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⇒ “5.2 Fresh Air Intake,

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1. Component Location Overview - Heating 9

1.2 Component Location Overview - Components Inside Front Passenger

Compartment
1 - Driver Side Footwell Vent

ling. Refer to
⇒ “5.5 Driver Side Foot‐
well Vent, Removing
and Installing”,
page 117 .
❑ Overview. Refer to
⇒ “5.1 Overview - Air
Routing and Air Distri‐
bution in Passenger
Compartment”,
page 113 .
2 - Temperature Regulator
Door Motor - V68-
ling. Refer to
⇒ “7.5 Left Temperature
Door Motor V158 with
Left Temperature Door
Potentiometer/Actuator
G220 , Removing and
Installing”, page 136 . n AG. Volkswagen AG do
lkswage es n
3 - Air Distribution Door Motor byV
o ot g
ua
- V428- ir se
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tee
ho
❑ Removing and instal‐ aut or
ac
ling. Refer to ss
ce
e
⇒ “7.8 Front Air Distri‐

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Door Motor Position ility
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Sensor G642 , Remov‐ wit

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143 .
spec
es, in part or in w
4 - Dust and Pollen Filter

t to the co

ling. Refer to
rrectness of i
⇒ “4.11 Dust and Pollen Filter, Removing and Installing”, page 92 .

l purpos
5 - Recirculation Door Motor - V113-

❑ Removing and installing. Refer to
⇒ “7.4 Recirculation Door Motor V113 , Removing and Installing”, page 134 .
nf
ercia
orm
m
6 - Fresh Air Blower - V2-

atio
om
❑ Removing and installing. Refer to ⇒ “4.12 Fresh Air Blower V2 , Removing and Installing”, page 95 .
n in
or c
thi
e
7 - Front Passenger Side Footwell Vent

t
sd
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f
⇒ “5.6 Front Passenger Side Footwell Vent, Removing and Installing”, page 117 .
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ng
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❑ Overview. Refer to C py
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⇒ “5.1 Overview - Air Routing and Air Distribution in Passenger Compartment”, page 113 .
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8 - Auxiliary Heater Heating Element - Z35- with Auxiliary Air Heater Control Module - J604- cted agen
Prote AG.
❑ Checking. Refer to
⇒ “4.13 Auxiliary Heater Heating Element Z35 with Auxiliary Air Heater Control Module J604 , Checking”,
page 96 .
⇒ “4.14 Auxiliary Heater Heating Element Z35 with Auxiliary Air Heater Control Module J604 , Removing
and Installing”, page 97 .
10 Rep. Gr.80 - Heating, Ventilation

9 - Heater Core
❑ Removing and installing. Refer to ⇒ “4.15 Heater Core, Removing and Installing”, page 98 .
10 - Display and Control Head
⇒ “6.2 Display and Control Head, Removing and Installing”, page 126 .
AG. Volkswagen AG d
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do
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1. Component Location Overview - Heating 11

2 Actuators
⇒ “2.1 Component Location Overview - Front Actuators”,
page 12
⇒ “2.2 Temperature Regulator Door Motor V68 with Temperature
Regulator Door Motor Position Sensor G92 , Removing and In‐
stalling”, page 13
⇒ “2.3 Recirculation Door Motor V113 , Removing and Installing”,
page 13
⇒ “2.4 Air Distribution Door Motor V428 with Position Sensor Air
Distribution Door Motor Position Sensor G645 , Removing and n AG. Volkswagen AG do
wage
Installing”, page 13 Vo lks es n
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2.1 Component Location Overview - Front Actuators thoris tee
or
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Door Motor - V68-
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Diagnostic Tester .
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ling. Refer to
spec
es, in part or in w
⇒ “7.2 Temperature
t to the co
Regulator Door Motor
V68 with Temperature
rrectness of i
Position Sensor G92 ,
l purpos
ling”, page 131 .

❑ Replacing: initiate the
nf
ercia
basic setting using the
or
Vehicle Diagnostic
m
m
atio
Tester
om
n in
or c
2 - Air Distribution Door Motor
thi
te
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Diagnostic Tester .
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⇒ “7.9 Air Distribution
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Door Motor V428 with Prote AG.
Position Sensor Air Dis‐
tribution Door Motor Po‐
sition Sensor G645 , Re‐
moving and Installing”,
page 144 .
Vehicle Diagnostic
Tester
3 - Recirculation Door Motor -
V113-
Diagnostic Tester .
❑ Replacing: initiate the basic setting using the Vehicle Diagnostic Tester

2.2 Temperature Regulator Door Motor -

V68- with Temperature Regulator Door
Motor Position Sensor - G92- , Remov‐
ing and Installing wagen AG. Volkswagen AG doe
ks s no
Vol t gu
The removal and installation isedidentical
by to vehicles with an Air ara
Conditioning (A/C) system.hoRefer to
ris nte
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⇒ “7.2 Temperature Regulator
sa
ut Door Motor V68 with Temperature ra
c
s
ce
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stalling”, page 131 .

un
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2.3 Recirculation Door Motor - V113- , Re‐
erm
ab
ility
moving and Installing
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The removal and installation is identical to vehicles with an Air
ole,
spec
Conditioning (A/C) system. Refer to
t to the co
page 134 .
2.4 Air Distribution Door Motor - V428- with
rrectne
Position Sensor Air Distribution Door
ss o
cial p
f
ing and Installing
inform
mer
atio
m

o
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c
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Distribution Door Motor Position Sensor G645 , Removing and

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2. Actuators 13
3 Heater
⇒ “3.1 Overview - Heater”, page 14
⇒ “3.2 Fresh Air Blower V2 , Removing and Installing”,
page 19
⇒ “3.3 Fresh Air Blower Control Module J126 , Removing and
Installing”, page 19
olkswagen AG
en AG. V
⇒ “3.4 Dust and Pollen Filter, Removingolksand Installing”,
wag does
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page 19 ed
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⇒ “3.5 Heater, Removing and
au
thInstalling”,
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page 19 eo
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⇒ “3.6 Heater, Disassembling and Assembling”, page 19
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⇒ “3.7 Auxiliary Heater Heating Element Z35 with Auxiliary Air
itte
y li
Heater Control Module J604 , Checking”, page 20
erm
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ility
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Heater Control Module J604 , Removing and Installing”,
h re
hole
page 20
spec
es, in part or in w
⇒ “3.9 Heater Core, Removing and Installing”, page 20
t to the co
⇒ “3.10 Partition, Removing and Installing”, page 20
rrectness of i
3.1 Overview - Heater
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not the same. Interchanging components from different man‐

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ufacturers is not permitted. Refer to the Parts Catalog.

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♦ A heater manufactured by “Valeo” is shown in the following

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ufacturers. Refer to
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1 - Operating Lever
❑ For operating the de‐
froster and air distribu‐
tion door
- V428-
❑ With the Air Distribution
Door Motor Position
Sensor - G645-
❑ To check, use the Vehi‐
cle Diagnostic Tester in
the “Guided Fault Find‐
ing” function. Refer to
⇒ Wiring diagrams,
Troubleshooting &
Component locations.
ling. Refer to
page 144 .
3 - Screw
❑ 1 Nm
❑ Quantity: 2
4 - Screw
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diagrams, Troubleshooting & Component locations.

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⇒ “7.2 Temperature Regulator Door Motor V68 with Temperature Regulator Door Motor Position Sensor
t to the co
G92 , Removing and Installing”, page 131 .

7 - Operating Lever
rrectness of i
❑ For the operating of the warm air door

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8 - Heater
❑ There are different versions. Refer to ⇒ “1.1 Heater and A/C Unit Identification”, page 1 .
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❑ Interchanging components is not permitted.

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❑ The following illustrations show the heater manufactured by “Valeo”

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❑ The design is largely the same as the heater and Air Conditioning (A/C) unit design.
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❑ The expansion valve, condensation water drain, evaporator, etc. are not present.
do
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❑ (Only on vehicles without an A/C system) instead of the evaporator an airflow limiter is installed.
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❑ The seal for the plenum chamber rear wall does not have an opening for the expansion valve or it is
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❑ Removing and installing. Refer to ⇒ “4.5 Heater and A/C Unit, Removing and Installing”, page 83 .
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Prote AG.
3. Heater 15
9 - Defroster- and Air Distribution Door Actuator

⇒ “7.10 Air Distribution Door Adjuster, Removing and Installing”, page 147 .
Heater, Heater Core, Auxiliary Heater Heating Element
1 - Screw
❑ 2 Nm
2 - Coolant Pipe for the Heater
Core
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❑ Coolant supply from en‐ ss a c
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Coolant Pipes, Remov‐
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106 .
spec
3 - Clamp
t to the co
Core
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❑ There are different ver‐
sions. Refer to the Parts
s
Catalog.
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❑ Coolant return to engine
inform
mer
atio
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⇒ “4.16 Heater Core
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❑ Replacing
6 - Cover
❑ For the heater core
7 - Screw
❑ 1 Nm
8 - Foam Spacer
❑ For sealing/insulating
❑ For vehicles without an A/C system, without opening for the expansion valve. Refer to the Parts Catalog.
❑ Observe installed position
9 - Bracket
❑ For the coolant pipes
10 - Foam Piece
❑ For insulating

11 - Heater
❑ For vehicles without an Auxiliary Heater Heating Element - Z35- with Auxiliary Air Heater Control Module
- J604- , the opening for the auxiliary heater is closed.
12 - Heater Core
❑ There are different versions. Refer to the Parts Catalog.
13 - Auxiliary Heater Heating Element - Z35- with Auxiliary Air Heater Control Module - J604-
page 96 .
14 - Screw
❑ 2 Nm
❑ Quantity: 2
15 - Wire
❑ For the Auxiliary Heater Heating Element - Z35- with Auxiliary Air Heater Control Module - J604-
16 - Ground (GND) Cable for the Auxiliary Heater Heating Element - Z35- with Auxiliary Air Heater Control
Module - J604-
❑ Nut 9 ± 1 Nm
❑ For the auxiliary heater
17 - Screw
❑ 2 Nm agen
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Air Intake Duct, Dust and Pollen Filter, Fresh Air Blower, Door h re
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Control
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3. Heater 17
1 - Plastic Screw or Plug (de‐

pending on version)
❑ 0.3 Nm
❑ Quantity: 2
2 - Partition
ling. Refer to
⇒ “4.20 Partition, Re‐
page 112 .
3 - Fresh Air Blower Housing
and Dust and Pollen Filter
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ling. Refer to
⇒ “5.4 Air Intake Duct,
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ling”, page 116 .
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6 - Not Installed
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Only for vehicles with Clima‐

tronic.
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❑ To check, use the Vehicle Diagnostic Tester in the “Guided Fault Finding” function. Refer to ⇒ Wiring Prote AG.
9 - Screw
❑ 1 Nm
❑ Quantity: 2
Note
On vehicles without an A/C system

and on vehicles with electric-manual
climate control system without an
activated charcoal insert from the
manufacturer.
❑ Replacement interval. Refer to ⇒ Maintenance Intervals; Rep. Gr. 03 .

❑ Removing and installing. Refer to ⇒ “4.11 Dust and Pollen Filter, Removing and Installing”, page 92 .
11 - Cover
❑ For dust and pollen filter
13 - Fresh Air Blower Control Module - J126-
⇒ “4.10 Fresh Air Blower Control Module J126 , Removing and Installing”, page 91 .
14 - Screw AG. Volkswagen AG d
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3.3 Fresh Air Blower Control Module -
J126- , Removing and Installing
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3.4 Dust and Pollen Filter, Removing and
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tion in
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3.5 Heater, Removing and Installing
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It is not necessary to extract the refrigerant and remove the ex‐
pansion valve. The further removal and installation is identical to
vehicles with an Air Conditioning (A/C) system. Refer to
⇒ “4.5 Heater and A/C Unit, Removing and Installing”,
page 83 .
3.6 Heater, Disassembling and Assembling

It is not necessary to extract the refrigerant and remove the ex‐
pansion valve and the evaporator or to disassemble. The further
procedure is identical to vehicles with an Air Conditioning (A/C)
system. Refer to
⇒ “4.6 Heater and A/C Unit, Disassembling and Assembling”,
page 87 .
3. Heater 19
3.7 Auxiliary Heater Heating Element - Z35- AG. Volkswagen

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Checking is identical to vehicles with an Air Conditioning
ss
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system. Refer to
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un
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Heater Control Module J604 , Checking”, page 96 .
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3.8 Auxiliary Heater Heating Element - Z35-
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- J604- , Removing and Installing
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page 97 .
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3.9 Heater Core, Removing and Installing
nform
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⇒ “4.15 Heater Core, Removing and Installing”, page 98 .
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3.10 Partition, Removing and Installing
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4 Air Routing
⇒ “4.1 Overview - Air Routing and Air Distribution in Passenger
Compartment”, page 21
⇒ “4.2 Driver Side Footwell Vent, Removing and Installing”, page
21
⇒ “4.3 Front Passenger Side Footwell Vent, Removing and In‐
⇒ “4.4 Rear Footwell Vent, Removing and Installing”, page 21
⇒ “4.5 Fresh Air Intake, Removing and Installing”, page 22
⇒ “4.6 Fresh Air Intake Cover, Removing and Installing”,
page 22
⇒ “4.7 Air Intake Duct, Removing and Installing”, page 22
⇒ “4.8 Passenger Compartment Forced Air Extraction, Check‐
ing”, page 22
⇒ “4.9 Passenger Compartment Forced Air Extraction, Removing
and Installing”, page 22
⇒ “4.10 Air Guide for the Defrost Air Vent, Removing and Instal‐
ling”, page 22
⇒ “4.11 Air Guide for Center Vent, Removing and Installing”, page
22
4.1 Overview - Air Routing and Air Distribu‐

tion in Passenger Compartment
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The overview of the air ducts and air Vdistribution
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interior is identical to a vehicle with ed an
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ara
tem. Refer to horis nte
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⇒ “5.1 Overview - Air Routing s aut and Air Distribution in Passenger ra
c
Compartment”, page 113 .s
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4.2 Driver Side Footwell Vent, Removing

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and Installing
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4.3 Front Passenger Side Footwell Vent,

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4.4 Rear Footwell Vent, Removing and In‐

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⇒ “5.7 Rear Footwell Vent, Removing and Installing”, page 118 .
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4. Air Routing 21
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Golf 2015 ➤ , Golf Variant 2015yV
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Heating, Ventilation andrisAir
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tee
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4.5 Fresh Air Intake, Removing and Instal‐
ss
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ling
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⇒ “5.2 Fresh Air Intake, Removing and Installing”, page 115 .
h re
hole
spec
4.6 Fresh Air Intake Cover, Removing and
es, in part or in w
Installing
t to the co
rrectness of i
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page 115 .
4.7 Air Intake Duct, Removing and Installing
nform
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ion in
⇒ “5.4 Air Intake Duct, Removing and Installing”, page 116 .
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4.8 Passenger Compartment Forced Air Ex‐
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⇒ “5.9 Passenger Compartment Forced Air Extraction, Check‐
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Prote AG.

traction, Removing and Installing
⇒ “5.10 Passenger Compartment Forced Air Extraction, Remov‐
ing and Installing”, page 119 .
4.10 Air Guide for the Defrost Air Vent, Re‐

⇒ “5.11 Air Guide for Defrost Air Vent, Removing and Installing”,
page 120 .
4.11 Air Guide for Center Vent, Removing

and Installing
121 .

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Heating, Ventilation
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5 Display and Control Head
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⇒ “5.1 Overview - Display and Control Head”, page 23
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⇒ “5.2 Display and Control Head, Removing and Installing”, page
ole,
24
spec
t to the co
5.1 Overview - Display and Control Head
rrectne
Note
s
Not all the buttons are used, depending on the vehicle equipment
s o
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level and may vary in location.
f inform
mer
atio
1 - Heated Driver Seat Adjuster om
n
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- E94-
thi
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❑ Optional
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❑ The seat heating as 3
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ng
t.
settings. An LED indi‐
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❑ If no LED is illuminated, Prote
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the seat heater is
switched off.
2 - Rear Window Defogger
Button
❑ Rear window defroster
remains on for 4 to 20
minutes, depending on
exterior temperature.
3 - Recirculating Air Mode But‐
ton
Note
The recirculating air mode turns off

during ignition and returns to fresh
air mode.
4 - Heated Front Passenger

Seat Adjuster - E95-
❑ Optional
❑ The seat heating as 3
settings. An LED indi‐
cates which setting is
selected.
❑ If no LED is illuminated,
the seat heater is
switched off.
5 - Air Distribution Control
Knob
6 - Air Distribution Display
7 - Blower Speed Control Knob
❑ To the left: decreases the blower speed
❑ To the right: increases the blower speed
5. Display and Control Head 23

AG. Volkswagen AG d
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Golf 2015 ➤ , Golf Variant 2015 ➤ rise
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Heating, Ventilation and Air Conditioning - Edition
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8 - Blower Speed Display
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9 - Temperature Control Knob
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❑ To the left: lower the temperature
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❑ To the right: increases the temperature
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10 - Temperature Setting Display
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es, in part or in w
t to the co
5.2 Display and Control Head, Removing
rrectness of i
and Installing
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ercia
⇒ “6.2 Display and Control Head, Removing and Installing”, page
126 .
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6 Additional Components for Control

and Regulation
⇒ “6.1 Outside Air Temperature Sensor G17 , Removing and
6.1 Outside Air Temperature Sensor -

G17- , Removing and Installing
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6. Additional Components for Control and Regulation 25

87 – Air Conditioning
1 Component Location Overview - A/C
System
⇒ “1.1 Component Location Overview - Components Outside of
⇒ “1.2 Component Location Overview - Components Inside Front
1.1 Component Location Overview - Components Outside of Passenger Com‐

partment
1 - Vehicle Interior Forced Air

Extraction
Diagnostic Tester . Re‐
fer to
⇒ “5.9 Passenger Com‐
partment Forced Air Ex‐
traction, Checking”,
page 119 .
ling. Refer to
⇒ “5.10 Passenger
Compartment Forced
Air Extraction, Remov‐
119 .
2 - A/C Humidity Sensor -
G260-
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❑ Checking: via the Vehi‐ ksw
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cle Electrical System byV
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Control Module - J519- ris ed
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using the Vehicle Diag‐ aut
ho eo
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nostic Tester in the “Gui‐
ss c
ded Fault Finding” func‐
ce
le
un
pt
tion. Refer to ⇒ Wiring

an
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itte
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diagrams, Trouble‐
rm
ab
shooting & Component

pe
ility
locations.
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wit
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ling. Refer to
spec
⇒ “8.5 A/C Humidity

es, in part or in w
t to the co
Sensor G260 , Remov‐

153 .
rrectness of i
3 - Expansion Valve
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ling. Refer to
⇒ “2.4 Expansion Valve,
nform
ercia
Removing and Installing”, page 37 .

m
❑ Tightening Specifications. Refer to ⇒ “2.1 System Overview - Refrigerant Circuit”, page 32 .

com
tion in
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4 - Dryer Bag
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❑ Removing and installing. Refer to ⇒ “2.6 Dryer Bag, Removing and Installing”, page 42 .
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❑ Overview. Refer to ⇒ “2.2 Overview - Condenser”, page 35 .

