D4B804B254B-Heating Ventilation and Air Conditioning

Service
Repair Manual
Golf 2013 ➤
Golf Variant 2014 ➤
Heating, Ventilation and Air Conditioning
Edition 10.2014 AG. Volkswagen AG d
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Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
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00 - General, Technical oris Data
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80 - Heating, Ventilation
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87 - Air Conditioning
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2014 Volkswagen AG, Wolfsburg D4B804B254B

Golf 2013 ➤ , Golf Variant 2014 ➤
Heating, Ventilation and Air Conditioning - Edition 10.2014
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Handling Refrigerant Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Start/Stop System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 High Voltage System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 Safety Precautions near High Voltage Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Cooling System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.6 Parking/Auxiliary Heater Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Heater and A/C Unit Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Odors in Vehicles with A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Vehicles with Start/Stop System General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Type Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Working on the Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Refrigerant Circuit Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Heating Output, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.4 Cooling Output, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5 Technical Data .......................................................... 62
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80 - Heating, Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
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1 Component Location Overview - Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

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1.1 Component Location Overview - Components Outside of Passenger Compartment . . . . 63

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1.2 Component Location Overview - Components Inside Front Passenger Compartment . . . . 67

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2 Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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2.1 Component Location Overview - Front Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

2.2 Temperature Regulator Door Motor V68 with Temperature Regulator Door Motor Position
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Sensor G92 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

2.3 Recirculation Door Motor V113 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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3.1 Overview - Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

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3.2 Fresh Air Blower V2 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

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3.3 Fresh Air Blower Control Module J126 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 79
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3.4 Dust and Pollen Filter, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

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3.5 Heater, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

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3.6 Heater, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

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Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
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3.9 Heater Core, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.10 Partition, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4 Air Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.1 Overview - Air Routing and Air Distribution in Passenger Compartment . . . . . . . . . . . . . . 81
4.2 Driver Side Footwell Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.3 Front Passenger Side Footwell Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 81
4.4 Rear Footwell Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Contents i
4.5 Fresh Air Intake, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

4.6 Fresh Air Intake Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.7 Air Intake Duct, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.8 Passenger Compartment Forced Air Extraction, Checking . . . . . . . . . . . . . . . . . . . . . . . . 82
4.9 Passenger Compartment Forced Air Extraction, Removing and Installing . . . . . . . . . . . . 82
4.10 Air Guide for Defrost Air Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.11 Center Instrument Panel Vent Air Guide, Removing and Installing . . . . . . . . . . . . . . . . . . 82
5 Display and Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.1 Overview - Display and Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.2 Display and Control Head, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
6 Additional Components for Control and Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
6.1 Outside Air Temperature Sensor G17 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 85
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2 Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
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2.1 System Overview - Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
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2.2 Overview - Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
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2.3 Refrigerant Circuit Pressure Sensor G805 , Removing and Installing . . . . . . . . . . . . . . . . 109
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2.4 Expansion Valve, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
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2.5 Condenser, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
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2.6 Dryer Bag/Dryer Cartridge, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.7 Low Pressure Side Refrigerant Line Balance Weight, Removing and Installing . . . . . . . . 126
2.8 Evacuating and Charging Valve, Removing and Installing, Low and High Pressure Side . . 127
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2.9 A/C Pressure/Temperature Sensor G395 , Removing and Installing . . . . . . . . . . . . . . . . . . 128
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2.10 Heater and A/C Unit Refrigerant Cut-Off Valve N541 , Removing and Installing . . . . . . . . 129
2.11 High Voltage Battery Heater Core Refrigerant Cut-Off Valve N542 , Removing and
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Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
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2.12 High Voltage Battery Heat Exchanger, Removing and Installing . . . . . . . . . . . . . . . . . . . . 133
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2.13 Refrigerant Lines with Inner Heat Exchanger, Removing and Installing . . . . . . . . . . . . . .
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2.14 Refrigerant Line with Restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

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2.15 Condenser/Evaporator Refrigerant Line, Removing and Installing . . . . . . . . . . . . . . . . . . 142

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2.16 Condenser/A/C Compressor Refrigerant Line, Removing and Installing . . . . . . . . . . . . . . 144

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2.17 A/C Compressor/Evaporator Refrigerant Line, Removing and Installing . . . . . . . . . . . . . . 146

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3 A/C Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
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3.1 Overview - A/C Compressor Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
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3.2 Overview - Belt Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
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3.3 A/C Compressor, Removing and Installing on Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
3.4 A/C Compressor, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
3.5 A/C Compressor Fuse S355 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3.6 Pressure Relieve Valve on A/C Compressor, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3.7 Belt Pulley, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
4 Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
4.1 Component Location Overview - Front Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
4.2 Temperature Regulator Door Motor V68 with Temperature Regulator Door Motor Position
4.3 Defroster Door Motor V107 with Defroster Door Motor Position Sensor G135 , Removing and
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
4.4 Recirculation Door Motor V113 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 183
4.5 Left Temperature Door Motor V158 with Left Temperature Door Potentiometer/Actuator
G220 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
4.6 Right Temperature Door Motor V159 with Right Temperature Door Potentiometer/Actuator
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4.7 Fresh Air/Recirculating Air/Back Pressure Door Motor V425 with Fresh Air/Recirculating Air/
Back Pressure Door Motor Position Sensor G644 , Removing and Installing . . . . . . . . . . 195
4.8 Front Air Distribution Door Motor V426 with Air Distribution Door Motor Position Sensor
4.9 Air Distribution Door Motor V428 with Position Sensor Air Distribution Door Motor Position
4.10 Air Distribution Door Adjuster, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
5 Front Heater and A/C Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
5.1 Overview - Heater and A/C Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
5.2 Overview - Attachments for Heater and A/C Unit and Air Intake Housing . . . . . . . . . . . . . . 218
5.3 Overview - Evaporator Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
5.4 Overview - Air Distribution Housing Doors and Partitions . . . . . . . . . . . . . . . . . . . . . . . . . . 222
5.5 Heater and A/C Unit, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
5.6 Heater and A/C Unit, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
5.7 Air Distribution Housing, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
5.8 Heater and A/C Unit Bracket, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
5.9 Evaporator, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
5.10 Fresh Air Blower Control Module J126 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 233
5.11 Dust and Pollen Filter, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
5.12 Fresh Air Blower V2 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
5.15 Heater Core, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
5.16 Heater Core Coolant Pipes, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
5.17 Evaporator TemperaturenSensor AG. VolksG308
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5.19 Condensation ise Water Drain, Removing and Installingante. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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6.1 Overview - Air Routing and Air Distribution in Passenger Compartment . . . . . . . . . . . . . . 271
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6.2 Fresh Air Intake, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

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6.3 Fresh Air Intake Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

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6.4 Air Intake Duct, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

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6.5 Driver Side Footwell Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

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6.6 Front Passenger Side Footwell Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 277
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6.7 Rear Footwell Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

6.8 Rear Center Console Vent Air Guide Channel, Removing and Installing . . . . . . . . . . . . . . 279
6.9 Passenger Compartment Forced Air Extraction, Checking . . . . . . . . . . . . . . . . . . . . . . . . 280
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6.10 Passenger Compartment Forced Air Extraction, Removing and Installing . . . . . . . . . . . . 281
6.11 Air Guide for Defrost Air Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 282
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6.12 Center Instrument Panel Vent Air Guide, Removing and Installing . . . . . . . . . . . . . . . . . . 282
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7 Coolant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

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7.1 High Voltage Heater (PTC) Z115 , Incorporation in Coolant Circuit . . . . . . . . . . . . . . . . . . 283
atio
m
7.2 High Voltage Battery Heat Exchanger Incorporation in the High Voltage System Coolant
o
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Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
thi
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7.3 High Voltage Battery Coolant Valve N688 , Removing and Installing . . . . . . . . . . . . . . . . 290
iv
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pr
7.4 High Voltage Battery Coolant Pump V590 , Removing and Installing . . . . . . . . . . . . . . . . 291
um
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7.5 High Voltage Heater (PTC) Z115 / High Voltage Heater (PTC) Control Module J848 ,
t.
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8 Display and Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
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8.1 Component Location Overview - Display and Control Head . . . . . . . . . . . . . . . . . . . . . . . . 297
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8.2 Display and Control Head, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
9 Additional Components for Control and Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
9.1 Sunlight Photo Sensor G107 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Contents iii
9.2 Air Quality Sensor G238 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304

9.3 Function of Air Quality Sensor G238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
9.4 Outside Air Temperature Sensor G17 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 307
9.5 A/C Humidity Sensor G260 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
9.6 Left Vent Temperature Sensor G150 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 307
9.7 Right Vent Temperature Sensor G151 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 308
9.8 Footwell Vent Temperature Sensor G192 , Removing and Installing . . . . . . . . . . . . . . . . 309
10 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
11 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
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iv Contents
00 – General, Technical Data

1 Safety Precautions
(Edition 10.2014)
⇒ “1.1 Handling Refrigerant Safety Precautions”, page 1
⇒ “1.2 Start/Stop System Safety Precautions”, page 1
⇒ “1.3 High Voltage System Safety Precautions”, page 1
⇒ “1.4 Safety Precautions near High Voltage Components”, page
2
⇒ “1.5 Cooling System Safety Precautions”, page 2
⇒ “1.6 Parking/Auxiliary Heater Safety Precautions”, page 2
1.1 Handling Refrigerant Safety Precau‐

tions
There Is A Risk of Frostbite Through Refrigerant.
When working on the Air Conditioning (A/C) system refrigerant
can come out under pressure. Frostbite on the skin and other
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parts of the body is possible. ksw
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– Wear protective gloves. d by ua
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– Wear protective eyewear.
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– Extract refrigerant and open the refrigerant circuit immediate‐ ce
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– If the refrigerant was extracted more than 10 minutes in the ab

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past and the refrigerant circuit was not opened, extract the re‐ wit
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frigerant again. The refrigerant circuit pressure comes from

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evaporation.
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Risk of Destroying the Refrigerant Lines.

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Destroying the refrigerant lines by ripping in the inner foil is pos‐

sible.
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– Never bend the refrigerant lines to a radius smaller than r =

100 mm.
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1.2 Start/Stop System Safety Precautions

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There Is A Risk of Injury From the Engine Starting Unexpectedly.

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The engine can start unexpectedly on vehicles with an activated

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Start/Stop System. A visible message appears in the instrument

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cluster indicating whether the Start/Stop System is activated.

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– Deactivate the Start/Stop System: Turn off the ignition.

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1.3 High Voltage System Safety Precau‐ Cop py
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Extremely Dangerous Due to High Voltage.
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The high voltage system is under high voltage. Death or serious

bodily injury by electric shock.
– Individuals with electronic/medical life- and health sustaining
machines in or on their person cannot perform any work on
high voltage systems. Life- and health sustaining machines
are for example pain killer pumps, implanted defibrillators,
pacemakers, insulin pumps, and hearing aids.
1. Safety Precautions 1
– Have the high voltage system de-energized by a qualified per‐

son.
There Is A Risk of Injury From the Engine Starting Unexpectedly.
On electric - hybrid vehicles an active ready mode is difficult to
identify. Parts of the body can be clamped or pulled.
– Turn off the ignition.
– Place the ignition key outside of the vehicle interior.
Risk of Damaging the High Voltage Cables.
Misuse can damage the insulation of high voltage cables or high
voltage connectors.
– Never support objects on the high voltage cables and the high
voltage connectors.
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– Never support tools on the highsvoltage
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– Never sharply bend or
thokink the high voltage cables.
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– When connecting spay
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attention to the coding of the high volt‐
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1.4 Safety Precautions near High Voltage
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Extremely Dangerous Due to High Voltage.
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The high voltage system is under high voltage. Electrocution can
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cause death or very serious personal injury from damages high
voltage components and high voltage cables.
– Perform a visual inspection of the high voltage components
rrectness of i
and the high voltage cables.

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– Never use tools that are for cutting, deformed, or sharp edged.
– Never use welding, soldering, thermal adhesive or hot air.
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1.5 Cooling System Safety Precautions

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There Is A Risk of Burning from Hot Coolant

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The cooling system is under pressure when the engine is warm.

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There is a risk of scalding from hot steam and coolant.

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– Wear protective gloves. t. Cop py
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– Wear protective eyewear. yri
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– Reduce the pressure: cover the coolant reservoir cap with a
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cloth and carefully open.
1.6 Parking/Auxiliary Heater Safety Precau‐

tions
There Is A Risk of Fire and Explosion By the Parking/Auxiliary
Heater
In areas that are subject to fire and explosion, a spark or the high
temperature of the parking/auxiliary heater can ignite a fire or
cause an explosion. It is possible to be burned.
– In areas that are subject to fire and explosion, switch off the
parking/auxiliary heater.
Risk of Poisoning from the Exhaust Fumes
The parking/auxiliary heater produces poisonous exhaust fumes.
Respiratory system injury and poisoning are possible.
2 Rep. Gr.00 - General, Technical Data

– Only switch on the parking/auxiliary heater in closed areas

with an exhaust extracting system.
– Switch off the parking/auxiliary heater in closed areas with no
exhaust extracting system.
Risk of Damage By Engine Start
It is possible to damage the parking/auxiliary heater when fuel
system components are removed or opened (for example,wage
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– Never start the engine when fuel system
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moved or opened. sa
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Malfunctions Due to Air In the Fuel Supply
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After working on the fuel tank or the fuel delivery unit, the metering
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pump draws in air and sends the air to the parking/auxiliary heat‐
ility
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er. Parking/auxiliary heater malfunctions due to air in the parking/
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auxiliary heater fuel supply are possible.
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– Fill the fuel extraction tube with fuel.
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es, in part or in w
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Risk of Accident and Injury By the Activated Parking/Auxiliary
Heater Timer
For vehicles with an activated timer for the parking/auxiliary heat‐
rrectness of i
er, the parking/auxiliary heater can turn on unintentionally. Poi‐
soning by exhaust fumes and burns from hot parking/auxiliary
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heater components are possible, as well as the risk of fire and

explosion due to high temperatures.
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– Deactivate the timer for the parking/auxiliary heater.
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1. Safety Precautions 3
2 Identification
⇒ “2.1 Heater and A/C Unit Identification”, page 4
2.1 Heater and A/C Unit Identification

⇒ “2.1.1 Heater and A/C Unit Identification, Valeo”, page 4
⇒ “2.1.2 Heater and A/C Unit Identification, Denso”, page 4
2.1.1 Heater and A/C Unit Identification, Va‐

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Correct allocation must be observed when replacing components.

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Interchanging components from different manufacturers is not
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permitted. Refer to the Parts Catalog.
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– Remove the left footwell center console trim. Refer to ⇒ Body
h re
Interior; Rep. Gr. 68 ; Center Console; Overview - Center
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Console .
es, in part or in w
t to the co
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.
rrectness of i
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2.1.2 Heater and A/C Unit Identification, Den‐
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Note
Correct allocation must be observed when replacing components.

Interchanging components from different manufacturers is not
permitted. Refer to the Parts Catalog.

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 Denso.
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2. Identification 5
3 General Information
⇒ “3.1 Odors in Vehicles with A/C System”, page 6
⇒ “3.2 Vehicles with Start/Stop System General Information”,
page 6
⇒ “3.3 Type Label”, page 7
3.1 Odors in Vehicles with A/C System

♦ If there are unpleasant odors coming from the evaporator,
clean the evaporator.
♦ For cleaning the evaporator, Volkswagen has tested and ap‐
proved the Ultrasound A/C Cleaner - VAS6189B- as well as
the Suction Feed Spray Gun - VAG1538- with a suitable spray
nozzle.
♦ Instructions for cleaning the evaporator are provided with the
tools.
♦ As soon as Volkswagen approves new procedures, the rele‐
vant notes are to be found in the repair manual. Refer to ⇒
Refrigerant R134a Servicing; Rep. Gr. 00 ; Concerns .
3.2 Vehicles with Start/Stop System Gener‐

al Information
Read safety precautions when working on vehicles with start/stop
system. Refer to AG. Volkswagen AG d
agen page 1 .
⇒ “1.2 Start/Stop System Safety Precautions”, oes
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If the vehicle has a start-stop system,
ris
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utho the start-stop function:
mination conditions to deactivate eo
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♦ Use the Start/Stop button to switch off the Start/Stop System.
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♦ The battery state of charge does not make it possible to start

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the engine again (start voltage prediction).

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♦ The defrost function is active.

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♦ The heated front windshield is active.

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♦ The selected temperature deviates more than 8 °C (46.4 °F)

t to the co
from the actual temperature inside the vehicle.

♦ The engine RPM exceeds 1,200 RPM.
rrectne
♦ The Generator - C- is faulty, for example, the ribbed belt is torn.

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

s o
to 100 °C (77 to 212 °F).

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♦ Increasing the blower speed by more than 4 steps.

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Further information
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♦ For more information, refer to Self Study Program, Start/Stop

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3.3 Type Label

Type Label for the Refrigerant R134a and Refrigerant Oil Ca‐
pacities.
1- Refrigerant name
2- Refrigerant capacity
3- Refrigerant oil name
Note
♦ A filling tolerance of 500 ± 15 grams may deviate from the type

label.
♦ Refrigerant R134a and refrigerant oil capacities. Refer to
⇒ “5 Technical Data”, page 62 .
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3. General Information 7
4 Repair Information
⇒ “4.1 Working on the Refrigerant Circuit”, page 8
⇒ “4.2 Refrigerant Circuit Seals”, page 8
⇒ “4.3 Heating Output, Checking”, page 9
⇒ “4.4 Cooling Output, Checking”, page 31
4.1 Working on the Refrigerant Circuit

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Work performed that requires the circuit to be openedlkmust
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be performed by trained personnel. db
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ELSA contains all information regarding performing
utho repairs on eo
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vehicles with air conditioning and workingsswith
a refrigerant. Refer c
to ⇒ Refrigerant R134a Servicing; Rep. Gr. 00 ; A/C System,
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General Information; A/C System and Refrigerant R134a Safety
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Precautions .
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Information on tools for repairs in vehicles with climate control
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system can be found in ELSA. Refer to ⇒ Refrigerant R134a
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Servicing; Rep. Gr. 00 ; Special Tools .
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ELSA contains usage information for the A/C Service Station
es, in part or in w
t to the co
when working on vehicles with an A/C system. Refer to ⇒ Re‐
frigerant R134a Servicing; Rep. Gr. 00 ; A/C Service Station,
Working with .
rrectness of i
Under certain conditions, the dryer bag should no longer be re‐
placed each time the refrigerant circuit is opened. Refer to ⇒
l purpos
Refrigerant R134a Servicing; Rep. Gr. 00 ; Components, Re‐

placing in ELSA.
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The operation and procedure for flushing with refrigerant is de‐

m
a
scribed in ELSA . Refer to ⇒ Refrigerant R134a Servicing; Rep.
com
tio
Gr. 00 ; Refrigerant Circuit, Removing Contaminants; Refrigerant
n in
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Circuit, Flushing (Cleaning) with Refrigerant R134a .
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4.2 Refrigerant Circuit Seals do

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♦ Replace the seals.
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♦ Coat the seals with refrigerant oil before installing.
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♦ Make sure seals are seated properly on pipe or in groove. cted agen
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♦ Perform the work under clean conditions (even the smallest

deposit such as a hair may cause a leak).
Note
♦ Only install seals that are resistant to refrigerant R134a and

corresponding refrigerant oil. These seals are color-coded to
avoid mistakes (currently “red”, “light purple” or “dark purple”).
Refer to the Parts Catalog.
♦ The dimensions -a and b- are different depending on the com‐
ponent location of the seal. Refer to the Parts Catalog.
♦ In addition to the color-coded seals, black seals are also in‐
stalled during production for certain connections.

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4.3 Heating Output, Checking
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⇒ “4.3.1 Information on Checking Heat Output and Tools Re‐
pt
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quired”, page 9
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⇒ “4.3.2 Heating Output and Temperature Door Actuation, Check‐
ility
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ing, Vehicles without A/C System”, page 11
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ing, Vehicles with Manual Climate Control System”, page 14
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ing, Vehicles with Automatic Climate Control System (Without
High Voltage System)”, page 18
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ing, Vehicles with High Voltage System and Automatic Climate
ss
Control System”, page 23
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4.3.1 Information on Checking Heat Output
mer
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and Tools Required
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Note
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This repair manual only outlines the checking procedure. Perform
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the detailed function test for the heating as described in the Gui‐
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ded Fault Finding using the Vehicle Diagnostic Tester in the
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“Guided Fault Finding” function.
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Special tools and workshop equipment required

♦ Vehicle Diagnostic Tester
♦ A standard thermometer (for temperature measurements, if
necessary a thermometer with two measuring probes for si‐
multaneous measurement, for example, for temperature on
the right and left)
Note
If the coolant system is not bled completely after being filled, then
air can get into the heater core for the heater. This will reduce the
heating output and noises may result or the customer may com‐
plain there are different air temperatures coming out of the vents.
Corrective action for poor heating output or noises from coolant

circuit:
• For vehicles without a high voltage system, perform a test
drive at high engine speed (at least 10 minutes, engine speed
above 2500 RPM), while selecting a low gear to prevent ex‐
cessive vehicle speed.
• If the customer complains of poor heating output at certain
engine speeds, check the incorporation of the heater core for
the heater in the engine coolant circuit. Refer to ⇒ Rep. Gr.
19 ; Coolant System/Coolant (Connection Diagram for Coolant
Hoses).
• If the customer complains of poor heating output on a vehicle
with a high voltage system, check the incorporation of the
heater core for the heater in the coolant circuit as well as the
activation and the function of the different shut-off valves,
coolant pumps and the High Voltage Heater (PTC) - Z115-
before performing the heating output test using the Vehicle
Diagnostic Tester in the “Guided Fault Finding” (for the Air
Conditioning (A/C) system and the engine control module).
Refer to
4. Repair Information 9
⇒ “7.1 High Voltage Heater (PTC) Z115 , Incorporation in

Coolant Circuit”, page 283 and ⇒ Rep. Gr. 19 ; Coolant Sys‐
tem/Coolant (Connection Diagram for Coolant Hoses).
Note
♦ For vehicles without an A/C system with a Start-Stop System,

the stop function is prevented depending on the setting on the
Heater Control Module - J65- control head (for example, the
heater is on). As soon as there is a request for heating, the
engine is started.
♦ In vehicles with a manually regulated A/C system and a Start-
Stop System, the stop function is prevented depending on the
setting on the A/C Control Module - J301- control head (for
example, the heater is on). As soon as there is a request for
heating, the engine is started. In cooling mode, the A/C Control
Module - J301- does not limit the stopenfunction.
AG. Volkswagen AG
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♦ If the A/C Humidity Sensor -bG260- is not installed on vehicles
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with a A/C Control Module ris - J301- , a permissible stop time is
ed ran
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currently calculated by au
t characteristic curves which are influ‐
ho
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enced by the measured outside air temperature, the “recircu‐
ac
ss
lated-air mode” function and operating status of the windshield
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wipers. The calculated time must be greater than 20 seconds
an
itte
so that the stop function is permitted by the A/C Control Mod‐
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ule - J301- . The stop time can be shortened at a lower outside
ility
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air temperature, when recirculated-air mode is active and/or
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when raining to prevent the front and door windows from fog‐
h re
ging up. If the calculated time for the stop function is less than
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spec
20 seconds, this is prevented.
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♦ In vehicles with an automatically regulated A/C system and a t to the co

Start-Stop System, the stop function is prevented depending
on the setting on the Climatronic Control Module - J255- con‐
rrectness of i
trol head. If, for example, “Defrost” is selected, the stop func‐
tion is not possible or will be interrupted and the engine will
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start. The same applies in the case of heating and cooling. The
difference between the set specified and actual temperature
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exceeds a certain value. Use the Vehicle Diagnostic Tester in

the “Guided Fault Finding” Function.
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♦ Depending on the different conditions, the coolant which flows

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through the heater core for the heater in the A/C unit is warmed
or
his
e
either by the engine or by the High Voltage Heater (PTC) -

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Z115- on vehicles with a high voltage system. Refer to

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t.
Coolant Circuit”, page 283 , ⇒ Rep. Gr. 19 ; Coolant System/
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Coolant (Connection Diagram for Coolant Hoses) and use the
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Vehicle Diagnostic Tester in the “Guided Fault Finding” func‐
ht
pyri by
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tion (for the A/C system and the engine control module).
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Prote AG.
♦ Depending on the engine version, an After-Run Coolant Pump

- V51- may be installed in the coolant circuit to support the
engine coolant pump on vehicles with a high voltage system.
Refer to ⇒ Rep. Gr. 19 ; Coolant System/Coolant (Connection
Diagram for Coolant Hoses) and ⇒ Wiring diagrams, Trouble‐
shooting & Component locations. The After-Run Coolant
Pump - V51- can be actuated in “stop mode” (engine stopped)
to maintain the coolant flow rate through the heater core for
the heater on vehicles with a Start/Stop System.
♦ Depending on the engine version, a Coolant Shut-Off Valve -
N82- may be installed in the coolant circuit on vehicles without
a high voltage system. Refer to ⇒ Rep. Gr. 19 ; Coolant Sys‐
tem/Coolant (Connection Diagram for Coolant Hoses) and
⇒ Wiring diagrams, Troubleshooting & Component locations.
The Coolant Shut-Off Valve - N82- is then activated by the
Engine Control Module - J623- , for example, when heating
output is not requested by the Heater Control Module - J65- /

AG. Volkswagen AG d
agen oes
olksw not
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d by ara
orise Golf 2013 ➤ , Golf nVariant
tee 2014 ➤
h
aut Heating, Ventilation and Air Conditioning - Edition or
a 10.2014
ss c
ce
e
nl
A/C Control Module - J301- / Climatronic Control Module -
pt
du
an
J255- and the engine is still cold. Use the Vehicle Diagnostic
itte
y li
Tester in the “Guided Fault Finding” function (for the engine
erm
ab
ility
control module). With an activated Coolant Shut-Off Valve -
ot p
wit
N82- , no warmed up coolant can flow the heater core for the
, is n
h re
heater.
hole
spec
♦ On vehicles with a high voltage system different shut-off
es, in part or in w
t to the co
valves, coolant pumps and a High Voltage Heater (PTC) -
Z115- are installed in the refrigerant circuit. These compo‐
nents make sure that also in electric driving mode the vehicle
interior (with the engine switched off) can be heated. Refer to
rrectness of i
l purpos
Coolant Circuit”, page 283 .
4.3.2 Heating Output and Temperature Door
nform
ercia
Actuation, Checking, Vehicles without

m
at
om
A/C System
ion
c
in t
or
his
e

at
do
riv
quired”, page 9
p
cum
for
Test Requirements
en
ng
t.
yi Co
op py
• Coolant circuit bled according to specifications. Refer to ⇒ t. C rig
gh ht
Rep. Gr. 19 ; Coolant System/Coolant . yri
p by
o Vo
by c lksw
cted
• All air guides, covers and seal OK and properly installed
agen
Prote AG.
• Seal between engine compartment, hood and plenum cham‐

ber is OK and installed correctly. To check, refer to ⇒ Body
Exterior; Rep. Gr. 50 ; Bulkhead ; (Overview - Plenum Cham‐
ber Cover).
• If installed: After-Run Coolant Pump - V51- and the Coolant
Shut-Off Valve - N82- function is OK.
• The air flow through the dust and pollen filter is not affected by
dirt in the filter. To check, refer to
⇒ “5.11 Dust and Pollen Filter, Removing and Installing”, page
234 .
• The air intake for the heater (in fresh-air and recirculated-air
modes) is not affected by dirt or retrofitted components.
• The vehicle is not exposed to sunlight.
• Engine is warm; coolant temperature is greater than 80 °C
(176 °F).
• The Diagnostic Trouble Code (DTC) memory for the Heater
Control Module - J65- control head was checked and erased
and the basic setting was performed using the Vehicle Diag‐
nostic Tester in the “Guided Fault Finding” function.
• The coding and adaptation of the Heater Control Module - J65-
control head was checked using the Vehicle Diagnostic Tester
in the “Guided Fault Finding” function.
• Vehicles with TDI engine: the actuation and function of the
Auxiliary Heater Heating Element - Z35- is OK. Use the Vehi‐
cle Diagnostic Tester in the “Guided Fault Finding” function.
• Vehicles with a gasoline engine and an Auxiliary Heater Heat‐
ing Element - Z35- (introduction not yet finalized): the actua‐
tion and function of the Auxiliary Heater Heating Element -
Z35- is OK. Use the Vehicle Diagnostic Tester in the “Guided
Fault Finding” function.
• Vehicles with a parking heater: the actuation and function of
the parking heater is OK. Use the Vehicle Diagnostic Tester
Checking
– Close the hood, doors, windows and sunroof.
– Open all instrument panel vents.
– Start the engine and adjust the following settings on the Heater
Control Module - J65- control head.
• Turn the temperature setting regulator -21- to the “cold” stop.
• Set the air distribution regulator -4- to “instrument panel vent”.
• Turn the fresh air blower regulator -16- to the maximum speed.
– Measure the ambient temperature.
– Measure the temperature of the air coming out of the left and
right instrument panel vents with a thermometer.
Specified values:
. Volkswagen AG
gen AG does
• After five minutes the measured values must be aVomaximum
lksw
a
not
of 15 °C (59 °F) greater than the measured ambient
ed
by temper‐ gu
ara
ature. ho
ris nte
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t
au ra
• The temperature deviation between the
ss left and right side is c
less than 8 °C (46.4 °F).
ce
le
un
pt
an
d
itte
If the target values are not reached, check the following:
y li
erm
ab
ility
♦ Check the seal between the engine compartment, engine
ot p
wit
hood and plenum chamber and repair if necessary. Refer to
is n
h re
⇒ Body Exterior; Rep. Gr. 50 ; Bulkhead ; (Plenum Chamber
ole,
Cover Assembly Overview).
spec
t to the co
♦ Repeat the test while measuring the temperature of air drawn
in via the fresh air intake for the heater in the plenum chamber
with one of the two temperature sensors with the engine hood
closed. The permissible increase of air temperature in the
rrectne
heater (between the air inlet in the fresh air intake and the air
outlet from the instrument panel vents) is a maximum of 10 °
ss
C (50 °F).
o
cial p
f in
If the temperature in the heater increases more than 10 °C (50 °
form
mer
F), check the following: atio

om
♦ Actuation and function of the Temperature Regulator Door

n
c
i
or
Motor - V68- using the Vehicle Diagnostic Tester in the “Gui‐

thi
te
sd
ded Fault Finding” function.

iva
o
pr
cum
r
♦ Function of the temperature door in the heater. Refer to

fo
en
ng
⇒ “5.7 Air Distribution Housing, Removing and Installing”,

t.
yi Co
op
page 230 .
C py
ht. rig
rig ht
py by
♦ Foam seal on the heater core for the heater. Refer to co Vo
by lksw
⇒ “5.15 Heater Core, Removing and Installing”, page 244 .
cted agen
Prote AG.

– Set the highest possible temperature.

• Turn the temperature setting regulator -21- to the “warm” stop.
Target values with an engine temperature of about 90 °C (194 °
F):
• The temperature of the air from the instrument panel vents n AG. Volkswagen A
goes above 55 °C (131 °F). olks
wage
G do
es n
o V t gu
by ara
• The temperature deviation between the left and rright
ise
d side is
nte
less than 8 °C (46.4 °F). ut
ho eo
ra
a c
ss
ce
le
un
pt
an
♦ Coolant circuit bleeding. Refer to ⇒ Rep. Gr. 19 ; Coolant
d
itte
y li
System/Coolant .
erm
ab
ility
ot p
♦ Incorporation of the heater core for the heater into coolant cir‐
wit
is n
cuit. Refer to ⇒ Rep. Gr. 19 ; Coolant System/Coolant
h re
ole,
(Connection Diagram for Coolant Hoses).
spec
♦ Foam seal on the heater core for the heater. Refer to
t to the co
rrectne
ss
o
cial p
f
inform
page 230 .
mer
atio
♦ Engine coolant thermostat. The engine coolant may not heat
om
n
properly if the coolant thermostat is malfunctioning. Refer to
c
i
or
n
⇒ Rep. Gr. 19 ; Coolant Pump/Thermostat .
thi
te
sd
iva
o
r
♦ Engine coolant pump. Refer to ⇒ Rep. Gr. 19 ; Coolant Pump/

p
cum
r
fo
Thermostat .
en
ng
t.
yi Co
op
♦ If installed: check the function of the After-Run Coolant Pump C py
t. rig
- V51- and the Coolant Shut-Off Valve - N82- using the Vehicle
gh ht
pyri by
Diagnostic Tester in the “Guided Fault Finding” function.
co Vo
by lksw
cted agen
Prote AG.
Note
♦ For vehicles without an After-Run Coolant Pump - V51- , set

the engine speed to 2000 RPM and repeat the test if neces‐
sary. If the air temperature goes above 55 °C (131 °F) when
repeating the test at a higher engine speed, this indicates that
there is too little coolant flowing through the heater core for the
heater. Cause: The delivery rate of the engine coolant pump
is too low while idling or the incorporation of the heater core
for the heater into the coolant circuit is not according to the
specification. Refer to ⇒ Rep. Gr. 19 ; Coolant System/Cool‐
ant (Connection Diagram for Coolant Hoses).
♦ If too little warmed up coolant flows through the heater core
for the heater, the required heat output is not reached.
– Set the lowest possible temperature.

AG. Volkswagen
• Turn the temperature setting regulator -21- toagthe
lksw
en “cold” stop. AG doe
sn
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– Measure the temperature of the air risecoming out of the left and
db ran
tee
right instrument panel vents with thoa thermometer. or
s au ac
Specified values: s
ce
e
nl
pt
• After five minutes the measured values must be a maximum du
an
itte
y li
of 15 °C (59 °F) greater than the measured ambient temper‐
erm
ab
ature.
ility
ot p
wit
, is n
• The temperature deviation between the left and right side is
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

page 230 .
nf
ercia
or
m
m
atio
om
n in
or c
♦ Measured value for the Evaporator Temperature Sensor -
thi
e
G308- using the Vehicle Diagnostic Tester in the “Guided Fault

t
sd
iva
o
Finding” function.
r
rp
cu
o
m
f
en
ng
t.
yi Co
4.3.3 Heating Output and Temperature Door Cop py
t. rig
gh
Actuation, Checking, Vehicles with Man‐
ht
pyri by
Vo
co lksw
by
ual Climate Control System
cted agen
Prote AG.
Refer to
quired”, page 9
Test Requirements
• Coolant circuit bled according to specifications. Refer to ⇒
Rep. Gr. 19 ; Coolant System/Coolant .
ber Cover).
234 .
• The air intake for the heater and Air Conditioning (A/C) Unit
(in fresh air and recirculating air modes) is not affected by dirt
or retrofitted components.
• The A/C system cooling output was checked and is OK. Refer
to
⇒ “4.4.3 Cooling Output, Checking, Vehicles with Manual Cli‐
mate Control System”, page 36 .
(176 °F).

• The Diagnostic Trouble Code (DTC) memory for the A/C Con‐
trol Module - J301- control head was checked and erased and
the basic setting was performed in the “Guided Fault Finding”
function on the Vehicle Diagnostic Tester .
• The coding and adaptation of the A/C Control Module - J301-
control head was checked using the Vehicle Diagnostic Tester AG. Volkswagen
in the “Guided Fault Finding” function. lksw
agen AG do
es n
o ot g
yV ua
• Vehicles with TDI engine: the actuation and function
ris
ed of the
b ran
tee
Auxiliary Heater Heating Element - Z35- is OK. th Use the Vehi‐
o
or
au
cle Diagnostic Tester in the “Guided Fault Finding” function. ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
Z35- is OK. Use the Vehicle Diagnostic Tester in the “Guided ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Checking
– Close the hood, doors, windows and sunroof.
– Start the engine and adjust the following settings on the control
head:
• Turn the air distribution regulator -7- to the “instrument panel
vent” stop.
• A/C compressor on: The indicator lamp in the A/C button -2-
illuminates.
– Let the A/C system run for several minutes at maximum cool‐
ing output while the engine is running.
– Compare the measured values with the displayed measured
value for the Evaporator Temperature Sensor - G308- using
the Vehicle Diagnostic Tester in the “Guided Fault Finding”
function.
Specified values:
• The measured values for the air temperature from the left and
right vents must not be lower than the measured value of the
Evaporator Temperature Sensor - G308- and also not greater
than the maximum of 7 °C (44.6 °F) after five minutes. Use the
tion. agen
AG. Volkswagen AG d
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olks no
• The deviation of dthe
by measured air temperatures from
V t gu the left
ara
and right vents
or is less than 8 °C (46.4 °F).
ise nte
e h
ut or
If the target values
ss
a
are not reached, check the following: ac
ce
e
nl

pt
du
an

itte
y li
erm

ab
ility
ot p
♦ Function of the temperature door in the A/C unit. Refer to

wit
, is n

h re
hole
page 230 .
spec
es, in part or in w

t to the co

rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Set the highest possible temperature.

• Turn the temperature setting regulator -11- to the “warm” stop.
F):
• The temperature of the air from the instrument panel vents
goes above 55 °C (131 °F).
• The temperature deviation between the left and right side is
en AG. V
olkswagen AG
ag does
ksw not
Vol 19 ; Coolant
♦ Coolant circuit bleeding. Refer to ⇒ Rep.byGr. gu
ara
System/Coolant . ris
ed
nte
ho eo
ut
♦ Incorporation of the heater core sfor
s a the heater into coolant cir‐
ra
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
page 230 .
rrectne
ss
o
cial p
f inform
mer
Thermostat .
atio
om
n
♦ If installed: check the function of the After-Run Coolant Pump
c
i
or
- V51- and the Coolant Shut-Off Valve - N82- using the Vehicle n thi
te
sd
a

iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Note Cop py
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gh ht
pyri by
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by c lksw
cted agen
the engine speed to 2000 RPM and repeat the test if neces‐ Prote AG.
– Set the lowest possible temperature.