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26 Rep. Gr.87 - Air Conditioning

5 - Outside Air Temperature Sensor - G17-

❑ Checking: via the Vehicle Electrical System Control Module - J519- using the Vehicle Diagnostic Tester
in the “Guided Fault Finding” function. Refer to ⇒ Wiring diagrams, Troubleshooting & Component loca‐
tions.
⇒ “8.4 Outside Air Temperature Sensor G17 , Removing and Installing”, page 153 .
6 - Condenser
❑ With integrated receiver/dryer
❑ Removing and installing. Refer to ⇒ “2.5 Condenser, Removing and Installing”, page 40 .
Note
Under certain conditions, the receiv‐

er/dryer and the dryer bag does not
need to be replaced each time the
refrigerant circuit is opened. Refer to
⇒ Refrigerant R134a Servicing;
Rep. Gr. 00 ; A/C System, General
Information .
7 - A/C Compressor
❑ Overview. Refer to ⇒ “3.1 Overview - A/C Compressor Power Unit”, page 57 .
❑ Removing and installing. Refer to ⇒ “3.4 A/C Compressor, Removing and Installing”, page 63 .
AG. Volkswagen AG d
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❑ Removing from and attaching to the bracket.
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⇒ “3.3 A/C Compressor, Removing y V Installing on Bracket”, page 61
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8 - Evacuating and Charging Valve,autHigh
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Pressure Side or
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Caution
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Danger due to refriger‐
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ant coming out under
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defective valve in the re‐
ole,
frigerant circuit. spec

Danger of frost bite to t to the co

skin and other parts of
the body.
Only
♦ remove when the
rrectne
refrigerant circuit is emp‐

ty. The connection does
not have a valve. Refer to
ss
⇒ Refrigerant R134a
o
cial p
Servicing; Rep. Gr. 00 ;

inform
A/C System, General In‐

mer
formation .
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⇒ “2.9 Evacuating and Charging Valve, Removing and Installing, Low and High Pressure Side”,
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page 55 .
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9 - Refrigerant Circuit Pressure Sensor - G805-
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diagrams, Troubleshooting & Component locations. Prote AG.

⇒ “2.3 Refrigerant Circuit Pressure Sensor G805 , Removing and Installing”, page 36 .
1. Component Location Overview - A/C System 27

10 - Evacuating and Charging Valve, Low Pressure Side
Caution
Danger due to refriger‐
ant coming out under
pressure when there is a
defective valve in the re‐
frigerant circuit.
Danger of frost bite to
skin and other parts of
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❑ From the condenser and Air Conditioning (A/C) compressor
⇒ “2.7 Refrigerant Lines with Inner Heat Exchanger, Removing and Installing”, page 52 .
12 - Air Quality Sensor - G238- rrectness of i
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❑ Checking. Refer to Vehicle Diagnostic Tester in the “Guided Fault Finding” function and ⇒ Wiring dia‐
grams, Troubleshooting & Component locations.
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⇒ “8.2 Air Quality Sensor G238 , Removing and Installing”, page 151 .
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❑ Function mode. Refer to ⇒ “8.3 Function of Air Quality Sensor G238 ”, page 151 .
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⇒ “5.5 Driver Side Foot‐

well Vent, Removing
and Installing”,
page 117 .
⇒ “5.1 Overview - Air
Routing and Air Distri‐
bution in Passenger
Compartment”,
page 113 .
3 - Footwell Vent Temperature
Sensor - G192-
❑ Only for vehicles with
Climatronic.
⇒ “8.8 Footwell Vent Temperature Sensor G192 , Removing and Installing”, page 155 .
4 - Front Air Distribution Door Motor - V426- or Air Distribution Door Motor - V428-
⇒ “7.8 Front Air Distribution Door Motor V426 with Air Distribution Door Motor Position Sensor G642 ,
❑ Component Location Overview. Refer to
⇒ “7.1 Component Location Overview - Front Actuators”, page 128 .
5 - Left Temperature Door Motor - V158- or Temperature Regulator Door Motor - V68-
⇒ “7.5 Left Temperature Door Motor V158 with Left Temperature Door Potentiometer/Actuator G220 ,
1. Component Location Overview - A/C System 29

6 - Evaporator
❑ Only for vehicles with an Air Conditioning (A/C) system.
❑ Removing and installing. Refer to ⇒ “4.9 Evaporator, Removing and Installing”, page 90 .
7 - Sunlight Photo Sensor - G107-
⇒ “8.1 Sunlight Photo Sensor G107 , Removing and Installing”, page 150 .
8 - Evaporator Temperature Sensor - G308-
❑ Only for vehicles with an A/C system.
⇒ “4.17 Evaporator Temperature Sensor G308 , Removing and Installing”, page 108 .
9 - Defroster Door Motor - V107-
⇒ “7.3 Defroster Door Motor V107 with Defroster Door Motor Position Sensor G135 , Removing and
10 - Right Temperature Door Motor - V159-
⇒ “7.6 Right Temperature Door Motor V159 with Right Temperature Door Potentiometer/Actuator G221 ,
⇒ “7.1 Component Location Overview - Front Actuators”, page 128 . Volkswa AG. gen AG
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11 - Dust and Pollen Filter olks
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12 - Recirculation Door Motor - V113- or Fresh Air/Recirculating
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❑ Recirculation Door Motor - V113- , Removing and installing. Refer to
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❑ Fresh Air/Recirculating Air/Back Pressure Door Motor - V425- , Removing and installing. Refer to
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⇒ “7.7 Fresh Air/Recirculating Air/Back Pressure Door Motor V425 with Fresh Air/Recirculating Air/Back
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Pressure Door Motor Position Sensor G644 , Removing and Installing”, page 140 .
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❑ Component Location Overview. Refer to h re

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13 - Right Vent Temperature Sensor - G151-

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⇒ “8.7 Right Vent Temperature Sensor G151 , Removing and Installing”, page 154 .
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❑ An incorrectly installed vent temperature sensor causes flow-generated noise

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15 - Front Passenger Side Footwell Vent

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⇒ “5.6 Front Passenger Side Footwell Vent, Removing and Installing”, page 117 .
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⇒ “5.1 Overview - Air Routing and Air Distribution in Passenger Compartment”, page 113 .
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16 - Condensation Water Drain Hose

❑ Checking. Refer to ⇒ “4.18 Condensation Water Drain, Checking”, page 109 .
⇒ “4.19 Condensation Water Drain, Removing and Installing”, page 110 .
page 96 .
18 - Heater Core
19 - Display and Control Head
⇒ “6.2 Display and Control Head, Removing and Installing”, page 126 .
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AG.
2 Refrigerant Circuit
⇒ “2.1 System Overview - Refrigerant Circuit”, page 32
⇒ “2.2 Overview - Condenser”, page 35
⇒ “2.3 Refrigerant Circuit Pressure Sensor G805 , Removing and
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⇒ “2.9 Evacuating and Charging Valve, Removing and Installing,
Low and High Pressure Side”, page 55
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2.1 System Overview - Refrigerant Circuit
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– When working on the refrigerant circuit, note the information.
Refer to
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⇒ “4.1 Refrigerant Circuit, Specialized Repairs”, page 6 .
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1 - Refrigerant Line - Low Pres‐
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Refer to the Parts Cata‐

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❑ Balance weight remov‐
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to
⇒ “2.8 Low Pressure
Side Refrigerant Line
Balance Weight, Re‐
page 54 .
2 - Refrigerant Line - High
Pressure Side
❑ To the refrigerant line
with the inner heat ex‐
changer
3 - Refrigerant Line with Inner
Heat Exchanger
❑ In the inner heat ex‐
changer, the flowing flu‐
id warm refrigerant on
the high pressure side is
delivered into the low
pressure side as flow‐
ing, vapor, cold refriger‐
ant to increase the effi‐
ciency of the Air Condi‐

tioning (A/C) system

❑ From the condenser and A/C compressor
⇒ “2.7 Refrigerant Lines with Inner Heat Exchanger, Removing and Installing”, page 52 .
4 - Expansion Valve
❑ Function and removal and installation. Refer to
⇒ “2.4 Expansion Valve, Removing and Installing”, page 37
5 - A/C Compressor
❑ Overview. Refer to ⇒ “3.1 Overview - A/C Compressor Power Unit”, page 57 .
❑ Removing and installing. Refer to ⇒ “3.4 A/C Compressor, Removing
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❑ Removing from and attaching to the bracket. Refer toVol
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⇒ “3.3 A/C Compressor, Removing and Installing by Bracket”, page 61 .
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Information .
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⇒ “2.6.1 Dryer Bag, Removing and Installing, Denso Condenser”, page 42 .
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❑ Modine condenser. Refer to

⇒ “2.6.2 Dryer Bag, Removing and Installing, Modine Condenser”, page 44 .
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❑ Removing and installing. Refer to ⇒ “2.5 Condenser, Removing and Installing”, page 40 .
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10 - Bolt
❑ 8 Nm
11 - Bolt
❑ 10 Nm
12 - Bolt
❑ 22 Nm
13 - Relief Valve on A/C Compressor
❑ Checking. Refer to ⇒ “3.5 Pressure Relieve Valve on A/C Compressor, Checking”, page 67 .
14 - Connector with A/C Compressor Regulator Valve - N280-
15 - Oil Drain Plug
❑ Tightening specification:
♦ Denso A/C compressor - 30 Nm
♦ Sanden A/C compressor - 10 Nm
2. Refrigerant Circuit 33
Caution
For faulty oil drain plug
seal on the A/C com‐
pressor.
Only
♦ remove when the
refrigerant circuit is emp‐
ty. The connection does
not have a valve. Refer to
⇒ Refrigerant R134a
Servicing; Rep. Gr. 00 ;
formation .

16 - Cap
❑ Modine: 5 Nm
17 - Bolt
❑ 8 Nm
18 - High Pressure Side Service Connection
❑ Cap: 0.4 ± 0.1 Nm
❑ Valve: 2 ± 0.2 Nm
❑ Removing and installing. AG. Volkswagen AG d
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1 - Condenser
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page 40 .
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4 - Bolt
❑ 8 Nm
5 - Bolt
❑ 8 Nm
❑ From the Air Condition‐
ing (A/C) compressor
7 - Seal
versions
before installing
8 - Bracket
❑ For the refrigerant lines
9 - Cap
❑ Modine: 3 Nm
10 - Snap Ring
11 - Cap
❑ Replace if damaged
12 - Seal
❑ Replacing. Refer to the Parts Catalog for the versions
❑ Coat with refrigerant oil before installing
13 - Dryer Bag
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♦ Modine condenser. Refer to
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♦ Keihin condenser. Refer to ⇒ “2.6.3 Dryer Bag, Removing and Installing, Keihin Condenser”, page 47 .
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Information . Prote AG.
2.3 Refrigerant Circuit Pressure Sensor -

Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Commercially Available 12-edge 1/2" Socket Long, 24 Open‐
ing
Removing
Refer to

WARNING

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Install in reverse order of removal.

Tightening Specifications
♦ Refer to Refrigerant Circuit Pressure Sensor - G805-
-item 19- ⇒ Item 19 (page 34) .
2.4 Expansion Valve, Removing and Instal‐

ling
♦ A/C Service Station - VAS6007A- or succeeding model
♦ Engine Bung Set - VAS6122-
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.
Removing
Refer to
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♦ To prevent the ingress of dampness all components of the re‐
frigerant circuit which have been opened must be sealed with
rrectness of i
suitable plugs.
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♦ On some vehicles, connecting pipe from charge air cooler

should be removed. Refer to ⇒ Engine Mechanical, Fuel In‐
jection and Ignition; Rep. Gr. 21 ; Charge Air System; Over‐
nform
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view - Charge Air System .

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All Vehicles
– Remove the sheet metal nuts -1 and 3-.
– Fold the heat shield -2- as far forward as possible -arrow-.
WARNING

– Extract refrigerant.

– Remove the bolt -1-.

– Disconnect the refrigerant line -2- with the inner heat exchang‐
er from the expansion valve. n AG. Volkswagen AG do
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– Remove the bolts -1 and 3-.
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– Remove the expansion valve -4- from the heat shield insula‐
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– Seal the open lines and connections with clean plugs from the
rrectne
Engine Bung Set - VAS6122- .
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– Replace the seals -1 and 4- on the connecting tubes Prote
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-2 and 3- to the evaporator.
– Press in the refrigerant pipe -2- by hand on the expansion

valve.
– Install the bolt -1- by hand and the tighten to the specified
tightening specification.
Note
♦ The expansion valve is available in different versions (same

housing but different control characteristic). Refer to the Parts
Catalog for allocation.
♦ Inspect the refrigerant pipes leading to the evaporator for deb‐
ris and damage.
♦ Coat the seals with refrigerant oil before installing.
♦ Pay attention that the seal on the evaporator connecting tube
is seated correctly.
♦ If the heat protection insulation -2- is missing or not installed
correctly, it can cause reduced output of the Air Conditioning
(A/C) system (change of the set control characteristic due to
radiant heat).
♦ Refer to
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♦ Cap
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suitable plugs.
♦ Environmentally hazardous draining of refrigerant is an of‐
fense punishable by law.
Perform the following work first:

– Turn off all electric consumers.
– Turn off the ignition.
– Remove the key.

– Extract the refrigerant, for example, using the A/C Service

Station - VAS6007A- .
Removing
Refer to
– Remove the front bumper cover. Refer to ⇒ Body Exterior;
Rep. Gr. 63 ; Front Bumper; Bumper Cover, Removing and
Installing .
– Release the air guide -2- from the mount -arrow- upward.
– Press the attachment -4- downward in direction of -arrow- and
pull the air guide -2- forward.
– Remove the air guide downward.
WARNING

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– Remove the refrigerant lines -3- from the connection on the
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condenser.
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– Seal off the line connections.
hole
spec
es, in part or in w
– Have a second technician release the left and right tabs -1- in
t to the co
direction of -arrow A- and remove the condenser -3- upward
out of the mounts -B arrows-.
rrectness of i
– Remove the condenser -3- downward.
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– Replace the seals.

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♦ Refer to ⇒ “2.2 Overview - Condenser”, page 35

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♦ Overview - Front Bumper. Refer to ⇒ Body Exterior; Rep. Gr.

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♦ Commercially Available Pick-up Tool
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Note
♦ See notes. Refer to

⇒ “2.1 System Overview - Refrigerant Circuit”, page 32 .
equipment catalog.
suitable plugs.
– Extract refrigerant, for example, using A/C Service Station -

VAS6007A- , only then open the refrigerant circuit.
Removing
Refer to
– Remove, depending on the charge air system engine compo‐
nents. Refer to ⇒ Engine Mechanical, Fuel Injection and
Ignition; Rep. Gr. 21 ; Charge Air System; Overview - Charge
Air System .
– Remove the radiator grille. Refer to ⇒ Body Exterior; Rep. Gr.
66 ; Radiator Grille/Front Trim; Radiator Grille, Removing and
Installing .

out of the mounts in direction of -arrow B-.
– Move the condenser as far forward as possible.
WARNING

ant circuit after that. wage
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• If the refrigerant was extracted bmore than 10 minutes in
yV t gu
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the refrigerant again. Pressure
sa
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– Remove the sealing plug -A-.
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– Remove the dryer carrier -C- with the dryer bag -D- upward
spec
from the receiver/dryer.
t to the co
– Remove the filter element -E- upward from the receiver/dryer
using, for example, a pick-up tool.
rrectne
– Seal the open receiver/dryer with the sealing plug -A- to pre‐
vent dirt and moisture from getting in.
ss o
cial p
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mer
atio
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Cop py
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Prote AG.
Installing
Note
♦ Replace the sealing plug, seal and dryer bag after every open‐
ing of the receiver/dryer. Refer to Parts Catalog.
♦ Keep the dryer bag air-tight package closed as long as possi‐
ble. Do not remove the dryer bag until just before replacing the
dryer bag in the condenser. The dryer bag absorbs moisture
in a very short time and become unusable.
♦ Coat the seals for the plug with refrigerant oil before installing.
– Using the opening, inspect the receiver/dryer on the condens‐

er for dirt and damage on the threaded- and sealing surfaces.
– Install the filter element -E- with the correct side into the con‐
denser receiver/dryer.
– Remove the dryer bag -D- from the package and insert it into
the dryer carrier -C-.
– Insert the dryer bag together with the dryer cartridge into the
condenser receiver/dryer.
– Position and install the sealing plug -A-.
swage es n
♦ Refer to ⇒ “2.2 Overview - Condenser”, by V page 35
olk ot g
ua
d ran
ir se
♦ Radiator Grille/Front Trim; Overview
t ho - Radiator Grille. Refer to tee
or
⇒ Body Exterior; Rep. Gr. 66 au ; Radiator Grille/Front Trim; ac
ss
Radiator Grille, Removing and Installing .
ce
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♦ T50 Socket
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Caution
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Note

equipment catalog.
suitable plugs.

Removing
Refer to
nents. Refer to ⇒ Engine Mechanical, Fuel Injection and
Ignition; Rep. Gr. 21 ; Charge Air System; Overview - Charge
Air System .
Installing .
out of the mounts in direction of -arrow B-.
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rrectness of i
– Remove the cap -1- using the T50 Socket .

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45
AG.
2. Refrigerant Circuit
– Push in the cap -1- slightly.
WARNING

– Remove the snap ring -arrow-.

– Install a M12 bolt in the cover and carefully pull it out of the
receiver/dryer -2-.
– Remove the dryer bag with a commercially available pick-up
tool from the receiver/dryer.
– Make a 2 mm diameter welding wire with the following dimen‐

sions.
a - 380 mm
b - maximum 7 mm
c - maximum 6 mm
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Hook the welding wire
hor onto the strainer exactly as illustrated to tee o
ut
prevent damagessto the receiver/dryer
a ra
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e
– Carefully remove the filter (strainer) -2- from the receiver/dryer

nl
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with the welding wire -1-.

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– If the work is not completed, close open receiver/dryer with the

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cap -1- to prevent dirt and moisture from entering.

nform
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at
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ate
do
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for
en
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t.
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Cop py
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rig ht
py by
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Installing
Note
Replace the cap, seal and dryer bag after every opening of the
receiver/dryer. Refer to Parts Catalog.

– Insert the filter element (with strainer) -2- with the correct side
into the condenser receiver/dryer.
• The filter element must be pushed in until stop.
Note
Keep the dryer bag air-tight package closed as long as possible.

Do not remove the dryer bag until just before replacing the dryer
bag in the condenser. The dryer bag absorbs moisture in a very
short time and become unusable.
olkswagen AG
en AG. V
– Remove the dryer bag from the kswpackage and insert it into
ag does
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– Insert the cap -1- sand
s a push it far enough downward so that the
ra
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circlip -arrow- can engage in the groove.
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Note
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Coat the seal for the cap with refrigerant oil before installing.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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– Install the cap -1- using the T50 Socket .

nform
ercia
♦ ⇒ “2.2 Overview - Condenser”, page 35

m
at
om
ion
♦ Radiator Grille/Front Trim; Overview - Radiator Grille. Refer to

c
in t
or
⇒ Body Exterior; Rep. Gr. 66 ; Radiator Grille/Front Trim;

his
ate
Radiator Grille, Removing and Installing .

do
priv
cum
for
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t.
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Keihin Condenser
♦ A/C Service Station - VAS6007A-
♦ T50 Socket
olkswagen AG
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Golf 2015 ➤ , Golf ksVariant
wag 2015 ➤ does
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Vol
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gu
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a
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Caution
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♦ Cap
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♦ Seals
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♦ Dryer bag
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Note
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♦ The previously used service stations can still be used. Refer
for
en
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to the V.A.G workshop equipment catalog.

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♦ All open refrigerant circuit components must be sealed with
t. rig
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suitable plugs to prevent any humidity from entering them.
p by
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– Extract the refrigerant, using for example the A/C Service Sta‐
tion - VAS6007A- , only then open the refrigerant circuit.
Removing
Refer to
nents. Refer to ⇒ Rep. Gr. 21 ; Overview - Charge Air System .
– Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Radiator Grille/Front
Trim; Radiator Grille, Removing and Installing .
Vehicles without Direct Access to the Cap
– Remove the front bumper cover. Refer to ⇒ Body Exterior;
Rep. Gr. 63 ; Front Bumper; Bumper Cover, Removing and
Installing .

– Release the air guide -2- from the mount -arrow- upward.
– Press the retainer -4- downward in the direction of the
-arrow- and pull the air guide -2- forward.
– Remove the air guide downward.
Vehicles with Direct Access to the Cap
AG. Volkswagen AG d
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spec
es, in part or in w
the direction of the -arrow A- and remove the condenser -3-
t to the co
upward out of the mounts in the direction of the -arrow B-.
All Vehicles
rrectness of i
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Dryer Bag, Version 1
nform
mercia
a
com
tion in
r
te o
thi
s
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t.
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olkswagen AG
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Golf 2015 ➤ , Golf Variant 2015 ➤ olks
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– Push in the cap -1- slightly. ss
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WARNING
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• Evacuate the refrigerant and immediately open the refrig‐ es, in part or in w
erant circuit afterward.
t to the co
• If more than 10 minutes have elapsed since evacuating
the refrigerant and the refrigerant circuit was not opened,
rrectness of i
evacuate the refrigerant again. Pressure in the refrigerant
circuit is caused by evaporation.
l purpos
nform
ercia
– Remove the snap ring -arrow-.

m
at
– Install a M12 bolt in the cover and carefully pull it out of the
om
ion
receiver/dryer -2-.
c
in t
or
his
te
– Remove the dryer bag with a commercially available pick-up

a
do
riv
tool from the receiver/dryer.

p
cum
for
en
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t.
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– Make a 2 mm welding wire with the following dimensions. ht. Cop py
rig
rig ht
a - 380 mm py by
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b - maximum 7 mm Prote AG.
c - maximum 6 mm
Hook the welding wire onto the strainer exactly as illustrated to

prevent damage to the receiver/dryer
– Carefully remove the strainer -2- from the receiver/dryer using
the welding wire -1-.
– If the work is not completed, close open receiver/dryer with the

cap -1- to prevent dirt and moisture from entering.
Installing
Install in reverse order of removal and note the following:
Note
Replace the cap, seal and dryer bag after every opening of the
receiver/dryer. Refer to Parts Catalog.


– Insert the filter element (with screen) -2- into the condenser
receiver/dryer on the proper side. AG. Volkswagen n AG do
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Note ss
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Keep the dryer bag air-tight package closed as long as possible.
an
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Do not remove the dryer bag until just before replacing the dryer
erm
ab
bag in the condenser. The dryer bag absorbs moisture in a very
ility
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short time and become unusable.
wit
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spec
– Remove the dryer bag from the package and insert it into the
t to the co
– Insert the cap -1- and push it far enough downward so that the
snap ring -arrow- can engage in the groove.
rrectness
Note
o
cial p
f inform
mer
atio
om
n
c
i
or
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te
sd
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t.
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ht ht
rig by
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Prote AG.
♦ Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Radiator Grille/Front
Trim; Overview - Radiator Grille .
Dryer Bag, Version 2
– Remove the dryer bag -D- upward from the receiver/dryer.
Note
AG. Volkswagen AG d
agen oes
olksw not
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♦ Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Radiator Grille/Front
Trim; Overview - Radiator Grille .
rrectness o
cial p
f inform
mer
atio
m
2.7 Refrigerant Lines with Inner Heat Ex‐

o
n
c
i
or
n thi
changer, Removing and Installing
te
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Special tools and workshop equipment required cum

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t.
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Co
Cop py
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♦ A/C Service Station - VAS6007A- or succeeding model yri
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cted
agen
Prote AG.
Caution


♦ Seals
Note
Certain tools are required to discharge the refrigerant circuit,

these work procedures must only be performed by trained per‐
sonnel as well. Refer to ⇒ Refrigerant R134a Servicing .

Removing
– Loosen the hose clamp -3-.
– Remove the bolt -2- and tilt the air guide pipe with the con‐
nection downward and remove it from the turbocharger.
AG. Volkswagen AG d
agen oes
olksw not
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For All Vehicles
ss a c
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nl
– Remove the sheet metal nuts -1 and 3-.
pt
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– Fold the heat shield -2- as far forward as possible -arrow-.
erm
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ility
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WARNING
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spec
es, in part or in w
t to the co
• Extract the refrigerant and immediately open the refriger‐ rrectness of i
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ercia
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– Disconnect the refrigerant line -6- with the inner heat exchang‐
um
for
en
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er from the expansion valve.

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– Remove the nuts -1 and 3- and remove the refrigerant lines
t. C rig
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-2 and 4-. p by
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– Remove the refrigerant line -5- with the inner heat exchanger. Prote AG.
Installing
• Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition;
Rep. Gr. 21 ; Turbocharger; Overview - Turbocharger .
– Replace the seals. Refer to the Parts Catalog. for the correct
version.
AG. gen AG Volkswa
– Clean the connections on the expansion agen -2- and on the
valve does
olksw not
V
inner heat exchanger -4- and inspect
ed b them for damage.
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or
– Thoroughly clean the refrigerant
au
th lines around the connection eo
ra
area and check for damage.ss c
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Note
erm
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♦ Coat the seals with refrigerant oil before installing.
wit
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h re
hole
♦ Make sure the seals fit correctly inside the groove on each
spec
refrigerant line.
es, in part or in w
t to the co
– Insert the seals -1 and 3- into the groove on the inner heat
exchanger connection.
rrectness of i
– Insert the inner heat exchanger on the expansion valve.
l purpos
– Tighten the bolt -5-.
nform
ercia
– Install the refrigerant lines -2 and 4- with the inner heat ex‐
m
changer on the connections.
at
om
ion
c
– Install and tighten the nuts -1 and 3-.

in t
or
his
ate
do
priv
cum
or
♦ Refer to
f
en
ng
t.
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Co
Cop py
t. rig
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pyri by
Vo
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Prote AG.
2.8 Low Pressure Side Refrigerant Line Bal‐

ance Weight, Removing and Installing
Removing
Note
♦ It is required to remove the refrigerant line to remove and in‐

stall the balance weight.
♦ An additional balance -2- weight may be present on this re‐
frigerant line -1- depending on the refrigerant line version and
the production period. Refer to the Parts Catalog.

– Remove the bolts -3-.

– Remove the balance weight -2- from the refrigerant line - low
pressure side -1-.
Installing
– Install the balance weight -2- to the specified dimension -a- 30
± 5 mm on the refrigerant line-low pressure side -1-.
– Tighten the bolts -3-.
Note
♦ Pay attention, that the balance weight -2- is seated securely

on the refrigerant line and does not touch or can come in con‐
tact with other components during operation.
♦ The refrigerant line-low pressure side -1- must not be crushed
by the additional weight -B-.
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gen AG does
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Tightening Specification y V olk not
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Component hor Tightening Specifications eo
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Balance weight
ss
bolts 10 ± 1 Nm
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2.9 Evacuating and Charging Valve, Re‐

y li
erm
ab
ility
moving and Installing, Low and High
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Pressure Side h re
ole,
spec

t to the co
♦ Torque Wrench 1783 - 2-10Nm - VAG1783-

♦ A/C Service Station - VAS6007A- (or succeeding model)
rrectne
♦ Torque Wrench 1783 - 1/4" Drive Ratchet - VAS6234-

s
♦ Refrigerant Sockets - T10364-

s o
cial p
f inform
mer
Note
atio
om
n
c
♦ Environmentally hazardous draining of refrigerant is an of‐

or
n thi
e
fense punishable by law.

t
sd
iva
o
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♦ To prevent the ingress of dampness, all components of the

um
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fo
en
ng
refrigerant circuit which have been opened must be sealed

t.
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with suitable plugs. Cop py
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Removing by c lksw
cted agen
Prote AG.
Refer to
– Remove the cap -3-.
WARNING

– Extract the refrigerant circuit, for example, using the A/C Serv‐
ice Station - VAS6007A- (or succeeding model). Then imme‐
diately replace the valve -2-.
– Remove the valve insert -2- from the refrigerant line.
Installing
– Install in reverse order of removal.
♦ Refer to
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
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aut ra
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nl
pt
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erm
ab
ility
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spec
es, in part or in w
t to the co
rrectness of i
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ercia
orm
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n in
or c
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Prote AG.

3 A/C Compressor
⇒ “3.1 Overview - A/C Compressor Power Unit”, page 57
⇒ “3.2 Overview - Belt Pulley”, page 59
⇒ “3.3 A/C Compressor, Removing and Installing on Bracket”,
page 61
⇒ “3.4 A/C Compressor, Removing and Installing”, page 63
⇒ “3.5 Pressure Relieve Valve on A/C Compressor, Checking”,
page 67
⇒ “3.6 Belt Pulley, Removing and Installing”, page 68
3.1 Overview - A/C Compressor Power Unit
Note
The illustration shows one version. Refer to the Parts Catalog for
allocation.
1 - Ribbed Belt
ling. Refer to ⇒ Rep.
Gr. 13 ; Cylinder Block,
Belt Pulley Side; Ribbed
Belt, Removing and In‐
stalling .
❑ Mark the rotation direc‐
tion, install on correctagen AG. Volkswagen AG d
side. Refer to ⇒ VRep. olks
w oes
not
gu
Gr. 13 ; Cylinder ed by
Block, ara
nte
is
Belt Pulley thor Side; Ribbed eo
Belt, Removing
s au and In‐ ra
c
stalling
s
.
ce
le
un
pt
2 - Sub-Assembly Bracket
an
d
itte
y li
rm
❑ Optional
ab
pe
ility
❑ To remove and install.

ot
wit
, is n
Refer to ⇒ Rep. Gr. 13 ;

h re
Cylinder Block, Belt Pul‐

hole
spec
ley Side; Auxiliary Com‐

es, in part or in w
ponents Bracket, Re‐

t to the co
moving and Installing .

3 - Seal
rrectness of i

l purpos

correct version.
nform
ercia
before installing
m
a
com
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4 - Screw
on in
r
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❑ 22 Nm
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❑ High pressure side

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❑ Low pressure side
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3. A/C Compressor 57
7 - Bolt
❑ 22 Nm
8 - Seal
❑ Replacing. Refer to the Parts Catalog for the correct version.
9 - A/C Compressor Regulator Valve - N280-
10 - A/C Compressor
❑ Removing and installing. Refer to ⇒ “3.4 A/C Compressor, Removing and Installing”, page 63 .
❑ Removing from and attaching to the bracket. Refer to
⇒ “3.3 A/C Compressor, Removing and Installing on Bracket”, page 61 .
11 - Bolt
❑ 25 Nm AG. Volkswagen AG d
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❑ Quantity: 3 by
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12 - Belt Pulley hor eo
aut ra
❑ With overloads protection
s c
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❑ Overview. Refer to ⇒ “3.2 Overview - Belt Pulley”, page 59 .

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13 - Alignment Sleeve ility
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❑ Quantity: 2 h re
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spec
es, in part or in w
t to the co
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ate
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3.2 Overview - Belt Pulley

⇒ “3.2.1 Overview - Belt Pulley, Denso A/C Compressor”,
page 59
⇒ “3.2.2 Overview - Belt Pulley, Sanden A/C Compressor”, page
60
3.2.1 Overview - Belt Pulley, Denso A/C Compressor
1 - Screw
❑ 4.5 Nm
❑ Quantity: 3
2 - Cap
3 - Nut
❑ 25 Nm
– Hold the belt pulley se‐
curely with a commer‐
cially available oil filter
band wrench to loosen
and tighten the hex nut. . Volkswage
AG n AG d
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4 - Drive Plateby V o gu
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❑ The se
rioverload protection nte
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takes
au
t
over when the tor‐ ra
c
s que is excessive (for ex‐
ce
le
ample, if the Air Condi‐

un
pt
an
d
tioning (A/C) compres‐

itte
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sor runs with resistance)

erm
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and the belt pulley runs

ility
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freely without driving the

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A/C compressor.
ole,
spec
5 - Circlip
t to the co
❑ Replace after removing.

❑ Install on the proper side
- the flat side faces A/C
rrectne
compressor
6 - Belt Pulley
ss o
cial p

f in

form
mer
Catalog.
atio
m
❑ Is sensitive to impact, be
o
n
c
i
or
careful when handling

thi
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pr
ling. Refer to ⇒ “3.6 Belt Pulley, Removing and Installing”, page 68 .

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7 - A/C Compressor
Co
Cop py
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❑ Clean the A/C compressor driveshaft before setting the belt pulley on it
rig
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3.2.2 Overview - Belt Pulley, Sanden A/C Compressor
1 - Nut
❑ 25 Nm
Note
The Air Conditioning (A/C) com‐

pressor input shaft may be covered
with a plastic cap to protect the
threads on it (the plastic cap is not
illustrated).

curely with a commer‐
cially available oil filter
band wrench to loosen
and tighten the hex nut.
– The thread of the nut,

which was screwed in
with locking compound,
must be cleaned (for ex‐ AG. Volkswagen AG d
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ample, using a thread byV
ol not
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tap). Otherwise, there isrised ara
nte
a danger that the inputut
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shaft breaks off during
ss a c
assembly. ce
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itte
– Clean the thread of the

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A/C compressor input
ility
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shaft with a wire brush.

wit
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– Insert the nut with lock‐

hole
spec
ing compound. Refer to

es, in part or in w
the Parts Catalog for the

t to the co
locking compound.
2 - Bolt
rrectness of i
❑ 12 Nm
l purpos

curely with a commercially available oil filter band wrench to loosen and tighten the bolts.
nform
ercia
– The threaded bolt holes, into which the self-locking bolts or bolts with locking compound are screwed,
m
at
om
must be cleaned (for example with a thread tap). Otherwise, there is a danger that the bolts break off
ion
c
during assembly.
in t
or
his
ate
do
– Clean the thread of the bolts, which are screwed in with locking compound, with a wire brush. Then insert
priv
the bolts with locking compound. For the locking compound. Refer to the Parts Catalog.
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3 - Drive Plate Cop py
ht. rig
❑ The overload protection (securing spring elements), takes over when the torque is excessive (for exam‐
rig ht
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ple, if the A/C compressor runs with resistance) and the belt pulley runs freely without driving the A/C
by c lksw
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compressor. Prote AG.
❑ Drive plate spring elements dampen vibrations and noise

4 - Circlip
❑ Install on proper side, beveled insertion edge -A- faces away from A/C compressor - install flat side faces
the A/C compressor
5 - Belt Pulley
❑ With rubber elements -B- and threaded plates -C- for decoupling belt pulley from A/C compressor input
shaft, dampens vibrations and noise

Note
♦ The threaded plates can also be

connected to each other by a
ring, depending on the version.
♦ For “cold climate” vehicles (for
example, central and north Eu‐
rope), A/C compressors with a
smaller stroke may be installed.
On these A/C compressors, the
belt pulley is slightly different
from the one illustrated here (the
rubber elements -B- are, for ex‐
ample, not present). Refer to
Parts Catalog.
6 - A/C Compressor
❑ Clean the A/C compressor driveshaft before setting the belt pulley on it
3.3 A/C Compressor, Removing and Instal‐

ling on Bracket olks
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Special tools and workshop equipment required rised ara
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♦ Torque Wrench 1331 5-50Nm - VAG1331- ss au ra
c
ce
le
un
pt
an
d
itte
Note
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rm
ab
pe
ility
Pay attention to the turn off conditions for vehicles with the Start/
ot
wit
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Stop System. Refer to
h re
hole
spec
page 3 .
es, in part or in w
t to the co
ELSA contains all information regarding performing repairs on
vehicles with air conditioning and working with refrigerant. Refer
rrectness of i
to ⇒ Refrigerant R134a Servicing; Rep. Gr. 00 ; A/C System,
General Information .
l purpos
ELSA contains all information on tools for repairs in vehicles with

climate control system. Refer to ⇒ Refrigerant R134a Servicing; nform
ercia
Rep. Gr. 00 ; Special Tools .

m
Removing
com
tion in
r

te o
thi
Refer to
s
iva
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rp
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fo
en
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– Remove the noise insulation under the engine. Refer to ⇒

n
t.
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op
Body Exterior; Rep. Gr. 66 ; Noise Insulation; Overview - C py
t. rig
Noise Insulation .
gh ht
pyri by
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by c lksw
Depending on the engine type, remove the right front wheel hous‐ cted agen
Prote AG.
ing liner. Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing
Liner; Front Wheel Housing Liner, Removing and Installing .
– Remove the ribbed belt. Refer to ⇒ Rep. Gr. 13 ; Cylinder
Block, Belt Pulley Side; Ribbed Belt, Removing and Installing .
Heating, Ventilation and Air Conditioning A- GEdition 12.2015
. Volkswagen A
n G do
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Volks ot g
– Disconnect the connector -6- fromedtheby Air Conditioning (A/C) ua
ran
compressor -1-. horis tee
ut or
a ac
– Remove the hex bolt -5- andssthen remove the A/C compressor
-1-.
ce
e
nl
pt
du
an
itte
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erm
ab
Note
ility
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Do not loosen the refrigerant pipes on the A/C compressor if only
hole
the auxiliary components bracket is being removed.
spec
es, in part or in w
t to the co
rrectness of i
– Attach the A/C compressor to the body with something suita‐
ble, for example, welding wire.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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rig ht
py by
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Prote AG.