– Measure the temperature of the eair coming
n AG. Volkswaout
genof
AGthe left and
right instrument panel vents
olkswith a thermometer.
wag does
no
V t gu
by a
– Compare the measured ris
ed values with the displayed measuredran
te
value for the Evaporator
aut
ho
Temperature Sensor - G308- using e or a
the Vehicle Diagnostic
ss Tester in the “Guided Fault Finding” c
function.
ce
e
nl
pt
du
an
itte
Specified values:
y li
erm
ab
• The measured values must not be smaller than the measured
ility
ot p
value of the Evaporator Temperature Sensor - G308- and also
wit
, is n
h re
not greater than maximum 7 °C (44.6 °F) after five minutes.
hole
Use the Vehicle Diagnostic Tester in the “Guided Fault Find‐
spec
ing” function.
es, in part or in w
t to the co
• The deviation of the measured air temperatures from the left
and right vents is less than 8 °C (46.4 °F).
rrectness of i
l purpos

nform
ercia

m
at
om
i
on
c
page 230 .
in t
or
his
ate

do
priv

um
for
en
ng
t.
yi Co
op
C py
t. rig
gh ht
yri by
Actuation, Checking, Vehicles with Au‐
op Vo
by c lksw
cted agen
tomatic Climate Control System (With‐
Prote AG.
out High Voltage System)

Refer to
quired”, page 9
Test Requirements
ber Cover).
234 .
• The A/C system cooling output was checked and is OK. Refer
to
⇒ “4.4.4 Cooling Output, Checking, Vehicles with Automatic

Climate Control System (without High Voltage System)”, page

41 .
(176 °F).
• The Diagnostic Trouble Code (DTC) memory for the Clima‐
tronic Control Module - J255- control head was checked and
erased and the basic setting was performed on the Vehicle
• The coding and adaptation of the Climatronic Control Module
- J255- control head was checked using the Vehicle Diagnostic
Tester in the “Guided Fault Finding” function.
• Vehicles with TDI engine: the actuation and function of the
Auxiliary Heater Heating Element - Z35- is OK. Use the Vehi‐
Z35- is OK. Use the Vehicle Diagnostic Tester in the “Guided
Checking
– Close the doors, hood, the windows, the sunroof and the rear
lid.
– Start the engine.
AG. Volkswagen AG d
agen oes
olksw not
V gu
by ara
Note orised
nte
h eo
aut ra
If on a vehicle with the Start-Stop-function the engine does not ss c ce
le
start or was switched off via the “Start-Stop-function”, for exam‐

un
pt
ple, by changing the temperature setting on the Climatronic Con‐

an
d
itte
y li
trol Module - J255- control head to “LOW” and activating the “A/
erm
ab
C” function, start the engine.

ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Golf 2013 ➤ , Golf Variant 2014 ➤ olksw
AG. V agen AG
Heating, Ventilation and Air
lksw
Conditioning
agen - Edition
do10.2014
es n
o ot g
yV ua
edb ran
– Motor starts (or starts hafter
or
is changing the settings): tee
aut or
ac
• Set the temperature ss preset “cold” via the regulators
-21 and 11-: “LO” for the driver and front passenger side in the
ce
e
nl
pt
display -1 and 8- of the Climatronic Control Module - J255- . du
an
itte
y li
erm
ab
• Press the buttons -4 and 5- for the “instrument panel vents”
ility
ot p
and “footwell vents”.
wit
, is n
h re
hole
spec
• A/C compressor on: The indicator lamp in the A/C button
es, in part or in w
t to the co
-10- illuminates.
ing output while the engine is running.
rrectness of i
– “Read measured values” for the Left Vent Temperature Sen‐
l purpos
sor - G150- / Right Vent Temperature Sensor - G151- and the

Evaporator Temperature Sensor - G308- using the Vehicle
nf
ercia
orm
m
– Compare the measured values of the Left Vent Temperature
atio
m
Sensor - G150- / Right Vent Temperature Sensor - G151- /

o
n in
c
Footwell Vent Temperature Sensor - G192- with the measured

or
thi
e
value of the Evaporator Temperature Sensor - G308- .

t
sd
iva
o
r
rp
cu
Specified values:
o
m
f
en
ng
t.
yi
• The measured values for the Left Vent Temperature Sensor -
Co
Cop py
G150- / Right Vent Temperature Sensor - G151- / Footwell
t. rig
gh ht
yri
Vent Temperature Sensor - G192- must not be smaller than p by
o Vo
by c lksw
the value for the Evaporator Temperature Sensor - G308- and Prote
cted agen
also not greater than maximum 7 °C (44.6 °F) after five mi‐
AG.
nutes. Use the Vehicle Diagnostic Tester in the “Guided Fault

• The deviation between the two measured values for the Left
Vent Temperature Sensor - G150- / Right Vent Temperature
Sensor - G151- must not be greater than 8 °C (46.4 °F).
Note
Using a hand, check if there is actually air coming out of the ac‐
tivated vents.

– Set the highest possible temperature for the driver side.

• Set the temperature preset “warm” via the regulator -21-: “HI”
for the driver side in the display -1- for the Climatronic Control
Module - J255- .
sor - G150- / Right Vent Temperature Sensor - G151- / Foot‐
well Vent Temperature Sensor - G192- .
F):
• The temperature increases to above 55 °C (131 °F) in the dis‐
play field with the measured value for the Left Vent Tempera‐
ture Sensor - G150- / Footwell Vent Temperature Sensor -
G192- .
• The temperature increases less than 10 °C (50 °F) in the dis‐
play field with the measured value for the Right Vent Temper‐
ature Sensor - G151- .
System/Coolant .
♦ Actuation and function of the Left Temperature Door Motor -
V158- and the Right Temperature Door Motor - V159- using
function.
♦ Measured values for the Left Vent Temperature Sensor -
Vent Temperature Sensor - G192- using the Vehicle Diagnos‐
tic Tester in the “Guided Fault Finding” function.
en AG. V
olkswagen AG
ag does
ol ksw not
♦ Function of the temperature doors for y Vthe left and right side in gu
db ara
the A/C unit. Refer to ris
e nte
⇒ “5.7 Air Distribution Housing,
aut Removing and Installing”,
ho eo
ra
page 230 . ss c
ce
e
nl

pt
du
an
itte

y li
erm
ab

ility
ot p

wit
, is n
h re
Thermostat .
hole
spec
♦ If installed: check the function of the After-Run Coolant Pump

es, in part or in w
- V51- and the Coolant Shut-Off Valve - N82- using the Vehicle
t to the co

rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
21
by lksw
cted agen
Prote AG.
4. Repair Information
Note

the engine speed to 2000 RPM and repeat the test if neces‐
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
– Set the highest possible temperature for the front passenger
orise nte
eo
side. auth
ra
ss c
ce
le
un
pt
for the front passenger side in the display -8- for the Clima‐
an
d
itte
tronic Control Module - J255- .
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
F):
rrectness of i
l purpos
• The deviation between the display fields for the measured val‐
ues of the Left Vent Temperature Sensor - G150- / Right Vent
Temperature Sensor - G151- / Footwell Vent Temperature
nform
ercia
Sensor - G192- is less than 8 °C (46.4 °F).

m
a
com
ti
If the target values are not reached, check the components as
on in
described above. Refer to ⇒ page 21 .
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Set the lowest possible temperature for the driver and front
passenger side.
. Volkswagen AG
a gen AG does
• Set the temperature preset “cold” via the Vol regulators
ksw not
gu
-21 and 11-: “LO” for the driver and efront
d by passenger side in the ara
nte
display -1 and 8- of the Climatronic
tho
ris Control Module - J255- . eo
au ra
– “Read measured values” forssthe Left Vent Temperature Sen‐ c
ce
e
nl
pt
du
well Vent Temperature Sensor - G192- and Evaporator
an
itte
y li
Temperature Sensor - G308- . erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Specified values:
rrectness of i
Vent Temperature Sensor - G192- must not be smaller than
l purpos
the value for the Evaporator Temperature Sensor - G308- and

nform
ercia
m
at
om
• The deviation between the measured values for the Left Vent
ion
c
Temperature Sensor - G150- / Right Vent Temperature Sen‐
in t
or
sor - G151- / Footwell Vent Temperature Sensor - G192- must
his
ate
do
riv
not be greater than 8 °C (46.4 °F).

p
cum
for
en
ng
t.
yi Co
op
C py
ht. rig
rig ht
py by
o Vo
the Vehicle Diagnostic Tester in the “Guided Fault Finding” by c lksw
cted agen
function. Prote AG.
♦ Function of the temperature doors for the left and right side in
the A/C unit. Refer to
page 230 .
♦ Check the measured values for the Left Vent Temperature
Footwell Vent Temperature Sensor - G192- and Evaporator
Temperature Sensor - G308- using the Vehicle Diagnostic

Actuation, Checking, Vehicles with High
Voltage System and Automatic Climate
Control System
– Note safety precautions. Refer to
⇒ “1.1 Handling Refrigerant Safety Precautions”, page 1 .
– See notes. Refer to
⇒ “4.1 Working on the Refrigerant Circuit”, page 8 .
– Observe safety precautions when working on the high voltage
system. Refer to
⇒ “1.3 High Voltage System Safety Precautions”, page 1 .
– Pay attention to safety precautions for working near high volt‐
age components. Refer to
⇒ “1.4 Safety Precautions near High Voltage Components”,

page 2 .
– Pay attention to the high voltage system danger classification.
Refer to ⇒ Rep. Gr. 00 ; High Voltage System Danger Clas‐
sification .
Working on A High Voltage System when Activated or with the
Ignition Turned On
– Charge the vehicle batteries, for example, using the Battery
Charger - VAS5904- in the battery support mode to minimize
the number of automatic engine starts during the test- and
measuring procedures while the ready mode is active. Refer
to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery,
Charging .
– Move the selector level into position “P”, activate the parking
brake and arrange the necessary tools for testing and meas‐
uring procedures that require the ready mode to be active or
that require the ignition to be on, so that they cannot come into
contact with the turning components of the engine and so that
they are not in the vicinity of the turning components of a run‐
ning engine.
Note
♦ Also move the selector lever into position “P” and activate the
parking brake for testing and measuring procedures which re‐
quire the ignition to be on, but do not require the ready mode
to be active.
♦ Ready mode is displayed in thegeInstrument
n AG. VolkswaCluster
gen AG Control
Module - J285- . Refer toVothe
lkswOwner's Manual.
a d oes
not
by gu
ara
Activate and deactivate the ready mode. Refer to the Owner's
d
♦ orise nte
Manual (consultauthe
th display in the Instrument Cluster Control e or a
Module - J285-ss ). c
ce
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nl
pt
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an
Refer to
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erm
ab
ility
quired”, page 9
ot p
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Test Requirements
h re
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spec

es, in part or in w

t to the co

rrectness of i

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ber Cover).
nf
ercia
orm

m
atio
m

o
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c
234 .
or
thi
te
sd
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iv
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en
ng
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op
• The function of the different shut-off valves, coolant pumps
C py
t. rig
gh
and the High Voltage Heater (PTC) - Z115- is OK. Refer to
ht
pyri by
Vo
o
⇒ “7.1 High Voltage Heater (PTC) Z115 , Incorporation in by c lksw
cted agen
Coolant Circuit”, page 283 and use the Vehicle Diagnostic Prote AG.
Tester in the “Guided Fault Finding” function (for the A/C sys‐
tem and the engine control module).

AG. Volkswagen AG d Golf 2013 ➤ , Golf Variant 2014 ➤
agenHeating, Ventilationoesand Air Conditioning - Edition 10.2014
olksw not
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• The A/C system coolingthooutput was checked and is OK. Refer
r eo
to ss au ra
c
ce
e
nl
Climate Control System (without High Voltage System)”, page
pt
du
an
41 .
itte
y li
erm
ab
ility
ot p
(176 °F).
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
♦ The engine will not always start with a sufficiently charged
High Voltage Battery 1 - AX2- . If the coolant in the engine is
rrectness of i
colder than approximately 70 °C (158 °F), the coolant which
flows through the heater core for the heater is warmed by the
l purpos
High Voltage Heater (PTC) - Z115- and is delivered by the

High Temperature Circuit Coolant Pump - V467- . So that the
nform
ercia
coolant flows properly through the heater core, not only do the
High Temperature Circuit Coolant Pump - V467- , the Coolant
m
at
Change-Over Valve 2 - N633- and the Transmission Coolant
om
io
Valve - N488- have to be activated correctly, the check valves
n
c
in t
or
in the coolant circuit must be installed correctly and their func‐
his
ate
tion must be OK. Refer to
do
riv

p
cum
for
en
ng
t.
yi
Co
Cop py
ht. rig
♦ If the coolant temperature in the engine is greater than 75 °C
rig ht
py by
o Vo
(167 °F), the High Voltage Heater (PTC) - Z115- is no longer by c lksw
cted agen
activated. So that the coolant flows though the heater core for Prote AG.
the heater, the High Temperature Circuit Coolant Pump -

V467- is activated when the engine is off. So that the coolant
flows properly through the heater core, not only do the High
Temperature Circuit Coolant Pump - V467- , the Coolant
Change-Over Valve 2 - N633- and the Transmission Coolant
Valve - N488- have to be activated correctly, the check valves
in the coolant circuit must be installed correctly and their func‐
tion must be OK. Refer to
• The Diagnostic Trouble Code (DTC) memory for the Clima‐

tronic Control Module - J255- control head and the Engine
Control Module (ECM) (for example, the Engine Control Mod‐
ule - J623- ) was checked and erased and the basic setting
was performed on the Vehicle Diagnostic Tester in the “Gui‐
• The coding and adaptation of the Climatronic Control Module
- J255- control head was checked using the Vehicle Diagnostic
Checking
lid.
– Turn on the ignition.
– Move the selector lever into position P.
– Activate the parking brake.
– Open the hood.

– Connect the charger, for example Battery Charger -
VAS5095A- to the jump start point for the 12V vehicle electrical
system
– Activate the ready mode (the engine does not need to start at
first).
Note
With the ready mode active and the temperature preset “warm”
on the Climatronic Control Module - J255- A/C control head (“HI”
in the display), the coolant flow through the heater and A/C unit
heater core is maintained with the engine off via the High Tem‐
perature Circuit Coolant Pump - V467- . Refer to
⇒ “7.1 High Voltage Heater (PTC) Z115 , Incorporation in Coolant
Circuit”, page 283 and ⇒ Rep. Gr. 19 ; Coolant Pump/Thermo‐
stat .
AG. Volkswagen AG d
agen oes
♦ Motor starts (or starts after changing the settings): olksw not
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d by ara
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Note ss a c
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pt
du
For vehicles with a high voltage system, the engine can run or be
an
itte
y li
switched off depending on the setting on the Climatronic Control
erm
ab
Module - J255- control head, the coolant temperature, the charge
ility
ot p
level of the High Voltage Battery 1 - AX2- etc.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

• Set the temperature preset “cold” via the regulators

display -1 and 8- of the Climatronic Control Module - J255- .
• Press the buttons -4 and 5- for the “instrument panel vents”
and “footwell vents”.
-10- illuminates.
• “Eco” mode not activated: nothing appears in the display -3-
of the Climatronic Control Module - J255- .
ing output while the ready mode is active.
sor - G150- / Right Vent Temperature Sensor - G151- and the
Evaporator Temperature Sensor - G308- using the Vehicle
Specified values:
• The deviation between the two measured
AG. Volksvalues
wagen Afor the Left
agen / Right Vent Temperature
Vent Temperature Sensor -olG150- G do
es n
ksw
Sensor - G151- must not V greater than 8 °C (46.4 °F).ot gu
ybe
d b ar
e an
ris tee
utho or
a ac
Note ss
ce
e
nl
pt
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an
Using a hand, check if there is actually air coming out of the ac‐
itte
y li
erm
tivated vents.
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Set the highest possible temperature for the driver side.

for the driver side in the display -1- for the Climatronic Control
Module - J255- .
Specified values with an engine temperature of about 90 °C (194
°F):
play field with the measured value for the Left Vent Tempera‐
ture Sensor - G150- / Footwell Vent Temperature Sensor -
G192- .
• The temperature increases less than 10 °C (50 °F) in the dis‐
System/Coolant .
the Vehicle Diagnostic Tester in the n“Guided
AG. VolksFault Finding”
wagen A
function. olks
wage
G do
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♦ Measured values for the ris Left Vent Temperature Sensor -
ed nte
G150- / Right Vent Temperature
ut
ho Sensor - G151- / Footwell eo
ra
Vent Temperatures Sensor - G192- using the Vehicle Diagnos‐
s a c
tic Tester in the “Guided Fault Finding” function.
ce
e
nl
pt
du
an
♦ Function of the temperature doors for the left and right side in
itte
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erm

ab
ility

ot p
wit
page 230 .
, is n
h re
hole

spec

es, in part or in w
t to the co

♦ The activation and function of the High Voltage Heater (PTC)
- Z115- , the High Temperature Circuit Coolant Pump - V467-
rrectness of i
etc. (refer to
l purpos

Coolant Circuit”, page 283 ) as well as the incorporation of
these components in the refrigerant circuit. Use the Vehicle
nf
ercia
Diagnostic Tester in the “Guided Fault Finding” function. Refer

orm
to ⇒ Rep. Gr. 19 ; Coolant System/Coolant (Connection Di‐

m
atio
m
agram for Coolant Hoses).

o
n in
or c

thi
te
sd
a
Thermostat .
iv
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.

Note
♦ So that the warmed coolant from the High Voltage Heater

(PTC) - Z115- or from the engine can flow through the heater
and A/C unit heater core, the High Temperature Circuit Cool‐
ant Pump - V467- , the Coolant Change-Over Valve
. Volk2sw-aN633-
gen AG
gen AG
and the Transmission Coolant Valve o- lkN488- swa (by the does
not
respective ECM) must also be activated. d byV So that the coolant gu
ara
flows in the correct direction, hthe
orise
check valves in the coolant nte
eo
circuit must be installed correctly
aut and it must be OK. For more ra
information, refer to ss c
ce
le

un
pt
Coolant Circuit”, page 283 , ⇒ Rep. Gr. 19 ; Coolant System/
an
d
itte
y li
Coolant (Connection Diagram for Coolant Hoses) and ⇒ Wir‐
erm
ab
ing diagrams, Troubleshooting & Component locations. Use
ility
ot p
the Vehicle Diagnostic Tester in “Guided Fault Finding”).
wit
is n
h re
ole,
spec
t to the co
– Set the highest possible temperature for the front passenger
side.
rrectne
s
for the front passenger side in the display -8- for the Clima‐
s o
tronic Control Module - J255- .
cial p
f inform
mer
atio
m

o
n
c
i
or
n thi
e

t
sd
va
F):
i
o
pr
cum
r
fo
en
ng

t.
yi Co
play field with the measured value for the Right Vent Temper‐ . Cop py
ht rig
rig ht
py by
co Vo
• The deviation between the display fields for the measured val‐
by lksw
cted agen
Prote
ues of the Left Vent Temperature Sensor - G150- / Right Vent
AG.
Temperature Sensor - G151- / Footwell Vent Temperature

Sensor - G192- is less than 8 °C (46.4 °F).
If the target values are not reached, check the components as
described above. Refer to ⇒ page 28 .
– Set the lowest possible temperature for the driver and front
passenger side.
– “Read measured values” for the Left Vent Temperature Sen‐ . Volkswagen AG
sor - G150- / Right Vent Temperature Sensor - G151- / Foot‐kswagen AG does
not
l
well Vent Temperature Sensor - G192- and Evaporator by V o gu
ara
Temperature Sensor - G308- . ris
ed
nte
ho eo
ut
– Compare the measured values of the Left Vent sTemperature
sa
ra
c
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e
nl
pt
du
an
itte
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erm
ab
Specified values:
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
• The deviation between the measured values for the Left Vent
l purpos
Temperature Sensor - G150- / Right Vent Temperature Sen‐

sor - G151- / Footwell Vent Temperature Sensor - G192- must
nf
ercia
not be greater than 8 °C (46.4 °F).
orm
m
atio
om
n in
c

or
thi
e

t
sd
iva
o
r
rp
cu
function.
o
m
f
en
ng
t.
yi Co
♦ Function of the temperature doors for the left and right side in . Cop py
ht rig
rig ht
by
⇒ “5.7 Air Distribution Housing, Removing and Installing”, copy Vo
by lksw
page 230 . cted agen
Prote AG.

♦ Check the measured values for the Left Vent Temperature
Footwell Vent Temperature Sensor - G192- and Evaporator

4.4 Cooling Output, Checking

⇒ “4.4.1 Information on Checking Cooling Output and Tools Re‐
quired”, page 31
⇒ “4.4.2 Test Requirements”, page 32
⇒ “4.4.3 Cooling Output, Checking, Vehicles with Manual Climate
⇒ “4.4.4 Cooling Output, Checking, Vehicles with Automatic Cli‐
mate Control System (without High Voltage System)”,
page 41
mate Control System (with High Voltage System)”, page 46
⇒ “4.4.6 Determining Malfunction if Deviation from Specified Val‐
ue”, page 57
⇒ “4.4.7 Determining Malfunction of Temperature Increase Down‐
stream from Evaporator”, page 58
⇒ “4.4.8 Ice Formation on Evaporator, Localizing Malfunction”,
page 59
4.4.1 Information on Checking Cooling Output

and Tools Required
AG. Volkswagen AG d
agen oes
ksw
Note by Vol not
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ara
d
rise nte
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This repair manual only outlines the aut checking procedure. Perform
h
ra
the detailed function test for thes heating as described in the Gui‐
s c
ce
e

nl
pt
du

an
itte
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erm
ab
ility
ot p
wit
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♦ Vehicle Diagnostic Tester h re

hole
spec
♦ A standard thermometer (for temperature measurements, if
es, in part or in w
necessary a thermometer with two measuring probes for si‐

t to the co
multaneous measurement, for example, for temperature on

the right and left)
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ With the Start/Stop System, the stop function is disabled de‐

pending on the setting on the A/C Control Module - J301- (for
example, the heater is on). As soon as there is a request for
heating, the engine is started. In cooling mode, the A/C Control
Module - J301- does not limit the stop function. Use the Vehicle
♦ If the A/C Humidity Sensor - G260- is not installed on vehicles
with a A/C Control Module - J301- , a permissible stop time is
currently calculated by characteristic . Volkswcurves
agen AG which are influ‐
enced by the measured w agen AG air temperature,
outside does the “recircu‐
ks n
lated-air mode” function
y Vol and operating status of theotwindshield
gu
db ara
wipers. The calculated
orise time must be greater than 20 seconds
nte
so that theaustop
th function is permitted by the A/C Control Mod‐ eo
ra
ule - J301-
s . The stop time can be shortened at a lower outside
s c
air temperature, when recirculated-air mode is active and/or
ce
e
nl
pt
du
when raining to prevent the front and door windows from fog‐
an
itte
y li
ging up. If the calculated time for the stop function is less than
erm
ab
20 seconds, this is prevented.
ility
ot p
wit
, is n
♦ With the Start/Stop Function, the stop function is disabled de‐
h re
pending on the setting on the Climatronic Control Module -
hole
spec
J255- control head. If, for example, “Defrost” is selected, the
es, in part or in w
stop function is not possible or will be interrupted and the en‐

t to the co
gine will start. The same applies in the case of heating and
cooling. The difference between the set specified and actual
temperature exceeds a certain value. Use the Vehicle Diag‐
rrectness of i
nostic Tester in the “Guided Fault Finding” Function.

l purpos
4.4.2 Test Requirements

nf
ercia
• Ambient temperature greater than 15 °C (59 °F).

rm
m
atio
m
• Radiator and condenser are clean (if necessary clean).

o
n in
or c
• The ribbed belt, which drives the Air Conditioning (A/C) com‐
thi
te
sd
a
pressor, is OK and tensioned correctly. The belt pulley is

iv
o
r
rp
cu
actually driving the A/C compressor (vehicles without a high

o
m
f
voltage system).
en
ng
t.
yi Co
op py
• All air guides, covers and seal OK and properly installed t. C rig
gh ht
pyri by
• Seal between engine compartment, engine hood and plenum
o Vo
by c lksw
cted
chamber is OK and installed correctly. To check, refer to ⇒
agen
Prote AG.
Body Exterior; Rep. Gr. 50 ; Bulkhead ; (Plenum Chamber
Cover Assembly Overview).
234 .
• The air intake for the heater and A/C Unit (in fresh air and
recirculating air modes) is not affected by dirt or retrofitted
components.
• Vehicles without glove compartment cooling: glove compart‐
ment cooling connection is sealed on the A/C unit.
• Vehicles with glove compartment cooling: glove compartment
cooling connection is installed on the A/C unit according to the
specification.
(176 °F).
• The Diagnostic Trouble Code (DTC) memory for the A/C Con‐
trol Module - J301- / Climatronic Control Module - J255- control

head was checked and erased, the basic setting performed

and the A/C Control Module - J301- / Climatronic Control Mod‐
ule - J255- coding checked using the Vehicle Diagnostic VTest‐
. olkswagen AG
er in the “Guided Fault Finding” function. swa
gen AG does
k not
y Vol gu
• A/C Control Module - J301- / Climatronic d bControl Module - ara
ise nte
J255- adaptation checked using the tVehicle
hor Diagnostic Tester eo
ss
au ra
c
ce
e
• All instrument panel vents and, if present, vents in the rear
nl
pt
du
an
center console are opened.
itte
y li
erm
ab
• Check that the air outlet from the rear footwell vents (under the
ility
ot p
front seats) is not blocked by the floor mats or other objects.
wit
, is n
h re
• Engine hood closed.
hole
spec
On Vehicles with A High Voltage System (hybrid vehicles)
es, in part or in w
t to the co
♦ The ignition is switched on and the ready mode is activated
(note the display in the instrument cluster), the engine starts
or only runs, for example, when the High Voltage Battery 1 -
rrectness of i
AX2- is not charged enough or the hood is unlocked. Refer to
l purpos
the Owner's Manual.

♦ With the ignition switched on and the temperature preset
nform
ercia
“warm” on the Climatronic Control Module - J255- A/C control

head (“HI” in the display), the coolant flow through the heater
m
at
and A/C unit heater core is maintained via the High Temper‐
om
ion
ature Circuit Coolant Pump - V467- . Refer to
c
in t
or
his
ate
Coolant Circuit”, page 283 and ⇒ Rep. Gr. 19 ; Coolant
do
priv
c
Pump/Thermostat .
um
for
en
ng
t.
yi
Co
Cop py
t. rig
– Move the selector lever into position P.
gh ht
pyri by
Vo
co lksw
by
– Activate the parking brake. cted agen
Prote AG.

– Open the hood.
– Connect the charger, for example Battery Charger -
VAS5095A- to the jump start point for the 12V vehicle electrical
system
– Activate the ready mode (the engine does not need to start at
first).
For Vehicles without A High Voltage System
– The engine runs (if necessary adjust the settings on the control
head (the A/C Control Module - J301- or the Climatronic Con‐
trol Module - J255- ) in the direction “heat”).
Vehicles with Manually Controlled A/C System

– Adjust the following settings on the A/C Control Module - J301-
control head:
• A/C compressor on: The indicator lamp in the A/C button -2-
illuminates.
• Recirculating air mode on: the indicator lamp in the Recir-
culation button -4- illuminates.
• Turn the air distribution regulator -7- to the “instrument panel

vent” stop.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Vehicles with Automatic Climate Control System (with and without

a High Voltage System):
– Adjust the following settings on the Climatronic Control Mod‐
ule - J255- control head:
• “Auto” mode: the indicator lamp in the AUTO button -14- illu‐
minates.
. Volkswagen AG
gen AG d
• Air Conditioning (A/C) compressor
Vol
ksw
a
on: The indicator
oes lamp in
not
the A/C button -10-edilluminates.
b y gu
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• Turn the fresh aair
ut blower regulator -16- to the maximum speed. or a
s s c
ce
le
un
pt
an
d
Note
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ab
pe
ility
The indicator lamp in the AUTO button turns off when the fresh air
ot
wit
blower speed is changed manually.
, is n
h re
hole
spec
For All Vehicles
es, in part or in w
t to the co
Note
rrectness of i
The maximum possible fresh air blower speed depends on sev‐
l purpos
eral conditions (vehicle voltage, etc.)
nform
ercia
Function with the engine running (on vehicles without a high volt‐
age system):
m
a
com
tio
Function with ready mode active (on vehicles with a high voltage
n in
r
te o
system):
thi
s
iva
do
• Run the coolant fan(s) -V7- / -V177- . The actuation and speed
r
rp
cum
fo
depend on the pressure in the refrigerant circuit and the engine

en
ng
t.
temperature.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
Note
c by lksw
cted agen
Prote AG.
♦ The coolant fan(s) -V7- / -V177- are only switched from a cer‐
tain pressure in the refrigerant circuit (from a pressure of 9 bar
(130 psi) at this time) depending on the A/C Control Module -
J301- / Climatronic Control Module - J255- control head ver‐
sion. The coolant fan actuation is displayed in the “Read
measured values” function using the Vehicle Diagnostic Test‐
er in the “Guided Fault Finding” function.
♦ Depending on the Engine Control Module (ECM), the specified
and the actual speed of the Coolant Fans -V7- and -V177- can
vary from one another. Use the Vehicle Diagnostic Tester in
the “Guided Fault Finding” function.
• The fresh air blower runs at maximum speed.
Note
The maximum possible fresh air blower speed depends on sev‐

eral conditions (vehicle voltage, etc.)
• The A/C system goes into recirculated-air mode. Approxi‐

mately one minute after starting the engine (activating the
ready mode), the back pressure/fresh air door is closed and
the recirculation door is opened. The fresh air blower extracts
the air from passenger compartment below instrument panel /
behind the glove compartment.
If one of these prerequisites is not met: agen
AG. Volkswagen AG d
oes
olksw not
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– Check the Diagnostic Trouble Code (DTC) ed by memory, perform ara
nte
an output diagnostic test and readththe
o measured values using
ris
eo
the Vehicle Diagnostic Tester ins athe
u “Guided Fault Finding” ra
c
function. s
ce
le
un
pt
Continuation
an
d
itte
y li
rm
ab
Refer to
pe
ility
ot
wit
, is n
h re
hole
spec
Refer to
es, in part or in w
t to the co
mate Control System (without High Voltage System)”,
page 41
rrectness of i
Refer to
l purpos
mate Control System (with High Voltage System)”, page 46
nform
ercia
4.4.3 Cooling Output, Checking, Vehicles with

Manual Climate Control System
m
a
com
tion in
r
Refer to
te o
thi
s
iva
do
quired”, page 31
r
rp
cum
fo
en
ng
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op py
Note t. C rig
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pyri by
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o
by c lksw
This repair manual only outlines the checking procedure. Perform Prote
cted AG.
agen
Procedure
• The requirements for testing the cooling capacity are fulfilled.
Refer to ⇒ “4.4.2 Test Requirements”, page 32 .
– Measure the ambient temperature: it must be warmer than 15
°C (59 °F).
lid.

– Switch off the Air Conditioning (A/C) compressor on the A/C

Control Module - J301- control head: the indicator lamp in the
A/C button -2- does not illuminate.
– “Read measured values” using the Vehicle Diagnostic Tester

Checking
G. Volkswage
– Read the actuation of the A/C waCompressor
gen A Regulator
n AG d
oes Valve -
N280- . Volks not
gu
by a d ran
ise
• The actuation of uthe
tho A/C compressor (by the A/C Compressor e or
r te
Regulator Valve
ss - N280- ) is switched off: 0 A (amps) or 0% is
a ac
displayed.
ce
e
nl
pt
du
an
– Read the measured value for the Refrigerant Circuit Pressure
itte
y li
Sensor - G805- .
erm
ab
ility
ot p
• The pressure in the refrigerant circuit is same as the measured
wit
, is n
outside temperature or greater than the value in the chart.
h re
hole
spec
Ambient Temperature in ° Pressure Display (pressure in bar)
es, in part or in w
t to the co
15 3.0
20 4.0
rrectness of i
25 5.0
l purpos
30 6.0
35 7.0
nf
ercia
orm
m
atio
om
n in
c
Note
or
thi
te
sd
iva
♦ At absolute pressure, 0 bar corresponds to absolute vacuum.

o
r
rp
cu
Normal ambient pressure equals approximately 1 bar (14.5

o
m
f
en
ng
psi) absolute pressure and 0 bar pressure. On the scales of

t.
yi Co
op
most pressure gauges, 0 bar pressure corresponds to an ab‐ C py
ht. rig
solute pressure of one bar (can be seen from -1 mark below rig ht
py by
0).
co Vo
by lksw
cted agen
Prote AG.
♦ Pressure in refrigerant circuit is governed by ambient temper‐
ature. On account of heat given off by components (for exam‐
ple, the radiator), pressure displayed with a warm engine will
be slightly higher than that given for the respective ambient
temperature.
If the displayed pressure in the refrigerant circuit is lower than in

the table:
– Check the Refrigerant Circuit Pressure Sensor - G805- signal
using the Vehicle Diagnostic Tester in the “Guided Fault Find‐
ing” function.
If no fault is determined at the Refrigerant Circuit Pressure Sensor
- G805- , there is insufficient refrigerant in the circuit.
If the displayed pressure in the refrigerant circuit is OK:

– Adjust the following settings on the A/C Control Module - J301-
control head:
♦ Turn the temperature setting regulator -11- to the “cold” stop.
♦ Turn the air distribution regulator -7- to the “instrument panel
vent” stop.
♦ A/C compressor on: The indicator lamp in the A/C button -2-
illuminates.
♦ Recirculating air mode on: the indicator lamp in the Recir-
culation button -4- illuminates.
♦ Turn the fresh air blower regulator -9- to the maximum speed.
– Check the display in the display fields:
• The current calculated by the A/C Control Module - J301- ,
which flows via the A/C Compressor Regulator Valve - N280- ,
is greater than 0.3 Amps (30%). The A/C compressor is
switched on.
• The displayed pressure increases above the value when the
compressor is switched off.
If the displayed pressure does not change and the actuation of
the A/C compressor is OK:
– Check once more if the calculated current actually flows via
the A/C Compressor Regulator Valve - N280- and the A/C
compressor is actually being driven.
If the current is actually flowing via the A/C Compressor Regulator
Valve - N280- and the A/C compressor is being driven, then the
fault is in the refrigerant circuit. It is possible that the A/C com‐
pressor regulation is not OK.
– The necessary work may only be performed by G qualified per‐
sonnel. If this is not possible, transfer thelkvehicle n A . Volkswagen AG
swage to a shop that does n
has the necessary tools and equipment y V and where the work
o ot g
ua
db
can be performed by qualified personnel.
oris
e Refer to ran
tee
⇒ “4.1 Working on the Refrigerantauth Circuit”, page 8 . Bring the or
ac
detected problems to the attention
ss of the workshop.
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
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
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o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
yri by
38
op Vo
by c lksw
Rep. Gr.00 - General, Technical Data Prote
cted AG.
agen
Note
♦ The A/C Control Module - J301- actuates the A/C Compressor

Regulator Valve - N280- so that the air temperature reaches
the specified value downstream of the evaporator (about 2 to
6 °C (35.6 to 42.8 °F)).
♦ After vehicle start, a value greater than 0.55 A (75%) is dis‐
played for the activation of the A/C Compressor Regulator
Valve - N280- depending on the measured temperature, the
engine speed and the electrical system voltage. As soon as
the temperature measured by the Evaporator Temperature
Sensor - G308- nears the specified value, the activation, and
thus the compressor output, is reduced.
♦ Under certain operating conditions, moisture in the refrigerant
circuit can lead to ice build-up on the A/C Compressor Regu‐
lator Valve - N280- and on the expansion valve. A/C compres‐ n AG. Volkswagen AG do
sor regulation is reduced by this ice build-up. The olksevaporator
wage es n
ot g
is cooled too intensely and freezes. The iceeon d b the evaporator
yV ua
ran
may cause various customer concerns. hRefer oris to tee
⇒ “4.4.8 Ice Formation on Evaporator,sLocalizing
au
t
Malfunction”, or
ac
page 59 . s
ce
e
nl
pt
du
♦ If little or no current is displayed in the measured values for
an
itte
the A/C Compressor Regulator Valve - N280- activation,
y li
erm
ab
check the actuation of the A/C Compressor Regulator Valve -
ility
ot p
N280- using the Vehicle Diagnostic Tester in the “Guided Fault
wit
, is n
h re
hole
spec
es, in part or in w
– Press the Recirculation button -4- on the A/C Control Mod‐
t to the co
ule - J301- control head.
• The indicator lamp in the button for the “recirculating air mode”
rrectness of i
illuminates.
l purpos
– Set engine speed of 2000 rpm (start of time measurement).

nform
ercia

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Compare the displayed measured value for the Evaporator

Temperature Sensor - G308- with the values in the diagram.
A - Air temperature measured by the Evaporator Temperature
Sensor - G308-
B - Ambient Temperature
C - Permissible Tolerance Range
• Depending on the ambient temperature, the measured air
temperature should be after 5 minutes within the shown toler‐
ance range.
If the required values are not reached:
– Compare the measured value with the displayed measured
value for the Evaporator Temperature Sensor - G308- .
If the measured values only slightly deviate from each other:
– Perform the procedure for identifying malfunctions if the target
values are not reached. Refer to
⇒ “4.4.6 Determining Malfunction if Deviation from Specified
Value”, page 57 .
If the measured value for the Evaporator Temperature Sensor -
G308- is greater than the determined measured value:
– Make sure the Evaporator Temperature Sensor - G308- is in‐
stalled correctly (refer to
⇒ “5.17 Evaporator Temperature Sensor G308 , Removing
and Installing”, page 262 ) and perform an electrical test for
this sensor using the Vehicle Diagnostic Tester in the “Guided
Note
The A/C system function can be recognized, for example, by. Vthe
gen AG
olkswagen AG
does
swa
refrigerant pipe on the low pressure side (thick yline
V from the inner
olk not
gu
heat exchanger to the A/C compressor) coolingised off.
b ara
nt
r ee
ho
aut or
ac
If the measured value for the Evaporator
ss Temperature Sensor -
ce
G308- and the A/C system cooling output is OK:

le
un
pt
an
d
itte
y li
erm
ab

ility
ot p
wit
– Compare the measured values on the thermometer and for the

is n
h re
Evaporator Temperature Sensor - G308- .

ole,
spec
• The determined measured values must not be smaller than

t to the co

not greater than maximum 7 °C (44.6 °F) after five minutes.
If the determined measured values are smaller:
rrectne

stalled correctly and check the electrical connections for con‐
ss o
tact resistance. Replace the faulty sensor. Use the Vehicle

cial p
f i

nform
mer

atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
40
by lksw
cted agen
Rep. Gr.00 - General, Technical Data Prote AG.
– Check the actuation and function of the temperature door. To

do so, determine the malfunction with the temperature in‐
crease downstream of the evaporator (refer to
⇒ “4.4.7 Determining Malfunction of Temperature Increase
Downstream from Evaporator”, page 58 ) and use the Vehi‐

Automatic Climate Control System
(without High Voltage System)
Refer to
quired”, page 31
Note

Procedure
♦ The requirements for testing the cooling capacity are fulfilled.
°C (59 °F).
lid.
– Open all instrument panel vents and, if present, the vents in
the rear center console. n AG. Volkswagen A ge G do
swa es n
– Start the engine. by Volk ot g
ua
ed ran
ris tee
tho or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Switch off the Air Conditioning (A/C) compressor on the Cli‐

matronic Control Module - J255- control head: the indicator
lamp in the A/C button -10- does not illuminate.
Checking
– Read the actuation of the A/C Compressor Regulator Valve -
N280- .
• The actuation of the A/C compressor (by the A/C Compressor
Regulator Valve - N280- ) is switched
gen AG off: 0 A (amps)
. Volkswagen AG
doesor 0%
swa
will be displayed. y Volk not
gu b ara
ed
– Read the measured tho
risvalue for the Refrigerant Circuit Pressurentee
Sensor - G805-s a.u or
ac
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
C
ot
wit
, is n
h re
15 3.0
hole
spec
20 4.0
es, in part or in w
t to the co
25 5.0
30 6.0
rrectness of i
35 7.0
l purpos
Note
nform
ercia

m
a
com
ti

on in

r
te o
thi
most pressure gauges, 0 bar pressure corresponds to an ab‐

s
iva
do
solute pressure of one bar (can be seen from -1 mark below

r
rp
cum
0).
fo
en
ng
t.
yi Co
♦ Pressure in refrigerant circuit is governed by ambient temper‐ Cop py
ht. rig
rig ht
by
ple, the radiator), pressure displayed with a warm engine will copy Vo
by lksw
be slightly higher than that given for the respective ambient cted agen
Prote AG.
temperature.

the table:
– Check the Refrigerant Circuit Pressure Sensor - G805- signal
using the Vehicle Diagnostic Tester in the “Guided Fault Find‐
ing” function.
If no fault is determined at the Refrigerant Circuit Pressure Sensor
- G805- , there is insufficient refrigerant in the circuit.
– The necessary work may only be performed by qualified per‐
sonnel. If this is not possible, transfer the vehicle to a workshop
that has the necessary tools and equipment and where the
work can be performed by qualified personnel. Refer to
⇒ “4.1 Working on the Refrigerant Circuit”, page 8 . Bring the
detected problems to the attention of the workshop.


minates.
-10- illuminates.
• If a displayed current that is flowing via the A/C Compressor
Regulator Valve - N280- is greater than 0.3 amps (30%): the
A/C compressor is switched on.
• The displayed pressure increases above the value when the
compressor is switched off.
– Check once more if the A/C compressor is actually being driv‐
en and the A/C Compressor Regulator Valve - N280- is being
activated. agen
AG. Volkswagen AG d
o w es n
olks ot g
If the current is actually flowing via the A/C Compressor ed
by Regulator
V ua
ran
Valve - N280- and the A/C compressor is beinghodriven, ris then the tee
fault is in the refrigerant circuit. It is possible sthat
au the A/C com‐
t or
ac
pressor regulation is not OK. s
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
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
♦ The Climatronic Control Module - J255- actuates the A/C

Compressor Regulator Valve - N280- so that the air tempera‐
ture reaches the specified value downstream of the evaporator
(about 2 to 6 °C (35.6 to 42.8 °F)).
♦ After vehicle start, a value greater than 0.55 A is displayed for
the activation of the A/C Compressor Regulator Valve - N280-
depending on the measured temperature, the engine speed
and the vehicle voltage. As soon as the temperature measured
by the Evaporator Temperature Sensor - G308- nears the
specified value, the activation, and thus the A/C compressor
output, is reduced. n AG. Volkswagen AG ge does
swa
♦ Under certain operating conditions,
by
Vol
k
moisture in the refrigerant
not
gu
circuit can lead to ice build-up
ris
ed on the A/C Compressor Regu‐
a ran
tee
lator Valve - N280- and
utho on the expansion valve. A/C compres‐ or
sor regulation is reduced
ss
a
by this ice build-up. The evaporator ac
is cooled too intensely and freezes. The ice on the evaporator
ce
le
un
pt
may cause various customer concerns. Refer to
an
d
itte
y li
rm
ab
page 59 .
pe
ility
ot
wit
♦ If no or very little current is displayed in the measured values
, is n
h re
for the A/C Compressor Regulator Valve - N280- actuation,
hole
spec
check the actuation of the A/C Compressor Regulator Valve -
es, in part or in w
N280- using the Vehicle Diagnostic Tester in the “Guided Fault
t to the co
– Press the Recirculation button -6- on the Climatronic Con‐ rrectness of i

trol Module - J255- control head.
l purpos
illuminates.
nform
ercia
– Set engine speed of 2000 rpm (start of time measurement).

m
a
com
tion in

r
te o
thi

s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Compare the displayed measured value for the Evaporator

Temperature Sensor - G308- with the values in the diagram.
Sensor - G308-
ance range.
– Compare the measured values for the Left Vent Temperature
Sensor - G150- and the Right Vent Temperature Sensor -
G151- with the displayed measured value for the Evaporator
Note
The temperature of the air coming out of the left and right instru‐
ment panel vents can also be measured with a thermometer.
If the measured values of the Evaporator Temperature Sensor - AG. Volkswagen AG d

agen
G308- and Left Vent Temperature Sensor - G150- / Right Vent Volksw
oes
not
Temperature Sensor - G151- only deviate from each otheredslight‐
by gu
ara
ly: thoris nte
e or
au ac
– Perform the procedure for identifying malfunctions
ss if the target
ce
le
un
pt
an
d
itte
y li
Value”, page 57 .
erm
ab
ility
ot p
wit
is n
G308- is greater than the measured value for the Left Vent
h re
Temperature Sensor - G150- or Right Vent Temperature Sensor
ole,
spec
- G151- :
t to the co
rrectne
ss o
cial p
f inform
mer
Note
atio
om
The A/C system function is recognizable, for example, when the

c
i
or
n thi
refrigerant pipe on the low pressure side (thick line) cools off.
te
sd
iva
o
pr
cum
r
fo

en
ng
t.
G308- and the A/C system cooling output is OK and there are no op
yi Co
complaints, the cooling output test ends.
C py
t. rig
gh ht
yri by
If the measured value for the Evaporator Temperature Sensor - cop Vo
by lksw
G308- (and the A/C system cooling output) is not OK:
cted agen
Prote AG.

values are not reached (required cooling output not reached).
Refer to
Value”, page 57 .

G308- (and the A/C system cooling output) is OK and there is a
complaint due to excessive or different vent temperatures for the
A/C system:
– Check the actuation of the temperature doors in the A/C unit
(refer to
page 230 ) and use the Vehicle Diagnostic Tester in the “Gui‐

Automatic Climate Control System (with
High Voltage System)
Refer to AG. Volkswagen AG d
⇒ “4.4.1 Information on Checking Cooling Output and Tools Re‐ agen oes
olksw not
V
quired”, page 31 ed by gu
ara
is nte
or
– Note safety precautions. Refer to au
th eo
ra
⇒ “1.1 Handling Refrigerant Safety Precautions”,s page 1 .
s c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
system. Refer to
, is n
h re
hole
spec
es, in part or in w
t to the co
page 2 .
rrectness of i
l purpos
sification .
Working On A High Voltage System when Activated or with the
nf
ercia
o
Ignition Turned On
rm
m
atio
m
– Charge the vehicle batteries, for example, using the Battery

o
n in
c
Charger - VAS5904- in the battery support mode to minimize

or
thi
e
the number of automatic engine starts during the test- and

t
sd
iva
measuring procedures while the ready mode is active. Refer o

r
rp
cu
to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery,

o
m
f
en
ng
Charging .
t.
yi Co
Cop py
t. rig
– Move the selector level into position “P”, activate the parking yri
gh by
ht
brake and arrange the necessary tools for testing and meas‐
op Vo
by c lksw
uring procedures that require the ready mode to be active or
cted agen
Prote AG.
that require the ignition to be on, so that they cannot come into
contact with the turning components in the engine and so that
they are not in the vicinity of the turning components of a run‐
ning engine.
Note
parking brake for testing and measuring procedures which re‐
to be active.
♦ Ready mode is displayed in the Instrument Cluster Control
Module - J285- . Refer to the Owner's Manual.
♦ Activate and deactivate the ready mode. Refer to Owner's
Manual (consult the display in the Instrument Cluster Control
Module - J285- ).

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
orise nte Golf 2013 ➤ , Golf Variant 2014 ➤
h eo
aut Heating, Ventilation and r a Air Conditioning - Edition 10.2014
c
ss
ce
le
Procedure
un
pt
an
d
itte
y li
♦ The requirements for testing the cooling capacity are fulfilled.
rm
ab
pe
ility
ot
wit
, is n
h re
°C (59 °F).
hole
spec
es, in part or in w
t to the co
lid.
– Open all instrument panel vents and, if present, the vents in
rrectness of i
the rear center console.
l purpos
Note
nform
ercia
♦ Ready mode is displayed in the Instrument Cluster Control

m
a
Module - J285- .
com
tion in
♦ Activate the ready mode (and observe the display in the In‐
r
te o
thi
strument Cluster Control Module - J285- ). Refer to the Own‐
s
iva
do
er's Manual.
r
rp
cum
fo
en
g
n
t.
yi Co
op
parking brake for testing and measuring procedures which re‐ C py
t. rig
gh ht
yri by
to be active.
op Vo
by c lksw
cted agen
Prote AG.
– The ignition is turned on and ready mode is active, the engine

starts or only runs when, for example, the High Voltage Battery
1 - AX2- has not been charged enough.
Note
To check the cooling output on a vehicle with a high voltage sys‐

tem the engine must not be running ( Electrical A/C Compressor
- V470- ).
– Switch off the Air Conditioning (A/C) compressor on the Cli‐

matronic Control Module - J255- control head: the indicator
lamp in the A/C button -10- does not illuminate.
wage es n
– “Read measured values” using the Vehicle Diagnostic Tester yV
olks ot g
ua
in the “Guided Fault Finding” function. ir se
d b ran
o tee
th
Checking au or
ac
ss
ce
♦ Read out the activation of the Electrical A/C Compressor -
le
un
pt
V470- (compressor shut-off conditions and compressor
an
d
itte
y li
speed).
rm
ab
pe
ility
♦ Read the measured value of the Refrigerant Circuit Pressure
ot
wit
, is n
Sensor - G805- (the A/C Pressure/Temperature Sensor -
h re
G395- , depending on the vehicle version).
hole
spec
es, in part or in w
t to the co
Note
♦ For the following test, various measured values can be selec‐
rrectness of i
ted in Guided Fault Finding and displayed in a table on the
l purpos

tion.
nform
ercia
♦ The Electrical A/C Compressor - V470- is supplied with electric

energy via a fuse installed in the Electric Drive Power and
m
a
Control Electronics - JX1- . Refer to
com
tion in
⇒ “3.5 A/C Compressor Fuse S355 , Removing and Installing”,
r
te o
thi
page 165 , ⇒ Rep. Gr. 93 ; Electric Drive Power and Control
s
iva
Electronics and ⇒ Wiring diagrams, Troubleshooting & Com‐
do
r
rp
c
ponent locations.
um
fo
en
ng
t.
yi Co
op
♦ The A/C compressor is turned off and there is no compressor
C py
t. rig
gh
speed displayed.
ht
pyri by
Vo
co lksw
by
♦ The pressure in the refrigerant circuit is same as the measured
cted agen
Prote AG.
C
15 3.0
20 4.0
25 5.0
30 6.0
35 7.0

Note

most pressure gauges, 0 bar pressure corresponds to an ab‐
solute pressure of one bar (can be seen from -1 mark below
0).
♦ Depending on version of the Climatronic Control Module -
J255- A/C control head, only integer values may be displayed
as a measured value, if the pressure
olkswagenmeasured lies between
two values the display
w en AG. V back
agswitches and forth.
AG do
e
lks s no
Vo t gu
by
♦ The displays
ris
edfor the activation of the A/C compressor
ara
nt are dif‐
ferent. For
ut a mechanically driven A/C compressor, the otarget
ho
ee
ra
and actual
ss
a current for the activation of the A/C Compressor
c
Regulator Valve - N280- are displayed. On an Electrical A/C
ce
e
nl
pt
Compressor - V470- , the target speed, which is calculated by
du
an
itte
the Climatronic Control Module - J255- and transmitted to the
y li
erm
ab
A/C Compressor Control Module - J842- , and the actual
ility
ot p
speed of the Electrical A/C Compressor - V470- , which is de‐
wit
, is n
termined by the A/C Compressor Control Module - J842- , are
h re
shown in a measured value on the Vehicle Diagnostic Tester
hole
spec
in the “Guided Fault Finding” function (for the A/C system).
es, in part or in w
t to the co
♦ Pressure in refrigerant circuit is governed by ambient temper‐
ple, the radiator), pressure displayed with a warm engine will
be slightly higher than that given for the respective ambient rrectness of i
temperature.
l purpos

nform
ercia
the table:
m
at
– Check the signal of the Refrigerant Circuit Pressure Sensor -

om
io
G805- (the A/C Pressure/Temperature Sensor - G395- de‐

n
c
in t
or
pending on the vehicle version) using the Vehicle Diagnostic

his
te

a
do
priv
cum
or
When no fault can be identified on the Refrigerant Circuit Pres‐

f
en
ng
sure Sensor - G805- (the A/C Pressure/Temperature Sensor -

t.
yi Co
op
G395- depending on the version of the vehicle) there is too little
C py
t. rig
gh
refrigerant in the circuit.
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

minates.
-10- illuminates.
• The activation of the Electrical A/C Compressor - V470- (com‐
pressor shut-off conditions and compressor speed). The Elec‐
trical A/C Compressor - V470- is activated via the A/C
Compressor Control Module - J842- by request from the -
J255- so that the RPM is greater than 800.
• Check the measured value of the Refrigerant Circuit Pressure
Sensor - G805- (the A/C Pressure/Temperature Sensor -
G395- ) (refrigerant pressure). The displayed pressure increa‐
ses above the value when the compressor is switched off.
• Read the activation of the Heater and A/C Unit Refrigerant
Cut-Off Valve - N541- and the High Voltage Battery Heater
Core Refrigerant Cut-Off Valve - N542- . The Heater and A/C
Unit Refrigerant Cut-Off Valve - N541- is not activated, the
activation of the High Voltage Battery Heater Core Refrigerant
Cut-Off Valve - N542- depends on if the High Voltage Battery
1 - AX2- must be cooled. AG. Volkswagen n AG do
wage es n
Volks ot g
by ua
ed ran
oris tee
th or
au ac
ss
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
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Note
♦ The target speed for the Electrical A/C Compressor - V470- is

calculated by the Climatronic Control Module - J255- A/C con‐
trol head. The request is sent via the data bus to the A/C
Compressor Control Module -. VJ842-
olkswag. eUse
n AG the Vehicle Diag‐
gen AG
nostic Tester in theolk“Guided
swa Fault Finding” dFunction.
oes
not
V gu
by a
♦ The A/C compressor
ris
ed operates in the driving mode with
ran a
te
speed ofau800
tho to 8600 revolutions/minute. eo
ra
ss c
♦ The A/C compressor is not actuated at the maximum specified
ce
e
nl
speed (of approximately 8500/min) on a stopped or slow mov‐
pt
du
an
ing vehicle (until the vehicle reaches a speed of about 45km/
itte
y li
erm
h) (the A/C compressor speed is limited to approximately
ab
ility
5000/min).
ot p
wit
, is n
h re
hole
energy via a fuse installed in the Electric Drive Power and
spec
es, in part or in w
t to the co
rrectness of i
ponent locations.
l purpos
♦ The A/C compressor output (the delivery volume) is not always

sufficient with a A/C compressor speed of 5000/min, a very
high exterior temperature (more than 35 °C (95 °F)) and a high
nf
ercia
fresh air blower speed (inefficient environmental controls) at

lowering the air temperature to the target value downstream orm
m
atio
m
of the evaporator. To check the regulation of the A/C com‐

o
n in
c
pressor under these conditions, for example, activate the fresh

or
thi
air blower only with approximately 40% of the maximum volt‐

te
sd
iva
age and check the temperature at a reduced fresh air blower

o
r
rp
cu
speed using the Vehicle Diagnostic Tester in the “Guided Fault

o
m
f
en
ng
Finding” Function (for the A/C system).

t.
yi Co
Cop py
♦ If little or no speed is displayed as a measured value (although ht. rig
rig ht
the required air temperature downstream of the evaporator is
py by
co Vo
by lksw
not yet achieved; the speed is less than 4000 /min), check the
Prote
cted AG.
agen
activation of the Electrical A/C Compressor - V470- by the A/
C Compressor Control Module - J842- using the Vehicle Di‐
agnostic Tester in “Guided Fault Finding” function.
♦ The Heater and A/C Unit Refrigerant Cut-Off Valve - N541-
and the High Voltage Battery Heater Core Refrigerant Cut-Off
Valve - N542- are open without current.
♦ The Heater and A/C Unit Refrigerant Cut-Off Valve - N541- is
activated for example, when no cooling output is needed by
the A/C system, but the High Voltage Battery 1 - AX2- (the
Electric Drive Power and Control Electronics - JX1- ) must be
cooled.
♦ The High Voltage Battery Heater Core Refrigerant Cut-Off
Valve - N542- is activated for example, when cooling output is
needed by the A/C system, but the Hybrid Battery Unit - AX1-
and / or the Electric Drive Power and Control Electronics - JX1-
do not need to be cooled.
– In the “read measured values” function, read out the refriger‐

ant circuit pressure measured by the Refrigerant Circuit Pres‐
sure Sensor - G805- (by the A/C Pressure/Temperature
Sensor - G395- ). The displayed pressure goes over the value
when the A/C compressor is switched off. Use the Vehicle Di‐
agnostic Tester in the “Guided Fault Finding” Function.
– Check the activation and the function of the Heater and A/C
Unit Refrigerant Cut-Off Valve - N541- ; the Heater and A/C
Unit Refrigerant Cut-Off Valve - N541- must not be activated.
ing” function.
– Check the installation position of the Heater and A/C Unit Re‐
frigerant Cut-Off Valve - N541- ; it must be installed on the
proper side (arrow shows the refrigerant flow direction from
the condenser to the expansion
wage
n AG. Vvalve).
olkswageRefer
n AG d to
oes
⇒ “2.4 Expansion yValve,
Volks Removing and Installing”, not
gu
page 110 . ised b ara
n r tee
ho
When the A/C sa
utcompressor is being driven and the Heater andor A/ ac
C Unit Refrigerant Cut-Off Valve - N541- is not activated (and is
s
ce
e
installed correctly), there is a fault in the refrigerant circuit. There

nl
pt
du
an
may be too little refrigerant in the refrigerant circuit or the Heater
itte
y li
and A/C Unit Refrigerant Cut-Off Valve - N541- is closed.
erm
ab
ility
ot p
wit
, is n
sonnel. If this is not possible, transfer the vehicle to a shop that
h re
hole
has the necessary tools and equipment and where the work
spec
can be performed by qualified personnel. Refer to
es, in part or in w
t to the co
rrectness of i
Note
l purpos
♦ The Electrical A/C Compressor - V470- is activated by the A/

C Compressor Control Module - J842- (at the request of the
nform
ercia
Climatronic Control Module - J255- A/C control head), so that

m
the air temperature reaches the specified value downstream

at
om
io
of the evaporator (approximately 2 to 6 °C (35.6 to 42.8 °F)).

n
c
in t
or
his
e
♦ After the vehicle starts, the engine speed and the A/C com‐
at
do
riv
pressor electrical system voltage are activated with a speed

p
cum
or
greater than 3000 /min depending on the measured tempera‐

f
en
g
ture. As soon as the temperature measured by the Evaporator

n
t.
yi Co
op
Temperature Sensor - G308- nears the specified value, the C py
ht. rig
activation, and thus the compressor output, is reduced. rig ht
py by
co Vo
by lksw
♦ Under certain operating conditions, residual moisture in the cted agen
Prote AG.
refrigerant circuit can lead to ice build-up on the evaporator
expansion valve in the A/C system. The A/C compressor/ ex‐
pansion valve regulation is reduced by this ice build-up. The
evaporator is either cooled too little or too intensely and po‐
tentially freezes. The ice on the evaporator may cause various
customer concerns. Refer to
page 59 .

– Press the Recirculation button -6- on the Climatronic Con‐

trol Module - J255- control head.
illuminates.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
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
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Heating, Ventilationgand
en AGAir
. VoConditioning
lkswagen AG
d
- Edition 10.2014
wa oes
olks not
yV gu
– Compare the displayed
ed b measured value for the Evaporator
ara
nte
ris
Temperatureuth Sensor - G308- with the values in the diagram.
o eo
a ra
ss c
ce
le
Sensor - G308-
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
ance range.
t to the co
– Compare the measured values for the Left Vent Temperature
rrectness of i
Sensor - G150- and the Right Vent Temperature Sensor -
G151- with the displayed measured value for the Evaporator
l purpos

nform
mercia
a
com
t
Note
ion in
r
te o
thi
♦ The temperature of the air coming out of the left and right in‐
s
iva
do
strument panel vents can also be measured with a thermom‐
r
rp
cum
eter.
fo
en
ng
t.
yi Co
♦ The A/C system function is recognizable, for example, when Cop py
. rig
the refrigerant pipe on the low pressure side (thick line) cools
t
gh ht
yri by
off. cop Vo
by lksw
cted agen
Prote
♦ The A/C compressor is not actuated at the maximum specified
AG.
speed (of approximately 8500/min) on a stopped or slow mov‐

ing vehicle (until the vehicle reaches a speed of about 45km/
h) (the A/C compressor speed is limited to approximately
5000/min).
♦ The A/C compressor output (the delivery volume) is not always
sufficient with an A/C compressor speed of 5000/min, a high
exterior temperature (more than 30 °C (86 °F)) and a high
fresh air blower speed (inefficient environmental controls) at
lowering the air temperature to the target value downstream
of the evaporator. To check the regulation of the A/C com‐
pressor under these conditions, for example, activate the fresh
air blower only with approximately 40% of the maximum volt‐
age and check the temperature at a reduced fresh air blower
speed using the Vehicle Diagnostic Tester in the “Guided Fault
Finding” Function for the A/C system.
If the measured values of the Evaporator Temperature Sensor -

G308- and Left Vent Temperature Sensor - G150- / Right Vent
Temperature Sensor - G151- only deviate from each other slight‐
ly:
Value”, page 57 .
G308- is greater than the measured value for the Left Vent
Temperature Sensor - G150- or Right Vent Temperature Sensor
- G151- :


G308- and the A/C system cooling output is OK and there are no
complaints, the cooling output test ends.
G308- (and the A/C system cooling output) is not OK:
values are not reached (required cooling output not reached).
Refer to
Value”, page 57 .
G308- (and the A/C system cooling output) is OK and there is a
complaint due to excessive or different vent temperatures for the
A/C system:
– Check the actuation of the temperature doors in the A/C unit
(refer to
page 230 ) and use the Vehicle Diagnostic Tester in the “Gui‐
If the measured value of the Evaporator Temperature Sensor -
G308- (and thus the A/C system cooling output) is OK, and if there
is a complaint due to a lack of cooling output for the high voltage
system components
– Check the activation and function of the High Voltage Battery
Heater Core Refrigerant Cut-Off Valve - N542- ; the High Volt‐
AG. Volkswagen AG d
age Battery Heater Core Refrigerant kswCut-Off
agen Valve - N542- oes n
Vol
must not be activated, when thebycooling output for the cooling ot gua
of the high voltage system components
rised
is requested. Refer to ran
tee
⇒ “7.2 High Voltage Battery
aut Heat Exchanger Incorporation in
ho
or
ac
the High Voltage Systemss Coolant Circuit”, page 288 and use
ce
le
un
pt
function.
an
d
itte
y li
rm
ab
– Check the installation position of the High Voltage Battery

pe
ility
Heater Core Refrigerant Cut-Off Valve - N542- ; it must be

ot
wit
installed on the proper side (arrow shows the refrigerant flow

, is n
h re
direction from the condenser to the high voltage battery heat

hole
spec
exchanger). Refer to
es, in part or in w
⇒ “2.11 High Voltage Battery Heater Core Refrigerant Cut-Off

t to the co
Valve N542 , Removing and Installing”, page 131 .

– Check the incorporation of the high voltage battery heat ex‐
rrectness of i
changer in high voltage system coolant circuit. Refer to

⇒ “7.2 High Voltage Battery Heat Exchanger Incorporation in
l purpos
the High Voltage System Coolant Circuit”, page 288 and ⇒

nform
ercia
– Check the function and activation of the High Voltage Battery

Coolant Pump - V590- and the High Voltage Battery Coolant
m
a
com
Valve - N688- using the Vehicle Diagnostic Tester in the “Gui‐

ion in
ded Fault Finding” (for hybrid battery management system).

r
te o
thi
Refer to
s
iva
do

r
rp
cum

fo
en
g

n
t.
yi Co
Cop py
If the A/C compressor is being driven, the High Voltage Battery
t. rig
gh ht
yri
Heater Core Refrigerant Cut-Off Valve - N542- is not activated
p by
co Vo
by lksw
(and is installed correctly) and no fault can be determined in the Prote
cted AG.
agen
high voltage system coolant circuit, then there is a fault in the
refrigerant circuit. The constriction (restrictor) in the refrigerant
line between the High Voltage Battery Heater Core Refrigerant
Cut-Off Valve - N542- and the high voltage battery heat exchang‐
er or the High Voltage Battery Heater Core Refrigerant Cut-Off
Valve - N542- may be closed. Refer to
⇒ “2.14 Refrigerant Line with Restrictor”, page 141 .
Note

Valve - N542- is closed in the A/C system regulated mode; it
is activated by the Climatronic Control Module - J255- A/C
control head. Only when the coolant output via the high voltage
battery heat exchanger is required from the High Voltage Bat‐
tery 1 - AX2- and / or the Electric Drive Power and Control
Electronics - JX1- the Climatronic Control Module - J255- wage
es n
switches off the activation for the High Voltage Battery Heater yV
olks ot g
ua
Core Refrigerant Cut-Off Valve - N542- and the refrigerant ir secan
d b ran
tee
flow via the restrictor in the refrigerant line into the highuthvoltage
o
or
battery heat exchanger and cool it. The High Voltage ss Battery
a ac
1 - AX2- is only cooled, however, when the High Voltage Bat‐
ce
le
un
pt
tery Coolant Pump - V590- is also activated correctly. For
an
d
cooling the Electric Drive Power and Control Electronics - JX1- itte
y li
erm
ab
and the High Voltage Battery Charger Control Module -
ility
ot p
J1050- , the High Voltage Battery Coolant Valve - N688- and
wit
is n
the Coolant Pump in front of Electric Drive Power and Control
h re
Electronics - V508- must also be activated correctly. Use the
ole,
spec
tion (for hybrid battery management system). Refer to
t to the co
rrectne
♦ The Climatronic Control Module - J255- A/C control head de‐
tects a fault in the connection between the Climatronic Control
ss
Module - J255- and the High Voltage Battery Heater Core Re‐
o
cial p
f i
frigerant Cut-Off Valve - N542- . Depending on its version, the
nform
Climatronic Control Module - J255- switches off the Electrical
mer
A/C Compressor - V470- activation when there is a fault and
atio
m
there is no more coolant output.

o
n
c
i
or
n thi
e
♦ Depending on the version of the Climatronic Control Module -

t
sd
va
J255- A/C control head, the High Voltage Battery Heater Core
i
o
pr
cum
r
Refrigerant Cut-Off Valve - N542- is not activated if the Elec‐

fo
en
ng
trical A/C Compressor - V470- output diagnostic test mode is

t.
yi Co
op
being performed, so that the cooling function of the high volt‐ C py
t. rig
age battery heat exchanger can be checked using the Vehicle
gh ht
pyri by
co Vo
by lksw
cted agen
Prote AG.
Valve - N542- -A- is open without current, which means that
the high voltage battery heat exchanger is being cooled as
long as the High Voltage Battery Heater Core Refrigerant Cut-
Off Valve - N542- is not activated when A/C system is in
operation. If, with the ignition switched off, another shut-off
valve is connected (with the same electrical values as the in‐
stalled High Voltage Battery Heater Core Refrigerant Cut-Off
Valve - N542- -A-) or if a coil -B- is removed from the shut-off
valve -D- (if the connector to the coil -B- must be disconnected
to remove it, it must be reconnected), the cooling function of
the high voltage battery heat exchanger can be checked, with‐
out a fault being detected in the Climatronic Control Module -
J255- . Refer to
⇒ “2.12 High Voltage Battery Heat Exchanger, Removing and
Installing”, page 133 .
♦ To remove the coil -B-, remove the bolts -C- (do not disconnect
the connector with the ignition switched on, or reconnect be‐
fore switching the ignition on after removing).

agen oes
olksw Heating, Ventilation
not and Air Conditioning - Edition 10.2014
yV gu
edb ara
ris ntee
♦ If the cooling
ut output of the vehicle is OK and the high voltage
ho or
battery heat
ss
a exchanger is cooled correctly with the High Volt‐ ac
age Battery Heater Core Refrigerant Cut-Off Valve - N542- not
ce
le
un
pt
activated, check the activation of the High Voltage Battery
an
d
itte
Heater Core Refrigerant Cut-Off Valve - N542- as well as the
y li
erm
ab
incorporation of the high voltage battery heat exchanger in the
ility
ot p
low temperature coolant circuit, and also the activation and
wit
is n
function of the related components when there is a complaint.
h re
ole,
spec
ing” function for the hybrid battery management system). Re‐
fer to
t to the co
rrectne
♦ If the cooling output of the vehicle is OK and the high voltage
battery heat exchanger is not being cooled with an unactuated
ss
High Voltage Battery Heater Core Refrigerant Cut-Off Valve -
o
cial p
f i
N542- (or a removed coil -B-), it could be due to a closed
nform
restrictor in the refrigerant line -E-. Refer to
mer
atio
om
n
c
i
or
n thi
– If there is a fault in the refrigerant circuit the necessary work
te
sd
a
may only be performed by qualified personnel. If this is not

iv
o
pr
c
possible, transfer the vehicle to a workshop that has the nec‐
um
r
fo
en
ng
essary tools and equipment and where the work can be per‐ yi
t.
Co
formed by qualified personnel. Refer to t. Cop py
rig
gh ht
yri by
detected problems to the attention of the workshop. cop Vo
by lksw
cted agen
Prote AG.
4.4.6 Determining Malfunction if Deviation

from Specified Value
The required cooling output is not attained. Refer to
Control System”, page 36 ,
mate Control System (without High Voltage System)”, page 41
and
mate Control System (with High Voltage System)”, page 46 .
Note

If a target value is not reached, this can be caused by various

things:
– Determine the cause using the Vehicle Diagnostic Tester in
Possible causes for the deviation of the target value:
♦ Dirty radiator or Air Conditioning (A/C) system condenser.
♦ Retrofitted components at or in the front end.
♦ Fault in the activation or function of the Coolant Fans -V7- / -
V177- .
♦ Fault in the coolant circuit, the coolant gets too hot.
♦ Fault in the activation of the A/C Compressor Regulator Valve

- N280- by the A/C Control Module - J301- / Climatronic Con‐
trol Module - J255- (vehicles without a high voltage system).
♦ Requests transmitted by one of the other control modules to
the A/C Control Module - J301- / Climatronic Control Module
- J255- to switch off the A/C Compressor Regulator Valve -
N280- actuation (vehicles without a high voltage system).
♦ Fault in the A/C Compressor Regulator Valve - N280- function
(vehicles without a high voltage system).
♦ Fault in the refrigerant circuit or A/C compressor.
♦ Fault in the activation or the function of the Battery Regulation
Control Module - J840- , the Electrical A/C Compressor -
V470- , the A/C Compressor Control Module - J842- or the
Heater and A/C Unit Refrigerant Cut-Off Valve - N541-
If a fault was detected in the refrigerant circuit by the “Guided Fault
Finding”:
– If there is a fault in the refrigerant circuit the necessary work
may only be performed by qualified personnel. If this is not
possible, transfer the vehicle to a workshop that has the nec‐
essary tools and equipment and where the work can be per‐
formed by qualified personnel. Refer to
4.4.7 Determining Malfunction of Tempera‐

ture Increase Downstream from Evapo‐
rator
The temperature increase in the Air Conditioning (A/C) unit is too
great. Refer to
Control System”, page 36 ,
olkswagen ACli‐
mate Control System (without High Voltage w en AG. V
agSystem)”, page 41G do
es n
ks
and y Vol ot g
ua
d b
⇒ “4.4.5 Cooling Output, Checking,
orise Vehicles with Automatic Cli‐ ran
tee
mate Control System (with High
au Voltage System)”, page 46 .
th or
a
ss c
ce
le
un
pt
Note
an
d
itte
y li
erm
ab
ility

ot p
wit
is n
h re

ole,

spec
t to the co
If a target value is not reached due to a temperature increase

downstream from the evaporator, this can be caused by various
things:
rrectne
– Determine the cause using the Vehicle Diagnostic Tester in

ss o
cial p
Possible causes for the deviation of the target value:

inform
mer
♦ Due to a fault in the activation, the temperature doors do not

atio
m
reach the end stops correctly in the A/C unit.

o
n
c
i
or
♦ One or several measured values of the temperature sensors

thi
te
sd
a
are faulty.
iv
o
pr
cum
r
fo
♦ Warmed up air flows by the temperature doors set in the “cold”

en
ng
t.
position.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Note
This fault can be determined as follows: Clamp off both coolant

hoses from the engine to the heater and A/C unit heater core us‐
ing, for example, the Hose Clamps - Up To 40mm - 3093- and
then repeat the cooling output test. If the measured values are
then OK, this indicates a fault near the temperature doors.
4.4.8 Ice Formation on Evaporator, Localizing

Malfunction
Vehicles without A High Voltage System
♦ The A/C Control Module - J301- / Climatronic Control Module
- J255- control head actuates the A/C Compressor Regulator
Valve - N280- so that the air temperature reaches the specified
value downstream of the evaporator (about 2 to 6 °C (35.6 to
42.8 °F)).
♦ Depending on the measured temperature, engine speed and
electrical system voltage in “Read measured values” of the A/
C Control Module - J301- / Climatronic Control Module - J255-
control head for the actuation of the A/C Compressor Regu‐
lator Valve - N280- , a value greater than 0.55 A (75%) is
displayed after vehicle start. Use the Vehicle Diagnostic Test‐
er in the “Guided Fault Finding” function. As soon as the
temperature measured by the Evaporator Temperature Sen‐
sor - G308- nears the specified value, the activation, and thus
the compressor output, is reduced.
AG. Volkswagen AG d
agen
♦ Ice build-up can occur olks on the evaporator under
w oes
noextreme
t gu cir‐
yV
cumstances for ed particularly unfavorable Air Conditioning
b ara
n
(A/C)
system settingsris (for example, airflow direction is set toteethe in‐
tho or
struments au panel vents and these vents are closed, set to MAX ac
AC fors a minimal fresh air blower speed). At this setting, air is
ce
e
nl
no longer flowing through the evaporator and is making the

pt
du
an
temperature at the Evaporator Temperature Sensor - G308-

itte
y li
higher than the actual evaporator temperature. It can be as‐

erm
ab
ility
sumed for the A/C system regulation, that the measured value
ot p
wit
of the Evaporator Temperature Sensor - G308- corresponds

, is n
h re
to the actual evaporator temperature and continues to activate

hole
the A/C Compressor Regulator Valve - N280- and the evapo‐

spec
es, in part or in w
rator cools too much.

t to the co

circuit can lead to ice build-up on the A/C compressor regulator
valve and on the expansion valve. A/C compressor regulation
rrectness of i
is reduced by this ice build-up. The evaporator is cooled too

l purpos
intensely and freezes. The freeze-up of the evaporator can be

the cause for the following customer complaints. Refer to
⇒ page 60 .
nform
ercia
Vehicles with A High Voltage System

m
at
om
io
♦ The Electrical A/C Compressor - V470- is activated via the A/

n
c
in t
or
C Compressor Control Module - J842- by the Climatronic Con‐

his
te
trol Module - J255- A/C control head, so that the air tempera‐
a
do
riv
ture reaches the specified value downstream of the evaporator

p
cum
or
(approximately 2 to 6 °C (35.6 to 42.8 °F)).

f
en
ng
t.
yi Co
op
C py
ht. rig
energy via a fuse installed in the Electric Drive Power and rig ht
py by
Vo
co lksw
by
cted agen
Prote AG.
ponent locations.
♦ After the turning on the ignition and depending on the speed
of the vehicle, the measured temperature and the electrical
system voltage, a value for the A/C compressor RPM greater

than 3000 /min is displayed. As soon as the temperature
measured by the Evaporator Temperature Sensor - G308-
nears the specified value, the activation, and thus the com‐
pressor output, is reduced.
♦ Ice build-up can occur on the evaporator under extreme cir‐
cumstances for particularly unfavorable A/C system settings
(for example, airflow direction is set to the instrument panel
vents and these vents are closed, set to MAX AC for a minimal
fresh air blower speed). At this setting, air is no longer flowing
through the evaporator and is making the temperature at the
Evaporator Temperature Sensor - G308- higher than the ac‐
tual evaporator temperature. It can be assumed for the A/C
system regulation, that the measured value for the Evaporator
Temperature Sensor - G308- corresponds to the actual evap‐
orator temperature and continues to activate the Electrical A/
C Compressor - V470- at a higher speed and the evaporator
cools too much.
♦ If the A/C system is switched off and coolant output is required
via the high voltage battery heat exchanger by the Battery
Regulation Control Module - J840- (for the High Voltage Bat‐
tery 1 - AX2- ) or by the Electric Drive Power and Control
Electronics - JX1- , it can also lead to evaporator ice-up under
unfavorable conditions if the Heater and A/C
AG. VUnit
olkswaRefrigerant
gen AG
agen do
Cut-Off Valve - N541- function is Vonot
lksw OK. The Climatronic es not
gu
Control Module - J255- A/Cecontrol db
y head activates the Elec‐ ara
nte
trical A/C Compressor - tV470-
ho
ris
and the Heater and A/C Unit eo
Refrigerant Cut-Off Valves au - N541- . If the Heater and A/C Unit ra
c
Refrigerant Cut-Off Valve
s
- N541- does not close, the evapo‐
ce
e
nl
rator cools so much that the condensation water on the evap‐

pt
du
an
orator slats freezes, because there is no regulation of the
itte
y li
evaporator temperature. Check the function of the Heater and

erm
ab
ility
A/C Unit Refrigerant Cut-Off Valve - N541- using the Vehicle

ot p
wit
Diagnostic Tester in the “Guided Fault Finding” (for the A/C

, is n
h re
system).
hole
spec

es, in part or in w
t to the co
circuit can lead to ice build-up on the expansion valve. A/C

compressor regulation is reduced by this ice build-up. The
evaporator is cooled too intensely and freezes. The freeze-up
of the evaporator can be the cause for the following customer
rrectness of i
complaints. Refer to ⇒ page 60 .