Installing
– Thoroughly clean the contact surfaces on the A/C compressor
and bracket.
– Insert the alignment sleeve -arrows- in the A/C compressor.
Note
Make sure the alignment sleeves are seated correctly and the
contact surfaces are clean. Alignment sleeves that are installed
incorrectly and dirty or damaged contact surfaces can lead to
alignment irregularities between the compressor and engine.
Alignment irregularities over operating time cause damage to the
A/C compressor. n AG. Volkswagen AG age does
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Caution oris eo
th
au ra
c
ss
Risk of damaging the A/C compressor.
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an
♦ Refrigerant oil may accumulate in the compression cham‐
itte
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ber of the removed A/C compressor depending on how it
erm
ab
ility
was stored.
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♦ Turn the A/C compressor by hand approximately 10 rev‐
h re
hole
olutions before installing the ribbed belt after installing a
spec
new A/C compressor or adding fresh refrigerant oil in order
es, in part or in w
t to the co
to avoid damaging the A/C compressor when using it for
the first time.
rrectness of i
l purpos
♦ Refer to
nform
ercia
Pay attention to the following when starting the engine for the first
m
at
time after filling the refrigerant circuit:
om
ion
c
in t
r
– Follow the information on operating the A/C system after in‐

o
his
te
stalling the A/C compressor. Refer to ⇒ Refrigerant R134a

a
do
riv

p
cum
for
en
ng
t.
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3.4 A/C Compressor, Removing and Instal‐ Cop py
t. rig
gh ht
ling pyri by
Vo
o
by c lksw
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Prote
AG.

Note
♦ Perform Guided Fault Finding “A/C compressor first start”

whenever a new Air Conditioning (A/C) compressor is instal‐
led.
♦ Pay attention to the turn off conditions for vehicles with the
Start/Stop System. Refer to
page 3 . wage
e ks s no
Vol t gu
♦ If the A/C compressor is sent in foredabwarranty
y claim, document ara
the extracted refrigerant quantity
tho
ris and add in the claim. nte
eo
au ra
♦ Flush the refrigerant circuitsswith R134a refrigerant under the c
following conditions:
ce
e
nl
pt
du
an
itte
♦ In the event of dirt or other contamination in the refrigerant
y li
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ab
circuit.
ility
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♦ If vacuum reading is not maintained on evacuating a leak-free
wit
, is n
h re
refrigerant circuit (pressure build-up due to moisture in refrig‐
hole
erant circuit).
spec
es, in part or in w
t to the co
♦ If the refrigerant circuit has been left open for longer than nor‐
mal (for example, following an accident).
♦ If pressure and temperature measurements in the refrigerant
rrectness of i
circuit indicate the likelihood of moisture
l purpos
♦ In the event of doubt about the amount of refrigerant oil in the

circuit.
nform
ercia
♦ The A/C compressor must be replaced on account of internal

damage (for example, noise or no output).
m
at
om
ion
c
♦ If only the auxiliary component bracket is being removed, it is in t

or
not necessary to loosen the refrigerant lines on the A/C com‐

his
ate
pressor. Attach the A/C compressor to the body with wire.

do
priv
cum
for
en
ng
t.
ELSA contains the procedure for flushing with refrigerant R134a.
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Refer to ⇒ Refrigerant R134a Servicing; Rep. Gr. 00 ; A/C Sys‐
C py
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tem, General Information .
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cted
ELSA contains all information regarding performing repairs on
agen
Prote AG.
vehicles with air conditioning and working with refrigerant. Refer
to ⇒ Refrigerant R134a Servicing; Rep. Gr. 00 ; A/C System,
General Information .
ELSA contains all information on tools for repairs in vehicles with
climate control system. Refer to ⇒ Refrigerant R134a Servicing;
Rep. Gr. 00 ; Special Tools .
Removing
Refer to
– Remove the noise insulation under the engine. Refer to ⇒
Body Exterior; Rep. Gr. 66 ; Underbody Panel; Overview -
Underbody Panels .
Depending on the engine type, remove the right front wheel hous‐
ing liner. Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing
Liner; Front Wheel Housing Liner, Removing and Installing .

WARNING

– Remove the bolts -3- and disconnect the refrigerant lines

-2 and 4- from the A/C compressor -1-.
– Disconnect the connector -6- from the A/C compressor -1-.
– Remove the hex bolt -5- and then remove the A/C compressor
-1-.
lkswage es n
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byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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un
pt
an
d
itte
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ab
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.
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Cop py
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pyri by
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cted agen
Prote AG.
Installing
• Perform Guided Fault Finding “A/C compressor first start”
whenever a new A/C compressor is installed.
– Thoroughly clean the contact surfaces on the A/C compressor
and bracket.
– Insert the alignment sleeve -arrows- in the A/C compressor.
Note
♦ Make sure the alignment sleeves are seated correctly and the
contact surfaces are clean. Alignment sleeves that are instal‐
led incorrectly and dirty or damaged contact surfaces can lead
to alignment irregularities between the compressor and en‐
gine. Alignment irregularities over operating time cause dam‐
age to the A/C compressor.
♦ If the A/C compressor is replaced due to certain complaints
(for example, internal damage), the refrigerant circuit must be
cleaned. Refer to ⇒ Refrigerant R134a Servicing; Rep. Gr.
00 ; Refrigerant Circuit, Removing Contaminants .
♦ There is an unspecified amount of refrigerant oil in the re‐
moved A/C compressor, so therefore pay attention to the
information on replacing the A/C compressor. Refer to ⇒ Re‐
frigerant R134a Servicing; Rep. Gr. 00 ; A/C System, General
Information .
AG. Volkswagen AG d
agen oes
olksw not
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Caution ed b ara
nte
ris
ho eo
ut ra
Risk of damaging thess A/C compressor.
a c
ce
e
nl
♦ Refrigerant oil may accumulate in the compression cham‐

pt
du
an
ber of the removed A/C compressor depending on how it

itte
y li
was stored.
erm
ab
ility
ot p
♦ Turn the A/C compressor by hand approximately 10 rev‐

wit
, is n
olutions before installing the ribbed belt after installing a

h re
hole
new A/C compressor or adding fresh refrigerant oil in order

spec
to avoid damaging the A/C compressor when using it for

es, in part or in w
t to the co
the first time.

rrectness of i
l purpos
♦ Refer to
nf
ercia
Pay attention to the following when starting the engine for the first
or
time after filling the refrigerant circuit:

m
m
atio
om
– Follow the information on operating the A/C system after in‐

n in
or c
stalling the A/C compressor. Refer to ⇒ Refrigerant R134a

thi
te
sd

iva
o
r
rp
cu
– After installing a new A/C compressor or fresh refrigerant oil

o
m
f
en
ng
has been filled into compressor (for example, after blowing

t.
yi Co
op
through the A/C system), turn ribbed belt pulley of A/C com‐
C py
ht. rig
pressor 10 rotations by hand before starting the engine. This rig ht
py by
Vo
prevents damage to the A/C compressor.
co lksw
by
cted agen
Prote AG.
– Start the engine with the A/C compressor already turned off
(indicator lamp button A/C is off) and wait until the idle RPM
stabilizes.
– Open the instrument panel vents.

– Select for example the temperature preset “Lo” on the Heater

and A/C Controls - EX21- .
– Turn on the A/C compressor (indicator lamp button AC is lit)
and let the engine idle for at least 5 minutes.
Note
♦ The A/C compressor is always driven by the ribbed belt pulley

(no A/C clutch).
♦ If the A/C compressor is blocked, the compressor shaft over‐
load protection is activated. The blockage is mostly recog‐
nized by deformations/bumps on the ribbed belt pulley. In
addition, the blockage can be recognized by the abraded rub‐
ber in the area of the ribbed belt pulley.
♦ The A/C compressor is equipped with a protected oil supply,
this prevents A/C compressor damage in the event AG.that
Volksthe
wagen AG
system is empty. This means that approximately
olksw
agen 40 to 50 does
not
cm3 of refrigerant oil remains in the eA/C
d by Vcompressor. gu
ara
is nte
or
♦ Only start the engine when theaurefrigerant
th circuit is filled. eo
ra
ss c
♦ The engine may only be started when the refrigerant circuit is
ce
e
nl
pt
installed correctly. For example; if the refrigerant lines are not
du
an
itte
connected to A/C compressor, when the engine is running the
y li
erm
ab
A/C compressor may heat up (via internal heat generation) so
ility
ot p
much that the A/C compressor will be damaged.
wit
, is n
h re
♦ A/C Compressor Regulator Valve - N280- is not activated
hole
when the refrigerant circuit is empty and the A/C compressor
spec
idles with the engine.
es, in part or in w
t to the co
♦ If it is necessary to start the engine with a discharged refrig‐
erant circuit:
rrectness of i
♦ Refrigerant circuit must be fully assembled.
l purpos
♦ At least a quarter of the prescribed refrigerant oil must be in

the A/C compressor.
nform
ercia
♦ Do not let the engine RPM go above 2,000.

m
at
om
♦ The engine should only run as long as is absolutely necessary,

ion
c
maximum 10 minutes.
in t
or
his
ate
do
priv
cum
or
3.5 Pressure Relieve Valve on A/C Com‐

f
en
ng
t.
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pressor, Checking
Co
Cop py
ht. rig
rig ht
Checking
py by
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♦ Function: Protects the refrigerant circuit against excessive
Prote AG.
pressure
Refer to
WARNING
There is a danger of ice-up.

Pressure relief valve will drain refrigerant with engine running
and high pressure in refrigerant circuit.
Turn the engine off.
Denso A/C Compressor Relief Valve

♦ The pressure relief valve -arrow- has operated when refriger‐
ant oil is found in the close vicinity.
♦ In this case, the vehicle must be taken to a specialized A/C
repair facility. Refer to
Note
For other A/C compressor manufactures the relief valve is located

in a similar place.
3.6 Belt Pulley, Removing and Installing

⇒ “3.6.1 Belt Pulley, Removing and Installing, Denso”,
page 68
⇒ “3.6.2 Belt Pulley, Removing and Installing, Sanden”,
page 70
3.6.1 Belt Pulley, Removing and Installing,

Denso
♦ Commercially Available Oil Filter Band Wrench
AG. Volkswagen AG d
agen oes
Caution olksw not
byV gu
ara
ed
ris nte
This procedure contains mandatory replaceable ut parts. Refer
ho eo
ra
ss a c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
♦ Circlip
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
♦ The belt pulley is sensitive to impact, for this reason handle it

especially carefully.
rrectness of i
♦ If the overload protection of the belt pulley is tripped, check the

Air Conditioning (A/C) compressor for ease of movement, be‐
l purpos
fore replacing the belt pulley. Replace an A/C compressor that

is not operating smoothly.
nf
ercia
♦ If the drive plate overload protection has activated, the belt

rm
m
pulley can be rotated using the outer part of the drive plate so
atio
om
that the A/C compressor shaft and the hexagon head on the
n in
or c
drive plate (inner part of the drive plate) do not rotate.

thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Removing
– Remove the cap -1-.
– Remove the bolts -arrows- by counterholding the belt pulley
with an oil filter band wrench.
– Remove the nut -2- by counterholding on the input shaft -1- of

the A/C compressor.
– Remove the drive plate -3- with the nut.
Note
. Volkswage
♦ The torque to drive the kA/C
swa compressor is transferred
gen AG n AG d
oes to the
drive plate via the threaded
yV
ol
connection.
n ot g
ua
edb ran
is
♦ If, while the A/C
ut
hor
compressor is working, the drive plate wastee
o
attached toss the A/C compressor shaft so tight, that it cannot r ac
a
be loosened (the 7 mm wrench cannot transmit the necessary
ce
e
nl
torque) then the A/C compressor must be replaced.

pt
du
an
itte
y li
erm
ab
ility
ot p
– Remove the circlip -2-.

wit
, is n
h re
– Remove the belt pulley -1-.

hole
spec
Installing
es, in part or in w
t to the co

rrectness of i
Note
l purpos
Replace the circlip.

nf
ercia
or
– Clean the A/C compressor input shaft before setting the belt
m
m
atio
pulley on it.
om
n in
or c
– Place the belt pulley onto the A/C compressor input shaft.
thi
te
sd
iva
• The fitting must be possible without much force.

o
r
rp
cu
o
m
f
– Insert the circlip on the proper side.

en
ng
t.
yi Co
op py
• Flat side faces the A/C compressor t. C rig
gh ht
pyri by
– Clean the input shaft thread for the A/C compressor before
co Vo
by lksw
cted
removing the drive plate.
agen
Prote AG.
Note
The thread of the new drive plate has already been greased with
a specific amount of a grease by the manufacturer.
♦ Refer to
⇒ “3.2.1 Overview - Belt Pulley, Denso A/C Compressor”,
page 59
AG. Volkswagen AG d
agen
3.6.2 Belt Pulley, Removing ksw and Installing,
oes
not
Vol gu
by ara
Sanden thorise
d
nte
eo
au ra
c
ss
Caution
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Circlip
rrectness of i
Note
l purpos
♦ The belt pulley is sensitive to impact, for this reason handle it

especially carefully.
nform
ercia
♦ If the overload protection of the belt pulley is tripped, check the

m
Air Conditioning (A/C) compressor for ease of movement, be‐
at
om
io
fore replacing the belt pulley. Replace an A/C compressor that
n
c
in t
is not operating smoothly.
or
his
ate
do
riv
♦ If the drive plate overload protection has activated, the belt

p
cum
pulley can be rotated using the outer part of the drive plate so
for
en
g
that the A/C compressor shaft and the hexagon head on the
n
t.
yi Co
drive plate (inner part of the drive plate) do not rotate. Cop py
t. rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.
– Remove and install the belt pulley. Refer to

⇒ “3.2.2 Overview - Belt Pulley, Sanden A/C Compressor”,
page 60 .

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
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4. Front Heater and A/C Unit 71

4 Front Heater and A/C Unit

⇒ “4.1 Overview - Heater and A/C Unit”, page 72
⇒ “4.2 Overview - Attachments for Heater and A/C Unit and Air
Intake Housing”, page 77
⇒ “4.3 Overview - Evaporator Housing”, page 79
⇒ “4.4 Overview - Air Distribution Housing Doors and Partitions”,
page 81
page 83 n AG. Volkswagen A ge G do
swa es
⇒ “4.6 Heater and A/C Unit,
y V Disassembling and Assembling”,
olk not
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page 87 edb ara
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au Housing, Removing and Installing”, ra
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page 89
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⇒ “4.8 Heater and A/C Unit Bracket, Removing and Installing”,
itte
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⇒ “4.9 Evaporator, Removing and Installing”, page 90
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⇒ “4.11 Dust and Pollen Filter, Removing and Installing”,
page 92
page 95 rrectness of i
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Heater Control Module J604 , Checking”, page 96
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page 97
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⇒ “4.15 Heater Core, Removing and Installing”, page 98

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⇒ “4.16 Heater Core Coolant Pipes, Removing and Installing”,

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page 106 yi
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⇒ “4.17 Evaporator Temperature Sensor G308 , Removing and
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Installing”, page 108 p by
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⇒ “4.18 Condensation Water Drain, Checking”, page 109 Prote AG.
⇒ “4.19 Condensation Water Drain, Removing and Installing”,

page 110
⇒ “4.20 Partition, Removing and Installing”, page 112
4.1 Overview - Heater and A/C Unit

⇒ “4.1.1 Overview - Heater and A/C Unit, Climatronic”,
page 72
4.1.1 Overview - Heater and A/C Unit, Clima‐

tronic
Note
♦ There are different versions and various manufacturers of the

heater and Air Conditioning (A/C) units. Individual components
of the different heater and A/C units are similar but not the
same. Interchanging components from different manufactur‐
ers is not permitted. Refer to the Parts Catalog.

♦ A heater and A/C unit manufactured by “Valeo” is shown in the

following illustrations. For distinguishing characteristics be‐
tween manufacturers. Refer to ⇒ “1 Identification”, page 1 .
Overview - Heater and A/C Unit, Left Side Door Control
1 - Operating Lever
❑ For operating the de‐
froster and air distribu‐
tion door
cle Diagnostic Tester in AG. Volkswagen AG d
the “Guided Fault Find‐ agen oes
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⇒ Wiring diagrams, orise nte
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Troubleshooting & auth
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Component locations. ss c
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Heater and Electric-Manual
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Climate Control System
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Air Distribution Door Motor -
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V428- with Air Distribution
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Door Motor Position Sensor -
hole
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G645-
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page 144 .
rm
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Climatronic
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❑ Front Air Distribution
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Door Motor - V426- with
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⇒ “7.8 Front Air Distri‐ Prote AG.
bution Door Motor V426 with Air Distribution Door Motor Position Sensor G642 , Removing and
3 - Screw
❑ 1 Nm
❑ Quantity: 2
4 - Screw
❑ 1 Nm
❑ Quantity: 3
5 - Screw
❑ 1 Nm
❑ Quantity: 2
6 - Temperature Regulator Door Motor

Heater and Electric-Manual Climate Control System

❑ Temperature Regulator Door Motor - V68- with Temperature Regulator Door Motor Position Sensor -
G92-
⇒ “7.2 Temperature Regulator Door Motor V68 with Temperature Regulator Door Motor Position Sensor
G92 , Removing and Installing”, page 131 .
Climatronic
❑ Left Temperature Door Motor - V158- with Left Temperature Door Potentiometer/Actuator - G220-
⇒ “7.5 Left Temperature Door Motor V158 with Left Temperature Door Potentiometer/Actuator G220 ,
7 - Operating Lever
❑ For warm-air door
8 - Heater and A/C Unit AG. Volkswagen AG d
agen
❑ The heater and the heater and A/C unit ol have
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that
not are the same
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rised to ⇒ “1 Identification”, page 1 . nte
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❑ Interchanging components ais ut not permitted. ra
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❑ The following illustrations show the heater manufactured by “Valeo”
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9 - Defroster- and Air Distribution Door Actuator
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❑ Only on vehicles with heating or electric-manual climate control system
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hole
spec
⇒ “7.10 Air Distribution Door Adjuster, Removing and Installing”, page 147 .
es, in part or in w
t to the co
Overview - Heater and A/C Unit, Right Side Door Control
rrectness of i
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1 - Heater and A/C Unit

❑ Removing and instal‐ AG. Volkswagen AG d
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⇒ “4.5 Heater and A/C ed by
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Unit, Removing and In‐ horis nte
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stalling”, page 83 . aut ra
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2 - Operating Lever
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❑ For defroster door
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3 - Screw
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❑ 1 Nm
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❑ Quantity: 2
hole
spec
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4 - Defroster Door Motor -
t to the co
V107-
❑ With the Defroster Door
Motor Position Sensor -
rrectness of i
G135-
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❑ Only for Climatronic

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tion in
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Troubleshooting &
thi
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Motor V107 with De‐
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tion Sensor G135 , Re‐
agen
Prote AG.
page 132 .
5 - Right Temperature Door
Motor - V159-
❑ With Right Temperature
Door Potentiometer/Actuator - G221-
6 - Screw
❑ 1 Nm
❑ Quantity: 2
7 - Operating Lever
❑ For warm-air door
Overview - Heater and A/C Unit, Heater Core, Auxiliary Heater

Heating Element
The illustration shows Valeo heater.