l purpos
Possible Customer Complaints (all vehicles with and without a

high voltage system):
nform
ercia
♦ After a long drive, A/C system repeatedly or sporadically fails

m
at
(no cooling or heating performance), after switching off the

om
io
vehicle or A/C system and after a short time, the A/C function
n
c
in t
or
is OK again.
his
ate
do
riv
♦ Vehicles with automatically regulated A/C system: after a long

p
cum
or
drive, windows fog up from inside, windows are also not

f
en
ng
cleared by then pressing the “Defrost” button, after switching

t.
yi Co
op
off vehicle and after a short time, A/C function is OK again.
C py
t. rig
gh ht
yri by
Corrective measure:
op Vo
by c lksw
cted agen
Prote
– Check the measured value for the Evaporator Temperature
AG.
Sensor - G308- using the Vehicle Diagnostic Tester in the

If the measured value of the sensor is too high under the operating
conditions reported by the customer, even though the A/C system
is operating without difficulty at greater than, for example, 10 °C
(50 °F), depending on ambient temperature:
– Check the Evaporator Temperature Sensor - G308- . The
evaporator can ice up due to an incorrect measured value.

wage es n
If the measured value of the sensor is too olks under the operating
Vlow ot g
by ua
conditions reported by the customer, ris
e(at an ambient temperature
d ran
tee
above 0 °C (32 °F), longer whenuthito is lower than 0 °C (32 °F)): or
sa ac
– Check the refrigerant line from
s
the connection location on the
ce
le
right longitudinal member (from the inner heat exchanger or
un
pt
an
d
from the evaporator) to the A/C compressor (thick pipe, low
itte
y li
pressure side) with the engine running. If this line is thickly
erm
ab
ility
iced-up when complaint occurs (a thin layer of ice is permit‐ ot p
wit
ted), this indicates that the temperature in the evaporator is
is n
h re
too low.
ole,
spec
– There is a fault in the refrigerant circuit the A/C compressor
t to the co
control could not be OK.
– Check the pressures in the refrigerant circuit. Refer to ⇒ Re‐
frigerant R134a Servicing; Rep. Gr. 00 ; Pressures, Checking .
rrectne
sonnel. If this is not possible, transfer the vehicle to a shop that
ss o
has the necessary tools and equipment and where the work
cial p
f i
can be performed by qualified personnel. Refer to
nform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5 Technical Data
⇒ “5.1 Refrigerant R134a Capacities”, page 62
⇒ “5.2 Refrigerant Oil”, page 62
⇒ “5.3 Oil Distribution”, page 62
5.1 Refrigerant R134a Capacities

For complete R134a refrigerant capacity. Refer to ⇒ Mainte‐
nance ; Booklet 36.1
5.2 Refrigerant Oil

Do not use refrigerant oil that was stored for long periods of time
in open containers.
Refrigerant oil attracts moisture. Close any opened containers
immediately after use to prevent moisture from entering.
Refrigerant Oil Can Be Obtained Using Following Part Number;
for:
6SES14C; Denso G 052 300 A2
11PXE14; Sanden G 052 154 A2
6CVC140; Delphi G 052 154 A2 / G 052 300
A2
Hybrid; Visteon G 052 535 M2
r complete refrigerant oil capacity. Refer to ⇒ Maintenance ;
Booklet 36.1
5.3 Oil Distribution

The oil, which is located in the sump of the AGAir
. VolConditioning
kswagen AG (A/C)
compressor before initially switching agen
ksw on the air conditioneresys‐
do s
ol not
tem, is distributed through thed b refrigerant circuit as follows:
yV gu
ar
e an
ris tee
♦ A/C compressor approximately
ut
ho 50% or
a ac
ss
♦ Condenser approximately 10%
ce
e
nl
pt
du
an
♦ Suction hose approximately 10%

itte
y li
erm
ab
♦ Evaporator approximately 20%

ility
ot p
wit
♦ Receiver/dryer approximately 10%

, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

80 – Heating, Ventilation
1 Component Location Overview -
Heating
⇒ “1.1 Component Location Overview - Components Outside of
Passenger Compartment”, page 63
⇒ “1.2 Component Location Overview - Components Inside Front
. Volkswagen AG
Passenger Compartment”, w gen AG67
apage does
ks n ol ot g
yV ua
1.1 Component Location Overview - Com‐
ris
edb ran
tee
tho
ss
ponents Outside of Passenger Com‐
au
or
ac
partment
ce
e
nl
pt
du
an
itte
⇒ “1.1.1 Component Location Overview - Components Outside of
y li
erm
ab
ility
ot p
wit
, is n
h re
Passenger Compartment, Wagon”, page 65
hole
spec
1.1.1 Component Location Overview - Components Outside of Passenger Com‐
es, in part or in w
t to the co
partment
rrectness of i
1 - Vehicle Interior Forced Air
l purpos
Extraction
❑ Checking. Refer to
⇒ “6.9 Passenger Com‐
nform
ercia
partment Forced Air Ex‐

m
at
traction, Checking”,
om
io
page 280 .
n
c
in t
or
❑ Removing and instal‐

his
ate
do
riv
ling. Refer to
p
⇒ “6.10 Passenger
um
for
en
g
Compartment Forced
n
t.
yi Co
Air Extraction, Remov‐ Cop py
t. rig
ing and Installing”, page yri
gh by
ht
281 .
op Vo
by c lksw
cted agen
Prote
2 - Outside Air Temperature
AG.
Sensor - G17-
ling. Refer to
⇒ “9.4 Outside Air Tem‐
perature Sensor G17 ,
Removing and Instal‐
ling”, page 307 .
3 - Fresh Air Intake Cover
ling. Refer to
⇒ “6.3 Fresh Air Intake
Cover, Removing and
4 - Fresh Air Intake
ling. Refer to
⇒ “6.2 Fresh Air Intake,
ling”, page 273 .
1. Component Location Overview - Heating 63


partment, Golf RHD
1 - Vehicle interior forced air

extraction
page 280 .
ling. Refer to
Compartment Forced
Air Extraction, Remov‐
ing and Installing”, page
281 .
2 - Fresh air intake
ling. Refer to
⇒ “6.2.2 Fresh Air In‐
take, Removing and In‐
stalling, RHD”,
page 273 .
3 - Fresh air intake cover
ling. Refer to
⇒ “6.3.2 Fresh Air Intake
Cover, Removing and wage
es n
s
Installing, RHD”, yV
olk ot g
ua
page 275 . ir se
d b ran
tee
tho
or
4 - Outside Air Temperature au ac
ss
Sensor - G17-
ce
e
nl
pt
du
an
itte
ling. Refer to
y li
erm
ab
ility
ot p

wit
, is n

ling”, page 307 . h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
64 Rep. Gr.80 - Heating, Ventilation

Heating, Ventilation
genand
AG. VAir
olksConditioning
wagen AG
d
- Edition 10.2014
wa oes
olks not
yV gu
b ara
ed nte
ris
ho eo
partment, Wagon
t
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
Extraction
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
page 280 .
t to the co
ling. Refer to
rrectness of i
⇒ “6.10.2 Passenger
Compartment Forced
l purpos

ing and Installing, Golf
Wagon”, page 281 .
nform
ercia

m
at
om
Sensor - G17-
ion
c
in t
r

o
his
te
ling. Refer to
a
do
riv

p
cum
or

f
en
ng
t.
yi
Co
op py
ling”, page 307 . t. C rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote
AG.
ling. Refer to
⇒ “6.3 Fresh Air Intake
Cover, Removing and
ling. Refer to
⇒ “6.2 Fresh Air Intake,
ling”, page 273 .


AG. Volkswagen AG d
agen
partment, Golf
yV
olk Wagon RHD
sw oes
not
gu
b ara
ed nte
oris e
th or
1 - Vehicle interior
ss
forced air au ac
extraction
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
page 280 .
h re
hole
spec
ling. Refer to
es, in part or in w
t to the co
Compartment Forced
rrectness of i
l purpos

nform
ercia
ling. Refer to
m
at
om
io
n
c
in t
r
stalling, RHD”,
o
his
te
page 273 .
a
do
priv
cum
or

f
en
ng
t.
yi
Co
op py
ling. Refer to
t. C rig
gh ht
yri
⇒ “6.3.2 Fresh Air Intake p by
o Vo
by c
Cover, Removing and
lksw
cted agen
Prote
Installing, RHD”,
AG.
page 275 .
Sensor - G17-
ling. Refer to
ling”, page 307 .


ponents Inside Front Passenger Com‐
partment
⇒ “1.2.1 Component Location Overview - Components Inside
Front Passenger Compartment”, page 67
1.2.1 Component Location Overview - Components Inside Front Passenger

Compartment
1 - Driver Side Footwell Vent

ling. Refer to
⇒ “6.5 Driver Side Foot‐
well Vent, Removing
and Installing”,
page 276 .
❑ Overview. Refer to n AG. Volkswagen AG do
⇒ “6.1 Overview - Air lkswage es n
Vo ot g
Routing and Air Distri‐ ed by ua
ran
bution in Passengerthoris tee
or
Compartment”, s au ac
page 271 . s
ce
e
nl
pt
du
2 - Temperature Regulator
an
itte
y li
Door Motor - V68-
erm
ab
ility
ot p
wit
ling. Refer to
, is n
h re
⇒ “4.5 Left Temperature
hole
spec
Door Motor V158 with
es, in part or in w
Left Temperature Door

t to the co
Potentiometer/Actuator
G220 , Removing and
rrectness of i
3 - Air Distribution Door Motor

l purpos
- V428-
nform
ercia
ling. Refer to
⇒ “4.8 Front Air Distri‐
m
at
bution Door Motor V426

om
io
with Air Distribution

n
c
in t
or
Door Motor Position

his
ate
Sensor G642 , Remov‐

do
priv

um
for
199 .
en
ng
t.
yi Co
op
4 - Dust and Pollen Filter
C py
t. rig
gh ht
yri
p by
co Vo
by lksw
ling. Refer to Prote
cted AG.
agen
⇒ “5.11 Dust and Pollen Filter, Removing and Installing”, page 234 .
5 - Recirculation Door Motor - V113-
❑ Removing and installing. Refer to
⇒ “4.4 Recirculation Door Motor V113 , Removing and Installing”, page 183 .
6 - Fresh Air Blower - V2-
❑ Removing and installing. Refer to ⇒ “5.12 Fresh Air Blower V2 , Removing and Installing ”, page 238 .
7 - Front Passenger Side Footwell Vent
⇒ “6.6 Front Passenger Side Footwell Vent, Removing and Installing”, page 277 .
❑ Overview. Refer to
⇒ “6.1 Overview - Air Routing and Air Distribution in Passenger Compartment”, page 271 .

8 - Auxiliary Heater Heating Element - Z35- with Auxiliary Air Heater Control Module - J604-
⇒ “5.13 Auxiliary Heater Heating Element Z35 with Auxiliary Air Heater Control Module J604 , Checking”,
page 240 .
⇒ “5.14 Auxiliary Heater Heating Element Z35 with Auxiliary Air Heater Control Module J604 , Removing
and Installing”, page 242 . gen AG
. Volkswagen AG
a does
lksw n
9 - Heater Core db
yV
o ot g
ua
e ran
❑ Removing and installing. Refer to ⇒ “5.15 Heater
thoCore,
ris Removing and Installing”, page 244 t.ee
o
au ra
10 - Display and Control Head ss c
ce
le
un
pt
Removing and installing. Refer to ⇒ “8.2 Display and Control Head, Removing and Installing”, page 301 .
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
Compartment, RHD
h re
hole
spec
es, in part or in w
t to the co
1 - Recirculation Door Motor -
V113-
rrectness of i
ling. Refer to
l purpos
⇒ “4.4.2 Recirculation
Door Motor V113 , Re‐
moving and Installing,
nform
ercia
RHD”, page 184 .

m
a
com
tion in
r
te o
thi
ling. Refer to
s
iva
do
⇒ “5.11.2 Dust and Pol‐
r
rp
cum
len Filter, Removing and
fo
en
g
Installing, RHD”,
n
t.
yi Co
op
page 236 . C py
ht. rig
rig ht
by
3 - Temperature Regulator copy Vo
by lksw
Door Motor - V68- cted agen
Prote AG.
ling. Refer to
⇒ “4.2.2 Temperature
Regulator Door Motor
V68 , Removing and In‐
stalling, RHD”,
page 177 .
- V428-
ling. Refer to
⇒ “4.9.2 Air Distribution
RHD”, page 204 .
5 - Driver side footwell vent
ling. Refer to
⇒ “6.5.2 Driver Side
Footwell Vent, Remov‐
ing and Installing, RHD”, page 277 .
6 - Display and Control Head

7 - Heater core
❑ Removing and installing. Refer to ⇒ “5.15 Heater Core, Removing and Installing”, page 244 .
page 240 .
⇒ “5.14.2 Auxiliary Heater Heating Element Z35 with Auxiliary Air Heater Control Module J604 , Re‐
moving and Installing, RHD”, page 243 .
⇒ “5.12.2 Fresh Air Blower V2 , Removing and Installing, RHD”, page 239 .
10 - Front passenger side footwell vent
⇒ “6.6.2 Front Passenger Side Footwell Vent, Removing and Installing, RHD”, page 278 .
⇒ “6.1 Overview - Air Routing gand Air
en AG. VoDistribution
lkswagen AG in Passenger Compartment”, page 271 .
wa does
olks not
byV gu
ara
ed nte
ris
tho eo
au ra
c
ss
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
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2 Actuators
⇒ “2.1 Component Location Overview - Front Actuators”,
page 70
⇒ “2.2 Temperature Regulator Door Motor V68 with Temperature
Regulator Door Motor Position Sensor G92 , Removing and In‐
stalling”, page 72
⇒ “2.3 Recirculation Door Motor V113 , Removing and Installing”,
page 72
⇒ “2.4 Air Distribution Door Motor V428 with Position Sensor Air
Distribution Door Motor Position Sensor G645 , Removing and
Installing”, page 73 olkswage es n
o
yV t gu
db ara
2.1 Component Location Overview - Front
ho
ir se nte
eo
ut
Actuators
ss
a ra
c
ce
le
un
⇒ “2.1.1 Component Location Overview - Front Actuators”,
pt
an
d
page 70
itte
y li
erm
ab
2.1.1 Component Location Overview - Front Actuators
ility
ot p
wit
is n
h re
ole,
spec
Door Motor - V68-
t to the co
❑ Check using the Vehicle
Diagnostic Tester
❑ Removing and instal‐ rrectne
ling. Refer to
⇒ “4.2 Temperature
ss

o
cial p
f i
V68 with Temperature

nform

mer
Position Sensor G92 ,

atio
m

o
n
c
i
or
ling”, page 176 .

thi
te
sd
a
❑ Replacing: initiate basic

iv
o
pr
setting using the Vehicle

um
r
fo
en
ng
Diagnostic Tester . yi
t.
Co
op py
t. C rig
gh ht
yri
- V428- p by
co Vo
by lksw
cted agen
Prote AG.
Diagnostic Tester
ling. Refer to
⇒ “4.9 Air Distribution
Position Sensor Air Dis‐
tribution Door Motor Po‐
sition Sensor G645 , Re‐
moving and Installing”,
page 202 .
Diagnostic Tester .
V113-
Diagnostic Tester
ling. Refer to ⇒ “4.4 Recirculation Door Motor V113 , Removing and Installing”, page 183 .

❑ Replacing: initiate basic setting using the Vehicle Diagnostic Tester .
2.1.2 Component Location Overview - Front Actuators, RHD

V113-
Diagnostic Tester
ling. Refer to
⇒ “4.4 Recirculation
page 183 .
setting using the Vehicle n AG. Volkswagen AG do
Diagnostic Tester . lkswage es n
Vo ot gu
y
db ara
2 - Air Distribution Door Motorris
e nte
- V428- utho eo
ra
a c
ss
ce
e
nl
Diagnostic Tester
pt
du
an
itte
y li
erm
ab
ling. Refer to
ility
ot p
wit
, is n
h re
hole
spec
RHD”, page 204 .
es, in part or in w
t to the co
Diagnostic Tester . rrectness of i
l purpos
Door Motor - V68-

Diagnostic Tester
nform
ercia

m
at
ling. Refer to
om
ion
⇒ “4.2.2 Temperature
c
in t
or

his
ate

do
priv
stalling, RHD”,
um
for
page 177 .
en
ng
t.
yi Co
op
❑ Replacing: initiate basic setting using the Vehicle Diagnostic Tester . C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Actuators 71
2.2 Temperature Regulator Door Motor -

V68- with Temperature Regulator Door
Motor Position Sensor - G92- , Remov‐
ing and Installing
⇒ “2.2.1 Temperature Regulator Door Motor V68 with Tempera‐
ture Regulator Door Motor Position Sensor G92 , Removing and
Installing”, page 72
2.2.1 Temperature Regulator Door Motor -

ing and Installing
The removal and installation is identical to vehicles with an A/C
system. Refer to
stalling”, page 176 .

ing and Installing, RHD
system. Refer to
2.3 Recirculation Door Motor - V113- , Re‐

moving and Installing
. gen AG Volkswa
gen AG
⇒ “2.3.1 Recirculation Door Motor V113o,lkRemoving
swa and Instal‐ does no
ling”, page 72 ed
by
V t gu
ara
is nte
or
2.3.1 Recirculations aDoor Motor - V113- , Re‐
h eo
ut ra
c
s
ce
le
un
pt
an
d
itte

y li
erm
ab
system. Refer to
ility
ot p

wit
page 183 .
is n
h re
ole,
2.3.2 Recirculation Door Motor - V113- , Re‐

spec
moving and Installing, RHD

t to the co

system. Refer to
rrectne

page 183 .
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
72
Prote AG.
Rep. Gr.80 - Heating, Ventilation
AG. Volkswagen AG d
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Air Distribution Door Motor Position Sensor G645 , Removing and
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2.4.1 Air Distribution Door Motor - V428- with
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system. Refer to
2. Actuators 73
3 Heater
⇒ “3.1 Overview - Heater”, page 74
⇒ “3.2 Fresh Air Blower V2 , Removing and Installing”,
page 79
⇒ “3.3 Fresh Air Blower Control Module J126 , Removing and
⇒ “3.4 Dust and Pollen Filter, Removing and Installing”,
page 79
⇒ “3.5 Heater, Removing and Installing”, page 79
⇒ “3.6 Heater, Disassembling and Assembling”, page 79
⇒ “3.7 Auxiliary Heater Heating Element Z35 with Auxiliary Air
Heater Control Module J604 , Checking”, page 79
Heater Control Module J604 , Removing and Installing”,
page 80
⇒ “3.9 Heater Core, Removing and Installing”, page 80
⇒ “3.10 Partition, Removing and Installing”, page 80
3.1 Overview - Heater
Note
♦ There are different versions and manufacturers of the heater.

Individual components of the different heaters are similar but
not the same. Interchanging components from different man‐
ufacturers is not permitted. Refer to the Parts Catalog.
♦ A heater manufactured by “Valeo” is shown in the following
illustrations. For distinguishing characteristics between man‐
ufacturers, refer to
⇒ “2.1 Heater and A/C Unit ageIdentification”,
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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 and refer to
⇒ Wiring diagrams,
Troubleshooting &
Component locations. n AG. Volkswagen AG do
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3 - Screw
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4 - Screw
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❑ Quantity: 3
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5 - Screw
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❑ Quantity: 2
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7 - Operating Lever
❑ For the operating of the warm air door
8 - Heater
❑ There are different versions. Refer to ⇒ “2.1 Heater and A/C Unit Identification”, page 4 .
❑ Interchanging components is not permitted.
❑ The following illustrations show the heater manufactured by “Valeo”
❑ The design is largely the same as the heater and Air Conditioning (A/C) unit design.
❑ The expansion valve, condensation water drain, evaporator, etc. are not present.
❑ (only on vehicles without an A/C system) instead of the evaporator an airflow limiter is installed.
❑ 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.
❑ Removing and installing. Refer to ⇒ “5.5 Heater and A/C Unit, Removing and Installing”, page 224 .
3. Heater 75
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9- Defroster-
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⇒ “4.10 Air Distribution Door Adjuster, Removing and Installing”, page 207 .
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Heater, Heater Core, Auxiliary Heater Heating Element
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1 - Screw
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❑ 2 Nm
2 - Coolant Pipe for The Heater
rrectness of i
Core
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sions. Refer to the Parts
Catalog.
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❑ Coolant Supply from

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4 - Coolant pipe for the Heater
Core
Catalog.
❑ Coolant Return to En‐
gine
ling. Refer to
⇒ “5.16 Heater Core
Coolant Pipes, Remov‐
260 .
5 - Seal
Catalog.
❑ 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.
❑ Removing and installing. Refer to ⇒ “5.15 Heater Core, Removing
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and
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⇒ “5.13 Auxiliary Heater Heating Element Z35swith
au Auxiliary Air Heater Control Module J604 , Checking”,ac
page 240 . s
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15 - Wire
❑ For the Auxiliary Heater Heating Element - Z35- with Auxiliary Air Heater Control Module - J604-
rrectness of i
16 - Ground Cable for the Auxiliary Heater Heating Element - Z35- with Auxiliary Air Heater Control Module -
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❑ Nut 9 ± 1 Nm
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Air Intake Duct, Dust and Pollen Filter, Fresh Air Blower, Door
Control
3. Heater 77
1 - Plastic Screw or Plug (de‐

pending on version)
❑ 0.3 Nm
❑ Quantity: 2
2 - Partition
ling. Refer to
⇒ “5.20 Partition, Re‐
page 269 .
3 - Fresh Air Blower Housing
and Dust and Pollen Filter
4 - Screw
❑ 1 Nm
❑ Quantity: 2
5 - Air Intake Duct
❑ Do not dismantle
❑ With fresh- and air recir‐
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8 - Recirculation Door Motor - V113- rrectness of i
❑ Without position sensor with end switches in the end stops. Refer to ⇒ Wiring diagrams, Troubleshooting
& Component locations.
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❑ Removing and installing. Refer to ⇒ “5.11 Dust and Pollen Filter, Removing and Installing”, page 234 .
AG.
11 - Cover
❑ For dust and pollen filter

13 - Fresh Air Blower Control Module - J126-
⇒ “5.10 Fresh Air Blower Control Module J126 , Removing and Installing”, page 233 .
14 - Screw
❑ 1 Nm
❑ Quantity: 2
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The removal andss installation is identical to vehicles with an Air
a ra
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Conditioning (A/C) system. Refer to
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⇒ “5.12 Fresh Air Blower V2 , Removing and Installing ”,
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It is not necessary to extract the refrigerant and remove the ex‐

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pansion valve. The further removal and installation is identical to
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vehicles with an Air Conditioning (A/C) system. Refer to
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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
⇒ “5.6 Heater and A/C Unit, Disassembling and Assembling”,
page 228 .
3.7 Auxiliary Heater Heating Element - Z35-

with Auxiliary Air Heater Control Module
- J604- , Checking
Checking is identical to vehicles with an Air Conditioning (A/C)
system. Refer to
Heater Control Module J604 , Checking”, page 240 .
3. Heater 79

- J604- , Removing and Installing
page 242 .
3.9 Heater Core, Removing and Installing

3.10 Partition, Removing and Installing

⇒ “5.20 Partition, Removing and Installing”, page 269 .
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Prote AG.
4 Air Routing
⇒ “4.1 Overview - Air Routing and Air Distribution in Passenger
Compartment”, page 81
⇒ “4.2 Driver Side Footwell Vent, Removing and Installing”, page
81
⇒ “4.3 Front Passenger Side Footwell Vent, Removing and In‐
⇒ “4.4 Rear Footwell Vent, Removing and Installing”, page 81
⇒ “4.5 Fresh Air Intake, Removing and Installing”, page 82
⇒ “4.6 Fresh Air Intake Cover, Removing and Installing”,
page 82
⇒ “4.7 Air Intake Duct, Removing and Installing”, page 82
⇒ “4.8 Passenger Compartment Forced Air Extraction, Check‐
ing”, page 82
⇒ “4.9 Passenger Compartment Forced Air Extraction, Removing
and Installing”, page 82
⇒ “4.10 Air Guide for Defrost Air Vent, Removing and Installing”,
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tioning (A/C) system. Refer to

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Compartment”, page 271 .

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4.2 Driver Side Footwell Vent, Removing

and Installing
rrectne

ss
⇒ “6.5.1 Driver Side Footwell Vent, Removing and Installing”,

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page 276 .
nform
mer
4.3 Front Passenger Side Footwell Vent,

atio
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Removing and Installing

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⇒ “6.7 Rear Footwell Vent, Removing and Installing”, page 279 .
4. Air Routing 81
4.5 Fresh Air Intake, Removing and Instal‐

ling
⇒ “6.2 Fresh Air Intake, Removing and Installing”, page 273 .
4.6 Fresh Air Intake Cover, Removing and

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The removal and installation
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Conditioning (A/C) thsystem. Refer to
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Cover, Removing and Installing”, ra
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page 274 .
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4.7 Air Intake Duct, Removing and Installing

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⇒ “6.4 Air Intake Duct, Removing and Installing”, page 276 .
hole
spec
4.8 Passenger Compartment Forced Air Ex‐
es, in part or in w
t to the co
traction, Checking
The test is identical to a vehicle with an Air Conditioning (A/C)
rrectness of i
system. Refer to
⇒ “6.9 Passenger Compartment Forced Air Extraction, Check‐
l purpos
ing”, page 280 .

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traction, Removing and Installing

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4.10 Air Guide for Defrost Air Vent, Removing
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page 282 .
4.11 Center Instrument Panel Vent Air Guide,

⇒ “6.12 Center Instrument Panel Vent Air Guide, Removing and

5 Display and Control Head

⇒ “5.1 Overview - Display and Control Head”, page 83
⇒ “5.2 Display and Control Head, Removing and Installing”, page
84
5.1 Overview - Display and Control Head
1 - Heated Driver Seat Adjuster

❑ 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.
2 - Rear Window Defogger
Button
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es, in part or in w
♦ On vehicles for Japan “recircu‐

t to the co
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ignition.
rrectness of i
4 - Heated Front Passenger

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5 - Air Distribution Control Knob
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7 - Blower Speed Control Knob
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❑ To the left: decreases the blower speed

❑ To the right: increases the blower speed
8 - Blower Speed Display
9 - Temperature Control Knob
❑ To the left: lower the temperature
❑ To the right: increases the temperature
5. Display and Control Head 83

10 - Temperature Setting Display
5.2 Display and Control Head, Removing

and Installing
⇒ “8.2 Display and Control Head, Removing and Installing”, page
301 .
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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 85

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

ponents Outside of Passenger Com‐
partment
Passenger Compartment, Golf and Golf GTE”, page 86
Passenger Compartment, Golf Wagon”, page 90

partment, Golf and Golf GTE

Extraction
⇒ “6.9 Passenger Com‐ AG. Volkswagen AG d
partment Forced Air Ex‐ agen oes
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2 - A/C Humidity Sensor -

spec
G260-
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t to the co
❑ Check via the Vehicle

Electrical System Con‐
trol Module - J519- us‐
rrectness of i
ing the Vehicle Diagnos‐

tic Tester in the “Guided
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Refer to ⇒ Wiring dia‐
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⇒ “2.4 Expansion Valve,
ling”, page 110 .
86 Rep. Gr.87 - Air Conditioning

❑ Tightening specifications. Refer to ⇒ “2.1 System Overview - Refrigerant Circuit”, page 100 .
4 - Dryer Bag
⇒ “2.6 Dryer Bag/Dryer Cartridge, Removing and Installing”, page 118 .
❑ Overview. Refer to ⇒ “2.2 Overview - Condenser”, page 108 .
5 - Outside Air Temperature Sensor - G17-
❑ Check 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 locations.
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⇒ “2.3 Refrigerant Circuit Pressure Sensor G805 , Removing and Installing”, page 109 .
10 - Evacuating and Charging Valve, Low Pressure Side
page 127 .
11 - Refrigerant Line with Inner Heat Exchanger
❑ From the condenser and Air Conditioning (A/C) compressor
⇒ “2.13 Refrigerant Lines with Inner Heat Exchanger, Removing and Installing”, page 136 .
12 - Air Quality Sensor - G238-
⇒ “9.2 Air Quality Sensor G238 , Removing and Installing”, page 304 .
❑ Function mode. Refer to ⇒ “9.3 Function of Air Quality Sensor G238 ”, page 305 .
❑ Only for vehicles with Climatronic.
1. Component Location Overview - A/C System 87


❑ Removing and installing. Refer to ⇒ “6.3 Fresh Air Intake Cover, Removing and Installing”, page 274 .
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⇒ “9.4 Outside Air Temperature Sensor G17 , Removing and Installing”, page 307 .
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Components, Replacing .
10 - A/C Compressor
11 - Evacuating and Charging Valve, High Pressure Side
page 127 .
❑ 8 Nm
page 127 .
14 - Refrigerant line with inner heat exchanger
❑ From the condenser and A/C compressor


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4 - Dryer Bag
cations.
⇒ “9.4 Outside Air Temperature Sensor G17 , Removing and Installing”, page 307 .
6 - Condenser

Note

ing .
7 - A/C Compressor
8 - Evacuating and Charging Valve, High Pressure Side
page 127 .
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⇒ “6.3.2 Fresh Air Intake Cover, Removing and Installing, RHD”, page 275 .
6 - Expansion Valve
❑ Removing and installing. Refer to ⇒ “2.4 Expansion Valve, Removing and Installing”, page 110 .
7 - Dryer bag

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page 127 .
❑ 8 Nm
page 127 .
14 - Refrigerant line with inner heat exchanger


ponents Inside Front Passenger Com‐
partment
⇒ “1.2.1 Component Location Overview - Components Inside
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Compartment
1 - Left Vent Temperature Sen‐

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4 - Front Air Distribution Door Motor - V426- or Air Distribution Door Motor - V428-
⇒ “4.8 Front Air Distribution Door Motor V426 with Air Distribution Door Motor Position Sensor G642 ,
Removing and Installing”, page 199 .
❑ Component Location Overview. Refer to
⇒ “4.1 Component Location Overview - Front Actuators”, page 171 .

5 - Left Temperature Door Motor - V158- or Temperature Regulator Door Motor - V68-
⇒ “4.5 Left Temperature Door Motor V158 with Left Temperature Door Potentiometer/Actuator G220 ,
6 - Evaporator
❑ Only for vehicles with an Air Conditioning (A/C) system.
❑ Removing and installing. Refer to ⇒ “5.9 Evaporator, Removing and Installing”, page 231 .
7 - Sunlight Photo Sensor - G107-
⇒ “9.1 Sunlight Photo Sensor G107 , Removing and Installing”, page 303 .
8 - Evaporator Temperature Sensor - G308-
❑ Only for vehicles with an A/C system.
⇒ “5.17 Evaporator Temperature Sensor G308 , Removing and Installing”, page 262 .
9 - Defroster Door Motor - V107-
⇒ “4.3 Defroster Door Motor V107 with Defroster Door Motor Position Sensor G135 , Removing and
⇒ “4.1 Component Location Overview - wFront
agen Actuators”, page
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❑ Recirculation Door Motor - V113- , Removing and Installing. Refer to
rrectness of i
❑ Fresh Air/Recirculating Air/Back Pressure Door Motor - V425- , Removing and Installing. Refer to
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⇒ “4.7 Fresh Air/Recirculating Air/Back Pressure Door Motor V425 with Fresh Air/Recirculating Air/Back
Pressure Door Motor Position Sensor G644 , Removing and Installing”, page 195 .
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15 - Front Passenger Side Footwell Vent

⇒ “6.6 Front Passenger Side Footwell Vent, Removing and Installing”, page 277 .
16 - Condensation Water Drain Hose
❑ Checking. Refer to ⇒ “5.18 Condensation Water Drain, Checking”, page 264 .
⇒ “5.19 Condensation Water Drain, Removing and Installing”, page 265 .
page 240 .
18 - Heater Core
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Compartment, RHD

V113- or Fresh Air/Recirculat‐
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Motor - V425-
❑ Recirculation Door Mo‐
tor - V113- , Removing
and Installing. Refer to
⇒ “4.4.2 Recirculation
RHD”, page 184 .
❑ Fresh Air/Recirculating
Air/Back Pressure Door
Motor - V425- , Remov‐
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5 - Heater core
6 - Sunlight Photo Sensor - G107-
⇒ “9.1 Sunlight Photo Sensor G107 , Removing and Installing”, page 303 .
7 - Evaporator Temperature Sensor - G308-

⇒ “5.17.2 Evaporator Temperature Sensor G308 , Removing and Installing, RHD”, page 263 .
8 - Right Temperature Door Motor - V159-
⇒ “4.6.2 Right Temperature Door Motor V159 , Removing and Installing, RHD”, page 192 .
❑ Component Location Overview. agen
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10 - Footwell Vent Temperature Sensor - G192-
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⇒ “9.8 Footwell Vent Temperature Sensor G192 , Removing and Installing”, page 309 .
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11 - Driver side footwell vent

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⇒ “6.5.2 Driver Side Footwell Vent, Removing and Installing, RHD”, page 277 .
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❑ An incorrectly installed vent temperature sensor causes flow-generated noise

14 - Evaporator
❑ Removing and installing. Refer to ⇒ “5.9 Evaporator, Removing and Installing”, page 231 .
page 240 .
⇒ “5.14.2 Auxiliary Heater Heating Element Z35 with Auxiliary Air Heater Control Module J604 , Re‐
moving and Installing, RHD”, page 243 .
16 - Condensation water drain hose
❑ Checking. Refer to ⇒ “5.18 Condensation Water Drain, Checking”, page 264 .
⇒ “5.19.2 Condensation Water Drain, Removing and Installing, RHD”, page 267 .

17 - Front passenger side footwell vent

⇒ “6.6.2 Front Passenger Side Footwell Vent, Removing and Installing, RHD”, page 278 .
⇒ “5.12.2 Fresh Air Blower V2 , Removing and Installing, RHD”, page 239 .
19 - Left Vent Temperature Sensor - G150-
❑ An incorrectly installed vent temperature sensor causes flow-generated noise
⇒ “9.6 Left Vent Temperature Sensor G150 , Removing and Installing”, page 307 .
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⇒ “2.2 Overview - Condenser”, page 108
⇒ “2.3 Refrigerant Circuit Pressure Sensor G805 , Removing and
⇒ “2.4 Expansion Valve, Removing and Installing”, page 110
⇒ “2.5 Condenser, Removing and Installing”, page 116
⇒ “2.6 Dryer Bag/Dryer Cartridge, Removing and Installing”, page
118
⇒ “2.7 Low Pressure Side Refrigerant Line Balance Weight, Re‐
moving and Installing”, page 126
⇒ “2.8 Evacuating and Charging Valve, Removing and Installing,
Low and High Pressure Side”, page 127
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⇒ “2.15 Condenser/Evaporator Refrigerant Line, Removing and
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Balance Weight, Re‐
ss
page 126 .
o
cial p
f in
2 - Refrigerant Line - High
form
mer
Pressure Side
atio
m
❑ To the refrigerant line

o
n
c
i
with the inner heat ex‐
or
n thi
e
changer
t
sd
iva
o
pr
c
3 - Refrigerant Line with Inner
um
r
fo
en
ng
Heat Exchanger
t.
yi Co
op
❑ In the inner heat ex‐
C py
t. rig
gh
changer, the flowing flu‐
ht
pyri by
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o
id warm refrigerant on
c by lksw
cted agen
the high pressure side is Prote AG.
delivered into the low
pressure side as flow‐
ing, vapor, cold refriger‐
ant to increase the effi‐
ciency of the A/C sys‐
tem
4 - Expansion Valve
❑ Function and removal and installation ⇒ “2.4 Expansion Valve, Removing and Installing”, page 110
5 - A/C Compressor
6 - Receiver/Dryer with Dryer Bag
Note

ing .
2. Refrigerant Circuit 101

❑ Denso condenser. Refer to
⇒ “2.6.1 Dryer Bag, Removing and Installing, Denso Condenser”, page 118 .
❑ Modine condenser. Refer to
⇒ “2.6.2 Dryer Bag, Removing and Installing, Modine Condenser”, page 120 .
7 - Condenser
8 - Refrigerant Line
❑ To the condenser
9 - Nut
❑ 8 Nm
10 - Bolt
❑ 8 Nm
11 - Bolt
❑ 10 Nm
12 - Bolt n AG. Volkswagen AG do
lkswage es n
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❑ 22 Nm byV ua
d ran
ir se tee
o
13 - Relief Valve on A/C Compressorauth or
ac
ss
❑ Checking. Refer to ⇒ “3.6 Pressure Relieve Valve on A/C Compressor, Checking”, page 167 .
ce
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nl
pt
du
14 - Connector with A/C Compressor Regulator Valve - N280-
an
itte
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15 - Oil Drain Plug
ility
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♦ Denso A/C compressor - 30 Nm
, is n
h re
hole
♦ Sanden A/C compressor - 10 Nm
spec
es, in part or in w
t to the co
❑ Tightening specification:
16 - Cap
rrectness of i
❑ Modine: 5 Nm
l purpos

17 - Bolt
nf
ercia
or
❑ 8 Nm
m
m
atio
m
18 - High Pressure Side Service Connection

o
n in
or c
❑ Cap: 0.4 ± 0.1 Nm

thi
te
sd
iva
❑ Valve: 2 ± 0.2 Nm
o
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rp
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f
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ng
t.
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Co
op py
page 127 .
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gh ht
pyri by
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cted agen
Prote
❑ 5 ± 1 Nm
AG.