1 - Bolt
❑ 6 Nm
Core
Catalog.
❑ Coolant supply from en‐
gine
❑ Removing and instal‐ n AG. Volkswagen AG do
ling. Refer to lkswage es n
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⇒ “4.15 Heater Core, byV ua
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Removing and Instal‐ ir se tee
ho
ling”, page 98 . aut or
ac
ss
3 - Clamp
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Core
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Catalog.
spec
❑ Coolant return to engine
t to the co
ling. Refer to
⇒ “4.15 Heater Core,
rrectne
ling”, page 98 .
ss o
5 - Seal
cial p
f inform
mer
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Catalog.
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6 - Cover
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7 - Screw
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8 - Foam Spacer Prote AG.
❑ For sealing/insulating
9 - Bracket
❑ For the coolant pipes
10 - Foam Piece
❑ For insulating
11 - Heater and A/C Unit
❑ For vehicles without an Auxiliary Heater Heating Element - Z35- with Auxiliary Air Heater Control Module
- J604- the opening for the Auxiliary Heater Heating Element - Z35- is closed.
❑ Disassembling and assembling. Refer to
⇒ “4.6 Heater and A/C Unit, Disassembling and Assembling”, page 87 .
12 - Heater Core

❑ Activation, checking. Refer to
page 96 .
14 - Screw
❑ 2 Nm
❑ Quantity: 2
15 - Wire
❑ For the Auxiliary Heater Heating Element - Z35- with Auxiliary Air Heater Control Module - J604-
16 - Ground (GND) Cable
❑ Nut 9 ± 1 Nm
❑ For the auxiliary heater
17 - Screw
❑ 2 Nm
❑ Quantity: 3
18 - Screw Clamp
19 - Seal
4.2 Overview - Attachments for Heater and

A/C Unit and Air Intake Housing
AG. Volkswagen AG d
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♦ A “Valeo” air intake housing is shown in the following illustra‐

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tion. Refer to ⇒ “1 Identification”, page 1 for the different

hole
spec
manufacturers' distinguishing characteristics of the heater and

es, in part or in w
A/C units.
t to the co
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1 - Plastic Screw or Plug (De‐

pending on Version)
❑ 0.3 Nm
❑ Quantity: 2
2 - Partition
ling. Refer to
⇒ “4.20 Partition, Re‐
page 112 .
3 - Fresh Air Blower Housing
Upper Section
4 - Screw
❑ 1 Nm
❑ Quantity: 2
5 - Air Intake Duct
❑ Do not dismantle
❑ With fresh- and air recir‐
culation door
Catalog.
ling. Refer to
⇒ “5.4 Air Intake Duct,
Removing and Instal‐ agen
AG. Volkswagen AG d
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6 - Dust, Fresh and Air tho
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culation Door Adjuster au ac
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Door Adjuster, Removing and Installing”, page 147 .

wit
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7 - Screw
hole
spec
❑ 1 Nm
es, in part or in w
t to the co

❑ Quantity: 2
rrectness of i
8 - Actuator
l purpos
❑ To check, use the vehicle Vehicle Diagnostic Tester in the “Guided Fault Finding” function. Refer to
⇒ Wiring diagrams, Troubleshooting & Component locations.
nf
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atio
❑ Recirculation Door Motor - V113- without position sensor; with end switches in the end stops. Refer to
om
⇒ Wiring diagrams, Troubleshooting & Component locations.

n in
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❑ Fresh Air/Recirculating Air/Back Pressure Door Motor - V425- with Fresh Air/Recirculating Air/Back
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❑ Removing and installing. Refer to cted agen
Prote AG.
9 - Screw
❑ 1 Nm

❑ Quantity: 2
❑ Replacement interval. Refer to ⇒ Maintenance Tables .
❑ Removing and installing. Refer to ⇒ “4.11 Dust and Pollen Filter, Removing and Installing”, page 92 .
11 - Cover
❑ For dust and pollen filter
13 - Fresh Air Blower Control Module - J126-
⇒ “4.10 Fresh Air Blower Control Module J126 , Removing and Installing”, page 91 .
14 - Screw
❑ 1 Nm
❑ Quantity: 2
4.3 Overview - Evaporator Housing

AG. Volkswagen AG d
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♦ There
s aut are different versions and various manufacturers r a of the
c
heater
s and Air Conditioning (A/C) units. Individual components
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♦ A “Valeo” evaporator housing is shown in the following illus‐

wit
is n
tration. Refer to ⇒ “1 Identification”, page 1 for the different

h re
ole,
manufacturers' distinguishing characteristics of the heater and

spec
A/C units.
t to the co
rrectness o
cial p
f inform
mer
atio
om
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1 - Evaporator Housing Lower

Section
2 - Evaporator
❑ Only with A/C system
❑ Check the foam seals
for damage and that
they are correctly bon‐
ded
ling. Refer to
⇒ “4.9 Evaporator, Re‐
page 90 .
3 - Seal
❑ Only for vehicles with an
A/C system.
correct version.
before installing
4 - Retaining Plate
❑ To secure the refriger‐
ant line and secure the
expansion valve
5 - Expansion Valve AG. Volkswagen AG d
agen
❑ Only with A/C system Volksw
oes
not
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❑ Removing and riseinstal‐
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⇒ “2.4 Expansion
ss a
Valve, c
ce
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un
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ling”, page 37 .
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6 - Bolt
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ility
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❑ 10 Nm
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spec
❑ Quantity: 2
t to the co
7 - Seal/Insulation
❑ Heat insulation for expansion valve
rrectne
❑ The seal for the plenum chamber rear wall does not have an opening for the expansion valve or it is
sealed with a foam body on vehicles without an A/C system.
s
8 - Seal
s o
cial p

inform
mer
❑ Replacing. Refer to the Parts Catalog for the correct version.

atio
m

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9 - Screw
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❑ 1.5 Nm
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10 - Evaporator Housing Upper Section
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11 - Airflow Regulator
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❑ Only installed in vehicles without an A/C system.
Prote AG.

4.4 Overview - Air Distribution Housing Doors and Partitions

View from the Front
Note
♦ -Arrow- indicates direction of travel

♦ Refer to ⇒ “4.1 Overview - Heater and A/C Unit”, page 72 .
1 - Right Door for Warm Air

❑ From the heater core
❑ Activated via the right
door for cold air n AG. Volkswagen AG do
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2 - Operating Lever byV
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❑ For door control hor is tee
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3 - Right Door for Cold
ss Air
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❑ Activated collectively
spec
via the left door shaft for
t to the co
cold air and left operat‐
ing lever by the Temper‐
ature Regulator Door
Motor - V68-
rrectne
Climatronic
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❑ Activated by the Right

cial p
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Temperature Door Mo‐

nform
tor - V159- via the right

mer
atio
operating lever.
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4 - Right Operating Lever for

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Thermostat Door
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5 - “Defrost” Door Operating
Lever
❑ For the windshield and
door windows
❑ Only Climatronic
❑ Activated by the Defroster Door Motor - V107-
6 - “Defrost” Door Operating Lever
❑ For the windshield and door windows
❑ Only heater and electric-manual climate control system
❑ Activated by the Air Distribution Door Motor - V428- via the defrost and air distribution adjuster

7 - Air Distribution Door Operating Lever

❑ Activated by the Air Distribution Door Motor - V428- via the defrost and air distribution adjuster
Climatronic
❑ Activated by the Front Air Distribution Door Motor - V426- via the defrost and air distribution adjuster
8 - Left Operating Lever
❑ Activated by the Temperature Regulator Door Motor - V68-
Climatronic
❑ Activated by the Left Temperature Door Motor - V158-
9 - Left Door for Cold Air olkswagen AG
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❑ Activated by the Temperature Regulator Door Motor - V68- via the left operating lever.
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10 - Operating Lever
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11 - Left Door for Warm Air
❑ From the heater core
❑ Activated via the left door for cold air
rrectness of i
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View from Behind

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mercia
at
Note
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♦ -Arrow- indicates direction of travel

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♦ Refer to ⇒ “4.1 Overview - Heater and A/C Unit”, page 72 .

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1 - Rear Air Guide Channel

Door
❑ The air guide channel is
sealed with a sealing
plug
❑ Depending on the man‐
ufacturer, not always
present with the heater
and electric-manual cli‐
mate control system
(not necessary, since
the air guide channel is
sealed)
Climatronic
❑ For the rear vent in the
inside the center con‐
sole
2 - Operating Lever
❑ For door control
❑ Equipment levels with
Climatronic
❑ Not always present with
the heater and electron‐
ic-manually regulated
Air Conditioning (A/C)
system -1-. AG. Volkswagen AG d
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3 - Left Door for the Left Instru‐ d b ara
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4 - Operating Lever ss
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5 - Left Door for Center Vent

h re
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6 - Right Door for the Right Instrument Panel Vent

spec
es, in part or in w
t to the co
7 - Right Door for Center Vent

rrectness of i
4.5 Heater and A/C Unit, Removing and In‐

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stalling
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♦ Hose Clamps - Up To 25mm - 3094-

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♦ Shop Crane - Drip Tray - VAS6208-

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Removing
Note
To improve accessibility, additional components for example en‐

gine cover must be removed (depending on engine version).
Refer to ⇒ Rep. Gr. 10 ; Engine Cover; Engine Cover, Removing
and Installing .
– Vehicles with an Air Conditioning (A/C) system: extract refrig‐

erant for example using A/C Service Station - VAS6007A- ,
only then open the refrigerant circuit. See notes. Refer to
– Vehicles with an A/C system: Remove the refrigerant line with
the inner heat exchanger from the expansion valve. Refer to
– Place the Shop Crane - Drip Tray - VAS6208- under the en‐
gine.
WARNING
Contact with hot engine coolant can cause severe scalding. AG. Volkswagen AG d
agen oes
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Coolant temperature can be above 100 °C (212 °F)bywith Vol a not
gu
warm engine. The coolant system is under pressure. rised ara
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If necessary, reduce pressure and temperaturess before repairs.
au ra
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– Mark the coolant hoses -1 and 4-.
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The heater core is designed for a specific coolant flow direction.
es, in part or in w
Therefore, coolant hoses must be connected on the correct sides.
t to the co
– Clamp off the coolant hoses -1 and 4- using Hose Clamps -
Up To 25mm - 3094- . rrectness of i
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– Lift the clips -2 and 3-.

– Remove the coolant hoses -1 and 4- from the heater core for
nform
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the heater.
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– Connect a suitable hose -A- to the upper connection of the

heater core.
– Hold a suitable container -B- under the lower connection of the
heater core -C-.
– Carefully blow the remaining coolant above the hose-A- out of
the heater core and into the container -B- with a compressed-
air gun.
AG. Volkswagen AG d
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Note rised
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To seal off all open connections on expansion valve, sealing caps ss c
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from a replacement expansion valve can be used (preventing dirt

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and moisture from entering the system).
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itte
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ility
– Remove the instrument panel central tube. Refer to ⇒ Body
ot p
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Interior; Rep. Gr. 70 ; Instrument Panel Central Tube; Instru‐
, is n
h re
ment Panel Central Tube, Removing and Installing .
hole
spec
– Remove the air guide channel to the rear vent (vehicle-spe‐
es, in part or in w
t to the co
cific). Refer to
⇒ “5.8 Rear Center Console Vent Air Guide Channel, Remov‐
ing and Installing”, page 118 .
rrectness of i
– Lift the rear footwell vent underneath the front seat and pull
l purpos
rearward to facilitate removing the footwell vent from the heat‐

er and A/C Unit.
nf
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– Remove the rear footwell vent from the heater and A/C unit.
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– Disconnect the connector -3- from the Fresh Air Blower Con‐
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– Cover the carpet and Airbag Control Module - J234- in the

vehicle interior with a waterproof foil and water absorbing pa‐
per.
– Remove the condensation water drain hose -2- carefully from

the heater and A/C unit -1-.
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– Remove the heater and A/C unit -1- from the bracket on the
plenum chamber bulkhead.

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– Free up the cable channel -3-.

– Free up the wiring harness -2- at the mounts -4- -arrows-.
rrectne
– Remove the heater and A/C unit to the side.

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– Make sure the condensation water hose -3- is seated correct‐

ly.
– The coding -2- and -arrow- must line up with the heater and A/
C unit -1-.
– If a commercially available cable tie was used to secure the
condensation water drain -3-, replace it.
– The condensation water drain hose must be routed as shown
in the illustration from underneath the wiring harness of the
Airbag Control Module - J234- -4-.
– Add coolant. Refer to ⇒ Engine Mechanical, Fuel Injection and
Ignition; Rep. Gr. 19 ; Cooling System/Coolant; Coolant,
Draining and Filling .
– Fill with R134a refrigerant and refrigerant oil. Refer to
⇒ “5.1 Refrigerant R134a Capacities”, page 8 .
– Check the heater and A/C unit function.
♦ Refer to ⇒ “4.1 Overview - Heater and A/C Unit”, page 72
♦ Refer to
♦ Overview - Instrument Panel Central Tube. Refer to ⇒ Body
Interior; Rep. Gr. 70 ; Instrument Panel Central Tube; Over‐
view - Instrument Panel Central Tube .
♦ Engine cover. Refer to ⇒ Rep. Gr. 10 ; Engine Cover; Engine
Cover, Removing and Installing .
♦ Air filter housing. Refer to ⇒ Engine Mechanical, FuelAG. Volkswagen AG d
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and Ignition; Rep. Gr. 24 ; Air Filter; Air Filter
by
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and Glow Plug; Rep. Gr. 23 ; Air Filter;
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4.6 Heater and A/C Unit, Disassembling
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♦ There are different versions and various manufacturers of the

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♦ A heater and A/C unit manufactured by “Valeo” is shown in the

following illustrations. For distinguishing characteristics be‐
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tween manufacturers. Refer to ⇒ “1 Identification”, page 1 .

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1 - Air Distribution Housing

❑ Different versions
❑ Interchanging compo‐
nents is not permitted.
❑ The following illustra‐
tions show the heater
manufactured by “Va‐
leo”
❑ Depending on vehicle
equipment level with or
without the Auxiliary
Heater Heating Element
- Z35- with Auxiliary Air
Heater Control Module -
J604-
❑ Manufacturer differen‐
ces. Refer to
⇒ “1 Identification”,
page 1 .
2 - Wiring Harness
Catalog.
3 - Evaporator Housing
Note
For vehicles without an A/C system

an airflow regulator is installed inolkswagen AG d
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⇒ “4.8 Heater and A/C Unit Bracket, Removing and Installing”, page 89 .
spec
6 - Nut
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❑ 4.5 Nm
7 - Nut
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❑ 4.5 Nm
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8 - Right Bracket
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⇒ “4.8 Heater and A/C Unit Bracket, Removing and Installing”, page 89 .
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9 - Air Intake Housing

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4.7 Air Distribution Housing, Removing and

Installing
Removing
– Remove the heater and A/C unit. Refer to
page 83 .
– Remove the coolant pipes from the heater core. Refer to
⇒ “4.16 Heater Core Coolant Pipes, Removing and Installing”,
page 106 .
– Disconnect the connector from the fresh/recirculated air door
motor and free up the wiring harness.
– Remove screws -2-.
– Release the mounting tabs -1 and 3-.
– Tilt the air distribution housing -4- toward the rear -arrow- and
disengage.
Installing
♦ Refer to
⇒ “4.6 Heater and A/C Unit, Disassembling and Assembling”,
page 87
Note
The smallest leaks at the tongue and groove joint between the air
distribution housing and the evaporator housing can lead to whis‐
tling noises due to escaping air. Coat the connecting surfaces
lightly with, for example, silicone grease. wSilicone
gen AG grease. Refer
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– Fold the heat shield -2- behind the ABS unit to the side.
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– Remove the nuts -3 and 5-.

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– Remove the bracket -4- in the interior.

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Note
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If the nut above the ABS unit is not accessible as described, the
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refrigerant pipe with the inner heat exchanger must be removed.

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Installing
– Insert the bracket -1 and 3- into the mount on the heater and Volkswa
A/C unit -2- and bring the heater and A/C unit into the ainstal‐
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⇒ “4.5 Heater and A/C Unit, Removingss aand
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Installing”, ac
page 83 .
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– Tighten the nuts -3 and 5- on the brackets.
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– Install the remaining components.
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– Check the Diagnostic Trouble Code (DTC) memory and erase
any displayed entries using the Vehicle Diagnostic Tester in
the “Guided Fault Finding” function.
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Tightening Specifications:
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Component Tightening Specifications
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4.9 Evaporator, Removing and Installing
Caution


♦ Seals
Removing
Refer to
– Remove the heater and Air Conditioning (A/C) unit. Refer to
page 83 .

– Remove bolts -1-.

– Release the mounting tabs -4 and 5- -arrows-.
– Remove the evaporator housing upper section -3- from the
lower section -2-.
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– Remove the evaporator -2- from the evaporator housing lower
rrectness of i
section -1-.
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– Remove the expansion valve. Refer to

⇒ “2.4 Expansion Valve, Removing and Installing”, page 37 .
nform
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– Remove the seal/insulation -3- by pulling the moving part -5-

to the side -arrow-.
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– Remove the retaining plate -4- for the refrigerant lines.
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– Replace the seals.
AG.
Note
♦ The smallest leaks at the tongue and groove joint between the
upper and lower sections of the evaporator housing can lead
to whistling noises due to escaping air. Coat the connecting
surfaces lightly with, for example, silicone grease. Refer to the
Parts Catalog.
♦ Before inserting the evaporator, check condensation water
drain and clean drain if necessary.
♦ Before inserting evaporator, clean evaporator housing and the
evaporator, if necessary.
♦ Refer to ⇒ “4.3 Overview - Evaporator Housing”, page 79
4.10 Fresh Air Blower Control Module -

J126- , Removing and Installing
Removing
– Remove the partition. Refer to

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Golf 2015 ➤ , Golf Variant d b 2015 ➤
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Heating, Ventilation thand
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– Disconnect the connectors -1 and 3-.
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– Remove the bolts -arrows-.
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WARNING
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Risk of severe burns.
spec
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♦ If the Fresh Air Blower - V2- with the Fresh Air Blower
t to the co
Control Module - J126- was in operation before the re‐
moval, it may be hot.
rrectness of i
♦ Do not touch the hot radiating surface of the Fresh Air
Blower Control Module - J126- .
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– Remove the control module -2- from the Fresh Air Blower -
V2- .
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– Check the Fresh Air Blower - V2- function.

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Air Intake Housing”, page 77
AG.
4.11 Dust and Pollen Filter, Removing and

Installing
♦ Trim Removal Wedge - 3409-
♦ Blower Motor Cover Plate - T10532-
♦ Commercially Available Vacuum Cleaner
Removing
Note
♦ Handle customer property in the glove compartment carefully.

♦ Store objects from the glove compartment in a sealable plastic
bag.
– Bring the glove compartment lid into the service position. Refer
to ⇒ Body Interior; Rep. Gr. 68 ; Storage Compartments and
Covers; Glove Compartment Lid Service Position .

– Release the cover -1- in direction of -arrow- and remove.
– Push the Blower Motor Cover Plate - T10532- -2- under the
pollen filter -1-.
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♦ Carefully pull the dust and pollen filter out of the installation
shaft.
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– Remove the cover -1- in direction of -arrow C-.
rrectne
– Make sure that the Blower Motor Cover Plate - T10532- is not
removed with it.
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– Remove dirt and leaves from the Blower Motor Cover Plate -
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T10532- with a commercially available vacuum cleaner.
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– Install in reverse order of removal. When doing this, note the
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Note
♦ Different filters are planned for this vehicle depending on the

equipment level.
♦ On vehicles without an A/C system and on vehicles with elec‐
tronic-manually regulated A/C system (each without the Air
Quality Sensor - G238- ), a dust and pollen filter without an
activated charcoal element from the manufacturer is installed.
When servicing, a dust and pollen filter with an activated char‐
coal element may also be installed in these vehicles. Refer to
the Parts Catalog.
♦ On vehicles with a Climatronic (with Air Quality Sensor -
G238- ) a dust and pollen filter with an activated charcoal
element from the manufacturer is installed. Refer to the Parts
Catalog.
Dust and Pollen Filter with Activated Charcoal Insert

The dust and pollen filter with an activated charcoal insert is only
installed on vehicles with Air Quality Sensor - G238- .
The activated charcoal filter continues to function as a dust and
pollen filter, however in addition the activated charcoal filter can
also filter out gaseous pollutants, for example ozone, benzene,
nitrogen dioxide from the air flow. The basic task of the activated
charcoal layer in the dust and pollen filter is to keep load peaks
out of the passenger compartment.
The activated charcoal also has the task of removing certain gas‐
eous contaminants from the air flowing through. The activated
charcoal layer in the dust and pollen filter reacts differently to var‐
ious pollutants in the air.
♦ Certain pollutants bond permanently in the active-carbon lay‐
er.
♦ Others are converted into noxious bonds like in a catalytic
converter.

♦ For the rest the activated charcoal works as a condenser (ca‐

pacitor). With increasing load pollutants are absorbed, until a
certain saturation is reached. If the amount of pollutants de‐
creases, the activated charcoal layer continuously releases
the absorbed particles.
Under the following operating conditions the dust and pollen filter
must be replaced earlier than required, because a certain amount
of pollutant particles is permanently bonded to the activated char‐
coal layer.
♦ If the vehicle is driven in areas with heavy air pollution.
♦ If vehicle is driven with the “automatic recirculated-air mode”
switched off.
Note
♦ The active carbon layer in the dust and pollen filter is saturated
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4.12 Fresh Air Blower - V2- , Removing and
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If only the Fresh Air Blower - V2- is faulty, Fresh Air Blower Control
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Module - J126- removing and installing. Refer to
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Removing
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The Fresh Air Blower - V2- is accessible from footwell on front

passenger side.
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– Remove the bolt -2-, if equipped.
– Lift the securing tab -4- and turn the fresh air blower -1- clock‐
wise -arrow-. en AG. V
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problems during operation.
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Installing
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– Then check the Fresh Air Blower - V2- function.

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- J604- , Checking
Checking
♦ Vehicle Diagnostic Tester with Vehicle Diagnosis System -
Trigger Clamp - 100A - VAS5051B/7-
Test Conditions
• The intake temperature is below 19 °C (66.2 °F)
• The coolant temperature is below 80 °C (176 °F)
• The passenger compartment temperature is approximately 20
°C (68 °F)
• Battery voltage greater than 11 V
• Alternator load not greater than 50% (terminal DF)
• Engine RPM higher than 450
• Turn the interior temperature control to maximum heating. (For
vehicles with Climatronic select the high setting).
Test Sequence
Console .

– Using the Vehicle Diagnostic Tester and the Vehicle Diagnosis

System - Trigger Clamp - 100A - VAS5051B/7- measure the
current draw -arrows- on the Ground (GND) cable -1- from
Auxiliary Heater Heating Element - Z35- -2-.
Slight heating output ≈ 30A
Medium heating output ≈ 60A
Large heating output ≈ 80A

- J604- , Removing and Installing
Removing
– Remove the driver sideGknee airbag. Refer to ⇒ Body Interior;
A . Volkswagen AG d
Rep. Gr. 69 ; lKnee
ksw Airbags;
agen Overviewoe- sKnee
n Airbag .
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– Remove ris
edthe left footwell center console trim. Refer
b ara
nte to ⇒ Body
Interior;
utho Rep. Gr. 68 ; Center Console; Overview -e oCenter
ra
Console
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Disconnect the battery before assembly work. Refer to ⇒ Elec‐

hole
trical Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting

spec
and Connecting .
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– Loosen the nut -3- and then remove the Ground (GND) cable
-4-.
WARNING
Risk of severe burns.

♦ If the Auxiliary Heater Heating Element - Z35- with the
Auxiliary Air Heater Control Module - J604- was in opera‐
tion before the removal, it may be hot.
♦ Do not touch hot metal surfaces on the AuxiliarywHeater
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– Remove the Auxiliary Heater Heating Element - Z35- with the
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Auxiliary Air Heater Control Module - J604- -1- left from the
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heater and A/C unit -6-.
spec
Installing
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Pay attention to the correct position and threaded connection of
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4.15 Heater Core, Removing and Installing

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⇒ “4.15.2 Heater Core, Removing and Installing, Denso”,
AG.
page 102
4.15.1 Heater Core, Removing and Installing,

Valeo
♦ Compressed Air Gun, Commercially Available
Caution


♦ Seals

Removing
For All Vehicles
– Mark the installed position of the coolant hoses -1 and 4-.
Note
The heater core is designed for a specific coolant flow direction.

Therefore, coolant hoses must be connected on the correct sides.
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– Carefully blow the remaining coolant above the hose-A- out of
the heater core and into the container -B- with a compressed-
air gun. rrectness of i
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– Remove the driver side knee airbag. Refer to ⇒ Body Interior;

Rep. Gr. 69 ; Knee Airbags; Overview - Knee Airbag .
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rig ht
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Air Heater Control Module J604 , Removing and Installing”, by c lksw
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– Cover the area beneath the connections for the coolant hoses
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cover tabs -arrows-.
– Remove the heater core to the left.
Installing
Note
Replace the seals.
– With the heater core removed, check the heater shaft for deb‐
ris.
– If necessary, remove any dirt or coolant residue.
– Vehicles with a TDI engine: Check the removed auxiliary heat‐
er heating element shaft for debris and clean if necessary.

– Check the foam seals -2- attached to the heater core -1- for
damage and replace if necessary.
Note
♦ If not bonded correctly, the foam seal may curl up during in‐
sertion.
♦ Cold air may flow past heater core if the foam seal is damaged
or not properly installed.
– Check the heater core connection -3- and the connection -2-
for the coolant pipes for damage or debris.
– Clean the sealing surface for the seal and glaze it.
– Coat a new seal -4- with coolant (or lightly with silicone grease)
and attach it to the coolant pipe -1-.
– Carefully slide the heater core all the way into the heater and
A/C unit until stop.
Note
When inserting the heater core, make sure that the connections
and the coolant pipes are not damaged.
– Slide the coolant pipes into the heater core until stop.
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– Position a new clip -5- or screw clamp -2- on the coolant pipe/
heater core connection.
– Tighten the bolt -3-. Refer to
⇒ “4.1 Overview - Heater and A/C Unit”, page 72 .
– Check the clamp and screw-type clamp for proper seating on
the heater core and the coolant pipe connections. They must
not be touching the air distribution housing or any other com‐
ponents.
– Check the DTC memory and erase any displayed entries using
the Vehicle Diagnostic Tester in the “Guided Fault Finding”
function.
♦ Overview - Turbocharger. Refer to ⇒ Rep. Gr. 21 ; Turbo‐
charger; Overview - Turbocharger
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the heater.

heater core.
heater core -C-.
– Carefully blow the remaining coolant above the hose -A- out
of the heater core and into the container -B- with a com‐
pressed-air gun.
Console .
– Vehicles with an auxiliary air heater: remove the Auxiliary
Heater Heating Element - Z35- with the Auxiliary Air Heater
Control Module - J604- . Refer to
⇒ “4.14 Auxiliary Heater Heating Element Z35 with Auxiliary
Air Heater Control Module J604 , Removing and Installing”,
page 97 .
– Cover the area beneath the connections for the coolant hoses
in the plenum chamber and Airbag Control Module - J234- for
example with a waterproof foil and water absorbing paper.

– Remove the bolts -2- and remove the screw clamps -3-.
– Disconnect the coolant pipes.
Note
♦ If the coolant pipes cannot be disconnected due to stuck seals

cut through the coolant pipes at the positions marked with
-arrows- using the A/C Pipe Pliers - T40147- .
♦ Remove the severed coolant pipes -4 and 7- of the heater core
from the coolant pipes -1 and 11- to the engine.
– Remove the bolt -10- and then remove the bracket -9- for the
heater core.
– Remove the heater core -6- to the left.
Installing
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connection -1- for damage or debris.
and attach it to the coolant pipe.
– Carefully slide the heater core all the way into the heater and
A/C unit until stop.
Note
When inserting the heater core, make sure that the connections
and the coolant pipes are not damaged.
Caution
Risk of leaks at the heater core.

♦ Crushed seals, or coolant pipes that are tilted or have not
been inserted completely may lead to leaks.
– Attach the bracket -3- for the heater core onto the air distribu‐
tion housing and tighten the screw -4- to specification.
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4.16 Heater Core Coolant Pipes, Removing

and Installing
⇒ “4.16.1 Heater Core Coolant Pipes, Removing and Installing,
Valeo”, page 106
⇒ “4.16.2 Heater Core Coolant Pipes, Removing and Installing,
Denso”, page 107
4.16.1 Heater Core Coolant Pipes, Removing

and Installing, Valeo
Note
There are different versions and various manufacturers of the

heater and Air Conditioning (A/C) units. Individual components of
the different heater and A/C units are similar but not the same (for
distinguishing characteristics. Refer to
⇒ “1.1 Heater and A/C Unit Identification”, page 1 ). Interchanging
components from different manufacturers is not permitted. Refer
to the Parts Catalog.
Removing
page 83 .
– Remove the sealing boot -3- to the plenum chamber bulkhead.
– Remove the bracket -4- for the coolant pipes toathe
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heater core connection.
ponents.
– Install the heater and A/C unit. Refer to
page 83 .
4.16.2 Heater Core Coolant Pipes, Removing

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– Check the heater core connection -3- and the coolant pipe
connection -1- for damage or debris.
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grease) and attach it to the coolant pipe -1-.
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been inserted completely may lead to leaks.
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opening in the heater is sealed on vehicles with a heater.
Removing
– Remove the glove compartment. Refer to ⇒ Body Interior;
Rep. Gr. 68 ; Storage Compartments and Covers; Glove
Compartment, Removing and Installing .

– Release the Evaporator Temperature Sensor - G308- with a

Trim Removal Wedge - 3409- .
– Remove the Evaporator Temperature Sensor - G308- -2- from
the housing.
Installing
♦ Storage Compartments/Covers; Overview - Glove Compart‐
ment. Refer to ⇒ Body Interior; Rep. Gr. 68 ; Storage Com‐
partments and Covers; Overview - Glove Compartment .
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4.19 Condensation Water Drain, Removing

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Danger of the airbag control module malfunctioning caused by

corrosion on the connector.
♦ Seal the electric connector on the airbag control module
to protect it from moisture.
– Remove the connector from the Airbag Control Module - J234-

-4-.
– Cover the Airbag Control Module - J234- and connector -4-
with a waterproof cover.
– Carefully move the carpet aside and cover it in the area under
the condensation water hose with waterproof foil and water
absorbing paper.
– Remove the condensation water drain hose -3- carefully from
the heater and A/C unit -1- and the vehicle body -5-.
Installing
– The condensation water drain hose can only be correctly slid
onto the heater and A/C unit in one position until stop.

• The tab -arrow- on the connection must engage into the guide
-2-.
• If a commercially available cable tie was used to secure the
condensation water drain -3-, replace it.
• The condensation water drain hose must be routed as shown
in the illustration from underneath the wiring harness of the
Airbag Control Module - J234- -4-.
– Insert the condensation water drain hose -6- into the body
opening until it audibly engages.
• The bracket -2- on the condensation water drain hose must be

completely and with pre-tension clipped into the body opening
-1-.
• The sealing lip must not sit loosely on the body opening.
• The tabs -arrows- must be completely engaged.
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♦ Install the condensation water drain hose so that it is not twis‐

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♦ If the condensation water drain hose sits too loosely on the

heater and A/C unit connection secure it from falling with for
example a hose clamp. Hose clamps. Refer to the Parts Cat‐
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4.20 Partition, Removing and Installing

Removing
– Depending on the version remove the plastic screw or caps
-2- and partition -1-.
Installing
Note
Replace the caps with bolts. Refer to Parts Catalog.

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♦ Screws -2- -item 1- ⇒ Item 1 (pageaut 78) .
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5 Air Routing
⇒ “5.1 Overview - Air Routing and Air Distribution in Passenger
Compartment”, page 113
⇒ “5.2 Fresh Air Intake, Removing and Installing”, page 115
page 115
⇒ “5.4 Air Intake Duct, Removing and Installing”, page 116
117
⇒ “5.7 Rear Footwell Vent, Removing and Installing”, page 118
⇒ “5.8 Rear Center Console Vent Air Guide Channel, Removing
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5. Air Routing 113

1 - Air Routing
❑ For defrost air vent
ling. Refer to
⇒ “5.11 Air Guide for De‐
frost Air Vent, Removing
and Installing”,
page 120 .
2 - Air Routing
❑ For center vent
ling. Refer to
⇒ “5.12 Air Guide for
Center Vent, Removing
and Installing”,
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vent a cap is installed on the heater.
⇒ “5.8 Rear Center Console Vent Air Guide Channel, Removing and Installing”, page 118 .
7 - Left Rear Vent Air Guide Channel
❑ Removing and installing. Refer to ⇒ “5.7 Rear Footwell Vent, Removing and Installing”, page 118 .
8 - Footwell Vent
❑ Driver side
⇒ “5.5 Driver Side Footwell Vent, Removing and Installing”, page 117 .

5.2 Fresh Air Intake, Removing and Instal‐

ling
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– Remove risethe plenum chamber cover. Refer to ⇒ Body
d b ara
nt Exterior;
Rep.uthGr.
o 50 ; Bulkhead; Plenum Chamber Cover,eeRemoving or
and
ss Installing .
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– Remove the fresh air intake cover. Refer to
pt
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⇒ “5.3 Fresh Air Intake Cover, Removing and Installing”, page
itte
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115 .
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– Remove the Air Quality Sensor - G238- (only on vehicles with
wit
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h re
hole
⇒ “8.2 Air Quality Sensor G238 , Removing and Installing”,
spec
page 151 .
es, in part or in w
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– Remove the nuts -arrows-.
– Remove the fresh air intake -1- from the plenum chamber.
rrectness of i
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Assembly sequence:
m
– Align the air grille on the flange.

at
om
ion
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– Hold the air grille and install the outer nut until the center weld
in t
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studs.
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– Install the nut on the opposite side.

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Note
♦ The seal -2- must be seated correctly in the air grille.

♦ If the fresh air intake grille is damaged or installed incorrectly,
water can enter the fresh air intake. Complaints due to odor
problems coming from the heater/Air Conditioning (A/C) sys‐
tem and/or there is moisture in the passenger compartment
may result.
Nut 3 Nm
5.3 Fresh Air Intake Cover, Removing and

Installing
Removing
– Remove the right plenum chamber cover. Refer to ⇒ Body
Exterior; Rep. Gr. 50 ; Bulkhead; Plenum Chamber Cover,
Removing and Installing .
5. Air Routing 115

– Disconnect the cable connection for vehicles with heated

windshield from the cover for the fresh air intake -1-
– Unhook the fresh air intake cover -1- in direction of -arrow B-
and remove in direction of -arrow A-.
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♦ If the fresh air intake cover is damaged or installed incorrectly, ss c
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water can enter the fresh air intake. Complaints due to odor
un
pt
problems coming from the heater/A/C system and/or there is
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d
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moisture in the passenger compartment may result.
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♦ If the plenum chamber cover is damaged or incorrectly instal‐
wit
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led, water can enter the fresh air intake via the fresh air intake.
h re
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spec
Installing
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5.4 Air Intake Duct, Removing and Installing
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Removing
f inform
mer
– Remove the instrument panel central tube. Refer to ⇒ Body
atio
Interior; Rep. Gr. 70 ; Instrument Panel Central Tube; Instru‐
om
ment Panel Central Tube, Removing and Installing .
n
c
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– Remove the dust and pollen filter. Refer to

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⇒ “4.11 Dust and Pollen Filter, Removing and Installing”, page
pr
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92 .
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– Disconnect the connector -4- and free up the wiring harness. C py
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– Remove screws -2-.
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– Release the mounting tab -1- -arrow A-.

– Tilt the air intake duct -3- upward -arrow B- and disengage.
Installing
♦ Refer to

5.5 Driver Side Footwell Vent, Removing

and Installing
Removing
– Remove the screw -1-.
– Remove the driver side footwell vent -2-.
Installing
4.2 x 16 screw 1.5 Nm
♦ Overview - knee airbag. Refer to ⇒ Body Interior; Rep. Gr.
69 ; Knee Airbags; Overview - Knee Airbag .
5.6 Front Passenger Side Footwell Vent,

Removing
– Remove the screw -2- (if installed).
– Remove the screws -3-.
– Push the clip -4- in direction of -arrow- upward and unclip the
front passenger side footwell vent. en AG. V
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– Pull the instrument panel slightly forward. y Vol gu
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– Remove the front passenger side footwell thvent.
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Check the coolant hose to make sure it is secure on vehicles with

spec
glove compartment cooling.