20 - Low Pressure Side Service Connection
❑ Cap: 0.4 ± 0.1 Nm
❑ Valve: 2 ± 0.2 Nm
page 127 .

2.1.2 System Overview - Refrigerant Circuit,

Golf GTE
Electrically-driven A/C compressor, refrigerant lines. Refer to
⇒ page 103
High voltage battery heat exchanger, refrigerant cut-off valves
and expansion valve. Refer to ⇒ page 106
Electrically-Driven A/C Compressor, Refrigerant Lines
1 - Electrical A/C Compressor

- V470-
⇒ “3.1.2 Overview - A/C
Compressor Power
Unit, Golf GTE”,
page 151 .
❑ With A/C Compressor
Control Module - J842-
and Electrical A/C Com‐
pressor - V470-
ling. Refer to
⇒ “3.4.2 Electrical A/C
Compressor V470 , Re‐
Golf GTE”, page 163 .
2 - Seal
❑ Replacing. Forswthe n AG. Volkswagen AG do
agecor‐ es n
rect version, by V refer to the
olk ot g
ua
Parts rCatalog.
ise
d ran
tee
ho
❑ Coat au with refrigerant oil
t or
ac
before installing. Refer
ss
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le
to
un
pt
an
⇒ “4.2 Refrigerant Cir‐

d
itte
y li
cuit Seals”, page 8 .

erm
ab
ility
ot p

wit
is n
sure Side
h re
ole,
❑ From the connection

spec
point on the right longi‐

t to the co
tudinal member to the

Air Conditioning (A/C)
compressor
rrectne
❑ With outlet to the high

voltage battery heat ex‐
s
changer
s o
cial p
❑ Additional weight on the

inform
refrigerant line. Refer to

mer
⇒ “2.7 Low Pressure Side Refrigerant Line Balance Weight, Removing and Installing”, page 126 .
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Note
An additional weight (balance

weight in the refrigerant line to re‐
duce noise) may be present on this
refrigerant line depending on the re‐
frigerant line version and the pro‐
duction period. Make sure that this
component is not touching or can
come in contact with other compo‐
nents during operation (noise). Re‐
fer to the Parts Catalog.
4 - Bolt
❑ 22 Nm
❑ To the condenser
❑ Different versions (with and without connection for the A/C Pressure/Temperature Sensor - G395- ).
Refer to Parts Catalog.
6 - Bolt
❑ 22 Nm
7 - Outlet of the Refrigerant Line - High Pressure Side olks
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yV
❑ To the high voltage battery heat exchanger sed b ua
ran
ri tee
ho
8 - Seal au
t or
ac
ss
❑ Replacing. For the correct version, refer to the Parts Catalog.
ce
le
un
pt
❑ Coat with refrigerant oil before installing. Refer to ⇒ “4.2 Refrigerant Circuit Seals”, page 8 .
an
d
itte
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erm
ab
9 - Low Pressure Side Service Connection
ility
ot p
wit
is n
h re
ole,
page 127 .
spec
10 - Outlet of the Refrigerant Line - Low Pressure Side
t to the co
❑ To the high voltage battery heat exchanger
11 - Refrigerant Circuit Pressure Sensor - G805- connection
rrectne
❑ Only installed on specific versions (not installed for example vehicles for North America). Refer to the
Parts Catalog.
ss o
cial p
12 - High Pressure Side Service Connection

inform

mer
atio
m
page 127 .
o
n
c
i
or
n thi
e

t
sd
iva
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r
❑ 5 Nm
p
cum
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fo
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ng
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diagrams, Troubleshooting & Component locations. Cop py
t. rig
gh
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pyri by
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Prote AG.
❑ Only installed on specific versions (not installed for example vehicles for North America). Refer to the
Parts Catalog.

Note
♦ For vehicles with a Refrigerant

Circuit Pressure Sensor - G805-
or a A/C Pressure/Temperature
Sensor - G395- , the Electrical A/
C Compressor - V470- version
(with the A/C Compressor Con‐
trol Module - J842- ) and A/C
control head version (the Clima‐
tronic Control Module - J255- ) is
also different in addition to the
pressure sensor . Use the Vehi‐
cle Diagnostic Tester in the “Gui‐
ded Fault Finding” function and
refer to the Parts Catalog.
♦ Depending on the version of the
refrigerant line the Refrigerant
can also be installed on vehicles
with an A/C Pressure/Tempera‐
ture Sensor - G395- to close the
connection with valve securely.
On this vehicle the Refrigerant
is not connected to the vehicle AG. Volkswagen AG d
electrical system. olksw
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14 - Outlet of the Refrigerant Line - High Pressure
thori Side eo
u ra
❑ To the high voltage battery heat exchanger
ss a c
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nl
15 - Refrigerant Line - High Pressure Side
pt
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itte
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❑ From the condenser to the connection point on the right longitudinal member
erm
ab
❑ With outlet to the high voltage battery heat exchanger
ility
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❑ Different versions (with and without connection for the Refrigerant Circuit Pressure Sensor - G805- ).
h re
Refer to Parts Catalog.
hole
spec
es, in part or in w
16 - Seal
t to the co
17 - Refrigerant Line - Low Pressure Side rrectness of i
l purpos
❑ From the expansion valve to the connection point on the right longitudinal member
nf
ercia
orm
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om
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❑ From the Heater and A/C Unit Refrigerant Cut-Off Valve - N541- to the expansion valve
or c
thi
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❑ From the connection point on the right longitudinal member to the Heater and A/C Unit Refrigerant Cut-
t
sd
iva
Off Valve - N541-

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f
❑ Removing and Installing. Refer to ⇒ “2.4 Expansion Valve, Removing and Installing”, page 110 and
en
ng
t.
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Co
Cop py
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19 - Seal
ht
pyri by
Vo
co lksw
by
❑ Replacing. For the correct version. refer to the Parts Catalog. Prote
cted AG.
agen
20 - Heater and A/C Unit Refrigerant Cut-Off Valve - N541-
⇒ “2.10 Heater and A/C Unit Refrigerant Cut-Off Valve N541 , Removing and Installing”, page 129 .


❑ From the connection point on the right longitudinal member to the Heater and A/C Unit Refrigerant Cut-
Off Valve - N541-
⇒ “2.13.2 Refrigerant Lines with Inner Heat Exchanger, Removing and Installing, Golf GTE”,
page 139 .
22 - Nut
❑ 8 Nm
23 - Seal
24 - Bolt
❑ 8 Nm
High Voltage Battery Heat Exchanger, Refrigerant Cut-Off Valves

and Expansion Valve

sure Side
❑ From the expansion
valve to the connection
point on the right longi‐
tudinal member
ling. Refer to
⇒ “4.2 Refrigerant Cir‐
cuit Seals”, page 8 .
2 - Seal
❑ Replacing, for the cor‐
rect version, refer to the
Parts Catalog.
AG. Volkswagen AG d
❑ Coat with refrigerant oil agen oes
olksw not
before installing. Refer d by
V gu
ara
to orise nte
eo
⇒ “4.2 Refrigerant Cir‐ aut
h
ra
cuit Seals”, page 8 . ss c
ce
e
nl
pt
3 - Expansion Valve
du
an
itte
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erm
ab

ility
ot p
Catalog.
wit
, is n
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hole
spec
ling. Refer to
es, in part or in w

t to the co

ling”, page 110 .
rrectness of i
4 - Bolt
❑ 10 Nm
l purpos
❑ Quantity: 2
nform
ercia
5 - Seal
m
❑ Replacing. For the cor‐

at
om

on
c
in t
Parts Catalog.
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
yri by
106
op Vo
by c lksw
Rep. Gr.87 - Air Conditioning Prote
cted AG.
agen
6 - Bolt
❑ 8 Nm
❑ From the Heater and A/C Unit Refrigerant Cut-Off Valve - N541- to the expansion valve
❑ Refrigerant linewfrom agen the connection point
AG. Volkswagen AG d
oes on the right longitudinal member to the Heater and A/C Unit
Refrigeranty VCut-Off Valve - N541-
olks not
gu
db ara
❑ Removing orise and Installing. Refer to nte
⇒ “2.10
aut
h Heater and A/C Unit Refrigerant Cut-Off eValve or
a N541 , Removing and Installing”, page 129 and
⇒ss “2.13 Refrigerant Lines with Inner Heat Exchanger,c Removing and Installing”, page 136 .
ce
e
nl
pt
8 - Heat Exchanger for the High Voltage Battery
du
an
itte
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erm
ab
ility
ot p
wit
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h re
⇒ “2.12 High Voltage Battery Heat Exchanger, Removing and Installing”, page 133 .
hole
spec
9 - Seal
es, in part or in w
t to the co
rrectness of i
10 - Refrigerant Line - High Pressure Side (with restrictor)
l purpos
❑ From the High Voltage Battery Heater Core Refrigerant Cut-Off Valve - N542- to the high voltage battery
heat exchanger
❑ A constriction (restrictor) is installed in this refrigerant line. Refer to
nf
ercia
o
rm
m
atio
m
❑ To remove, remove the High Voltage Battery Heater Core Refrigerant Cut-Off Valve - N542- (refer to
o
n in
c
⇒ “2.11 High Voltage Battery Heater Core Refrigerant Cut-Off Valve N542 , Removing and Installing”,
or
thi
page 131 ) and remove the refrigerant line from the High Voltage Battery Heat Exchanger. Refer to
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
Note
t.
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Cop py
ht. rig
♦ The diameter of the restrictor
rig ht
py by
o Vo
hole is approximately 0.7 mm.
by c lksw
cted agen
Prote
Depending on the version of the
AG.
refrigerant line this constriction is

either installed fixed in the refrig‐
erant line or only inserted. For
the inserted version a strainer for
flowing deposits may be instal‐
led, which can be blocked by the
variable orifice.
♦ The restrictor limits the refriger‐
ant flow to the high voltage bat‐
tery heat exchanger with an
open High Voltage Battery Heat‐
er Core Refrigerant Cut-Off
Valve - N542- (and with this its
cooling output).
11 - Bolt
❑ 8 Nm
12 - High Voltage Battery Heater Core Refrigerant Cut-Off Valve - N542-
⇒ “2.11 High Voltage Battery Heater Core Refrigerant Cut-Off Valve N542 , Removing and Installing”,
page 131 .


❑ Refrigerant line to the High Voltage Battery Heater Core Refrigerant Cut-Off Valve - N542- from the
refrigerant line outlet - high pressure side (from the condenser to the connection point on the right lon‐
gitudinal member) -item 14- ⇒ Item 14 (page 105) .
14 - Seal
15 - Refrigerant Line - Low Pressure Side
❑ Refrigerant line from the high voltage battery heat exchanger to the outlet in the refrigerant line - low
pressure side (from the connection point on the right longitudinal member to the A/C compressor)
-item 10- ⇒ Item 10 (page 104)
16 - Refrigerant Line Bracket
2.2 Overview - Condenser

Condenser, Receiver/Dryer
Note
The image shows a Modine condenser.

AG. Volkswagen AG d
agen oes
olksw not
1 - Condenser ed byV gu
ara
is nte
❑ There are different ver‐ ut
hor eo
ss a ra
c
Catalog.
ce
le
un
pt

an
d
itte
y li
ling. Refer to
rm
ab
⇒ “2.5 Condenser, Re‐

pe
ility

ot
wit
, is n
page 116 .
h re
hole
spec
2 - Seal
es, in part or in w
t to the co
❑ Replacing. For the ver‐

sions, refer to the Parts
Catalog.
rrectness of i
❑ Coat with refrigerant oil

before installing
l purpos
nform
ercia
❑ To the inner heat ex‐

changer
m
a
com
tio
4 - Bolt
n in
r
te o
❑ 8 Nm
thi
s
iva
do
r
5 - Bolt
rp
cum
fo
en
g
❑ 8 Nm
n
t.
yi Co
op py
. C rig
ht ht
rig by
py
❑ From the Air Condition‐ co Vo
by lksw
ing (A/C) compressor
cted agen
Prote AG.
7 - Seal
❑ Replacing. For the ver‐
sions, refer to the Parts
Catalog.
before installing

8 - Bracket
❑ For the refrigerant lines
9 - Cap
❑ Modine: 3 Nm
10 - Snap Ring lkswage es n
o ot g
yV ua
11 - Cap ir se
d b ran
tee
o
❑ There are different
auth
versions. Refer to the Parts Catalog. or
ac
ss
❑ Replace if damaged
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le
un
pt
an
12 - Seal
d
itte
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erm
ab
❑ Replacing. For the versions, refer to the Parts Catalog.
ility
ot p
❑ Coat with refrigerant oil before installing
wit
is n
h re
13 - Dryer Bag
ole,
spec
t to the co
❑ Removing and installing:
♦ Denso condenser. Refer to ⇒ “2.6.1 Dryer Bag, Removing and Installing, Denso Condenser”, page 118 .
rrectne
♦ Modine condenser. Refer to
ss o
♦ Keihin condenser. Refer to ⇒ “2.6.3 Dryer Bag, Removing and Installing, Keihin Condenser”, page 123 .
cial p
f inform
14 - Strainer
mer
atio
om
n
c
❑ Removal and installation i

or
n thi
te
sd
a
♦ Denso condenser. Refer to ⇒ “2.6.1 Dryer Bag, Removing and Installing, Denso Condenser”, page 118 .
iv
o
pr
cum
r
fo
♦ Modine condenser. Refer to

en
ng
t.
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Co
Cop py
t. rig
gh
♦ Keihin condenser. Refer to ⇒ “2.6.3 Dryer Bag, Removing and Installing, Keihin Condenser”, page 123 .
ht
pyri by
Vo
co lksw
by
15 - Receiver/Dryer
cted agen
Prote AG.
❑ Is integrated on this version of the condenser
Note

ing .
2.3 Refrigerant Circuit Pressure Sensor -

♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Commercially available extra-long 12 edge socket, 1/2" 24-
wrench size (Dimensions DxL 32x82 mm
Removing


– Disconnect the connector -2-.
CAUTION
Danger or frostbite due to refrigerant coming out under pres‐
sure.
Frostbite on the skin and other parts of the body is possible.
– Wear protective gloves. n AG. Volkswagen AG do
wage es n
– Wear protective eyewear. yV
olks ot g
ua
d b ran
– If refrigerant flows out of the orefrigerant
ir se line longer than 1 tee
second when loosening the au pressure sensor, tighten the
th or
ac
pressure sensor and replace
ss the faulty check valve.
ce
le
– Extract refrigerant and open the refrigerant circuit immedi‐

un
pt
an
d
ately.
itte
y li
rm
ab
– If the refrigerant was extracted more than 10 minutes in the
pe
ility
past and the refrigerant circuit was not opened, extract the
ot
wit
, is n
refrigerant again. The refrigerant circuit pressure comes
h re
from evaporation.
hole
spec
es, in part or in w
t to the co
– Counterhold the refrigerant line with a suitable tool.
CAUTION
rrectness of i
l purpos
sure. If work is performed improperly the connection can tear

and refrigerant can flow out.
nform
ercia

m
– Wear protective gloves.

a
com
tion in
r
te o
thi
– Counterhold the refrigerant line with a suitable tool.

s
iva
do
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rp
cum
fo
– Remove the pressure sensor -1- with a Commercially Availa‐

en
ng
t.
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ble 12-Edge 1/2" Socket Long, 24mm . t. Cop py
rig
gh ht
Installing pyri by
Vo
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cted agen
Install in reverse order of removal. Prote AG.
Tightening Specifications
♦ Refer to Refrigerant Circuit Pressure Sensor - G805-
-item 19- ⇒ Item 19 (page 102) .
2.4 Expansion Valve, Removing and Instal‐

ling
⇒ “2.4.1 Expansion Valve, Removing and Installing, Golf and Golf
Wagon”, page 110
⇒ “2.4.2 Expansion Valve, Removing and Installing, Golf GTE”,
page 113
2.4.1 Expansion Valve, Removing and Instal‐

ling, Golf and Golf Wagon
♦ Torque Wrench 1331 5-50Nm - VAG1331- (5 to 50 Nm)

♦ Engine Bung Set - VAS6122-

♦ A/C Service Station
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
Note
♦ Extract the refrigerant using the A/C Service Station .

♦ The previously used service stations can still be used see shop
equipment catalog.
♦ To prevent the ingress of dampness all components of the re‐
frigerant circuit which have been opened must be sealed withAG. Volkswagen A
suitable plugs. lksw
agen G do
es n
o Vo t gu
by
♦ On some vehicles, connecting pipe from charge
ris
edair cooler
ara
nte
should be removed. Refer to ⇒ Rep. Gr. 21uth;oCharge Air Sys‐ eo
ra
tem; Overview - Charge Air System . ss
a c
ce
le
un
pt
Vehicles with a TDI Engine
an
d
itte
y li
rm
ab
– Press the release buttons on the hose -1- for the crankcase
pe
ility
ventilation and remove the hose from the cylinder head cover.
ot
wit
, is n
h re
– Free up the vacuum hoses at the air guide pipe -arrows-.
hole
spec
– Loosen the hose clamp -3-.
es, in part or in w
t to the co
– Pivot the air guide pipe with the connection rearward and re‐
move from the turbocharger.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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do
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cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

All Vehicles
– Remove the sheet metal nuts -1 and 3-.
– Fold the heat shield -2- as far forward as possible -arrow-.
CAUTION
sure.
ately.
refrigerant again. The refrigerant circuit pressure AG. Volkswagen AG d
swagen comes oes
from evaporation. by
Vol
k not
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ara
ed nte
oris e
th or
– Extract refrigerant. au ac
ss
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le
un
pt
– Remove the nuts -1 and 3- from the refrigerant line with the
an
d
itte
inner heat exchanger.
y li
rm
ab
pe
ility
– Remove the bolt -7-.
ot
wit
, is n
– Disconnect the refrigerant line with the inner heat exchanger
h re
hole
from the expansion valve.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
– Remove the bolts -1 and 3-.
Co
Cop py
t. rig
– Remove the expansion valve -4- from the heat shield insula‐
gh ht
pyri by
tion -2-.
o Vo
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cted agen
Prote AG.
– Seal the open lines and connections with clean plugs from the
Engine Bung Set - VAS6122- .
Installing

Install in reverse order of removal. Note the following:

– Replace the seals, version. Refer to the Parts Catalog.
– Replace the seals -1 and 4- on the connecting tubes
-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). Allocation. Refer
to the Parts Catalog.
♦ Inspect the refrigerant pipes leading to the evaporator for deb‐
ris and damage. AG. Volkswagen AG d
agen oes
lksw not
♦ Coat the seals with refrigerant
d by Vo oil before installing. gu
ara
ise nt
♦ Pay attention that
uthor
the seal on the evaporator connecting tubeee or
is seated correctly.
ss
a ac
ce
le
♦ If the heat protection insulation -2- is missing or not installed

un
pt
an
d
correctly, it can cause reduced output of the Air Conditioning

itte
y li
(A/C) system (change of the set control characteristic due to

rm
ab
pe
radiant heat).
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
♦ Refer to
t to the co
2.4.2 Expansion Valve, Removing and Instal‐

rrectness of i
ling, Golf GTE

l purpos

nform
ercia

m
a
com

ion in
r
te o

thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
113
cted agen
Prote AG.
2. Refrigerant Circuit
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
– Note safety precautions. Refer to . Volkswagen AG
⇒ “1.1 Handling Refrigerant Safety Precautions”, gen AG1 .
wapage does
olks no
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– See notes. Refer to ris
ed nte
⇒ “4.1 Working on the Refrigerant Circuit”,
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ra
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system. Refer to
pt
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page 2 .
spec
es, in part or in w
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sification .
rrectness of i
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Note
nform
ercia
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t
equipment catalog.
ion in
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frigerant circuit which have been opened must be sealed with
do
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suitable plugs.
um
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♦ On some vehicles, connecting pipe from charge air cooler
yi Co
op py
should be removed. Refer to ⇒ Rep. Gr. 21 ; Charge Air Sys‐ t. C rig
gh ht
tem; Overview - Charge Air System . yri
p by
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Prote AG.
– Remove the air guide pipes in front of the expansion valve.
– Loosen the bracket -A- for the High Voltage Battery Coolant
Valve - N688- from the plenum chamber bulkhead.


CAUTION
sure.
– Extract refrigerant and open the refrigerant circuit immedi‐ n AG. Volkswagen AG do
wage
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– If the refrigerant was extracted more than 10 ir se minutes in the
d ran
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past and the refrigerant circuit was not aopened,
utho
extract the or
ac
refrigerant again. The refrigerant circuit
ss pressure comes
from evaporation.
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erm
– Extract refrigerant.
ab
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– Remove the nuts -1 and 3- from the refrigerant line with the
h re
ole,
inner heat exchanger.
spec
t to the co
Note
rrectne
♦ This illustration shows the layout on a vehicle without a high
voltage system.
s
♦ On a vehicle with a high voltage system the Heater and A/C
s o
cial p
f
Unit Refrigerant Cut-Off Valve - N541- is installed in the re‐
inform
frigerant line- high pressure side. Refer to
mer
⇒ “2.10 Heater and A/C Unit Refrigerant Cut-Off Valve N541 ,
atio
m

o
n
c
i
or
n
♦ If necessary, disconnect the connector to the Heater and A/C
thi
te
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Unit Refrigerant Cut-Off Valve - N541- .

iv
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t.
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Cop py
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– Disconnect the refrigerant line with the inner heat exchanger
t
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from the expansion valve. cop Vo
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Prote AG.
– Remove the bolts -1 and 3-.
– Remove the expansion valve -4- from the heat shield insula‐
tion -2-.
Installing


– Replace the seals, version. Refer to the Parts Catalog.
Volkswagen AG
– Replace the seals -1 and 4- on the connecting
wage tubes
n AG. does
-2 and 3- to the evaporator. Volks not
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– Press in the refrigerant pipe -2- by hand on the expansion
es, in part or in w
valve.
t to the co
– Install the bolt -1- by hand and the tighten to the specified
tightening specification.
rrectness of i
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ate
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Note
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♦ The expansion valve is available in different versions (same
ht
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housing but different control characteristic). Allocation. Refer
co lksw
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cted agen
to the Parts Catalog. Prote AG.
♦ 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 A/C system
(change of the set control characteristic due to radiant heat).
♦ Refer to
2.5 Condenser, Removing and Installing


Note
equipment catalog. AG. Volkswagen AG d
agen oes
lksw not
♦ To prevent the ingress of dampnessby
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all components of the re‐ gu
ara
frigerant circuit which have is been opened must be sealed with
ed
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suitable plugs. aut
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Perform the following work first:

un
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– Turn off all electric consumers.
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– Remove the key.
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t to the co
Note
Environmentally hazardous draining of refrigerant is an offense
rrectne
punishable by law.
ss
Removing
o
cial p
f inform
mer
atio
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or
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thi
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– Remove the front bumper cover. Refer to ⇒ Body Exterior;

p
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Rep. Gr. 63 ; Front Bumper; Bumper Cover, Removing and

en
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t.
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Installing .
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– Release the air guide -2- from the mount -arrow- upward.
gh ht
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– Press the attachment -4- downward in direction of -arrow- and cted agen
Prote AG.
pull the air guide -2- forward.
– Remove the air guide downward.
CAUTION
sure.
ately.
from evaporation.
– Extract the refrigerant using the A/C Service Station .

– Remove the bolts -5-.
– Remove the refrigerant lines -3- from the connection on the
condenser.
– Seal off the line connections.

– Have a second technician release the left and right tabs -1- in
direction of -arrow A- and remove the condenser -3- upward
out of the mounts in direction of -B arrows-.
– Remove the condenser -3- downward.
Installing
– Replace the seals.
♦ Refer to ⇒ “2.2 Overview - Condenser”, page 108
♦ Overview - Front Bumper. Refer to ⇒ Body Exterior; Rep. Gr.
63 ; Front Bumper; Overview - Bumper Cover ,
AG. Volkswagen AG d
agen oes
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2.6 Dryer Bag/Dryer Cartridge, Removing
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itte
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⇒ “2.6.1 Dryer Bag, Removing and Installing, Denso Condenser”,
, is n
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page 118
hole
spec
⇒ “2.6.2 Dryer Bag, Removing and Installing, Modine Condens‐
es, in part or in w
t to the co
er”, page 120
⇒ “2.6.3 Dryer Bag, Removing and Installing, Keihin Condenser”,
page 123
2.6.1 Dryer Bag, Removing and Installing, rrectness of i

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Denso Condenser
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atio
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♦ Commercially available pick-up tool

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Note
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♦ See notes. Refer to
Co
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⇒ “2.1 System Overview - Refrigerant Circuit”, page 100 .
. C rig
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co Vo
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Prote AG.
equipment catalog.
suitable plugs.
– Extract refrigerant using the A/C Service Station , only then

open the refrigerant circuit.
Removing
– Remove, depending on the charge air system engine compo‐
nents. Refer to ⇒ 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.
CAUTION
sure.
– Wear protective gloves. lkswage es n
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byV ua
– Wear protective eyewear. ir se
d ran
tee
ho
– Extract refrigerant and open the arefrigerant
ut circuit immedi‐ or
ac
ately. ss
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– Remove the sealing plug -A-.
t to the co
– Remove the dryer carrier -C- with the dryer bag -D- upward
from the receiver/dryer.
rrectne
– Remove the filter element -E- upward from the receiver/dryer
using, for example, a pick-up tool.
ss
– Seal the open receiver/dryer with the sealing plug -A- to pre‐
o
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vent dirt and moisture from getting in.
inform
mer
Installing
atio
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Note
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♦ Replace the sealing plug, seal and dryer bag after every open‐ Cop py
ing of the receiver/dryer. Refer to Parts Catalog.
t. rig
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♦ Keep the dryer bag air-tight package closed as long as possi‐
by lksw
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ble. Do not remove the dryer bag until just before replacing the
AG.
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. gen AG
. Volkswagen AG
a does
lksw not
– Position and install the dsealing
by
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ara
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♦ Refer to ⇒ “2.2 sOverview - Condenser”, page 108
ce
e
nl
pt
du
♦ Radiator Grille/Front Trim; Overview - Radiator Grille. Refer to
an
itte
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⇒ Body Exterior; Rep. Gr. 66 ; Radiator Grille/Front Trim;
erm
ab
Overview - Radiator Grille .
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2.6.2 Dryer Bag, Removing and Installing,
rrectness of i
Modine Condenser
l purpos
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ercia
♦ T50 Socket
m
at
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Note
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ate
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♦ Extract the refrigerant using the A/C Service Station . C py
ht. rig
rig ht
py by
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equipment catalog. cted agen
Prote AG.

suitable plugs.

Removing
– Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Radiator Grille/Front
Trim; Radiator Grille, Removing and Installing .

. Volkswagen AG
out of the mounts in direction
swa
gen AG of -arrow B-.
does
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– Move the condenser
se
db as far forward as possible. ara
nte
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– Remove the cap -1- using the T50 Socket .
nform
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com
tion in
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t.
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Cop py
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cted agen
Prote AG.
– Push in the cap -1- slightly.
CAUTION
sure.
ately.
from evaporation.
– 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.

wage es n
Golf 2013 ➤ , Golf Variant 2014 ➤ yV
olks ot g
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– Make a 2 mm diameter welding wire with
ss the following dimen‐
sions.
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nl
pt
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Hook the welding wire onto the strainer exactly as illustrated to

prevent damage to the receiver/dryer
nf
ercia
or
– Carefully remove the filter (strainer) -2- from the receiver/dryer
m
m
atio
with the welding wire -1-.
om
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co lksw
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Prote AG.
– If the work is not completed, close open receiver/dryer with the

cap -1- to prevent dirt and moisture from entering.
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.
– Remove the dryer bag from the package and insert it into the
condenser receiver/dryer.

– Insert the cap -1- and push it far enough downward so that the
circlip -arrow- can engage in the groove.
Note
Coat the seal for the cap with refrigerant oil before installing.
– Install the cap -1- using the T50 Socket .

♦ Refer to ⇒ “2.2 Overview - Condenser”, page 108
♦ Radiator Grille/Front Trim;AGOverview
. Volkswagen-ARadiator Grille. Refer to
⇒ Body Exterior; swagenGr. 66 ; Radiator
Rep.
G do
Grille/Front
es Trim;
olk not g
Overview - Radiator
db
yV Grille . ua
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ris
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2.6.3 Dryer Bag, Removing and Installing,

wit
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Keihin Condenser
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t to the co
♦ T50 Socket
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Note
nform
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m

com
tion in
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thi
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equipment catalog.
fo
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ng
t.
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Cop py
t. rig
gh ht
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suitable plugs.
p by
co Vo
by lksw
cted agen
Prote AG.
Removing
– 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.
– Remove the cap -1- using the T50 Socket .
AG. Volkswagen AG d
agen oes
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– Push in the cap -1- slightly. ss a c
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CAUTION
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ately.
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from evaporation.
nform
mercia
– Remove the snap ring -arrow-.

com
tion in
– Install a M12 bolt in the cover and carefully pull it out of the
r
te o
thi
receiver/dryer -2-.
s
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– Remove the dryer bag with a commercially available pick-up

um
fo
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tool from the receiver/dryer.

n
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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cted agen
Prote AG.

– Make a 2 mm diameter welding wire with the following dimen‐

sions.
a - 380 mm
b - maximum 7 mm
c - maximum 6 mm
Hook the welding wire onto the strainer exactly as illustrated to

prevent damage to the receiver/dryer
– Carefully remove the filter (strainer) -2- from the receiver/dryer
with the welding wire -1-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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an
– If the work is not completed, close open receiver/dryer with the
itte
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cap -1- to prevent dirt and moisture from entering.

erm
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Installing
wit
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hole
spec
es, in part or in w
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Note
Replace the cap, seal and dryer bag after every opening of the
rrectness of i
receiver/dryer. Refer to Parts Catalog.

l purpos
nform
ercia

m

at
om
ion
c
– Insert the filter element (with strainer) -2- with the correct side
in t
or
into the condenser receiver/dryer.

his
ate
do
priv
• The filter element must be pushed in until stop.

um
for
en
ng
t.
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Cop py
Note
t. rig
gh ht
pyri by
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co lksw
by
Keep the dryer bag air-tight package closed as long as possible.
cted agen
Prote AG.
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.
– Remove the dryer bag from the package and insert it into the
condenser receiver/dryer.

– Insert the cap -1- and push it far enough downward so that the
circlip -arrow- can engage in the groove.
Note
Coat the seal for the cap with refrigerant oil before installing.
– Install the cap -1- using the T50 Socket .

AG. Volkswagen AG d
agen
Tightening Specifications o lksw
oes
not
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ara
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♦ Refer to ⇒ “2.2 Overview
orise - Condenser”, page 108 nte
eo
h
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♦ Radiator Grille/Front
ss a Trim; Overview - Radiator Grille. Refer to c
⇒ Body Exterior; Rep. Gr. 66 ; Radiator Grille/Front Trim;
ce
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un
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Overview - Radiator Grille .
an
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2.7 Low Pressure Side Refrigerant Line Bal‐ t to the co
ance Weight, Removing and Installing

rrectne

ss

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Removing
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page 2 .
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Note . Cop py
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♦ It is required to remove the refrigerant line to remove and in‐ co Vo
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stall the balance weight.
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Prote AG.
♦ 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 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-.
Tightening Specification
Component Tightening Specifications
Balance weight bolts 10 ± 1 Nm
2.8 Evacuating and Charging Valve, Re‐Volkswag

n AG.
moving and Installing, Low Vand olks High
en AG
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Pressure Side by gu
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Special tools and workshop equipment
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♦ Torque Wrench 1783 - 2-10Nm - VAG1783-

un
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an
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♦ Torque Wrench 1783 - 1/4" Drive Ratchet - VAS6234-
rm
ab
pe
ility
♦ Refrigerant Sockets - T10364-
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
♦ Environmentally hazardous draining of refrigerant is an of‐

rrectness of i
fense punishable by law.

l purpos
♦ To prevent the ingress of dampness, all components of the

refrigerant circuit which have been opened must be sealed
with suitable plugs.
nform
mercia
a
com
Removing
tion in
r
te o

thi
s

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fo

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⇒ “4.1 Working on the Refrigerant Circuit”, page 8 . Cop
yi Co
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– Pay attention to safety precautions for working near high volt‐ gh ht
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age components. Refer to cop Vo
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Prote AG.
page 2 .

AG. Volkswagen AG d
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Golf 2013 ➤ , Golf Variant 2014 ➤ oris nte
eo
th
Heating, Ventilation and Air Conditioning - Edition
s au 10.2014 ra
c
s
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un
pt
– Remove the cap -3-.
an
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ab
CAUTION
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ility
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hole
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ately.
l purpos
nform
ercia
from evaporation.
m
a
com
tion in
r
– Extract from the refrigerant circuit using the A/C Service Sta‐
te o
thi
tion . Then immediately replace the valve -2-.
s
iva
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cum
– Remove the valve insert -2- from the refrigerant line.
fo
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t.
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Installing . Cop py
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– Install in reverse order of removal. py by
co Vo
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cted
agen
Prote AG.
♦ Refer to
2.9 A/C Pressure/Temperature Sensor -

Note
Not installed in all vehicles and countries.
Removing
page 2 .
sification .
Rep. Gr. 63 ; Front Bumper .


– Check the refrigerant line and connection -4- for contamination
and if necessary clean.
CAUTION agen
AG. Volkswagen AG d
oes
olksw not
Danger or frostbite dued to by refrigerant coming out under pres‐
V gu
ara
sure. horise nte
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Frostbite on thessskin and other parts of the body is possible.
a ra
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erm
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ately.
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from evaporation.
– Loosen and remove the sensor -1-.
rrectness of i
– Seal the open connection -4- with clean plugs from the Engine
l purpos
Bung Set - VAS6122- .

Installing
nf
ercia
orm
m
atio
om
n in
• Check the connection -4- for contamination or damage if nec‐
or c
essary clean or replace the refrigerant line.

thi
te
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Note
ng
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Cop py
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Replace the seal -3-. Refer to rig ht
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⇒ “4.2 Refrigerant Circuit Seals”, page 8 . Allocation. Refer to the
co Vo
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Parts Catalog.
cted agen
Prote AG.
– Check the Diagnostic Trouble Code (DTC) memory and erase

any displayed entries using the Vehicle Diagnostic Tester in
A/C Pressure/Temperature 10 ± 1 Nm
Sensor - G395-
2.10 Heater and A/C Unit Refrigerant Cut-Off

Valve - N541- , Removing and Installing
Removing
page 2 .
sification .


– Discharge the refrigerant circuit. . Volkswagen AG
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– Loosen the bracket -A- (for the Solenoid
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– Loosen the heat shield -B- near the Heater and A/C Unit Re‐
n in
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frigerant Cut-Off Valve - N541- -D- and the refrigerant line

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-F- (to the coupling point on the right longitudinal member)
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from the plenum chamber bulkhead and carefully bend back.
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– Remove the spring nuts -1 and 3-.

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– Disconnect the connector -C- from the Heater and A/C Unit
Refrigerant Cut-Off Valve - N541- -D-.
CAUTION
sure.
ately.
from evaporation.
– Loosen the union nut -E-, while doing this counterhold on the
Heater and A/C Unit Refrigerant Cut-Off Valve - N541- -D-.
– Loosen the refrigerant line -F- (to the coupling point on the right
longitudinal member) from the bracket on the plenum chamber
bulkhead.

– Remove the Heater and A/C Unit Refrigerant Cut-Off Valve -

N541- -D-.
Installing
Installation is carried out in the reverse order while observing the
following.
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Check the routing of the refrigerant lines after attachment.riThey
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– Replace the seals -B-. Refer to
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⇒ “4.2 Refrigerant Circuit Seals”, page 8 . For the correct ver‐
rm
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sion, refer to the Parts Catalog.
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– Tighten the union nuts -E- all the way by hand.
hole
spec
– Secure the refrigerant line -F- (to the coupling point on the right
es, in part or in w
t to the co
longitudinal member) in the bracket on the plenum chamber
bulkhead.
– Tighten the union nuts -E- and while doing so, counterhold on
rrectness of i
the Heater and A/C Unit Refrigerant Cut-Off Valve - N541-
l purpos
-D- and make sure that the routing of the refrigerant line is
without tension.
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♦ Make sure when tightening the union nuts that the refrigerant
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♦ Check the routing of the refrigerant lines after attachment.
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They must be inserted into the provided brackets and must not
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come in contact with other components. C py
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– Check the Diagnostic Trouble Code (DTC) memory for the
Climatronic Control Module - J255- control head and erase
any displayed malfunctions, if necessary, using the Vehicle
Union nuts -E- 16.5 Nm
2.11 High Voltage Battery Heater Core Re‐

frigerant Cut-Off Valve - N542- , Remov‐
ing and Installing
Removing
page 2 .


Refer to ⇒ Rep. Gr. 00 ; High Voltage System Danger
agen
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sification . Volksw not
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– Turn off the ignition. oris tee
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– Discharge the refrigerant circuit.
ss
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CAUTION
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rrectness of i
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from evaporation.
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at
– Disconnect the connector -A- from the High Voltage Battery
om
io
Heater Core Refrigerant Cut-Off Valve - N542- -B-.
n
c
in t
or
his
e
– Loosen the union nuts -C-, and while doing so counterhold on

at
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the High Voltage Battery Heater Core Refrigerant Cut-Off

p
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Valve - N542- -B-.

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– Remove the refrigerant line -D- from the high voltage battery Cop py
ht. rig
heat exchanger. Refer to rig ht
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⇒ “2.14 Refrigerant Line with Restrictor”, page 141 . co Vo
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cted agen
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– Remove the Heater and High Voltage Battery Heater Core

Refrigerant Cut-Off Valve - N542- -D-.
Installing
Installation is carried out in the reverse order while observing the
following.
Note
♦ Note the installation instructions for the seals -B-. Refer to

⇒ “4.2 Refrigerant Circuit Seals”, page 8 .
come in contact with other components.
– Replace the seals -B-. For the correct version, refer to the
Parts Catalog.

Heating, Ventilation and
. Volkswage
Air Conditioning - Edition 10.2014
AG n AG d
agen oes
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– Check the restrictor in the refrigerant lined b -D- (to the high
yV volt‐ gu
ara
age battery heat exchanger) for dirt.oriRefer
se to nte
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⇒ “2.14 Refrigerant Line with Restrictor”,
aut
h
page 141 . ra
ss c
– Tighten the union nuts -C- all the way by hand.
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– Install the refrigerant line -D- on the high voltage battery heat
itte
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erm
exchanger. Refer to
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ility
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– Tighten the union nuts -C-, and while doing so, counterhold on is n
h re
ole,
the High Voltage Battery Heater Core Refrigerant Cut-Off
spec
Valve - N542- -B- and make sure that the routing of the refrig‐
t to the co
erant lines is without tension.
rrectne
Note
♦ Make sure when tightening the union nuts that the refrigerant
ss o
lines are not tensioned.
cial p
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atio
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come in contact with other components.

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♦ Pay attention to the notes for operating the Air Conditioning
te
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(A/C) system after charging. Refer to ⇒ Refrigerant R134a

i
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Servicing; Rep. Gr. 00 ; A/C Service Station, Working with .
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– Evacuate and charge the refrigerant circuit. Refer to ⇒ Re‐ t. C rig
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frigerant R134a Servicing; Rep. Gr. 00 ; A/C Service Station, yri
p by
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Working with .
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cted agen
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– Check the Diagnostic Trouble Code (DTC) memory for the
Climatronic Control Module - J255- control head and erase
any displayed malfunctions, if necessary, using the Vehicle
Union nuts -C- 16.5 Nm
2.12 High Voltage Battery Heat Exchanger,

♦ Hose Clamps - Up To 25mm - 3094-
♦ Spring Clip Pliers - VAS6499-
♦ Cooling System Tester - VAG1274B-
Removing
⇒ “1.5 Cooling System Safety Precautions”, page 2 .


page 2 .
gen AG
. Volkswagen AG
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Refer to ⇒ Rep. Gr. 00 ; High Voltage System Danger y Volk Clas‐ not
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– Extract refrigerant using the A/C Service Station
au , only then ac
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To prevent the ingress of dampness all components of the refrig‐
h re
erant circuit which have been opened must be sealed with suita‐
hole
spec
ble plugs.
es, in part or in w
t to the co
rrectness of i
CAUTION
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Burns on the skin and other parts of the body is possible.

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– Open the coolant reservoir cap for the high voltage system.
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Refer to ⇒ Rep. Gr. 19 ; Coolant System/Coolant . t. C rig
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– Loosen the coolant expansion tank for the engine coolant cir‐
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cted
cuit from the vehicle and tilt slightly to the side. Refer to ⇒ Rep.
agen
Prote AG.
Gr. 19 ; Coolant System/Coolant .
– Clamp the coolant hoses -A and B- with Hose Clamps - Up To
25mm - 3094- .
Note
The heater core is designed for a specific coolant flow direction.

Therefore, coolant hoses must be connected on the correct sides.
– Cover the area beneath connections for coolant hoses on the

heat exchanger -E- with absorbent paper.
– Remove coolant hoses -A and B- from connections on the heat
exchanger -E-.
– Close the open connections for the coolant hoses on the heat
exchanger -E- with clean plugs from the Engine Bung Set -
VAS6122- .
– Remove the bolts -F- from the refrigerant line to the heat ex‐
changer -E-.
– Remove the bolts -D-.

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– Loosen the heat exchanger -E- from the refrigerant lines
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-B and C- and remove together with the bracket -F-.
erm
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– Seal the open connections for the coolant hoses on the heat
wit
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exchanger -E- and on the refrigerant lines -B and C- with clean
h re
hole
plugs from the Engine Bung Set - VAS6122- .
spec
es, in part or in w
t to the co
Note
rrectness of i
The bracket -F- is secured with two bolts -G- on the heat ex‐
changer -E-.
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– Replace the seals -D-, For the correct version, refer to the
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Parts Catalog.
thi
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– Check the connection on the refrigerant line (-B- and -C-) and
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the heat exchanger -E- for debris and damage.
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– Insert the seal -3- into the groove -arrow- on the refrigerant t. C rig
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line connection -1-. yri
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Note
♦ If equipped, inspect the alignment pin -4- for damage and

check that it is seated correctly.
♦ Coat the seals with refrigerant oil before installing. Refer to
♦ Make sure the seals fit correctly inside the groove in the re‐
spective refrigerant line.
– The bracket -F- is secured with two bolts -G- on the heat ex‐
changer -E-, if the bolts -G- are loosened replace them (but do
not tighten them).
– Assemble the heat exchanger -E- with the refrigerant lines
-B and C- and secured with the bolts -A- (Do not tighten the
bolts -A-).

– Align the heat exchanger -E- free of tension and replace the
bolts -D-.
– Tighten the bolts -G- (tightening specification: 8 Nm).
– Tighten the bolts -D- (tightening specification: 8 Nm).
– Tighten the bolts -F- (tightening specification: 8 Nm).
– Install the coolant hoses -A and B- on the connections on the
heat exchanger -E-.
– Fill the coolant in the coolant expansion tank for the high volt‐
age system. Refer to ⇒ Rep. Gr. 19 ; Coolant System/
Coolant .
– Slightly raise the pressure in the coolant expansion tank for
the high voltage system, for example with the Cooling System
Tester - VAG1274B- . Refer to ⇒ Rep. Gr. 19 ; Coolant Sys‐
tem/Coolant
– Carefully open the bleeder screw -C-.
– Carefully open the Hose Clamps - Up To 25mm - 3094- on the
coolant hose -A- and allow coolant to flow into the heat ex‐
changer -E-.
– As soon as coolant flows out of the bleeder screw -C-, seal the
bleeder screw -C- again. . Volkswage
n AG n AG d
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When the removal and installation of the high voltage battery heat
s
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exchanger -E- is performed as described above there should be

nl
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no air in the high voltage system coolant circuit. If, for some other
itte
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erm
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ant circuit. Refer to ⇒ Rep. Gr. 19 ; Coolant System/Coolant .
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– If necessary, fill the coolant in the coolant expansion tank for h re

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the high voltage system. Refer to ⇒ Rep. Gr. 19 ; Coolant spec

es, in part or in w
System/Coolant .
t to the co
– Remove the Hose Clamps - Up To 25mm - 3094- and install

all removed or loosened components.
rrectness of i
– Perform remaining installation operations in reverse order of

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2.13 Refrigerant Lines with Inner Heat Ex‐

or
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a
changer, Removing and Installing

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⇒ “2.13.1 Refrigerant Lines with Inner Heat Exchanger, Removing

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and Installing, Golf and Golf Wagon”, page 136 Cop py
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⇒ “2.13.2 Refrigerant Lines with Inner Heat Exchanger, Removing p by
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2.13.1 Refrigerant Lines with Inner Heat Ex‐

changer, Removing and Installing, Golf
and Golf Wagon


Removing
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– Note safety precautions. Refer to Vol
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⇒ “1.1 Handling Refrigerant Safety Precautions”, page e1d b.y ara
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– See notes. Refer to au
th ra
⇒ “4.1 Working on the Refrigerant Circuit”, pages8 .
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Vehicles with A TDI Engine
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spec
– Free up the vacuum hoses at the air guide pipe -arrows-. es, in part or in w
t to the co
rrectness of i
– Remove the bolt -2- and tilt the air guide pipe with the con‐
nection downward and remove it from the turbocharger.
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om
io
For All Vehicles
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ately.
from evaporation.


– Disconnect the refrigerant line -6- with the inner heat exchang‐
er from the expansion valve.
– Remove the nuts -1 and 3- and remove the refrigerant lines
-2 and 4-.
– Remove the refrigerant line -5- with the inner heat exchanger.
– Seal the open lines and connections
gen AG
. Volkwith cleandplugs
swagen AG
from the
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Engine Bung Set - VAS6122-
y Volk . not
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Installing
rrectness of i
• Refer to ⇒ Rep. Gr. 21 ; Turbocharger; Overview - Turbo‐
charger .
l purpos
– Replace the seals. For the correct version, refer to the Parts nform
ercia
Catalog.
m
– Clean the connections on the expansion valve -2- and on the

a
com
tio
inner heat exchanger -4- and inspect them for damage.

n in
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thi
– Thoroughly clean the refrigerant lines around the connection

s
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area and check for damage.

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Note C py
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♦ Coat the seals with refrigerant oil before installing. by c lksw
cted agen
Prote AG.
♦ Make sure the seals fit correctly inside the groove on each
refrigerant line.
– Insert the seals -1 and 3- into the groove on the inner heat
exchanger connection.
– Insert the inner heat exchanger on the expansion valve.

– Tighten the bolt -5-.

– Install the refrigerant lines -2 and 4- with the inner heat ex‐
changer on the connections.
– Install and tighten the nuts -1 and 3-.
♦ Refer to
n AG. Volkswagen A age G do
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2.13.2 Refrigerant Lines with Inner Heat Ex‐
t to the co
changer, Removing and Installing, Golf
GTE
rrectness of i
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system. Refer to
page 2 .
sification .

– Loosen the bracket -A- (for the Solenoid Valve 1 - N88- ) from
the plenum chamber bulkhead.
– Loosen the heat shield -B- near the Heater and A/C Unit Re‐ n AG. Volkswagen AG do
frigerant Cut-Off Valve - N541- -D- and the refrigerant line olkswage es n
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-F- (to the coupling point on the right longitudinal member) byV ua
ed ran
from the plenum chamber bulkhead and carefully bend or
is back. tee
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pt
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CAUTION
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from evaporation.

– Disconnect the refrigerant line -6- with the inner heat exchang‐
er from the expansion valve.
– Remove the nuts -1 and 3- and remove the refrigerant lines
-2 and 4-.
– Remove the refrigerant line -5- with the inner heat exchanger.

swage es n
Installing byV
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• Refer to ⇒ Rep. Gr. 21 ; Turbocharger; Overview - Turbo‐
ss
ce
le
charger .
un
pt
an
d
itte
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– Replace the seals. For the correct version, refer to the Parts
rm
ab
Catalog.
pe
ility
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– Clean the connections on the expansion valve -2- and on the
, is n
h re
inner heat exchanger -4- and inspect them for damage.
hole
spec
– Thoroughly clean the refrigerant lines around the connection
es, in part or in w
t to the co
area and check for damage.
rrectness of i
Note
l purpos
♦ Coat the seals with refrigerant oil before installing. Refer to

nform
ercia
♦ Make sure the seals fit correctly inside the groove on each
m
refrigerant line.
a
com
tion in
r
te o
thi
– Insert the seals -1 and 3- into the groove on the inner heat
s
iva
exchanger connection.
do
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– Insert the inner heat exchanger on the expansion valve.
en
ng
t.
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– Tighten the bolt -5-. opyri
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c lksw
– Install the refrigerant lines -2 and 4- with the inner heat ex‐
by
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changer on the connections.
AG.
– Install and tighten the nuts -1 and 3-.

♦ Refer to
2.14 Refrigerant Line with Restrictor

page 2 .

AG. Volkswagen AG d
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Golf 2013 ➤ , Golf Variantut 2014 ➤
ho eo
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a
s Air Conditioning - Edition 10.2014
s c
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Note
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♦ This illustration shows a refrigerant line -A- with a permanently
installed restrictor -B- (without a strainer)
rrectness of i
♦ To remove the refrigerant line, remove the High Voltage Bat‐
tery Heater Core Refrigerant Cut-Off Valve - N542- (refer to
l purpos

Valve N542 , Removing and Installing”, page 131 ) and remove
the refrigerant line from the high voltage battery heat exchang‐
nform
ercia
er. Refer to
m
⇒ “2.12 High Voltage Battery Heat Exchanger, Removing and
a
com
tio
n in
r
te o
thi
♦ The diameter of the illustrated restrictor hole -B- is approxi‐
s
iva
do
mately 0.7 mm. Depending on the version of the refrigerant
r
rp
cum
line this constriction is either installed fixed in the refrigerant
fo
en
g
line or only inserted. For the inserted version a strainer for

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flowing deposits may be installed, which can be blocked by the C py
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variable orifice. gh ht
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♦ Before installing check the bore -B- for debris and if necessary Prote
cted AG.
agen
clean or replace.
♦ There are different versions. Refer to the Parts Catalog.
2.15 Condenser/Evaporator Refrigerant

Line, Removing and Installing
Removing
Installing .
– Remove the right engine mount. Refer to ⇒ Rep. Gr. 10 ;
Subframe Mount; Overview - Subframe Mount .

CAUTION
sure.
ately.
Volkswagen AG
n AG.in
– If the refrigerant was extracted more than 10lksminutes
wage the does
not
past and the refrigerant circuit was notdopened,
by Vo
extract the gu
ara
refrigerant again. The refrigerant circuit
orise pressure comes nte
from evaporation. auth eo
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un
pt
– Remove the nut -1-.
an
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– Disconnect the refrigerant lines.
erm
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ole,
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t to the co
rrectness o
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f inform
mer
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– Remove the bolt -5- of the lower refrigerant line -3-.

– Remove the refrigerant line -3- from the condenser -1-.
– Unclip and remove the refrigerant line -3- from the mountings.
Installing
Catalog. wage
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Vol t gu
– Coat the seals with refrigerant oil
ed before installing. Refer to
by ara
⇒ “4.2 Refrigerant Circuit Seals”,
horis page 8 . nte
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t
au ra
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ss
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Note
pt
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erm
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Make sure the seals fit correctly inside the groove on each refrig‐
ility
ot p
erant line.
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es, in part or in w
♦ Refer to
t to the co
♦ Subframe Mount; Overview - Subframe Mount. Refer to ⇒
rrectness of i
Rep. Gr. 10 ; Subframe Mount; Overview - Subframe Mount .
l purpos
♦ Front bumper cover. Refer to ⇒ Body Exterior; Rep. Gr. 63 ;

Front Bumper; Bumper Cover, Removing and Installing .
nf
ercia
or
2.16 Condenser/A/C Compressor Refriger‐
m
m
atio
m
ant Line, Removing and Installing

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Removing
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Depending on the engine, parts of the air filter are to be removed.
Refer to ⇒ Rep. Gr. 24 ; Air Filter; Overview - Air Filter Housing
or ⇒ Rep. Gr. 23 ; Air Filter; Overview - Air Filter Housing .
Depending on the engine, parts of the air routing are to be re‐
moved. Refer to ⇒ Rep. Gr. 24 ; Intake Manifold; Overview -
Intake Manifold or ⇒ Rep. Gr. 23 ; Intake Manifold; Overview -
Intake Manifold .
Depending on the engine, charge air system parts of the air rout‐
ing are to be removed. Refer to ⇒ Rep. Gr. 21 ; Charge Air
System .
Installing .
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 66 ; Noise Insulation .

CAUTION
sure.
ately.
from evaporation.
– Remove the bolt -5- of the upper refrigerant line -3-.

– Remove the refrigerant line -3- from the condenser -1-.
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es, in part or in w
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– Remove the bolt -3- for the refrigerant line -2-.

– Remove the refrigerant line.
Installing
Catalog.
– Coat the seals with refrigerant oil before installing. Refer to
Note
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Make sure the seals fit correctly inside
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♦ Refer to
ility
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⇒ “3.1 Overview - A/C Compressor Power Unit”, page 149
wit
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♦ Noise insulation. Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Noise
hole
Insulation .
spec
es, in part or in w
t to the co
♦ Front bumper cover. Refer to ⇒ Body Exterior; Rep. Gr. 63 ;
Front Bumper; Bumper Cover, Removing and Installing .
rrectness of i
2.17 A/C Compressor/Evaporator Refriger‐

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ant Line, Removing and Installing

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ercia

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Depending on the engine, parts of the air filter are to be removed.
Intake Manifold .
ing are to be removed. Refer to ⇒ Rep. Gr. 21 ; Charge Air
System .
Installing .

– Remove the noise insulation from underneath the engine. Re‐

fer to ⇒ Body Exterior; Rep. Gr. 66 ; Noise Insulation .
CAUTION
sure.
ately.
from evaporation.
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– Detach ethe d by Vcoolant expansion tank and move ua it to the
ran side.
ir s tee
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– Remove
auth the nut -3-. or
ac
ss
– Disconnect the refrigerant lines. ce
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– Remove the bolt -3- for the refrigerant line -4-.

– Unclip and remove the refrigerant lines from the mountings.
Installing
Catalog.
– Coat the seals with refrigerant oil before installing. Refer to
Note
Make sure the seals fit correctly inside the groove on each refrig‐
erant line.
♦ Refer to
♦ Refer to
♦ Noise insulation. Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Noise
Insulation .
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3 A/C Compressor
⇒ “3.2 Overview - Belt Pulley”, page 153
⇒ “3.3 A/C Compressor, Removing and Installing on Bracket”,
page 155
⇒ “3.4 A/C Compressor, Removing and Installing”, page 159
page 165
⇒ “3.6 Pressure Relieve Valve on A/C Compressor, Checking”,
page 167
⇒ “3.7 Belt Pulley, Removing and Installing”, page 168
3.1 Overview - A/C Compressor Power Unit

⇒ “3.1.1 Overview - A/C Compressor Power Unit, Golf and Golf
Wagon”, page 149
⇒ “3.1.2 Overview - A/C Compressor Power Unit, Golf GTE”, page
151
3.1.1 Overview - A/C Compressor Power Unit,

Golf and Golf Wagon
Note
The illustration shows one version.

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3. A/C Compressor 149

olkswagen AG
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Golf 2013 ➤ , Golf Variant 2014V➤ olks
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Heating, Ventilation and AirseConditioning
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1 - Ribbed Belt ss
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Gr. 13 ; Cylinder Block,
erm
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Belt Pulley Side; Ribbed
ility
Belt, Removing and In‐ ot p
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❑ Mark the rotation direc‐
es, in part or in w
tion, install on correct
t to the co
side. Refer to ⇒ Rep.
Gr. 13 ; Cylinder Block,
Belt Pulley Side; Ribbed
rrectness of i
Belt, Removing and In‐
stalling .
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2 - Sub-Assembly Bracket
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❑ Optional
❑ To remove and install,
m
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refer to ⇒ Rep. Gr. 13 ;
ion
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Cylinder Block, Belt Pul‐
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ley Side; Sub-Assembly

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Bracket, Removing and

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3 - Seal . Cop py
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❑ Replacing. For the cor‐ rig ht
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Parts Catalog.
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before installing
4 - Bolt
❑ 22 Nm
5 - High Pressure Side Refrig‐
erant Line
6 - Low Pressure Side Refrig‐
erant Line
7 - Bolt
❑ 22 Nm
8 - Seal
9 - A/C Compressor Regulator Valve - N280-
10 - Air Conditioning (A/C) Compressor
11 - Bolt
❑ 25 Nm
❑ Quantity: 3
12 - Belt Pulley with Overload Protection
❑ Overview. Refer to ⇒ “3.2 Overview - Belt Pulley”, page 153 .

13 - Alignment Sleeve
❑ Quantity: 2
3.1.2 Overview - A/C Compressor Power Unit, Golf GTE
1 - Electrical A/C Compressor

- V470-
❑ With A/C Compressor
Control Module - J842-
and Electrical A/C Com‐
pressor - V470-
ling. Refer to
⇒ “3.3 A/C Compressor,
on Bracket”, page 155
ling. Refer to
⇒ “3.4 A/C Compressor,
ling”, page 159 .
Note
♦ Check the attachment points of

the Air Conditioning (A/C) com‐
pressor and the engine bracket
before installing. The contact
surfaces must be clean and rust
and grease-free. Otherwise, re‐
pair the contact surfaces with the
Contact Surface Cleaning Set - G. Volkswagen
VAS6410- . Refer to ⇒ Electrical
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Equipment; Rep. Gr.by97 Vol . ot g
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♦ The Electrical uA/C
tho Compressor -
r tee
or
V470- is supplied
ss
a with electricity ac
through one on the Electric Drive
ce
le
un
Power and Control Electronics -

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JX1- installed fuses.

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2 - High Pressure Side Refrig‐

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erant Line
h re
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spec
3 - Bolt
❑ 25 Nm (with M 8 threads)
t to the co
4 - Seal
rrectne
❑ To replace. Refer to ⇒ “4.2 Refrigerant Circuit Seals”, page 8 . For the correct version, refer to the Parts
Catalog.
ss o
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❑ Lubricate lightly with refrigerant oil before installing.

f inform
mer
5 - Bolt
atio
m
❑ 25 Nm
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If the A/C compressor is secured
ss
au ac
with aluminum bolts (There are dif‐
ce
le
ferent versions. Refer to the Parts
un
pt
an
d
Catalog), use the aluminum bolts
itte
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rm
only once, then replace. Aluminum
ab
pe
ility
bolt tightening specification: 8 Nm + ot
wit
180° turn.
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6 - Ground (GND) Cable
es, in part or in w
t to the co
❑ Check the contact surface before attaching and clean if necessary.
Note
rrectness of i
The contact surfaces must be clean
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and rust and grease-free. Other‐

wise, repair the contact surfaces
nform
ercia
with the Contact Surface Cleaning

Set - VAS6410- . Refer to ⇒ Elec‐
m
a
trical Equipment; Rep. Gr. 97 .
com
tion in
r
te o
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7 - Bolt
s
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❑ 9 Nm
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8 - Seal
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❑ To replace, refer to ⇒ “4.2 Refrigerant Circuit Seals”, page 8 . For the correct version, refer to the Parts
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❑ Lubricate lightly with refrigerant oil before installing. cted agen
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9 - Low Pressure Side Refrigerant Line

10 - Bolt
11 - 8-Pin Connector
❑ With the control wire from the Climatronic Control Module - J255- control head. Refer to ⇒ Wiring dia‐
grams, Troubleshooting & Component locations
12 - High Voltage Cable to the Electric Drive Power and Control Electronics - JX1- (with High Voltage Battery
Charger Control Module - J1050- )

3.2 Overview - Belt Pulley

⇒ “3.2.1 Overview - Belt Pulley, Denso A/C Compressor”,
page 153
⇒ “3.2.2 Overview - Belt Pulley, Sanden A/C Compressor”, page
154
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.
4 - Drive Plate
❑ The overload protection
takes over when the tor‐
que is excessive (for ex‐
ample, if the Air Condi‐
tioning (A/C) compres‐
sor runs with resistance)
and the belt pulley runs
freely without driving the n AG. Volkswagen AG do
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5 - Circlip ris
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❑ Replacing au t ra
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❑ Install on the proper side
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- the flat side faces A/C

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6 - Belt pulley
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Catalog.
es, in part or in w
t to the co
❑ Is sensitive to impact, be
careful when handling
rrectness of i
ling. Refer to ⇒ “3.7 Belt Pulley, Removing and Installing”, page 168 .
l purpos
7 - A/C Compressor
❑ Clean the A/C compressor driveshaft before setting the belt pulley on it
nform
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at
om
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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‐
ample, using a thread
tap). Otherwise, there is
a danger that the input AG. Volkswagen AG d
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– Clean the thread of the s au ra
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A/C compressor input s
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shaft with a wire brush.
pt
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– Insert the nut with lock‐
erm
ab
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ing compound. For the
ot p
locking compound, refer
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spec
es, in part or in w
2 - Bolt
t to the co
❑ 12 Nm
rrectness of i
curely with a commercially available oil filter band wrench to loosen and tighten the bolts.
l purpos
– The threaded bolt holes, into which the self-locking bolts or bolts with locking compound are screwed,
must be cleaned (for example with a thread tap). Otherwise, there is a danger that the bolts break off
during assembly.
nf
ercia
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m
atio
– Clean the thread of the bolts, which are screwed in with locking compound, with a wire brush. Then insert
om
the bolts with locking compound. For the locking compound, refer to the Parts Catalog.
n in
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3 - Drive Plate
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❑ The overload protection (securing spring elements), takes over when the torque is excessive (for exam‐
o
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ple, if the A/C compressor runs with resistance) and the belt pulley runs freely without driving the A/C
t.
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4 - Circlip
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❑ Replacing
❑ 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
⇒ “3.3.1 A/C Compressor, Removing and Installing on Bracket,
Golf and Golf Wagon”, page 155
⇒ “3.3.2 A/C Compressor, Removing and Installing on Bracket,
Golf GTE”, page 157
3.3.1 A/C Compressor, Removing and Instal‐

ling on Bracket, Golf and Golf Wagon
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Pay attention to the turn off conditions for vehicles with the Start/
th or
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Stop System. Refer to ss
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page 6 .
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ELSA contains all information regarding performing repairs on

es, in part or in w
vehicles with air conditioning and working with refrigerant. Refer

t to the co

Precautions .
rrectness of i
Information on tools for repairs in vehicles with climate control

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system can be found in ELSA. Refer to ⇒ Refrigerant R134a

Servicing; Rep. Gr. 00 ; Special Tools .
nform
ercia
Removing
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on
c
⇒ “1 Safety Precautions”, page 1 .

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or
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ate

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t.
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– Remove the noise insulation under the engine. Refer to ⇒
Co
op py
Body Exterior; Rep. Gr. 66 ; Noise Insulation; Overview -
t. C rig
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Noise Insulation . p by
co Vo
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cted agen
Prote AG.

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 .
– Remove the ribbed belt. Refer to ⇒ Rep. Gr. 13 ; Cylinder
Block, Belt Pulley Side; Sub-Assembly Bracket, Removing
and Installing .
– Disconnect the connector -6- from the Air Conditioning (A/C)
compressor -1-.
– Remove the hex bolt -5- and then remove the A/C compressor
-1-.
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Do not loosen the refrigerant pipes on the A/C compressor
ss if only c
the auxiliary components bracket is being removed.
ce
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un
pt
an
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itte
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erm
ab
ility
ot p
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– Attach the A/C compressor to the body with something suita‐
h re
ole,
ble, for example, welding wire.
spec
Installing
t to the co
– Thoroughly clean the contact surfaces on the A/C compressor
rrectne
and bracket.
ss o
cial p
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atio
om
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– 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.
NOTICE
Risk of damaging the A/C compressor. Refrigerant oil may ac‐
cumulate in the compression chamber of the removed A/C
compressor.
– After installing a new A/C compressor or filling with fresh re‐
frigerant oil, turn the A/C compressor 10 times by hand
before installing the ribbed belt.
♦ Refer to
Pay attention to the following when starting the engine for the first
time after filling the refrigerant circuit:
– Follow the information on operating the A/C system after in‐
stalling the A/C compressor. Refer to ⇒ Refrigerant R134a
Servicing .

ling on Bracket, Golf GTE
Special tools and workshop equipment V
required
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♦ Torque Wrench 1331 5-50Nm
yV
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- VAG1331- (5 to 50eNm)
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– Note safety precautions.
ss Refer to
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es, in part or in w

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page 2 .
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DANGER
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Danger to life due to high voltage.

or c
thi
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Death or serious bodily injury by electric shock.

t
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– Have the high voltage system de-energized by a qualified

rp
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3. A/C Compressor
AG.
– De-energize the high voltage system. Refer to ⇒ Rep. Gr. 93 ;

High Voltage System, De-Energizing .
Body Exterior; Rep. Gr. 66 ; Noise Insulation; Overview
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Removing the right front wheel housing tliner.
ho
ris Refer to ⇒ Body e or
Exterior; Rep. Gr. 66 ; Wheel Housings aLiner; Front Wheel Hous‐
u ac
ing Liner, Removing and Installing . s
ce
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nl
pt
– Push aside the Electrical A/C Compressor - V470- -5- noise du
an
itte
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insulation (if installed) or partially remove to ensure that the
erm
ab
connectors and bolts are accessible.
ility
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– Disconnect the connector -2- from the Electrical A/C Com‐
h re
pressor - V470- -5-.
hole
spec
es, in part or in w
– Disconnect the high voltage cable -3- from the Electrical A/C
t to the co
Compressor - V470- -5-.
– Disconnect the potential equalization cable -4- from the Elec‐
rrectness of i
trical A/C Compressor - V470- -5-.
l purpos

– Remove the Electrical A/C Compressor - V470- -5-.
nform
ercia
NOTICE
m
at
om
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before installing the ribbed belt. Cop py
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– Secure the Electrical A/C Compressor - V470- -2- to the body Prote AG.
with a suitable equipment for example a welding wire -1-.
Installing
– Start the vehicle only after assembling the refrigerant circuit.
– Only start the vehicle when the refrigerant circuit is filled.
Note
♦ Inspect the attachment points for the Electrical A/C Compres‐

sor - V470- and engine prior to installing.
♦ The contact surfaces must be clean and rust and grease-free.
WARNING
Severe bodily injury or death by electrocution is possible.
– Have a qualified person put the high voltage system back
into service.
♦ Refer to

3.4 A/C Compressor, Removing and Instal‐
Vol
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ling
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⇒ “3.4.1 A/C Compressor, Removing and Installing,
ss
a Golf and Golf ac
Wagon”, page 159
ce
e
nl
pt
du
an
⇒ “3.4.2 Electrical A/C Compressor V470 , Removing and Instal‐
itte
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ling, Golf GTE”, page 163
erm
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ility
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ling, Golf and Golf Wagon
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spec
es, in part or in w
t to the co
Note
rrectness of i
♦ Perform Guided Fault Finding “A/C compressor first start”
whenever a new Air Conditioning (A/C) compressor is instal‐
l purpos
led.
♦ Pay attention to the turn off conditions for vehicles with the
nform
ercia
Start/Stop System. Refer to

m
at
om
i
page 6 .
on
c
in t
or
♦ If the A/C compressor is sent in for a warranty claim, document
his
ate
the extracted refrigerant quantity and add in the claim.
do
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cum
for
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ng

t.
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Cop py
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♦ Torque Wrench 1331 5-50Nm - VAG1331- (5 to 50 Nm) opyri
gh by
Vo
ht
c lksw
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Prote AG.

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
refrigerant circuit (pressure build-up due to moisture in refrig‐
erant circuit).
♦ 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
circuit indicate the likelihood of moisture
♦ In the event of doubt about the amount of refrigerant oil in the
circuit.
♦ The A/C compressor must be replaced on account of internal
damage (for example, noise or no output).
♦ If only the auxiliary component bracket is being removed, it is
not necessary to loosen the refrigerant lines on the A/C com‐
pressor. Attach the A/C compressor to the body with wire.
The procedure for flushing with refrigerant R134a is described in

ELSA . Refer to ⇒ Refrigerant R134a Servicing; Rep. Gr. 00 ;
Refrigerant Circuit, Removing Contaminants; Refrigerant Circuit,
Flushing (Cleaning) with Refrigerant R134a .
ELSA contains all information regarding performing repairs on
vehicles with air conditioning and working with refrigerant. Refer
Precautions . olks
wage es n
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b a
Information on tools forrisrepairs
ed in vehicles with climate control rante
system can be foundut in ELSA. Refer to ⇒ Refrigerant R134a
ho eo
ra
Servicing; Rep. Gr.
ss a
00 ; Special Tools . c
ce
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nl
Pay attention to the notes when operating. Refer to

pt
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⇒ page 162 .
itte
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erm
ab
Removing
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Refer to
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ercia

m
at
Body Exterior; Rep. Gr. 66 ; Noise Insulation; Overview -

om
ion
Noise Insulation .
c
in t
or
his
te
Depending on the engine type, remove the right front wheel hous‐
a
do
riv
ing liner. Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing

p
cum
or
Liner; Front Wheel Housing Liner, Removing and Installing .

f
en
ng
t.
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op
Depending on the engine, parts of the air filter are to be removed. C py
t. rig
gh ht
pyri by
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cted agen
Prote AG.


Intake Manifold .
ing are to be removed.wagRefer
en AG. to ⇒ Rep. Gr.
Volkswagen AG
doe21
s no
; Charge Air
s
System . yV
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ed n
– Remove tho
rithe
s
ribbed belt. Refer to ⇒ Rep. Gr. 13 ; tCylinder
ee
or
Block,au Belt Pulley Side; Sub-Assembly Bracket, Removing ac
ss
and Installing .
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pt
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CAUTION
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ately.
rrectness of i
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from evaporation.
nform
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a
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tion in
– Remove the bolts -3- and disconnect the refrigerant lines

r
te o
-2 and 4- from the A/C compressor -1-.

thi
s
iva
do
r
– Disconnect the connector -6- from the A/C compressor -1-.

rp
cum
fo
en
ng
– Remove the hex bolt -5- and then remove the A/C compressor
t.
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-1-. C py
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Installing cop Vo
by lksw
cted agen
Prote
AG.
• 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 AGcontact
. Volkswasurfaces
gen AG can lead
agen
to alignment irregularitiesVobetween
lksw the compressordoandes n en‐
ot g
gine. Alignment irregularities
edb
y over operating time cause dam‐ ua
ran
age to the A/C compressor.
thoris tee
or
au ac
♦ If the A/C compressor
ss is replaced due to certain complaints
(for example, internal damage), the refrigerant circuit must be
ce
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cleaned. Refer to ⇒ A/C System - with Refrigerant R134a .
an
itte
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ab
♦ There is an unspecified amount of refrigerant oil in the re‐
ility
ot p
moved A/C compressor, so therefore pay attention to the
wit
, is n
information on replacing the A/C compressor. Refer to ⇒ Re‐
h re
frigerant R134a Servicing .
hole
spec
es, in part or in w
t to the co
NOTICE
rrectness of i
compressor.
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ercia

orm
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♦ Refer to
t
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Pay attention to the following when starting the engine for the first
en
ng
t.
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time after filling the refrigerant circuit: t. Cop py
rig
gh ht
– Follow the information on operating the A/C system after in‐ pyri by
Vo
co
stalling the A/C compressor. Refer to ⇒ Refrigerant R134a
by lksw
cted agen
Prote
Servicing; Rep. Gr. 00 .
AG.
– After installing a new A/C compressor or fresh refrigerant oil

has been filled into compressor (for example, after blowing
through the A/C system), turn ribbed belt pulley of A/C com‐
pressor 10 rotations by hand before starting the engine. This
prevents damage to the A/C compressor.
– 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 that the
system is empty. This means that approximately 40 to 50
cm3 of refrigerant oil remains in the A/C compressor.
♦ Only start the engine when the refrigerant circuit is filled.
♦ The engine may only be started when the refrigerant circuit is
installed correctly. For example; if the refrigerant lines are not
connected to A/C compressor, when the engine is running the
A/C compressor may heat up (via internal heat generation) so
much that the A/C compressor will be damaged.
♦ A/C Compressor Regulator Valve - N280- is not activated
when the refrigerant circuit is empty and the A/C compressor
idles with the engine.
♦ If it is necessary to start the engine with a discharged refrig‐
erant circuit:
. Volkswag
♦ Refrigerant circuit must be
ksw
fully
agen assembled. AG does
AG en
ol not
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At least a quarterisof by
♦ ed the prescribed refrigerant oil must berain
ua
n
the A/C compressor.
tho
r tee
or
s au ac
♦ Do not let the
s engine RPM go above 2,000.
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♦ The engine should only run as long as is absolutely necessary,

an
itte
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maximum 10 minutes.
erm
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ility
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3.4.2 Electrical A/C Compressor - V470- , Re‐

h re
hole
spec
moving and Installing, Golf GTE

es, in part or in w
t to the co

rrectness of i
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nform
mercia
at
om
ion
c
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or
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ate
do
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Cop py
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♦ A/C Service Station cop Vo
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Prote AG.
Removing


system. Refer to
⇒ “1.4 Safety Precautions near High Voltage Components”, agen
AG. Volkswagen AG d
oes
page 2 . olksw not
byV gu
ara
ed
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Refer to ⇒ Rep. Gr. 00 ; High Voltage System Dangers Clas‐au ra
c
sification . s
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pt
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DANGER
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ab
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ility
Danger to life due to high voltage. ot
wit
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spec
person.
es, in part or in w
t to the co
rrectness of i
– Loosen the front section form the right front wheel housing lin‐
l purpos
er, until the Electrical A/C Compressor - V470- is accessible.

Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner;
nform
Overview - Front Wheel Housing Liner .
mercia
– Push aside the Electrical A/C Compressor - V470- -5- noise
a
com
tio
insulation (if installed) or partially remove to ensure that the
n in
connectors and bolts are accessible.
r
te o
thi
s
iva
do
– Disconnect the connector -2- from the Electrical A/C Com‐
r
rp
cum
pressor - V470- -5-.
fo
en
ng
t.
yi
– Disconnect the high voltage cable -3- from the Electrical A/C
Co
Cop py
Compressor - V470- -5-. ht. rig
rig ht
py by
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– Disconnect the ground cable -4- from the Electrical A/C Com‐ by c lksw
cted agen
pressor - V470- -5-. Prote AG.
– Extract the refrigerant using the A/C Service Station . See

notes. Refer to
CAUTION
sure.
ately.
from evaporation.

– Remove the refrigerant lines -1- and -6- from the Electrical A/
C Compressor - V470- -5-.
– Remove the Electrical A/C Compressor - V470- -5-.
Installing wage
es n
lks ot g
Vo
Install in reverse order of removal. Note the following: ed by ua
ran
ir s tee
o
– Start the engine only after assembling the refrigerant
auth
circuit. or
ac
ss
– Only start the engine when the refrigerant circuit is filled.
ce
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Note
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♦ Inspect the attachment points for the Electrical A/C Compres‐
h re
hole
sor - V470- and engine prior to installing.
spec
es, in part or in w
♦ The contact surfaces must be clean and rust and grease-free.
t to the co
NOTICE
rrectness of i
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compressor.
nform
ercia

m
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t
ion in
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WARNING
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C py
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– Have a qualified person put the high voltage system back p by
co Vo
lksw
into service.
by
cted agen
Prote AG.
♦ ⇒ “3.1 Overview - A/C Compressor Power Unit”, page 149
3.5 A/C Compressor Fuse - S355- , Remov‐

ing and Installing
♦ Torque Wrench 1783 - 2-10Nm - VAG1783-
Removing
system. Refer to
page 2 .