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4.2 x 16 screw 1.5 Nm
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5. Air Routing 117

5.7 Rear Footwell Vent, Removing and In‐

stalling
Removing
– Remove the sill panel strip. Refer to ⇒ Body Interior; Rep. Gr.
70 ; Passenger Compartment Trim; Sill Panel Strip, Removing
and Installing .
– Remove the front seat. Refer to ⇒ Body Interior; Rep. Gr. 72 ;
Front Seats; Front Seat, Removing and Installing .
– Remove the center console. Refer to ⇒ Body Interior; Rep.
Gr. 68 ; Center Console; Center Console, Removing and In‐
stalling .
– Lift the carpet near the vent.
– Pry out the cable clip -3-.
– Lift up the rear footwell vent -1- in direction of -B arrows-, move
it off of the heater and A/C unit -2- in direction of -arrow A- and
remove it to the side.
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– Check the cable clip -1- for damage before pressing onto the
footwell vent -2-.
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Note
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A loose cable clip or a damaged seal can cause flow-generated

nform
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noise.
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5.8 Rear Center Console Vent Air Guide

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Channel, Removing and Installing

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Removing C py
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– Remove the center console. Refer to ⇒ Body Interior; Rep. copy Vo
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Prote AG.

Note
If no rear vent is installed in the vehicle, a there is a cap -1- on

the air distribution housing. The cover -1- is remove in direction
of -arrow A-.
– Pivot the air guide channel -2- upward in direction of

-arrow B-, and release the catch on the air guide channel in
direction of -arrow C- and remove.
Installing
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♦ If the ventilation is to function properly, the ventilation open‐

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ings must not be covered.

spec
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♦ The ventilation frames are located in the rear side panels, be‐
t to the co
hind the bumper.

rrectness of i
The ventilation can be checked through the luggage compart‐

ment.
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Depending on the vehicle equipment level, it may be necessary

to remove additional components.
nf
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– Remove the side trim panels inside the luggage compartment.

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atio
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Refer to ⇒ Body Interior; Rep. Gr. 70 ; Luggage Compartment

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c
Trim Panels; Overview - Luggage Compartment Side Trim

or
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– The sealing lips in the vent frame on both sides of the vehicle
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must move freely and close by themselves.

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5. Air Routing 119

Removing
– Remove the rear bumper cover. Refer to ⇒ Body Exterior;
Rep. Gr. 63 ; Rear Bumper; Bumper Cover, Removing and
Installing .
– Release the tabs -arrows- using the Trim Removal Wedge -
3409- and remove the vent frame -1- from the side panel.
Installing
♦ Overview - rear bumper cover. Refer to ⇒ Body Exterior; Rep.
Gr. 63 ; Rear Bumper; Overview - Bumper Cover .
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Removing s
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pt
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an
itte
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Gr. 70 ; Instrument Panel; Instrument Panel, Removing and
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Installing .
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– Unclip the wiring harness -3- from the Sunlight Photo Sensor
h re
- G107- in direction of -arrow-.
hole
spec
es, in part or in w
– Remove the clips -2-.
t to the co
– Remove the air guide for the defrost air vent -1- upward from
the heater and A/C unit.
rrectness of i
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Tightening Specifications nform
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♦ Overview - instrument panel. Refer to ⇒ Body Interior; Rep.

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Gr. 70 ; Instrument Panel; Overview - Instrument Panel .

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5.12 Air Guide for Center Vent, Removing

and Installing
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– Remove the instrument panel. Refer to ⇒ Body Interior;
rised
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Gr. 70 ; Instrument Panel; Instrument Panel, aRemoving
ut
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and eo
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Installing . ss c
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– Remove the air guide for the center vent -1- upward from the
pt
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heater and A/C unit.
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5. Air Routing 121

6 Display and Control Head

⇒ “6.1 Component Location Overview - Display and AControl
G. Volkswagen AG d
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⇒ “6.2 Display and Control Head, Removing
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and Installing”, page ran
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126 ut
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6.1 Component Location Overview - Display
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⇒ “6.1.1 Component Location Overview - Display and Control
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Head, Electric-Manual Climate Control System”, page 122
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⇒ “6.1.2 Component Location Overview - Display and Control
hole
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Head, Climatronic”, page 124
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6.1.1 Component Location Overview - Display
and Control Head, Electric-Manual Cli‐
rrectness of i
mate Control System
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Note
nform
mercia
♦ An indicator lamp inside the controls indicates when the se‐
at
om
io
lected function is on.
n
c
in t
or
his
e
♦ If the lamp in the AC button does not come after the button is
at
do
riv
pushed, there may be a fault in the control module. Call up the

p
cum
or
Diagnostic Trouble Code (DTC) memory using the Vehicle Di‐

f
en
ng
agnostic Tester . If the fault stored in the DTC memory “A/C

t.
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compressor first start not performed” is present, then is it nec‐
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essary to perform a basic setting and an adaptation “A/C
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compressor first start” either in Guided Fault Finding or in Gui‐
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ded Functions. Prote AG.
page 3 .
♦ Not all the buttons are used, depending on the vehicle equip‐
ment level and may vary in location.

1 - Left Seat Heating Button -

E653-
❑ Optional
❑ The seat heating has
three settings. An Light
Emitting Diode (LED) in‐
dicates which setting is
selected.
the seat heater is
switched off.
2 - A/C Button
❑ The Air Conditioning (A/
C) compressor is set to
almost 0 delivery when
the AC button is off.
3 - Rear Window Defogger
Button
❑ Rear window defroster
remains on for 4 to 20
minutes, depending on
exterior temperature.
4 - Recirculating Air Mode But‐
ton
Note
The recirculating air mode turns off

during ignition and returns to fresh
air mode.
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5 - Immediate Heating Button olks
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for Parking/Auxiliary Heater d by V ua
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ON/OFF or OFF Button for oris
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Heating and Air Conditioning au th or
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ON/OFF ss
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❑ Depending on the equipment level

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❑ OFF button is pressed, the A/C does not work. There is no heating or ventilation.
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6 - Right Seat Heating Button - E654-

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❑ Optional
h re
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spec
❑ The seat heating has three settings. An LED indicates which setting is selected.
es, in part or in w
❑ If no LED is illuminated, the seat heater is switched off.

t to the co
7 - Air Distribution Control Knob

rrectness of i
8 - Air Distribution Display

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9 - Blower Speed Control Knob

❑ To the left: decreases the blower speed
nf
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❑ To the right: increases the blower speed

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10 - Blower Speed Display

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11 - Temperature Control Knob

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❑ To the left: lower the temperature

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❑ To the right: increases the temperature

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12 - Temperature Setting Display . Cop py
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6.1.2 Component Location Overview - Display

and Control Head, Climatronic
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Note oris tee
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♦ An indicator lampsinside the controls indicates when the se‐
ce
le
lected function is on. In addition to this, whenever a button or

un
pt
an
d
a control is selected, the function will briefly appear in the radio

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or radio/navigation system display.
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♦ To change from °C and °F in the radio or radio/navigation sys‐
wit
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tem display, go to the main menu in the instrument cluster. Call
h re
ole,
up the main menu with the rocker switch in the windshield
spec
wiper lever. Select settings, units and temperature .
t to the co
♦ If a new Heater and A/C Controls - EX21- with Climatronic
Control Module - J255- was installed, perform the Guided
Fault Finding or Guided Functions, the basic setting and adap‐
rrectne
tation “A/C compressor first start”.
ss
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cial p
f i
nform
page 3 .
mer
atio
m
♦ If the lamp in the AC button does not come on after the button
o
n
c
i
or
n
is pushed, there may be a fault in the control module. Call up
thi
e
the Diagnostic Trouble Code (DTC) memory using the Vehicle

t
sd
iva
Diagnostic Tester . If the DTC memory entry “A/C compressor o

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fo
first start not performed” is present, then it is necessary to

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t.
perform a basic setting and an adaptation of “A/C compressor
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first start” in Guided Fault Finding.
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♦ Pressing the button AUTO will reverse all settings which devi‐
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ate from the automatic operation.
agen
Prote AG.
♦ If there are differences from automatic operation, see the cor‐

responding user guide.
♦ When the OFF button is activated, the Climatronic does not
work. There is no heating or ventilation.
♦ When the OFF button is deactivated, the Climatronic works.
♦ The A/C button is pressed and the A/C compressor is on. The
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. The heating and ventilation operation continues to be
controlled electronically.
page 3 .
♦ Not all the buttons are used, depending on the vehicle equip‐
ment level and may vary in location.

1 - Left Temperature Display

❑ Shows the set tempera‐
ture for the driver side.
2 - Left Seat Heating Button -
E653-
❑ Optional
❑ The seat heating has
three settings. An Light
Emitting Diode (LED) in‐
dicates which setting is
selected.
the seat heater is
switched off. AG. Volkswagen AG d
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3 - Windshield Air Distribution by Vo gu
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Button rise
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❑ The LED turns on whens a ut ra
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4 - Center Air Distribution But‐
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❑ Air distribution to the up‐
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❑ The LED turns on when
the system is active.
t to the co
5 - Lower Air Distribution But‐
ton
rrectne
❑ Air distribution into the
footwell.
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6 - Air Recirculation Button

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❑ Manual and automatic recirculating air mode.

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❑ Press the button for recirculating air function to prevent polluted air from entering interior.
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Recirculating air is switched on automatically under the following conditions: Cop py
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• When the windshield washer system is operated, cop Vo
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• When the Air Quality Sensor - G238- is activated.
AG.
• When the reverse gear is engaged (this function is only active for two minutes after the engine is started).
• Blower speed on the Heater and A/C Controls - EX21- off
• Heater and A/C Controls - EX21- “OFF”.
7 - Right Seat Heating Button - E654-
❑ Optional
❑ The seat heating has three settings. An LED indicates which setting is selected.
❑ If no LED is illuminated, the seat heater is switched off.
8 - Right Temperature Display
❑ Shows the temperature set for the front passenger side
9 - Max A/C Button
❑ The LED turns on when the system is active.
❑ Run Air Conditioning (A/C) system with MAX A/C.

10 - A/C Button
❑ The A/C compressor is set to almost 0 delivery when the AC button is off. If the AUTO button is activated,
the heating and ventilation mode continues to be controlled electronically.
11 - Right Temperature Control
❑ The selected temperature will be shown in the display.
12 - Sync Button
❑ Synchronization of the climate zones to the driver value.
13 - Low Blower Speed
❑ Only for display no function
14 - AUTO Button
❑ In automatic mode the Climatronic maintains the selected vehicle temperature automatically. The air
temperature, the blower speed and the air distribution are adjusted automatically.
15 - SETUP Button
❑ Pressing the SETUP button calls up the climate control menu for adjustment for example of the recircu‐
lating air mode, and default functions.
16 - Blower Control
❑ By turning the knob, the blower speed can be individually adjusted.
❑ If the blower speed is manually adjusted, the function AUTO is automatically deactivated.
17 - High Blower Speed
❑ Only for display no function
18 - Immediate Heating Button Button for Parking/Auxiliary Heater On/Off or OFF Button for the A/C System
On/Off
❑ Depending on the equipment level agen
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❑ When the OFF button is activated,d b the Climatronic does not work. There
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19 - Max Defrost Button au
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❑ Air sucked in from the outside
s is directed to the windshield if installed causing the recirculating air mode
ce
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to shut off automatically.

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❑ In order to remove fog from front windshield quickly, the air temperature must be above 1.5 °C (35 °F).
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The A/C compressor is switched on and the blower is set to the highest.
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20 - Rear Window Defogger Button

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❑ It only works when the engine is running and turns off on its own after 10 minutes.
es, in part or in w
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21 - Left Temperature Control

❑ The selected temperature will be shown in the display.
rrectness of i
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6.2 Display and Control Head, Removing

and Installing
nform
mercia
at

om
ion
c
in t
r

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ate
do
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for
en
ng
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Cop py
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Prote AG.

Note
♦ Perform the replace control module function, a basic setting

and an adaptation “A/C compressor first start ” either in Guided
Fault Finding or in Guided Functions when installing a new
Climatronic Control Module - J255- or A/C Control Module -
J301- .
. Volkswagen AG
page 3 . swa
gen AG does
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Note
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The illustration shows a vehicle with electric manual climate con‐
pe
ility
trol system. The removing and installing on a vehicle with Clima‐
ot
wit
tronic is identical.
, is n
h re
hole
spec
– Unclip the trim -1- from the display and control head at the
es, in part or in w
points indicated -arrows- with the Trim Removal Wedge -
t to the co
3409- in direction of -arrow A-.
rrectness of i
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nform
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a
com
tion in
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– Remove the expanding rivets -2- in direction of -arrow A-.
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– Remove the display and control head -1- in direction of Cop py
-arrow B-.
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Installing
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Prote AG.
Note
Perform the replace control module function, a basic setting and

an adaptation “A/C compressor first start ” either in Guided Fault
Finding or in Guided Functions when installing a new Climatronic
Control Module - J255- or A/C Control Module - J301- .

en AG. V - Edition
olkswagen A12.2015
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7 Actuators ris nte
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⇒ “7.1 Component Location Overview - Front Actuators”,
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un
page 128
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⇒ “7.2 Temperature Regulator Door Motor V68 with Temperature
erm
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⇒ “7.3 Defroster Door Motor V107 with Defroster Door Motor Po‐
spec
sition Sensor G135 , Removing and Installing”, page 132
t to the co
page 134
rrectne
⇒ “7.5 Left Temperature Door Motor V158 with Left Temperature
Door Potentiometer/Actuator G220 , Removing and Installing”,
page 136
ss o
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f
⇒ “7.6 Right Temperature Door Motor V159 with Right Temper‐
inform
ature Door Potentiometer/Actuator G221 , Removing and Instal‐
mer
ling”, page 138
atio
om
n
⇒ “7.7 Fresh Air/Recirculating Air/Back Pressure Door Motor
c
i
or
n
V425 with Fresh Air/Recirculating Air/Back Pressure Door Motor
thi
te
sd
a
Position Sensor G644 , Removing and Installing”, page 140

iv
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pr
cum
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fo
⇒ “7.8 Front Air Distribution Door Motor V426 with Air Distribution
en
ng
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Door Motor Position Sensor G642 , Removing and Installing”,
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Distribution Door Motor Position Sensor G645 , Removing and
agen
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⇒ “7.10 Air Distribution Door Adjuster, Removing and Installing”,
page 147
7.1 Component Location Overview - Front

Actuators
⇒ “7.1.1 Component Location Overview - Front Actuators, Elec‐
tric-Manual Climate Control System”, page 128
⇒ “7.1.2 Component Location Overview - Front Actuators, Clima‐

tronic”, page 129
7.1.1 Component Location Overview - Front Actuators, Electric-Manual Climate

Control System

Door Motor - V68-
❑ With the Temperature
Position Sensor - G92-
Diagnostic Tester .
ling. Refer to
⇒ “7.2 Temperature
V68 with Temperature
Position Sensor G92 ,
ling”, page 131 .
Vehicle Diagnostic
Tester
- V428- AG. Volkswagen AG d
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❑ With the Air Distribution Volksw
oes
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page 144 .
rrectne
basic setting using the Vehicle Diagnostic Tester
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❑ Check using the Vehicle Diagnostic Tester .
cial p
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7.1.2 Component Location Overview - Front

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Pay attention to the turn off conditions for vehicles with the Start/ copy Vo
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page 3 .
7. Actuators 129
1 - Left Temperature Door Mo‐

tor - V158-
❑ With Left Temperature
Door Potentiometer/Ac‐
tuator - G220-
Diagnostic Tester .
ling. Refer to
⇒ “7.5 Left Temperature
Left Temperature Door
Potentiometer/Actuator
G220 , Removing and
Vehicle Diagnostic
Tester
2 - Front Air Distribution Door
Motor - V426- with Front Air
Distribution Door Motor Posi‐
tion Sensor - G642-
❑ With the Front Air Distri‐
bution Door Motor Posi‐
tion Sensor - G642-
Diagnostic Tester .
ling. Refer to
⇒ “7.8 Front Air Distri‐
bution Door Motor V426
with Air Distribution
Door Motor Position
Sensor G642 , Remov‐
ing and Installing”, page AG. Volkswagen AG d
143 . agen oes
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❑ Replacing: initiate the basic setting using the Vehicle isDiagnostic
ed b Tester ara
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3 - Fresh Air/Recirculating Air/Back Pressure Door Motor au - V425-
t or
ac
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❑ With Fresh Air/Recirculating Air/Back Pressure Door Motor Position Sensor - G644-
ce
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4 - Right Temperature Door Motor - V159-

t to the co
❑ With Right Temperature Door Potentiometer/Actuator - G221-

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5 - Defroster Door Motor - V107-

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❑ With the Defroster Door Motor Position Sensor - G135-

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Rep. Gr.87 - Air Conditioning
7.2 Temperature Regulator Door Motor -

V68- with Temperature Regulator Door
ing and Installing
Heater and Electric-Manual Climate Control System AG. Volkswagen AG d
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Special tools and workshop equipment required olksw not
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♦ Vehicle Diagnostic Tester horis
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– Equipment level with ignition lock: Remove the ignition key.
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WARNING
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spec
Risk of injury by the knee airbag.
t to the co
♦ Before working in the area of pyrotechnic components, the
person must “discharge static electricity”. Follow the safe‐
ty precautions when working on the airbag. Refer to ⇒
rrectne
Body Interior; Rep. Gr. 00 ; Safety Precautions; Pyro‐
technic Components Safety Precautions .
ss o
cial p
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– Remove the driver footwell vent. Refer to
mer
⇒ “5.5 Driver Side Footwell Vent, Removing and Installing”,
atio
m
page 117 .
o
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– Remove the operating lever -3- from the heater.

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The upper bolt is accessible with a commercially available small pyri by
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– Remove the Temperature Regulator Door Motor - V68- -1-.
7. Actuators 131
Installing
Note
♦ Check the function of the doors and linkage before installing.