Heating, Ventilation and Air Conditioningol-ksEdition
wage 10.2014 es n
o
yV t gu
db ara
– Pay attention to the high voltage system rise
danger classification. nte
ho eo
Refer to ⇒ Rep. Gr. 00 ; High Voltage aut System Danger Clas‐ ra
c
sification . ss
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le
un
pt
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itte
DANGER
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ility
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ole,
spec
person.
t to the co
rrectne
– Remove the bolts -2- from the cover -1-.
ss 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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
– Remove the fuse -3- from the high voltage cable connector
Prote AG.
-2- for the High Voltage Battery Charger 1 - AX4- in direction

of -arrow A-.
– Push the locking mechanism -4-.
– Remove the High Voltage Battery Charger 1 - AX4- high volt‐
age cable -2- from the Electric Drive Power and Control Elec‐
tronics - JX1- -1-.
– Remove the cover -1-.
– Release the retainers -3- in direction of arrows -A, B and C-.

– Unclip the retainers -2- upward.
– Remove the protection against contact -1-.

– Remove bolts -2-.

– Remove the A/C Compressor Fuse - S355- -1-.
Installing
NOTICE
The seal can be deformed if a contact protection is already in‐
stalled.
If the seal is deformed, it can cause leaks. As a result, there may
be moisture-related damage in the high voltage system.
– Replace the protection against contact for the Electric Drive
Power and Control Electronics - JX1- after disassembling.
Replace the cover bolts for the Electric Drive Power and Control
Electronics - JX1- after disassembling.
Cover Tightening Sequence

Volkswagen AG
– Install the cover
swabolts.
gen AG
.
does
olk not
yV gu
– Tighten isedthe bolts in the sequence -5, 6 and 1-.
b ara After that,
nte the
sequence
hor can be in any order. eo
aut ra
ss c
WARNING
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ab

ility
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– Have a qualified person put the high voltage system back

wit
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into service.
hole
spec
es, in part or in w
– Operate the high voltage system. Refer to ⇒ Rep. Gr. 93 ;

t to the co

rrectness of i
♦ Overview - Electric Drive Power and Control Electronics. Refer

l purpos
to ⇒ Rep. Gr. 93 ; Electric Drive Power and Control Electron‐

ics .
nf
ercia
or
3.6 Pressure Relieve Valve on A/C Com‐

m
m
atio
m
pressor, Checking
o
n in
or c
thi
te
Checking
sd
iva
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♦ Function: Protects the refrigerant circuit against excessive

o
m
f
en
ng
pressure
t.
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Cop py
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rig by
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cted agen
Prote AG.


CAUTION
There is a risk of frostbite through refrigerant. The pressure re‐
lief valve drains refrigerant when the engine is running and the
refrigerant circuit pressure is too high.
– Turn the engine off.
Denso Air Conditioning (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.
3.7 Belt Pulley, Removing and Installing

⇒ “3.7.1 Belt Pulley, Removing and Installing, Denso”,
page 168
⇒ “3.7.2 Belt Pulley, Removing and Installing, Sanden”,
page 170
3.7.1 Belt Pulley, Removing and Installing,AG. Volkswagen AG d

Denso yV
olksw
agen oes
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ed ran
oris tee
th or
Note au ac
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♦ The belt pulley is sensitive to impact, for this reason handle it

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especially carefully.
erm
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ility
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♦ If the overload protection of the belt pulley is tripped, check the

wit
A/C compressor for ease of movement, before replacing the

, is n
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belt pulley. Replace an A/C compressor that is not operating

hole
spec
smoothly.
es, in part or in w
t to the co
♦ If the drive plate overload protection has activated, the belt

pulley can be rotated using the outer part of the drive plate so
that the Air Conditioning (A/C) compressor shaft and the hex‐
rrectness of i
agon head on the drive plate (inner part of the drive plate) do
not rotate.
l purpos

nf
ercia
♦ Commercially available oil filter band wrench

rm
m
atio
om
n in
or c
thi
te
sd
iva
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ng
t.
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Cop py
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168
op Vo
by c lksw
Rep. Gr.87 - Air Conditioning Prote
cted AG.
agen
Removing
and Installing .
– Remove the cap -1-.
. Volkswagen AG
does gen AG
– Remove the bolts -arrows-Vol
ksw by counterholding the
a
nbelt
ot g pulley
with an oil filter band
ed by wrench. ua
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– Remove the nut -2- by counterholding on the input shaft -1- of
ility
ot
the A/C compressor.
wit
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hole
– Remove the drive plate -3- with the nut.
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ The torque to drive the A/C compressor is transferred to the
drive plate via the threaded connection.
l purpos
♦ If, while the A/C compressor is working, the drive plate was
attached to the A/C compressor shaft so tight, that it cannot
nform
ercia
be loosened (the 7 mm wrench cannot transmit the necessary

torque) then the A/C compressor must be replaced.
m
a
com
tion in
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te o
thi
– Remove the circlip -2-.

s
iva
do
r
rp
– Remove the belt pulley -1-.

um
fo
en
ng
t.
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Installing
Co
Cop py
t. rig
gh
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Replace the circlip.
– Clean the A/C compressor input shaft before setting the belt
pulley on it.
– Place the belt pulley onto the A/C compressor input shaft.
• The fitting must be possible without much force.
– Insert the circlip on the proper side.
• Flat side faces the A/C compressor
– Clean the input shaft thread for the A/C compressor before
removing the drive plate.
Note
The thread of the new drive plate has already been greased with
a specific amount of grease by the manufacturer.
♦ Refer to
⇒ “3.2.1 Overview - Belt Pulley, Denso A/C Compressor”,
page 153

3.7.2 Belt Pulley, Removing and Installing,

Sanden
Note
♦ The belt pulley is sensitive to impact, for this reason handle it

especially carefully.
♦ If the overload protection of the belt pulley is tripped, check the
Air Conditioning (A/C) compressor for ease of movement, be‐
fore replacing the belt pulley. Replace
n AG. Voan
lkswA/C
agencompressor
AG do that
is not operating smoothly.olks
wage es n
ot V gu
by a
♦ If the drive plate overload
ris
ed protection has activated, the belt
ran
te
pulley can be rotated
ut
ho using the outer part of the drive plate soe or a
that the A/C scompressor
sa shaft and the hexagon head on the c
drive plate (inner part of the drive plate) do not rotate.
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
and Installing .
wit
, is n
h re
hole
– Remove and install the belt pulley. Refer to
spec
⇒ “3.2.2 Overview - Belt Pulley, Sanden A/C Compressor”,
es, in part or in w
page 154 .
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4 Actuators
⇒ “4.1 Component Location Overview - Front Actuators”,
page 171
⇒ “4.3 Defroster Door Motor V107 with Defroster Door Motor Po‐
sition Sensor G135 , Removing and Installing”, page 179
page 183
⇒ “4.5 Left Temperature Door Motor V158 with Left Temperature
Door Potentiometer/Actuator G220 , Removing and Installing”,
page 187
⇒ “4.6 Right Temperature Door Motor V159 with Right Temper‐
ature Door Potentiometer/Actuator G221 , Removing and Instal‐
ling”, page 190
⇒ “4.7 Fresh Air/Recirculating Air/Back Pressure Door Motor
V425 with Fresh Air/Recirculating Air/Back Pressure Door Motor
Position Sensor G644 , Removing and Installing”, page 195
⇒ “4.8 Front Air Distribution Door Motor V426 with Air Distribution
Door Motor Position Sensor G642 , Removing and Installing”,
page 199
A n AG d G. Volkswage
agen
⇒ “4.10 Air Distribution Door Adjuster, Removing
Volksw and Installing”, oes
not
gu
page 207 ed by ara
n
ris tee
tho
4.1 Component Location Overview - Front ss
au or
ac
Actuators
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le
un
pt
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d
itte
⇒ “4.1.1 Component Location Overview - Front Actuators, Elec‐

y li
rm
ab
tric-Manual Climate Control System”, page 171

pe
ility
ot
wit
⇒ “4.1.3 Component Location Overview - Front Actuators, Clima‐

, is n
h re
tronic”, page 173

hole
spec
4.1.1 Component Location Overview - Front Actuators, Electric-Manual Climate

es, in part or in w
t to the co
Control System
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
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co lksw
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cted agen
Prote AG.
4. Actuators 171
Door Motor - V68-
❑ With the Temperature
Position Sensor - G92-
Diagnostic Tester
ling. Refer to
⇒ “4.2 Temperature
V68 with Temperature
Position Sensor G92 ,
ling”, page 176 .
Diagnostic Tester .
- V428- n AG. Volkswagen AG do
lkswage es n
Vo ot g
❑ With the Air Distribution
ed
by ua
ran
Door Motor hPosition
oris tee
Sensor - sG645-
au
t or
ac
s
ce
le
un
pt
Diagnostic Tester
an
d
itte
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rm
ab
ling. Refer to
pe
ility
ot

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, is n

h re
hole

spec

es, in part or in w
t to the co

page 202 .
rrectness of i

l purpos
Diagnostic Tester .
3 - Recirculation Door Motor - V113-
nform
ercia
❑ Check using the Vehicle Diagnostic Tester

m
a
com

ion in
r
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thi

s
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cum
fo
en
ng
t.
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Cop py
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Vo
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Prote AG.

4.1.2 Component Location Overview - Front Actuators, Electric-Manual Climate

Control System, RHD
Door Motor - V68-
❑ Check using the VehicleVolkswa
Diagnostic Tester agen
AG. gen AG
does
olksw not
❑ Removing ed b and instal‐
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ara
ling.hoRefer
ris to nte
eo
⇒a “4.2.2 Temperature
ut ra
c
sRegulator Door Motor
s
ce
e

nl
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an
stalling, RHD”,
itte
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page 177 .
erm
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ility
ot p
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4.1.3 Component Location Overview - Front

Actuators, Climatronic
Pay attention to the turn off conditions for vehicles with the Start/
Stop System. Refer to
page 6 .
4. Actuators 173
1 - Left Temperature Door Mo‐

tor - V158-
❑ With Left Temperature
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tuator - G220-
Diagnostic Tester
ling. Refer to
⇒ “4.5.1 Left Tempera‐
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ling”, page 187 .
Diagnostic Tester .
2 - Front Air Distribution Door
Motor - V426- with Front Air
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3 - Fresh Air/Recirculating Air/Back Pressure Door Motor - V425-

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⇒ “4.6.1 Right Temperature Door Motor V159 , Removing and Installing”, page 190 .
❑ With the Defroster Door Motor Position Sensor - G135-

4.1.4 Component Location Overview - Front Actuators, Climatronic, RHD
1 - Fresh Air/Recirculating Air/

Back Pressure Door Motor -
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basic setting using the Vehicle Diagnostic Tester
3 - Left Temperature Door Motor - V158-
❑ with Left Temperature Door Potentiometer/Actuator - G220-
⇒ “4.5.2 Left Temperature Door Motor V158 , Removing and Installing, RHD”, page 188 .
❑ With the Defroster Door Motor Position Sensor - G135-
⇒ “4.3.2 Defroster Door Motor V107 with Defroster Door Motor Position Sensor G135 , Removing and
Installing, RHD”, page 181 .
❑ with Right Temperature Door Potentiometer/Actuator - G221-
⇒ “4.6.2 Right Temperature Door Motor V159 , Removing and Installing, RHD”, page 192 .
4. Actuators 175
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– Discharge static electricity: Briefly touch the door striker pin.
– Remove the driver footwell vent. Refer to

⇒ “6.5 Driver Side Footwell Vent, Removing and Installing”,
page 276 .
– Remove the operating lever -3- from the heater.
Note
The upper bolt is accessible with a commercially available small

bit-ratchet.
– Remove the bolts -arrows-.

– Remove the Temperature Regulator Door Motor - V68- -1-.

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position and switch the ignition off.
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any moving parts (for example, the lever on the actuator).
any displayed entries, then perform the “basic setting” using
function.
– Check the heater and A/C unit function.
♦ Refer to ⇒ “5.1 Overview - Heater and A/C Unit”, page 213

V68- , Removing and Installing, RHD
Heater and electronic-manually regulated A/C system:
Removing
– Remove the partition. Refer to
⇒ “5.20.2 Partition, Removing and Installing, RHD”,
page 270 .
– Remove the footwell center console trim panel. Refer to ⇒
Body Interior; Rep. Gr. 68 ; Center Console; Overview - Cen‐
ter Console .
4. Actuators 177
Note

bit-ratchet.

– Remove the Temperature Regulator Door Motor - V68- -1-.
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♦ ⇒ “5.1 Overview - Heater and A/C Unit”, page 213
♦ Footwell center console trim panel. Refer to ⇒ Body Interior;
Rep. Gr. 68 ; Center Console; Overview - Center Console .
4.3 Defroster Door Motor - V107- with De‐

froster Door Motor Position Sensor -
⇒ “4.3.1 Defroster Door Motor V107 with Defroster Door Motor
Position Sensor G135 , Removing and Installing”, page 179
4.3.1 Defroster Door Motor - V107- with De‐

4. Actuators 179

– Remove the key.
Removing
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function.
♦ Storage Compartments and Covers; Overview - Glove Com‐
partment. Refer to ⇒ Body Interior; Rep. Gr. 68 ; Storage
Compartments and Covers; Overview - Glove Compartment .
4.3.2 Defroster Door Motor - V107- with De‐

G135- , Removing and Installing, RHD
– Remove the key.
Removing
– Remove the instrument panel. Refer to ⇒ Body Interior; Rep.
Gr. 70 ; Instrument Panel; Instrument Panel, Removing and
Installing .
4. Actuators 181
– Remove screws -2-.

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

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

on the actuating arm -2-.
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Rep. Gr.87 - Air Conditioning Prote AG.
4.4 Recirculation Door Motor - V113- , Re‐

⇒ “4.4.1 Recirculation Door Motor V113 , Removing and Instal‐
ling”, page 183

Heater and Electronic-Manually Regulated A/C System
Note
The actuator has end stops with integrated end switches instead
of a position sensor.
Perform the Following Work First

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4. Actuators 183
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mounts.
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Heater and electronic-manually regulated A/C system:

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ment Panel Central Tube, Removing and Installing .
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4. Actuators 185
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mounts.
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– Remove the Left Temperature Door Motor - V158- -1-.
4. Actuators 187
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4. Actuators 189
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⇒ “4.7.1 Fresh Air/Recirculating Air/Back Pressure Door Motor
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4.8 Front Air Distribution Door Motor - V426-

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⇒ “4.9.1 Air Distribution Door Motor V428 , Removing and Instal‐
ling”, page 202



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4.10 Air Distribution Door Adjuster, Remov‐

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⇒ “4.9 Air Distribution Door Motor V428 with Position Sensor
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4. Actuators 207
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moving and Installing, Climatronic
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⇒ “4.8 Front Air Distribution Door Motor V426 with Air Distri‐
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5 Front Heater and A/C Unit

AG. Volkswagen AG d
⇒ “5.1 Overview - Heater and A/C Unit”,
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n
213 oes
not
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⇒ “5.2 Overview - Attachments ris
ed bfor Heater and A/C Unit and Air ara
nte
Intake Housing”, page 218 ut
ho eo
ra
a c
ss
⇒ “5.3 Overview - Evaporator Housing”, page 220
ce
le
un
pt
⇒ “5.4 Overview - Air Distribution Housing Doors and Partitions”,
an
d
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page 222
erm
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ility
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page 224
h re
ole,
spec
page 228
t to the co
page 230
rrectne
⇒ “5.8 Heater and A/C Unit Bracket, Removing and Installing”,
page 230
ss o
⇒ “5.9 Evaporator, Removing and Installing”, page 231
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e
page 234
t
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⇒ “5.12 Fresh Air Blower V2 , Removing and Installing ”,
um
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page 238
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Heater Control Module J604 , Checking”, page 240 py by
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page 242
⇒ “5.15 Heater Core, Removing and Installing”, page 244
⇒ “5.16 Heater Core Coolant Pipes, Removing and Installing”,
page 260
⇒ “5.17 Evaporator Temperature Sensor G308 , Removing and
⇒ “5.18 Condensation Water Drain, Checking”, page 264
⇒ “5.19 Condensation Water Drain, Removing and Installing”,
page 265
⇒ “5.20 Partition, Removing and Installing”, page 269
5.1 Overview - Heater and A/C Unit

⇒ “5.1.1 Overview - Heater and A/C Unit, Climatronic”,
page 213
5.1.1 Overview - Heater and A/C Unit, Clima‐

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

heater and A/C units. Individual components of the different
heater and A/C units are similar but not the same. Interchang‐
ing components from different manufacturers is not permitted.
5. Front Heater and A/C Unit 213

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

following illustrations. Distinguishing characteristics between
manufacturers. Refer to ⇒ “2 Identification”, page 4 .
Overview - Heater and A/C Unit, Left Side Door Control
1 - Operating Lever
❑ For operating the de‐
AG. Volkswagen AG d
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tion door by
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2 - Air Distribution Door Motor ut
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❑ To check, use the Vehi‐ ss c
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the “Guided Fault Find‐
an
itte
y li
ing” function. Refer to
erm
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ility
ot p
Troubleshooting &
wit
, is n
Component locations.
h re
hole
spec
Heater and electric-manual cli‐
es, in part or in w
mate control system:
t to the co
Air Distribution Door Motor -
V428- with Air Distribution
rrectness of i
Door Motor Position Sensor -
G645-
l purpos

ling. Refer to
nform
ercia

m
at
om
io
n
c
in t
r

o
his
te

a
do
riv

p
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or
page 202 .
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❑ Front Air Distribution op Vo
by c lksw
Door Motor - V426- with cted agen
Prote AG.
Front Air Distribution
Door Motor Position
Sensor - G642-
ling. Refer to
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-
⇒ “4.2 Temperature Regulator Door Motor V68 with Temperature Regulator Door Motor Position Sensor
G92 , Removing and Installing”, page 176 .
Climatronic:
❑ Left Temperature Door Motor - V158- with Left Temperature Door Potentiometer/Actuator - G220-
⇒ “4.5 Left Temperature Door Motor V158 with Left Temperature Door Potentiometer/Actuator G220 ,
7 - Operating Lever
❑ For warm-air door
8 - Heater and Air Conditioning (A/C) Unit
❑ The heater and the heater and A/C unit have many components that are the same
❑ There are different versions. Refer to ⇒ “2 Identification”, page 4 .
❑ Interchanging components is not permitted.
❑ The following illustrations show the heater manufactured by “Valeo”
9 - Defroster- and Air Distribution Door Actuator
❑ Only on vehicles with heating or electric-manual climate control system
⇒ “4.10 Air Distribution Door Adjuster, Removing and Installing”, page 207 .
lkswage es n
Overview - Heater and A/C Unit, Right Side d bDoor
yV
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ility
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es, in part or in w
t to the co
rrectness of i
l purpos
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om
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ate
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Golf 2013 hor ➤ , Golf Variant 2014 ➤
is tee
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Heating,
au Ventilation and Air Conditioning - Edition 10.2014 ac
ss
ce
le
1 - Heater and Air Conditioning un
pt
an
d
itte
(A/C) Unit
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erm
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ility
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ling. Refer to
wit
is n
⇒ “5.5 Heater and A/C
h re
ole,
Unit, Removing and In‐
spec
t to the co
2 - Operating Lever
❑ For defroster door
rrectne
3 - Screw
❑ 1 Nm
ss o
❑ Quantity: 2
cial p
f inform
4 - Defroster Door Motor -
mer
V107-
atio
om
n
❑ With the Defroster Door
c
i
or
n
Motor Position Sensor -
thi
te
sd
a
G135-
iv
o
pr
cum
r
❑ Only for Climatronic

fo
en
ng
t.
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op py
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the “Guided Fault Find‐ p by
co Vo
ing” function. Refer to
by lksw
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Prote
AG.
Troubleshooting &
ling. Refer to
⇒ “4.3 Defroster Door
Motor V107 with De‐
froster Door Motor Posi‐
tion Sensor G135 , Re‐
page 179 .
5 - Right Temperature Door
Motor - V159-
❑ With Right Temperature Door Potentiometer/Actuator - G221-
⇒ “4.6 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 Air Conditioning (A/C) Unit, Heater Core,

Auxiliary Heater Heating Element
The illustration shows Valeo heater.

1 - Bolt AG. Volkswagen AG d

agen oes
❑ 6 Nm V olksw not
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2 - CoolanthorisPipe for Heater nte
eo
Core a ut ra
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an
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Catalog.
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❑ Coolant Supply from
ility
ot p
Engine
wit
, is n
h re
hole
ling. Refer to
spec
es, in part or in w
⇒ “5.15 Heater Core,
t to the co
ling”, page 244 .
3 - Clamp
rrectness of i
4 - Coolant Pipe for Heater
l purpos
Core
nform
ercia

m
Catalog.
at
om
io
❑ Coolant return to engine
n
c
in t
or
his
e

at
do
riv
ling. Refer to
p
cum
⇒ “5.15 Heater Core,

for
en
g

n
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op
ling”, page 244 . C py
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5 - Seal
p by
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Catalog.
❑ Replacing
6 - Cover
❑ For the heater core
7 - Screw
❑ 2 Nm
8 - Foam Spacer
❑ 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.
❑ Removing and Installing. Refer to ⇒ “5.5 Heater and A/C Unit, Removing and Installing”, page 224 .
❑ Disassembling and assembling. Refer to
⇒ “5.6 Heater and A/C Unit, Disassembling and Assembling”, page 228 .
12 - Heater Core

❑ Activation, checking. Refer to
page 240 .
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
Volkswa
19 - Seal agen
AG. gen AG
does
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❑ There are different versions. Refer
ed
b to the Parts Catalog.
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5.2 Overview - Attachments for Heater and ce
le
un
pt
an
d
A/C Unit and Air Intake Housing

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Note
h re
hole
spec

es, in part or in w
t to the co

rrectness of i

♦ A “Valeo” air intake housing is shown in the following illustra‐
l purpos
tion. Refer to ⇒ “2 Identification”, page 4 for the different

manufacturers' distinguishing characteristics of the heater and
nform
ercia
A/C units.
m
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tion in
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1 - Plastic Screw or Plug (de‐

pending on version)
❑ 0.3 Nm
❑ Quantity: 2
2 - Partition
AG. Volkswagen AG d
❑ Removing andoinstal‐ agen oes
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ling. Referedtoby
V gu
ara
⇒ “5.20hoPartition, Re‐
ris nte
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moving aut and Installing”, ra
c
pages 269 .
s
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3 - Fresh Air Blower Housing
an
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Upper Section
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4 - Screw
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❑ 1 Nm
h re
hole
❑ Quantity: 2
spec
es, in part or in w
t to the co
5 - Air Intake Duct
❑ With fresh- and air recir‐
culation door
rrectness of i
l purpos

Catalog.
nform
ercia
ling. Refer to
m
⇒ “6.4 Air Intake Duct, at

om
io
n
c
in t
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ling”, page 276 .

o
his
ate
❑ Do not dismantle
do
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or
6 - Dust, Fresh and Air Recir‐

f
en
ng
t.
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culation Door Adjuster
Co
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cted agen
ling. Refer to Prote AG.
Door Adjuster, Removing and Installing”, page 207 .
7 - Screw
❑ 1 Nm
❑ Quantity: 2
8 - Actuator
Heater and electric-manual climate control system:
❑ Recirculation Door Motor - V113- without position sensor; with end switches in the end stops. Refer to
⇒ Wiring diagrams, Troubleshooting & Component locations.
Climatronic:
❑ Fresh Air/Recirculating Air/Back Pressure Door Motor - V425- with Fresh Air/Recirculating Air/Back
Pressure Door Motor Position Sensor - G644-
9 - Screw
❑ 1 Nm

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❑ Quantity: 2
an
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❑ Replacement interval. Refer to ⇒ Maintenance ; Booklet 36.1 .
hole
spec
es, in part or in w
t to the co
11 - Cover
❑ For dust and pollen filter
rrectness of i
l purpos
nf
ercia
orm
m
13 - Fresh Air Blower Control Module - J126-
atio
om
n in
or c
thi
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sd
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⇒ “5.10 Fresh Air Blower Control Module J126 , Removing and Installing”, page 233 .
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14 - Screw t. Cop py
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❑ 1 Nm
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Prote AG.
5.3 Overview - Evaporator Housing
Note

♦ A “Valeo” evaporator housing is shown in the following illus‐
tration. Refer to ⇒ “2 Identification”, page 4 for the different
manufacturers' distinguishing characteristics of the heater and
A/C units.

1 - Evaporator Housing Lower

Section
2 - Evaporator
❑ Only with Air Condition‐
ing (A/C) system
❑ Check the foam seals
for damage and that
they are correctly bon‐
ded
ling. Refer to
⇒ “5.9 Evaporator, Re‐
page 231 .
3 - Seal
❑ Only for vehicles with an
A/C system.
❑ Replacing. For the cor‐
Parts Catalog.
before installing
4 - Retaining Plate
❑ Only with A/C system
❑ To secure the refriger‐
ant line and secure the
expansion valve
5 - Expansion Valve
❑ Only with A/C system AG. Volkswagen AG d
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⇒ “2.4 Expansion Valve, thor eo
Removing and Instal‐ ss au ra
c
ling”, page 110 .
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6 - Bolt
itte
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❑ 10 Nm
ility
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❑ Only with A/C system

wit
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❑ Quantity: 2 h re
hole
spec
7 - Seal/Insulation
es, in part or in w
t to the co
❑ Heat insulation for expansion valve

❑ 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.
rrectness of i
8 - Seal
l purpos

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ercia

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at
om
io
9 - Screw
n
c
in t
or
❑ 1.5 Nm
his
ate
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❑ Quantity: 8
p
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for
en
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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.
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5.4 Overview - Air Distribution Housing Doors and Partitions

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

♦ Refer to ⇒ “5.1 Overview - Heater and A/C Unit”, page 213 .
1 - Right Door for Warm Air

❑ From the heater core
❑ Activated via the right
door for cold air
2 - Operating Lever
❑ For door control
3 - Right Door for Cold Air
❑ From the evaporator
❑ Different versions
Heater and electric-manual cli‐
mate control system
❑ Activated collectively
via the left door shaft for
cold air and left operat‐
ing lever by the Temper‐
ature Regulator Door
Motor - V68-
Climatronic:
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❑ Activated by the Right y Volks ot g
ua
Temperature Door Mo‐ ed
b ran
ris
tor - V159- via theutright
ho
tee
or
operating lever.ss a ac
ce
e
4 - Right Operating Lever for

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Thermostat Door
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❑ Equipment version
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wit
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❑ Activated by the Right

hole
spec
Temperature Door Mo‐

es, in part or in w
tor - V159-
t to the co
5 - “Defrost” Door Operating

Lever
rrectness of i
❑ For the windshield and

door windows
l purpos
❑ Only Climatronic
nf
ercia
or
❑ Activated by the Defroster Door Motor - V107-

m
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atio
om
6 - “Defrost” Door Operating Lever

n in
or c
thi
❑ For the windshield and door windows

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sd
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❑ Only heater and electric-manual climate control system

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❑ Activated by the Air Distribution Door Motor - V428- via the defrost and air distribution adjuster
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Heater and electric-manual climate control system
AG.

❑ 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
AG. Volkswagen AG d
8 - Left Operating Lever agen oes
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Heater and electric-manual
ris climate control system
ed
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❑ Activated byssthe Temperature Regulator Door Motor - V68- r ac
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Climatronic:
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❑ Activated by the Left Temperature Door Motor - V158-
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9 - Left Door for Cold Air
wit
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❑ From the evaporator
h re
hole
spec
es, in part or in w
t to the co
Heater and electric-manual climate control system
❑ Activated by the Temperature Regulator Door Motor - V68- via the left operating lever.
rrectness of i
Climatronic:
l purpos
❑ Activated by the Left Temperature Door Motor - V158- via the left operating lever.
10 - Operating Lever
nform
ercia

m
at
om
11 - Left Door for Warm Air
ion
c
in t
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❑ From the heater core

o
his
ate
❑ Activated via the left door for cold air

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Note
AG.
♦ -Arrow-= direction of travel

♦ Refer to ⇒ “5.1 Overview - Heater and A/C Unit”, page 213 .

1 - Rear Air Guide Channel

Door
Heater and electric-manual cli‐ wage
es n
s
mate control system yV
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ua
d b ran
❑ The air guide channel is ir se tee
tho
or
sealed with a sealing au ac
ss
plug
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❑ Depending on the man‐
du
an
itte
ufacturer, not always
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present with the heater
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wit
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mate control system
h re
(not necessary, since
hole
spec
the air guide channel is
es, in part or in w
sealed)
t to the co
Climatronic (vehicle-specific)
rrectness of i
❑ For the rear vent in the
inside the center con‐
l purpos
sole
2 - Operating Lever
nform
ercia

m
at
❑ Equipment levels with
om
ion
Climatronic
c
in t
or
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e
❑ Not always present with

at
do
riv
the heater and electron‐

p
cum
or
ic-manually regulated A/
f
en
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C system -1-.
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3 - Left Door for the Left Instru‐
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4 - Operating Lever
AG.
❑ For operating the vent

doors
❑ Activated via the adjust‐
er -item 9- ⇒ Item 9 (page 215)
5 - Left Door for the Center Instrument Panel Vent
6 - Right Door for the Right Instrument Panel Vent
7 - Right Door for the Center Instrument Panel Vent
5.5 Heater and A/C Unit, Removing and In‐

stalling
♦ Shop Crane - Drip Tray - VAS6208-
♦ Commercially available compressed-air gun

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 or ⇒ Rep. Gr. 23 ; Engine Cover; Overview - Air
Filter Housing .
– Observe the safety instructions. Refer to

– Vehicles with Air Conditioning (A/C) system: Extract the re‐
frigerant using the A/C Service Station , 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
⇒ “2.13 Refrigerant Lines with Inner Heat Exchanger, Remov‐
– Place the Shop Crane - Drip Tray - VAS6208- under the en‐
gine. wage
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Vol t gu
– Mark the coolant hoses -1 and 4-. ed by ara
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– Clamp off the coolant hoses -1 and 4- using Hose Clamps -
h re
hole
Up To 25mm - 3094- .
spec
es, in part or in w
t to the co
CAUTION
rrectness of i
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ercia

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– Lift the clips -2 and 3-.

– Remove the coolant hoses -1 and 4- from the heater core for
the heater.
– Connect a section of hose -A- to the upper connection.
– Insert the compressed-air gun into the end of the hose.
– Hold a container -B- under the lower connection -C- and care‐
fully blow the coolant out of the heater core using the com‐
pressed-air gun.
Note
To seal off all open connections on expansion valve, sealing caps

from a replacement expansion valve can be used (preventing dirt
and moisture from entering the system).

– Remove the air guide channel to the rear vent (vehicle-spe‐
cific). Refer to
⇒ “6.8 Rear Center Console Vent Air Guide Channel, Remov‐
– Lift the rear footwell vent underneath the front seat and pull
rearward to facilitate removing the footwell vent from the heat‐
er and A/C Unit.
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gen AG does
– Remove the rear footwell vent from the Vheater
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wa and A/C unit. not
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– Disconnect the connector -3- fromtho the Fresh Air Blower Con‐ eo
trol Module - J126- . s au ra
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– Remove the connector -5- from the Airbag Control Module -

pt
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an
J234- (on the tunnel) -2-.

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vehicle interior with a waterproof foil and water absorbing pa‐
per. gen AG
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– Remove the heater and A/C unit to the side.

Installing
Note
The assistance of a second technician is necessary to install the

heater and A/C unit.

– 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 usedgeton Asecure the
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♦ Engine cover. Refer to ⇒ Rep. Gr. 10 ; Engine Cover; Engine
com
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Cover, Removing and Installing .
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♦ Air filter housing. Refer to ⇒ Rep. Gr. 23 ; Air Filter; Engine
s
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Note

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 ⇒ “2 Identification”, page 4 .

1 - Air Distribution Housing

❑ 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- AG. Volkswagen AG d
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❑ Manufacturer Vol differen‐
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For vehicles without an A/C system

an airflow regulator is installed in
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place of the evaporator.

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4 - Screw
❑ 1 Nm
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❑ Quantity: 3
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5 - Left Bracket
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❑ 4.5 Nm
8 - Right Bracket
❑ For heater and A/C unit
⇒ “5.8 Heater and A/C Unit Bracket, Removing and Installing”, page 230 .
9 - Air Intake Housing
10 - Screw
❑ 1 Nm
❑ Quantity: 2

5.7 Air Distribution Housing, Removing and

Installing
Removing
– Remove the heater and A/C unit. Refer to
page 224 .
– Remove the coolant pipes from the heater core. Refer to
⇒ “5.16 Heater Core Coolant Pipes, Removing and Installing”,
page 260 .
– Disconnect the connector from the fresh/recirculated air door
motor and free up the wiring harness.
– Release the mounting tabs -1 and 3-. . Volkswagen AG
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– Tilt the air distribution housing -4- toward they Vrear -arrow- and
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Note
The smallest leaks at the tongue and groove joint between the air
rrectness of i
distribution housing and the evaporator housing can lead to whis‐
tling noises due to escaping air. Coat the connecting surfaces
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lightly with, for example, silicone grease. Silicone grease. Refer

nform
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5.8 Heater and A/C Unit Bracket, Removing

on in
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heater and Air Conditioning (A/C) unit.
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Removing
page 224 .
– Fold the heat shield -2- behind the ABS unit to the side.
– Remove the nuts -3 and 5-.
– Remove the bracket -4- in the interior.
Note
If the nut above the ABS unit is not accessible as described, the
refrigerant pipe with the inner heat exchanger must be removed.
Refer to
⇒ “2.13 Refrigerant Lines with Inner Heat Exchanger, Removing
Installing
– Insert the bracket -1 and 3- into the mounts on the heater and
A/C unit -2- and bring the A/C unit into the installation position.
– Install the heater and A/C unit. Refer to
page 224 .
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– Remove the heater and Air Conditioning (A/C) unit. Refer to

page 224 .
– Remove bolts -1-.
– Release the mounting tabs -4 and 5- -arrows-.
– Remove the evaporator housing upper section -3- from the
lower section -2-.
– Remove the evaporator -2- from the evaporator housing lower

section -1-.
– Remove the expansion valve. Refer to
⇒ “2.4 Expansion Valve, Removing and Installing”,
page 110 .
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h re
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page 110 .
spec
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– Replace the seals.

t to the co
Note
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♦ 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
nform
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surfaces lightly with, for example, silicone grease. Silicone

m
grease. Refer to the Parts Catalog.

a
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tion in
♦ Before inserting the evaporator, check condensation water

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drain and clean drain if necessary.

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♦ Before inserting evaporator, clean evaporator housing and the

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5.10 Fresh Air Blower Control Module -

⇒ “5.10.1 Fresh Air Blower Control Module J126 , Removing and
5.10.1 Fresh Air Blower Control Module -

Removing
⇒ “5.20.1 Partition, Removing and Installing”, page 269 .
– Disconnect the connectors -1 and 3-.
CAUTION
There is a risk of burns from the hot radiating surface of the fresh
air blower control module.
It is possible to burn hands.
– Wear protective gloves. wage
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– Remove the control module -2- from the Fresh Air Blower
horis - tee
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⇒ “5.2 Overview - Attachments for Heater and A/C Unit and
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Air Intake Housing”, page 218
rrectness of i
5.10.2 Fresh Air Blower Control Module -
J126- , Removing and Installing, RHD
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page 270 . tion in

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♦ ⇒ “5.2 Overview - Attachments for Heater and A/C Unit and
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Installing
♦ Commercially Available Vacuum Cleaner
♦ Blower Motor Cover Plate - T10532-
♦ Trim Removal Wedge - 3409-
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 .

agen Heating, Ventilationoes and Air Conditioning - Edition 10.2014
AG. Volkswagen AG d
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cover -1- inrisedirection of -arrow- and remove.
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– Push the Blower Motor Cover Plate - T10532- -2- under the
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pollen filter -1-.

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-arrow B-.
NOTICE
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out of the dust and pollen filter due to incorrect seating of the
cover plate.
– Carefully remove the dust and pollen filter.
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– Install in reverse order of removal. When doing this, note the
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– Note installation position of the dust and pollen filter during
assembly.
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5.11.2 Dust and Pollen Filter, Removing and
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♦ Commercially Available Vacuum Cleaner
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♦ Blower Motor Cover Plate - T10532-
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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 the -direction of the arrow A- and re‐
move.
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– Push the Blower Motor Cover Plate - T10532-
hor -2- under the eo
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– Engage the cover -1- in the dust and pollen filter
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– Remove the cover -1- in the -direction of the arrow C-.
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– Make sure that the Blower Motor Cover Plate - T10532- is not
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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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5.12 Fresh Air Blower - V2- , Removing and
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⇒ “5.12.1 Fresh Air Blower V2 , Removing and Installing”,

page 238
5.12.1 Fresh Air Blower - V2- , Removing and

Installing
Note
If only the Fresh Air Blower - V2- is faulty, Fresh Air Blower Control
Module - J126- removing and installing. Refer to
Removing
The Fresh Air Blower - V2- is accessible from footwell on front
passenger side.
⇒ “5.20.1 Partition, Removing and Installing”, page 269 .


– Remove the bolt -2-, if equipped.
– Lift the securing tab -4- and turn the fresh air blower -1- clock‐
wise -arrow-.
– Remove the fresh air blower from the evaporator housing low‐
er section.
NOTICE
Risk of damaging the fresh air blower if operated incorrectly.
Volkswagen AG
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Removing
page 270 .
– Remove the footwell vent on the front passenger side. Refer
to
⇒ “6.6.2 Front Passenger Side Footwell Vent, Removing and

– Disconnect the connectors.

– Unclip the securing tab -arrows-.
– Remove the Fresh Air Blower - V2- -1- downward in the
-direction of the arrow-.
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function.
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– Then check the Fresh Air Blower - V2- function.
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5.13.1 Auxiliary Heater Heating Element - Z35-
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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

with Auxiliary Air Heater
AG. Volkswagen Control
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• Battery voltage greater than 11 V

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Test Sequence
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– Remove the center console. Refer to ⇒ Body Interior; Rep.