♦ Check if the lever and shafts are seated correctly in the
mounts.
– Mount the actuator -1- onto the air distribution housing. When
doing this, the toothed gear -2- on the actuator must engage
into the toothed gear -3- on the operating lever.
• The long tooth -4- must engage into the recess -arrow- on the
operating lever.
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♦ If the toothed gear onisthe
ed actuator and the toothed gear on the
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temperature door lever
thor do not face each other, turn the mount tee o
in the actuator.ss au ra
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♦ If the bolts cannot be installed, the actuator does not sit com‐
nl
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pletely on the housing. an

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– Switch on the ignition, connect the affected actuator to the ve‐ wit
hicle wiring harness and select the setting for the desired
, is n
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actuator position on the display control head (for example, the

hole
spec
center position). Wait until the actuator reaches the desired

es, in part or in w
position and switch the ignition off.

t to the co
– Install the wiring harness so that it cannot come in contact with

any moving parts (for example, the lever on the actuator).
rrectness of i

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any displayed entries, then perform the “basic setting”. Refer

to Vehicle Diagnostic Tester in the “Guided Fault Finding”
function.
nf
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7.3 Defroster Door Motor - V107- with De‐

en
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t.
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froster Door Motor Position Sensor -
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♦ Vehicle Diagnostic Tester
– Remove the key.
Removing
Rep. Gr. 68 ; Storage Compartments and Covers; Overview
- Glove Compartment .


– Remove the Defroster Door Motor - V107- -1-.
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7. Actuators 133
Installing
Note

mounts.
– The actuator mount -1- can only be installed in one position

on the actuating arm -2-.
• The actuator mount must be opposite the actuating arm as
shown in the illustration.
Note
If the mount and the actuating arm are not opposite each other,
turn the mount in the actuator.
– Switch on the ignition, connect the affected actuator to the ve‐

– Mount the actuator on the air distributionVhousing so that the
actuating arm reaches into the smountn AG. olkswagen AG do
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ed in the connection between the
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If the bolts cannot be installed, the actuator does not sit com‐
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7.4 Recirculation Door Motor - V113- , Re‐
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The actuator has end stops
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– Remove the Recirculation Door Motor - V113- -3- from the air
intake duct -2-.
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7. Actuators 135
Installing
Note

mounts.
– The fresh air door must be in the “open” position so the fresh
air comes into the vehicle.
• The actuating shaft -2- must contact the stop -1- -arrow- as
illustrated.
Note
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If the actuating shaft of the actuator is not set to “fresh-air mode” y Volk not
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stop, turn the mount in the actuator. risedb ara
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– Switch on the ignition, connect the affected actuator ss
to the ve‐ c
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– Mount the actuator to the air intake housing so that the ac‐
h re
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tuating shaft engages into the mount.
spec
• There must not be any play in the connection between the
t to the co
actuating shaft and the mount.
rrectne
Note
s
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mer

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– Check the heater and Air Conditioning (A/C) unit function.
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7.5 Left Temperature Door Motor - V158-

with Left Temperature Door Potentiom‐
eter/Actuator - G220- , Removing and
Installing


– Remove the key.
Removing
WARNING
Risk of injury by the knee airbag.

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. Volkswagen AG
does
person must “discharge static electricity”. Follow the ol s a
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ty precautions when working on the airbag. Refer ised to ⇒
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Body Interior; Rep. Gr. 00 ; Safety Precautions;
hor
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technic Components Safety Precautions ss .
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page 117 .
wit
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– Remove the operating lever -3- from the heater.
hole
spec
es, in part or in w
t to the co
Note
The upper bolt is accessible with a commercially available small
rrectness of i
bit-ratchet.
l purpos
nf
ercia
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m
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– Remove the Left Temperature Door Motor - V158- -1-.
om
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7. Actuators 137
swage es n
Installing byV
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Install in reverse order of removal. Note the following: tho tee
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Note
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hole
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into the toothed gear -3- on the temperature door lever.
rrectness of i
• The long tooth -4- must engage into the recess -arrow- on the
operating lever.
l purpos
nform
ercia
Note
m
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♦ If the toothed gear on the actuator and the toothed gear on the
on in
temperature door lever do not face each other, turn the mount
r
te o
thi
in the actuator.
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switching the positive and negative.
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function.
7.6 Right Temperature Door Motor - V159-

with Right Temperature Door Potenti‐
ometer/Actuator - G221- , Removing
and Installing
– Remove the key.

Removing
– Remove the operating lever -1- for the temperature door.
– Remove the Right Temperature Door Motor - V159- -2-.
AG. Volkswagen AG d
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7. Actuators 139
Installing
Note

mounts.
into the toothed gear -1- on the temperature door lever.
Volkswa
• The long tooth -4- must engage into thesrecess
agen -arrow- on the
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operating lever. by Vol not
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an
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temperature door lever do not face each other, turn the mount
erm
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in the actuator.
ility
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on
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Turn the actuator so far until it has reached a favorable position

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any displayed entries, then perform the “basic setting”. Refer cop Vo
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to Vehicle Diagnostic Tester in the “Guided Fault Finding” cted agen
Prote AG.
function.
7.7 Fresh Air/Recirculating Air/Back Pres‐

sure Door Motor - V425- with Fresh Air/
Recirculating Air/Back Pressure Door
ing and Installing


– Remove the key.
Removing
– Unclip the wiring harness.
– Remove the Fresh Air/Recirculating Air/Back Pressure Door
Motor - V425- -1- from the air intake duct.
AG. Volkswagen AG d
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7. Actuators 141
Installing
Note

mounts.

Note

– Mount the actuator on the air distribution housing so that the
actuating arm reaches into the mount -1- -arrow-.
actuator and the actuating arm. agen
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ment. Refer to ⇒ Body Interior; Rep. Gr. 68 ; Storage Com‐ gh ht
yri by
op Vo
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cted agen
Prote AG.

7.8 Front Air Distribution Door Motor - V426-

with Air Distribution Door Motor Position
Sensor - G642- , Removing and Instal‐
ling
– Remove the key.
Removing
Installing . AG. Volkswagen n AG do
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– If installed: Remove the Access/Start
Vol Authorization Control
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Module - J518- . Refer ris
eto ⇒ Electrical Equipment; Rep. Gr. ran
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94 ; Access/Start Authorization;
utho Component Location Over‐ or
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ss Authorization System .
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page 117 .
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♦ The bolts are behind the central tube and can be reached from
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rrectness of i
♦ To remove the bolts use a magnetic screwdriver or have a

l purpos
second technician hold a magnet over the bolts. If a bolt falls,

it goes into the tray for the cable duct and cannot be reached.
The instrument panel must then be removed to remove the
nform
ercia
bolt.
m
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– Remove the Front Air Distribution Door Motor - V426- -4-.

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Note

mounts.
7. Actuators 143
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Golf 2015 ➤ , Golf Variant 2015 ➤ wage
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– The actuator mount -1- can only be installed in one auposition
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– Mount the actuator on the air distribution housing so that the
mer
atio
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om
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Note


function.
7.9 Air Distribution Door Motor - V428- with

Position Sensor Air Distribution Door
ing and Installing
Removing
Installing .

AG. Volkswagen AG d
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– If installed: Remove the Access/Start Authorization Control
ce
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Module - J518- . Refer to ⇒ Electrical Equipment; Rep. Gr.
pt
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itte
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view - Access/Start Authorization System .
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page 117 .
spec
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Note
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♦ The bolts are behind the central tube and can be reached from
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♦ To remove the bolts use a magnetic screwdriver or have a

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m
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ion in
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– Remove the Air Distribution Door Motor - V428- -4-.
s
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7. Actuators 145
Installing
Note

mounts.

Note
turn the mount in the actuator. AG. Volkswagen AG d
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– Switch on the ignition, connect the affected actuatorho
rito the ve‐
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hicle wiring harness and select the setting for the
aut desired ra
c
ss example, the
actuator position on the display control head (for
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ility
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es, in part or in w
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Note
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switching the positive and negative. t. Cop py
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function.

kswage es n
7.10 Air Distribution Door Adjuster, Remov‐ ol ot g
byV ua
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ing and Installing utho tee
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ss
⇒ “7.10.1 Front Air Distribution Door Adjuster, Removing and In‐
ce
e
nl
stalling, Heater and Electric-Manual Climate Control System”,
pt
du
an
page 147
itte
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erm
ab
⇒ “7.10.2 Front Air Distribution Door Adjuster, Removing and In‐
ility
ot p
stalling, Climatronic”, page 148
wit
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7.10.1 Front Air Distribution Door Adjuster, Re‐
hole
spec
es, in part or in w
moving and Installing, Heater and Elec‐
t to the co
tric-Manual Climate Control System
Removing
rrectness of i
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Installing .
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– Remove the defroster vent air guide. Refer to

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⇒ “5.11 Air Guide for Defrost Air Vent, Removing and Instal‐
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defroster door -2-.
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– Remove the bolts -1, 4 and 8-.

– Remove the adjuster -9- upward.
Installing
– Install in reverse order of removal. Note the following:
Note

mounts.
– Check if the gears correlate correctly with one another.

• The square tooth -2- must engage into the gap -3- on the
toothed gear -1-.
7. Actuators 147
– When mounting the adjuster, the operating lever -5- must en‐
gage into the vent door lever -6- in the middle.
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⇒ “5.11 Air Guide for Defrost Air Vent, Removing and Instal‐
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– Remove the air distribution door motor. Refer to

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mounts.
– Check if the gears correlate correctly with one another.

• The square tooth -2- must engage into the gap -3- on the
toothed gear -1-.
– When mounting the adjuster, the operating lever -3- must en‐
gage into the vent door lever -4- in the middle.
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151
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⇒ “8.3 Function of Air Quality Sensor G238 ”, page 151
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⇒ “8.5 A/C Humidity Sensor G260 , Removing and Installing”,
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⇒ “8.6 Left Vent Temperature Sensor G150 , Removing and In‐
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– Unclip Sunlight Photo Sensor - G107- -1- in the direction of the
-arrow- out of the instrument cluster.
– Disconnect the connector.
Installing

8.2 Air Quality Sensor - G238- , Removing

and Installing
Note
♦ The Air Quality Sensor - G238- is only installed on vehicles

with climatronic.
♦ The Air Quality Sensor - G238- is installed at the right front on
the intake air grille in the plenum chamber.
♦ The Air Quality Sensor - G238- contains a highly sensitive
electronic component that 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‐
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– Pull the Air Quality Sensor - G238- -1- in direction of -arrow-.

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Do not store a removed Air Quality Sensor - G238- in areas where

they can come into contact with solvents, fuels, and certain chem‐
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8.3 Function of Air Quality Sensor - G238-

♦ Sensor for air quality detects pollutants in the ambient air
(mostly gasoline and/or diesel fumes).
♦ The Climatronic Control Module - J255- evaluates the signal
from the Air Quality Sensor - G238- . The Air Conditioning (A/
C) system is activated depending on the strength and type of
heavily polluted air.
At an outside temperature above approximately 2 °C (35.6 °F) the
recirculating air mode is switched on when there is only a slight
increase in pollutants in the ambient air.

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At an outside temperature between
approximately 2 °C (35.6 °F)
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switches on for approximately 15 seconds and the A/C compres‐
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system switches to the fresh air mode.
♦ “Automatic recirculating air mode” can be switched off at any
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time. If the function is active, the A/C compressor is switched
on with a request for “automatic recirculating air mode” and
also when the outside air temperature is below 2 °C (35.6 °F).
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the result that a recirculated-air request is generally applied
for less than 12 minutes given uniform ambient air pollution. If
a succession of peaks in the polluted air is detected, the A/C
system can operate over a longer period of time in recirculating
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 activated 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 recir‐
culating air 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 (the AC button is off),
then the Climatronic Control Module - J255- limits the “auto‐
matic recirculating air mode” to approximately 15 seconds to
prevent the windows from fogging up.
♦ So that fogged windows are cleared as quickly as possible,
the Climatronic Control Module - J255- does not permit recir‐
culated air operation during the “Defrost” operating mode.
♦ The Air Quality Sensor - G238- requires approximately 30
seconds to become operational once the ignition has been
switched on (warm-up time). During this time there is no re‐
quirement from the sensor to Climatronic Control Module -
J255- for “automatic recirculating air mode”.

♦ The Air Quality Sensor - G238- contains a highly sensitive

electronic component which can be damaged if it comes in
direct contact with solvents, fuels or chemicals. For this rea‐
son, do not install sensors that may have come into contact
with these substances.
8.4 Outside Air Temperature Sensor -

Removing
Installing .
– Unclip the Outside Air Temperature Sensor - G17- -1- from the
bracket -arrow-.
– Remove the Outside Air Temperature Sensor - G17- upward.
Installing
Note
Ensure electrical connector is seated correctly (water entry).

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– Removing and installing. Refer to ⇒ Electrical Equipment;

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Rep. Gr. 92 ; Windshield Wiper System; Rain/Light Recogni‐

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The diagnosis occurs via the Vehicle Electrical System Control

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Module - J519- .
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8.6 Left Vent Temperature Sensor - G150- ,

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Only for vehicles with Climatronic. For vehicles with heater or
electronic-manually regulated Air Conditioning (A/C) system the
openings on the air guide channels are closed with plugs.

– Remove the instrument panel side cover. Refer to ⇒ Body

Interior; Rep. Gr. 70 ; Instrument Panel; Instrument Panel Side
– Turn the vent temperature sensor -1- in direction of -arrow-
and remove it from the mount.
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An incorrectly installed vent temperature sensor causes flow-

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♦ Instrument panel; instrument panel side cover removing and

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installing. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Instrument

Panel; Instrument Panel Side Cover, Removing and Installing .
nform
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8.7 Right Vent Temperature Sensor -

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– Remove the instrument panel side cover. Refer to ⇒ Body

Interior; Rep. Gr. 70 ; Instrument Panel; Instrument Panel Side

– Turn the vent temperature sensor -1- in direction of -arrow-

and remove it from the mount.
Installing
– Replace the seal -3- if it is damaged or faulty.
Note
An incorrectly installed vent temperature sensor causes flow-

generated noise.

♦ Instrument panel; instrument panel side cover removing and
installing. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Instrument
Panel; Instrument Panel Side Cover, Removing and Installing .
8.8 Footwell Vent Temperature Sensor -

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8. Additional Components for Control and Regulation
– Slightly lift the Footwell Vent Temperature Sensor - G192-

-2-.
– Release the catches -arrows- with a Trim Removal Wedge -
3409- .
– Remove the Footwell Vent Temperature Sensor - G192- -2-
upward.
Installing
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9 Special Tools
Special tools and workshop

equipment required
♦ Torque Wrench 1783 -
2-10Nm - VAG1783-
♦ A/C Service Station -
VAS6007A- (or succeeding
model)
♦ Torque Wrench 1783 - 1/4"
Drive Ratchet - VAS6234-
♦ Refrigerant Sockets -
T10364-
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9. Special Tools 157

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10. Revision History 159

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.
•= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.
•= Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always
check with your authorized Volkswagen retailer parts department for the latest information.
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wa oestransmission vehicle, it will be necessary to gen AG d
•= Any time the battery has been disconnected
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b Module (TCM) basic settings using arathe VAG 1551 Scan Tool (ST).
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•= Never work under a unless it is solidly supported on a vehicle
lifted
for the purpose. Do not support
ss
ac
stands designed
ce
a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
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nl
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vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.
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•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
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battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and wit
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become inoperable, even if the correct code is used in a later attempt.
hole
spec
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•= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
t to the co
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
starting the vehicle while you are under it.
rrectness of i
•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
l purpos
others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
being fully alert.
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•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
m
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•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
o
his
te
goggles, gloves and other protective clothing whenever the job requires working with harmful substances.
a
do
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for
en
•=
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Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
n
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machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe . Cop py
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injury could result. opy
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•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
Prote AG.
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
AG. Volkswagen AG d
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Cautions & Warnings ss autho eo
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•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
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Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled
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fuel or oil.
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•= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
h re
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grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.
spec
Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.
es, in part or in w
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•= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be
crushed by heavy parts.
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•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
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•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
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might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
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•= 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.
•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of
the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
govern the disposal of wastes.
•= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be
serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
trained in related safety precautions, and familiar with regulations governing the discharging and disposal of
automotive chemical refrigerants.
•= 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 vehicle, never hold test equipment in your hands or lap while the
vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.
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Page 3 of 3
Version 1.0

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Service

Service Department. Technical Information

00 - General, Technical Data

All rights reserved.

Copyright © 2016 Volkswagen AG, Wolfsburg D4B804111B6

00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5.1 Refrigerant R134a Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5.2 Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5.3 Oil Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.3 Recirculation Door Motor V113 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Sensor G645 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.4 Dust and Pollen Filter, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.11 Air Guide for Center Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.2 Overview - Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.3 Refrigerant Circuit Pressure Sensor G805 , Removing and Installing . . . . . . . . . . . . . . . . 36

2.6 Dryer Bag, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

3.3 A/C Compressor, Removing and Installing on Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

3.5 Pressure Relieve Valve on A/C Compressor, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 67

4 Front Heater and A/C Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

4.1 Overview - Heater and A/C Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

4.3 Overview - Evaporator Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

5.4 Air Intake Duct, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

9 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

10 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

00 – General, Technical Data

1.1 Heater and A/C Unit Identification

1.1.1 Heater and A/C Unit Identification, Va‐

Correct allocation must be observed when replacing components.

– Remove the left footwell center console trim. Refer to ⇒ Body

1.1.2 Heater and A/C Unit Identification, Den‐

Correct allocation must be observed when replacing components.

Interchanging components from different manufacturers is not

– Remove the left footwell center console trim. Refer to ⇒ Body

Interior; Rep. Gr. 68 ; Center Console; Overview - Center

2 Rep. Gr.00 - General, Technical Data

2.1 Odors in Vehicles with A/C System

♦ Numerous procedures varying in their application and effect

2.2 Vehicles with Start/Stop System Gener‐

⇒ “3.2 Start/Stop System Safety Precautions”, page 5 .

If the vehicle has a start-stop system, perform the following ter‐

mination conditions to deactivate the start-stop function:

♦ Use the Start/Stop button to switch off the Start/Stop System.

♦ The battery state of charge does not make it possible to start

the engine again (start voltage prediction).

♦ The heated front windshield is active.

♦ The selected temperature deviates more than 8 °C (46 °F)

♦ The engine RPM exceeds 1,200 RPM.

♦ The Generator - C- is faulty, for example, the ribbed belt is torn.

♦ The coolant temperature is not in the specified range of 25 °C

to 100 °C (77 to 212 °F).

♦ Increasing the blower speed by more than four steps.

Do not bend or kink refrigerant lines excessively.

Danger due to refrigerant coming out under pressure.

2.4 Type Label

♦ In deviation from the type label, a filling tolerance of 500 ± 15

4 Rep. Gr.00 - General, Technical Data

3.1 Handling Refrigerant Safety Precau‐

♦ ELSA contains all safety precautions regarding performing re‐

Do not bend or kink refrigerant lines excessively.

On vehicles with the Start/Stop System, the engine could start

automatically and cause serious personal injury.

♦ If the Start/Stop System is activated (recognizable by a

message in the instrument cluster), it is possible to start