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– Loosen the instrument panel in the area of the glove compart‐
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ment until the instrument panel can be pulled forward to re‐

move the Auxiliary Heater Heating Element - Z35- .

– Using the Vehicle Diagnostic Tester and the Vehicle Diagnosis

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

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-4-.
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and pressing the release inward.
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– Never touch the metal surfaces of the heating element.
– Disconnect the connector -2- by sliding the retainer -5- upward

and pressing the release inward.
– Remove the Auxiliary Heater Heating Element - Z35- with the
Auxiliary Air Heater Control Module - J604- -1- left from the
heater and A/C unit -6-.
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Note
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Heater Heating Element - Z35- with the Auxiliary Air Heater
Control Module - J604- . Refer to
⇒ “5.14 Auxiliary Heater Heating Element Z35 with Auxiliary
Air Heater Control Module J604 , Removing and Installing”,
page 242 .
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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.
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or not properly installed.
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⇒ “5.1 Overview - Heater and A/C Unit”, page 213 .
– Check the clamp and screw-type clamp for proper seating on
the heater core and the coolant pipe connections. They must
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the heater.

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ant line -4- from the heater core.
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-1- from the heater core.

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for the coolant pipes for damage or debris.
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ponents.
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⇒ “5.1 Overview - Heater and A/C Unit”, page 213
Console .
♦ Knee Airbags; Overview - Knee Airbag. Refer to ⇒ Body In‐
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Denso, RHD

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Note

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Up To 25mm - 3094- .
– Lift the clips -2- and -3-.
– Remove the coolant hoses -1- and -4- from the heater core for
the heater.
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pressed-air gun.
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ponents.
Coolant .
function.
Console .

5.16 Heater Core Coolant Pipes, Removing

and Installing
⇒ “5.16.1 Heater Core Coolant Pipes, Removing and Installing,
Valeo”, page 260 n AG. Volkswagen AG do
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5.16.1 Heater Core Coolant Pipes, Removing
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There are different versions and various manufacturers of the
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heater and Air Conditioning (A/C) units. Individual components of
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the different heater and A/C units are similar but not the same (for
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⇒ “2.1 Heater and A/C Unit Identification”, page 4 ). Interchanging
rrectness of i
components from different manufacturers is not permitted. Refer
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– Remove the sealing boot -3- to the plenum chamber bulkhead.
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– Remove the foam piece -1-. p by
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– Lift the catch -7- and remove the clamp -6-. Prote AG.
– Remove the coolant pipe -5- from the heater core.

– Remove the screw clamp -9- and then remove the coolant pipe
-10- from the heater core.
– Remove the coolant pipes.
Installing
for the coolant pipes for damage or debris.
and attach it to the coolant pipe -1-.
NOTICE
and leaks.

– Position a new clip -5- or screw clamp -2- on the coolant

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5.16.2 Heater Core Coolant Pipes, Removing
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There are different versions and various manufacturers of the
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heater and Air Conditioning (A/C) units. Individual components of p by
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the different heater and A/C units are similar but not the same (for
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distinguishing characteristics, refer to
AG.
⇒ “2.1 Heater and A/C Unit Identification”, page 4 ). Interchanging

components from different manufacturers is not permitted. Refer
Removing
page 224 .
– Remove the sealing boot -3- to the plenum chamber bulkhead.
– Remove the bracket -4- for the coolant pipes to the left.
– Remove the foam piece -1-.
– Remove the bolts -5- and remove the screw-type clamps -6-.
– Remove the coolant pipes -7 and 8- from the heater core.

Installing
– Check the heater core connection -3- and the coolant pipe
connection -1- for damage or debris.
– Coat the new seals -2- with coolant (or lightly with silicone
grease) and attach it to the coolant pipe -1-.
NOTICE
and leaks.
– Never tilt the coolant pipe. AG. Volkswagen AG d
agen oes
– Slide the coolant pipes on completely. olksw not
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– Attach the new screw clamps -2- to the coolant
ss pipe/heater
core connection.
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– Tighten the bolt -1-.
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core and the coolant pipe connections. They must not be
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touching the air distribution housing or any other components.
hole
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page 224 .
– Check the Diagnostic Trouble Code (DTC) memoryand erase
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5.17 Evaporator Temperature Sensor -

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⇒ “5.17.1 Evaporator Temperature Sensor G308 , Removing and
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5.17.1 Evaporator Temperature Sensor -
Note
Only with vehicles with an Air Conditioning (A/C) system. The

opening in the heater is sealed on vehicles with a heater.

Removing
– Release the Evaporator Temperature Sensor - G308- with a
Trim Removal Wedge - 3409- .
– Remove the Evaporator Temperature Sensor - G308- -2- from
the housing.
Installing
5.17.2 Evaporator Temperature Sensor -

G308- , Removing and Installing, RHD
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♦ Trim Removal Wedge
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Only with vehicles with an A/C system. The opening in the heater
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– Release the Evaporator Temperature Sensor - G308- with a

Trim Removal Wedge - 3409- .
– Remove the Evaporator Temperature Sensor - G308- -2- from
the housing.
Installing
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5.18 yV
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Condensation Water Drain, Checking
b
ed ran
Checking thoris tee
or
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– Removessthe right footwell center console trim panel. Refer to
ce
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⇒ Body Interior; Rep. Gr. 68 ; Center Console; Overview -

nl
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Center Console .
an
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– Carefully fold back the carpet near the condensation water
ility
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drain hose far enough so that the condensation water drain
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hose is visible.
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– The tab -arrow- on the connection must engage into the guide
es, in part or in w
-2-. t to the co
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Prote AG.

– Insert the condensation water drain hose -6- into the body
opening until it audibly engages.
Note
♦ It must be possible to connect the condensation water drain

hose -1- to the connection on the heater and Air Conditioning
(A/C) unit without having any tension on it.
♦ The condensation water drain hose must fit securely to the
condensation water drain connection on the tunnel.
♦ The sealing lip -2- must not sit loosely on the body opening.
♦ The tabs -arrows- must be completely engaged.
Console .
5.19 Condensation Water Drain, Removing

and Installing
⇒ “5.19.1 Condensation Water Drain, Removing and Installing”,
page 265
5.19.1 Condensation Water Drain, Removing

and Installing
Removing
– Remove the right footwell center console trim panel. Refer to
Center Console .
lkswage es n
NOTICE o ot g
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ir se tee
Risk of damaging the airbag control module. If moisture
uth pene‐
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or
trates, the connectors will corrode. ss
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– Cover or seal the control module connectors after discon‐

nl
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necting to prevent moisture from entering.

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– Remove the connector from the Airbag Control Module - J234- wit
, is n
-4-.
h re
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spec
es, in part or in w
t to the co
rrectness of i
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nform
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at
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ate
do
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t.
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Prote AG.

– 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.
AG. Volkswagen AG d
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Prote AG.

• 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.
• If the pre-tensioning is not adequate, seal the area between
the body and the bracket, for example with silicone adhesive.
Note
♦ Install the condensation water drain hose so that it is not twis‐

ted or crushed.
♦ Make sure the carpet does not push up against the conden‐
sation water drain hose when installing.
♦ 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‐
alog.
Console .
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5.19.2 Condensation Water Drain, Removing byV
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Removing ss
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– Remove the right footwell center console trim panel. Refer to
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Center Console .
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the condensation water hose with waterproof foil and water
ole,
absorbing paper. spec

– Remove the foot rest. Refer to ⇒ Body Interior; Rep. Gr. 70 ;

t to the co
Passenger Compartment Trim; Foot Rest, Removing and In‐

stalling .
rrectne
NOTICE
s
Risk of damaging the airbag control module. If moisture pene‐

s o
cial p
trates, the connectors will corrode.

f inform
– Cover or seal the control module connectors after discon‐

mer
necting to prevent moisture from entering.

atio
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– Remove the connector from the Airbag Control Module - J234-

te
sd
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-5-.
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t.
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Prote AG.

– Cover the Airbag Control Module - J234- and connector -5-

with a waterproof cover.
the condensation water hose with waterproof foil and water gen AG. Volkswagen AG d
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absorbing paper. Vol
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– Remove the condensation water drain hose -3-ocarefully
ris
e
from tee
the heater and A/C unit -1- and the vehicle body
au
th
-4-. or
ac
ss
Installing
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du
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ab
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, is n
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spec
es, in part or in w
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• The condensation water drain hose -3- can only be correctly
l purpos
slid onto the heater and A/C unit -1- in one position until stop.
• The tab -arrow- on the connection must engage into the guide
nform
ercia
-2-.
m
at
• If a commercially available cable tie was used to secure the
om
ion
condensation water drain -3-, replace it.
c
in t
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te
• The condensation water drain hose must be routed as shown

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in the illustration from underneath the wiring harness of the

p
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Airbag Control Module - J234- -5-.

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Prote AG.

• The bracket -1- on the condensation water drain hose must be

completely and with pre-tension clipped into the body opening
-2-.
• The sealing lip must not sit loosely on the body opening.
• The tabs -arrows- must be completely engaged.
• If the pre-tensioning is not adequate, seal the area between
the body and the bracket, for example with silicone adhesive.
Refer to the Parts Catalog. AG. Volkswagen
agen AG do
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Note oris tee
th or
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ss
♦ Install the condensation water drain hose so that it is not twis‐
ce
le
ted or crushed.
un
pt
an
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♦ Make sure the carpet does not push up against the conden‐
rm
ab
sation water drain hose when installing.
pe
ility
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♦ If the condensation water drain hose sits too loosely on the
h re
heater and A/C unit connection secure it from falling with for
hole
spec
example a hose clamp. Hose clamps. Refer to the Parts Cat‐
es, in part or in w
alog.
t to the co
rrectness of i
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Console .
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5.20 Partition, Removing and Installing

m
a
com
tion in
⇒ “5.20.1 Partition, Removing and Installing”, page 269

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5.20.1 Partition, Removing and Installing

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Removing
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– Depending on the version remove the plastic screw or caps
rig
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-2- and partition -1-. cop Vo
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Installing
AG.
– Install in reverse order of removal.
Note
Replace the caps with bolts. Refer to Parts Catalog.
♦ Screws -2- -item 1- ⇒ Item 1 (page 219) .

5.20.2 Partition, Removing and Installing, RHD

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.
♦ Screws -2- ⇒ Item 1 (page 219) .
AG. Volkswagen AG d
agen oes
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es, in part or in w
t to the co
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c
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ate
do
priv
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t.
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Prote AG.

6 Air Routing
Compartment”, page 271
⇒ “6.2 Fresh Air Intake, Removing and Installing”, page 273
⇒ “6.3 Fresh Air Intake Cover, Removing and Installing”,
page 274
⇒ “6.4 Air Intake Duct, Removing and Installing”, page 276
⇒ “6.5 Driver Side Footwell Vent, Removing and Installing”, page
276
⇒ “6.6 Front Passenger Side Footwell Vent, Removing and In‐
⇒ “6.7 Rear Footwell Vent, Removing and Installing”, page 279
⇒ “6.8 Rear Center Console Vent Air Guide Channel, Removing
. Volkswagen AG
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⇒ “6.9 Passenger Compartment Forced
Vol
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a
not
ing”, page 280 ed by gu
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⇒ “6.10 Passenger Compartment
au
th Forced Air Extraction, Remov‐ eo
ra
s 281
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an
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page 282
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⇒ “6.12 Center Instrument Panel Vent Air Guide, Removing and
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6.1 Overview - Air Routing and Air Distribution in Passenger Compartment

spec
t to the co
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cial p
f inform
mer
atio
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6. Air Routing 271

1 - Air Guide for Defrost Air

Vent
❑ Removing and Instal‐
ling. Refer to
⇒ “6.11 Air Guide for De‐
frost Air Vent, Removing
and Installing”,
page 282 . agen
AG. Volkswagen AG d
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2 - Center Instrument Panel ed by gu
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❑ Removing and Instal‐ ss a c
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⇒ “6.12 Center Instru‐
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Guide, Removing and
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3 - Front Passenger Side Foot‐
ole,
well Vent
spec
t to the co
ling. Refer to
⇒ “6.6 Front Passenger
Side Footwell Vent, Re‐
rrectne
page 277 .
ss o
4 - Rear Footwell Vent, Re‐
cial p
f i
nform
mer
atio
m
ling. Refer to
o
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⇒ “6.7 Rear Footwell
i
or
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Vent, Removing and In‐
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5 - Air Guide Channel in Rear

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t.
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❑ Installed depending on
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vehicle equipment. For
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vehicles without a rear
agen
Prote AG.
center console air guide
channel vent a cap is installed on the heater.
❑ Removing and Installing. Refer to
⇒ “6.8 Rear Center Console Vent Air Guide Channel, Removing and Installing”, page 279 .
6 - Rear Center Console Air Guide Channel Vent
❑ Installed depending on vehicle equipment. For vehicles without a rear center console air guide channel
vent a cap is installed on the heater.
⇒ “6.8 Rear Center Console Vent Air Guide Channel, Removing and Installing”, page 279 .
7 - Rear Footwell Vent, Removing and Installing
❑ Removing and Installing. Refer to ⇒ “6.7 Rear Footwell Vent, Removing and Installing”, page 279 .
⇒ “6.5 Driver Side Footwell Vent, Removing and Installing”, page 276 .

6.2 Fresh Air Intake, Removing and Instal‐

ling
⇒ “6.2.1 Fresh Air Intake, Removing and Installing”, page 273
6.2.1 Fresh Air Intake, Removing and Instal‐

ling
Removing
– Remove the plenum chamber cover. Refer to ⇒ Body Exterior;
Rep. Gr. 50 ; Bulkhead; Plenum Chamber Cover, Removing
and Installing .
– Remove the fresh air intake cover. Refer to
⇒ “6.3 Fresh Air Intake Cover, Removing and Installing”, page
274 .
– Remove the Air Quality Sensor - G238- (only on vehicles with
climatronic). Refergto AG. Volkswagen AG d
a en
⇒ “9.2 Air Quality
Volksw Sensor G238 , Removing
oes
not and Installing”,
gu
page 304ed .
by ara
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is tee
or
– Remove
au
th the nuts -arrows-. or
ac
ss
– Remove the fresh air intake -1- from the plenum chamber.
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Installing
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Assembly sequence:
h re
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spec
– Align the air grille on the flange.

es, in part or in w
t to the co
– Hold the air grille and install the outer nut until the center weld
studs.
– Install the nut on the opposite side.
rrectness of i
– Install the outer vehicle nut.

l purpos
– Install the center nut.

nform
mercia
at
Note
om
ion
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in t
or
♦ The seal -2- must be seated correctly in the air grille.

his
ate
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♦ If the fresh air intake grille is damaged or installed incorrectly,

p
cum
or
water can enter the fresh air intake. Complaints due to odor
f
en
ng
t.
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problems coming from the heater/A/C system and/or there is
Co
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moisture in the passenger compartment may result.
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Prote AG.

Nut 3 Nm
6.2.2 Fresh Air Intake, Removing and Instal‐

ling, RHD
Removing
– Remove the plenum chamber cover. Refer to ⇒ Body Exterior;
Rep. Gr. 50 ; Bulkhead; Plenum Chamber Cover, Removing
and Installing .
6. Air Routing 273


⇒ “6.3.2 Fresh Air Intake Cover, Removing and Installing,
RHD”, page 275 .
– Remove the Air Quality Sensor - G238- (only on vehicles with
climatronic). Refer to
⇒ “9.2 Air Quality Sensor G238 , Removing and Installing”,
page 304 .
– Remove the nuts -arrows-.
– Remove the fresh air intake -1- from the plenum chamber.
Installing
Assembly sequence:
– Align the air grille on the flange.
– Hold the air grille and install the outer nut until the center weld
studs.
– Install the nut on the opposite side.
– Install the outer vehicle nut.
– Install the center nut.
Note
♦ The seal -2- must be seated correctly in the air grille.

♦ If the fresh air intake grille is damaged or installed incorrectly,
AG. Volkswagen AG d
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Component Tightening Specifications by Vol not
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6.3 Fresh Air Intake Cover, Removing and

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Installing
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⇒ “6.3.1 Fresh Air Intake Cover, Removing and Installing”,

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page 274
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spec
6.3.1 Fresh Air Intake Cover, Removing and

t to the co
Installing
Removing
rrectne
– Remove the right plenum chamber cover. Refer to ⇒ Body

Interior; Rep. Gr. 50 ; Bulkhead; Plenum Chamber Cover,
s
Removing and Installing .

s o
cial p
f inform
mer
atio
om
n
c
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t.
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Prote AG.

– 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-.
Note
♦ If the fresh air intake cover is damaged or installed incorrectly,

problems coming from the heater/Air Conditioning (A/C) sys‐
tem and/or there is moisture in the passenger compartment
may result.
♦ If the plenum chamber cover is damaged or incorrectly instal‐
led, water can enter the fresh air intake via the fresh air intake.
Installing
AG. Volkswagen AG d
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6.3.2 Fresh Air Intake Cover, Removing and d ara
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Installing, RHD ss aut ra
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Removing
pt
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– Remove the left plenum chamber cover. Refer to ⇒ Body In‐
erm
ab
terior; Rep. Gr. 50 ; Bulkhead; Plenum Chamber Cover,
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Removing and Installing .
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– Disconnect the cable connection for vehicles with heated
hole
spec
windshield from the cover for the fresh air intake -1-
es, in part or in w
– Unhook the fresh air intake cover -1- in the t to the co

-direction of the arrow B- and remove in the
-direction of the arrow A-.
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6. Air Routing 275

6.4 Air Intake Duct, Removing and Installing

Removing
– Remove the dust and pollen filter. Refer to
234 .
– Disconnect the connector -4- and free up the wiring harness.
– Loosen the heater and Air Conditioning (A/C) unit and pull
slightly forward.
– Release the mounting tab -1- -arrow A-.
– Tilt the air intake duct -3- upward -arrow B- and disengage.
Installing
♦ Refer to
6.5 Driver Side Footwell Vent, Removing

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– Remove the driver side footwell vent -2-.

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♦ Overview - knee airbag. Refer to ⇒ Body Interior; Rep. Gr.

69 ; Knee Airbags; Overview - Knee Airbag .

6.5.2 Driver Side Footwell Vent, Removing

and Installing, RHD
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♦ Overview - knee airbag. Refer to ⇒ Body Interior; Rep. Gr.
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69 ; Knee Airbags; Overview - Knee Airbag .

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6.6 Front Passenger Side Footwell Vent,

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⇒ “6.6.1 Front Passenger Side Footwell Vent, Removing and In‐
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Removing
6. Air Routing 277

– 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.
– Pull the instrument panel slightly forward.
– Remove the front passenger side footwell vent.
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– Remove the screws -3-. cted agen
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– Push the clip -4- in the -direction of the arrow- upward and
unclip the front passenger side footwell vent.
– Pull the instrument panel slightly forward.
– Remove the front passenger side footwell vent.
Installing
Note
Note the correct position of the coolant hoses for vehicles with
glove compartment cooling.
4.2 x 16 screw 1.5 Nm

6.7 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 .
Gr. 68 ; Center Console; Center
wage
nConsole,
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heater and Air Conditioning (A/C) unit -2- -arrow A- and re‐
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Note
A loose cable clip or a damaged seal can cause flow-generated

noise.
6.8 Rear Center Console Vent Air Guide

Channel, Removing and Installing
Removing
Gr. 68 ; Center Console; Center Console, Removing and In‐
stalling .
6. Air Routing 279

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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♦ The stale air escapes through the vent openings in the luggage
compartment trim.
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♦ If the ventilation is to function properly, the ventilation open‐

ings must not be covered.
nform
ercia
♦ The ventilation frames are located in the rear side panels, be‐
m
hind the bumper.

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The ventilation can be checked through the luggage compart‐

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Trim Panels; Overview - Luggage Compartment Side Trim
AG.
Panel .
– The sealing lips in the vent frame on both sides of the vehicle
must move freely and close by themselves.


traction, Removing and Installing
⇒ “6.10.1 Passenger Compartment Forced Air Extraction, Re‐
moving and Installing, Golf”, page 281
⇒ “6.10.2 Passenger Compartment Forced Air Extraction, Re‐
moving and Installing, Golf Wagon”, page 281
6.10.1 Passenger Compartment Forced Air Ex‐

traction, Removing and Installing, Golf
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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– Remove the rear bumper cover. Refer to ⇒ Body Exterior;

Rep. Gr. 63 ; Rear Bumper; Bumper Cover, Removing and
rrectness of i
Installing .
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– Release the tabs -arrows- using the Trim Removal Wedge -
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♦ Overview - rear bumper cover. Refer to ⇒ Body Exterior; Rep.
Gr. 63 ; Rear Bumper; Overview - Bumper Cover .
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Installing .
– Unclip the wiring harness -3- from the Sunlight Photo Sensor
- G107- in direction of -arrow-.
– Remove the clips -2-.
– Remove the air guide for the defrost -1- upward from the heat‐
er and Air Conditioning (A/C) unit.
Installing
6.12 Center Instrument Panel Vent Air Guide,

Removing
Installing .
– Remove the air guide for the center instrument panel vent
-1- upward from the heater and Air Conditioning (A/C) unit.
Installing

7 Coolant Circuit
⇒ “7.1 High Voltage Heater (PTC) Z115 , Incorporation in Coolant
Circuit”, page 283
⇒ “7.2 High Voltage Battery Heat Exchanger Incorporation in the
High Voltage System Coolant Circuit”, page 288
⇒ “7.3 High Voltage Battery Coolant Valve N688 , Removing and
⇒ “7.4 High Voltage Battery Coolant Pump V590 , Removing and
⇒ “7.5 High Voltage Heater (PTC) Z115 / High Voltage Heater
(PTC) Control Module J848 , Removing and Installing”,
page 292
7.1 High Voltage Heater (PTC) - Z115- , In‐

corporation in Coolant Circuit
Note
♦ The High Voltage Heater (PTC) - Z115- takes over the function
of the auxiliary heater on vehicles with a high voltage system.
♦ For vehicles with a high voltage system and a parking heater
installed as optional equipment, the High Voltage Heater
(PTC) - Z115- can be activated to heat the vehicle interior in‐
stead of the parking heater. Additional information. Refer to agen
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au
t or
ac
heater installed as optional equipment, the vehicless interior can
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be heated at a low ambient temperature with the ignition

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switched off via the function “parking air conditioner” and the
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High Voltage Heater (PTC) - Z115- (or cooled at a high ambi‐
erm
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ent temperature via the Air Conditioning (A/C) system).
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♦ Fill with coolant and bleed the coolant circuit. Refer to ⇒ Rep.
h re
hole
spec
es, in part or in w
♦ Incorporation of the A/C system heater core and the High Volt‐
t to the co
age Heater (PTC) - Z115- in the engine coolant circuit. Refer
to ⇒ Rep. Gr. 19 ; Coolant System/Coolant (Connection Di‐
agram for High Voltage System Coolant Hoses).
rrectness of i
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Note
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The -arrows- show the direction of flow for the coolant.

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7. Coolant Circuit 283

1 - Heater Core for the Heater

in the A/C Unit
❑ Incorporation of the
heater core in the en‐
gine coolant circuit. Re‐
fer to ⇒ Rep. Gr. 19 ;
Coolant System/Cool‐
ant (Connection Dia‐
gram for Coolant Ho‐
ses).
2 - High Voltage Heater (PTC)
- Z115- (with High Voltage
Heater (PTC) Control Module - AG. Volkswagen AG d
J848- ) agen oes
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❑ To check, use the Vehi‐ rised ara
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cle Diagnostic Tester in ut
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the “Guided Fault Find‐ ss a c
ing” function (of the A/C
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system) and refer to
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⇒ “7.5 High Voltage
es, in part or in w
t to the co
Heater (PTC) Z115 /
High Voltage Heater
(PTC) Control Module
J848 , Removing and In‐
rrectness of i
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❑ Additional information
for vehicles with a “Park‐
ing heater” as optional
nform
ercia
equipment. Refer to ⇒
m
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Air Conditioning; Rep.
n
c
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or
Gr. 00 ; General Infor‐
his
te
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3 - Transmission Coolant Valve - N488-

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4 - Coolant Supply to Transmission
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cted AG.
agen
19 ; Coolant System/Coolant (Connection Diagram for Coolant Hoses).
5 - Coolant Supply from Engine
❑ Incorporation of the parking heater in the engine coolant circuit. Refer to ⇒ Rep. Gr. 19 ; Coolant System/
Coolant (Connection Diagram for Coolant Hoses).
6 - Coolant Return to Engine
❑ Incorporation of the parking heater in the engine coolant circuit. Refer to ⇒ Rep. Gr. 19 ; Coolant System/
Coolant (Connection Diagram for Coolant Hoses).

Note
Depending on the engine, a valve

may be installed between the Cool‐
ant Change-Over Valve 2 - N633-
and the engine in the coolant return
which prevents the coolant from the
engine from flowing to the Coolant
Change-Over Valve 2 - N633- when
the engine is running. Refer to ⇒
Rep. Gr. 19 ; Coolant System/Cool‐
ant (Connection Diagram for Cool‐
ant Hoses).
wage es n
7 - Coolant Change-Over Valve yV
o2 - N633-
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❑ Incorporation of the ed
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teeRefer to ⇒ Rep. Gr. 19 ; Coolant System/
ran
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Coolant (Connection
auth Diagram for Coolant Hoses). or
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2 - N633- is activated by the re‐
h re
spective Engine Control Module
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spec
(ECM) (for example, by the En‐
es, in part or in w
gine Control Module - J623- )
t to the co
when heating output of the A/C
system is requested and the ve‐
hicle is in an electric driving
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mode. Use the Vehicle Diagnos‐
tic Tester in the “Guided Fault
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⇒ Wiring diagrams, Trouble‐ nf
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shooting & Component loca‐

or
tions.
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♦ If there is a complaint due to in‐

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sufficient heating output of the A/

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Diagnostic Tester in the “Guided
AG.
Fault Finding” function and refer

to ⇒ Wiring diagrams, Trouble‐
tions.

♦ So that the coolant warmed by

the High Voltage Heater (PTC) -
Z115- is delivered by the heater
and A/C unit heater core, the
High Temperature Circuit Cool‐
ant Pump - V467- and the Trans‐
mission Coolant Valve - N488-
must be activated (by the
respective ECM). So that the
coolant flows in the correct direc‐
tion the check valve in the cool‐
ant circuit must be installed cor‐
rectly and its function must be
OK. For more information, use
the Vehicle Diagnostic Tester in
the “Guided Fault Finding” func‐
tion and refer to ⇒ Rep. Gr. 19 ;
Coolant System/Coolant (Con‐
nection Diagram for Coolant Ho‐
ses) and ⇒ Wiring diagrams, n AG. Volkswagen AG do
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8 - High Temperature Pump - V467- CircuitssCoolant
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❑ Incorporation in the engine coolant circuit. Refer to ⇒ Rep. Gr. 19 ; Coolant System/Coolant (Connection
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Diagram for Coolant Hoses).
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♦ The High Temperature Circuit
es, in part or in w
Coolant Pump - V467- is activa‐
t to the co
ted by the respective ECM (for
example, by the Engine Control
Module - J623- ) when the heat‐ rrectness of i
ing output of the A/C system is
required. Use the Vehicle Diag‐
l purpos
nostic Tester in the “Guided

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orm

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atio
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tions.
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thi
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a
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proper side and is functioning

properly. Use the Vehicle Diag‐
nostic Tester in the “Guided
tions.

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♦ So that the coolant warmed by
pt
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Coolant Change-Over Valve 2 -
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N633- and the Transmission
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Coolant Valve - N488- must be
es, in part or in w
activated (by the respective en‐
t to the co
gine control module). So that the
coolant flows in the correct direc‐
tion the check valve in the cool‐
rrectness of i
ant circuit must be installed cor‐
rectly and its function must be
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OK. For more information, refer

to ⇒ Rep. Gr. 19 ; Coolant Sys‐
nform
tem/Coolant (Connection Dia‐
ercia
gram for Coolant Hoses) and

m
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⇒ Wiring diagrams, Trouble‐
com
tio
n in
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te o
tions. Use the Vehicle Diagnostic
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7.2 High Voltage Battery Heat Exchanger

Incorporation in the High Voltage Sys‐
tem Coolant Circuit
Note
♦ Fill with coolant and bleed the coolant circuit. Refer to ⇒ Rep.
♦ The following illustrations show only on component of the re‐
frigerant circuit components for the high voltage system. For
additional components not shown here, refer to ⇒ Rep. Gr.
19 ; Coolant System/Coolant .
♦ Incorporation of the high voltage battery heat exchanger in the
refrigerant circuit. Refer to
Coolant Circuit”, page 283 .
♦ If there is a complaint due to a lack of cooling of the high volt‐
age system components and the Air Conditioning (A/C) sys‐
tem cooling output is OK, check the cooling of the high voltage
battery heat exchanger using the cooling output test. Refer to
Climate Control System (with High Voltage System)”,
page 46 . While doing so, make sure that the high voltage bat‐
tery heat exchanger is actually being cooled. The High Voltage
Battery Heater Core Refrigerant Cut-Off Valve - N542- func‐
tion and the restrictor installed in the refrigerant circuit must be
OK. Refer to
⇒ “2.1.2 System Overview - Refrigerant Circuit,enGolf AG. VGTE”,
olkswagen AG
page 103 . If no malfunctions can be determined olkswag here in the does
not
refrigerant circuit, check the incorporationd by V of the High Voltage gu
ara
Battery Coolant Pump - V590- , the oris Coolant Pump in front of
e nte
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Electric Drive Power and Control Electronics - V508- , the
th
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Coolant Change-Over Valve 1 - N632- and the High Voltage
s c
ce
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Battery Coolant Valve - N688- in the high voltage system cool‐

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ant circuit, as well as their activation and function. Refer to ⇒

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Prote AG.

1 - High Voltage Battery Cool‐

ant Valve - N688-
❑ Incorporation in the high
voltage system coolant
circuit. Refer to ⇒ Rep.
Gr. 19 ; Coolant Sys‐
tem/Coolant .
ling. Refer to
⇒ “7.3 High Voltage
Battery Coolant Valve
N688 , Removing and
❑ Check the function and
activation of the High
Voltage Battery Coolant
Pump - V590- and the
High Voltage Battery
Coolant Valve - N688-
using the Vehicle Diag‐
nostic Tester in the “Gui‐
ded Fault Finding” func‐
tion for the A/C system
and the hybrid battery
management system.
Refer to ⇒ Rep. Gr. 19 ;
Coolant System/Cool‐
ant .
2 - Coolant Return from High
Voltage Battery 1 - AX2-
❑ Incorporation in the high
voltage system coolant
circuit. Refer to ⇒ Rep.
Gr. 19 ; Coolant Sys‐
tem/Coolant .
3 - Coolant supply to the High
Voltage Battery 1 - AX2- n AG. Volkswagen AG do
swage es n
❑ Incorporation in the high byV
olk ot g
ua
voltage system coolant circuit. Refer to ⇒ Rep.
ir seGr. 19 ; Coolant System/Coolant .
d ran
te
tho eo
4 - Bleed Screw ss
au ra
c
❑ Coolant circuit, bleeding. Refer to ⇒ Rep. Gr. 19 ; Coolant System/Coolant .
ce
le
un
pt
an
d
itte
5 - Heat Exchanger for the High Voltage Battery

y li
rm
ab
❑ Incorporation in the high voltage system coolant circuit. Refer to ⇒ Rep. Gr. 19 ; Coolant System/
pe
ility
Coolant .
ot
wit
, is n
h re
❑ Check the function and cooling of the heat exchanger via the A/C system using the Vehicle Diagnostic
hole
Tester in the “Guided Fault Finding” function (for the A/C system and the hybrid battery management
spec
es, in part or in w
system). Refer to
t to the co
⇒ “4.4.5 Cooling Output, Checking, Vehicles with Automatic Climate Control System (with High Voltage
System)”, page 46 .
rrectness of i
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6 - High Voltage Battery Coolant Pump - V590-

nform
ercia
Coolant .
m

a
com
tio
⇒ “7.4 High Voltage Battery Coolant Pump V590 , Removing and Installing”, page 291 .
n in
r
te o
❑ To check the function and activation, use the Vehicle Diagnostic Tester in the “Guided Fault Finding”
thi
s
iva
function.
do
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rp
cum
fo
en
ng
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Cop py
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289
by lksw
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Prote 7. Coolant Circuit
AG.
Note
♦ The High Voltage Battery Cool‐

ant Pump - V590- (and the High
Voltage Battery Coolant Valve -
N688- ) is activated by the High
Voltage Battery 1 - AX2- (by the
Battery Regulation Control Mod‐
ule - J840- ), when cooling for the
high voltage system compo‐
nents (the High Voltage Battery
1 - AX2- , the Electric Drive Pow‐
er and Control Electronics - JX1-
and/or the High Voltage Battery
Charger Control Module -
J1050- ) is required. Use the Ve‐
hicle Diagnostic Tester in the
“Guided Fault Finding” function
(for the hybrid battery manage‐
ment system) and refer to ⇒
Rep. Gr. 19 ; Coolant System/
Coolant .
sufficient cooling of the high volt‐
age system components, check
for correct installation on the
proper side and proper function
using the Vehicle Diagnostic
Tester in the “Guided Fault Find‐
ing” function (for the hybrid bat‐
tery management system) and
refer to ⇒ Rep. Gr. 19 ; Coolant
System/Coolant .
AG. Volkswagen AG d
♦ So that the Electric Drive Power olksw
agen oes
not
and Control Electronics - JX1- d by
V gu
ara
and the High Voltage Battery orise nte
eo
Charger Control Module - J1050- aut
h
ra
are cooled, the Coolant Pump in ss c
ce
le
front of Electric Drive Power and

un
pt
Control Electronics - V508- and
an
d
itte
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the Coolant Change-Over Valve
rm
ab
1 - N632- must also be activated
pe
ility
ot
(by the respective Engine Con‐
wit
, is n
trol Module (ECM)) and their

h re
hole
function must be OK. For addi‐

tional information, use the Vehi‐ spec
es, in part or in w
t to the co
cle Diagnostic Tester in the “Gui‐
ded Fault Finding” function (for
the hybrid battery management
system) and refer to ⇒ Rep. Gr.
rrectness of i
19 ; Coolant System/Coolant .
l purpos
7 - Coolant Supply from the High Voltage System Radiator

nform
ercia
Coolant .
m
a
com
tio
8 - Coolant Supply to the Coolant Pump in front of Electric Drive Power and Control Electronics - V508-
n in
r
te o
thi
s
iva
do
Coolant .
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rp
cum
fo
en
ng
t.
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op py
7.3 High Voltage Battery Coolant Valve -
t. C rig
gh ht
pyri by
N688- , Removing and Installing
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cted agen
Prote AG.


♦ Hose Clip Pliers - VAS6362-
Removing
⇒ “1.5 Cooling System Safety Precautions”, page
gen AG
. Vo2
lks.wagen AG
wa does
olks not
– Disconnect the connector -2-. byV gu
ara
ed nte
ris
tho eo
au ra
Note ss c
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e
nl
pt
du
an
Place a cloth underneath to catch any escaping coolant.
itte
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erm
ab
ility
ot p
wit
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hole
CAUTION
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nf
ercia
orm
m
atio
m
– Clamp off and remove the coolant hoses with the Hose
o
n in
c
Clamps - Up To 25mm - 3094- by loosening the hose clamps

or
thi
e
-3-.
t
sd
iva
o
r
rp
cu
– Remove the High Voltage Battery Coolant Valve - N688- .
o
m
f
en
ng
t.
yi
Installing
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Secure all hose connections with hose clamps used in standard

production. Refer to the Parts Catalog.
– Check the coolant level. Refer to ⇒ Rep. Gr. 19 ; Coolant

System/Coolant .
♦ Overview - Coolant Valves. Refer to ⇒ Rep. Gr. 19 ; Coolant
Pump/Thermostat .
7.4 High Voltage Battery Coolant Pump -

V590- , Removing and Installing
Removing
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 66 ; Noise Insulation .

CAUTION
– Clamp off and remove the coolant hoses with the Hose
Clamps - Up To 25mm - 3094- by loosening the hose clamps
-1-.
– Remove the bolt -3- and remove the High Voltage Battery
Coolant Pump - V590- .
AG. Volkswagen AG d
agen oes
Installing Volksw not
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d by ara
Install in reverse order of removal. Note the following: orise nte
eo
h
aut ra
ss c
ce
e
Note
nl
pt
du
an
itte
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erm
Secure all hose connections with hose clamps used in standard
ab
ility
production. Refer to the Parts Catalog.
ot p
wit
, is n
h re
– Check the coolant level. Refer to ⇒ Rep. Gr. 19 ; Coolant
hole
spec
System/Coolant .
es, in part or in w
t to the co
♦ Refer to ⇒ Rep. Gr. 19 ; Coolant Pump/Thermostat
rrectness of i
♦ Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Noise Insulation;
l purpos
Overview - Noise Insulation .
7.5 High Voltage Heater (PTC) - Z115- /
nform
ercia
High Voltage Heater (PTC) Control

m
at
om
io
Module - J848- , Removing and Instal‐
n
c
in t
or
his
e
ling
at
do
priv
cum
or

f
en
ng
t.
yi Co
♦ Commercially available five star bit-insert “TS30H” with Torx Cop py
t. rig
Bit - tamper proof pyri
gh by
Vo
ht
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lksw
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Prote AG.
Removing


system. Refer to
page 2 .
sification .
DANGER
person.

CAUTION n AG. Volkswagen AG do

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The cooling system is under pressure when the engine by V is warm.
o ot g
ua
There is a risk of scalding from hot steam and ed
ir scoolant.
ran
o tee
th or
Burns on the skin and other parts of the body
au is possible. ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
– Open the coolant reservoir cap -arrow- for the engine coolant
spec
circuit.
t to the co
– Remove the rear noise insulation. Refer to ⇒ Body Exterior;
Rep. Gr. 66 ; Noise Insulation .
rrectnes
Note s o
cial p
f inform
The High Voltage Heater (PTC) - Z115- is installed with the brack‐
mer
et and the heat shield -C- on the underbody in the center tunnel
atio
m
in the area of the catalytic converter.

o
n
c
i
or
n thi
te
– Remove bolts -A and B-.

sd
iva
o
pr
cum
r
– Carefully tilt the High Voltage Heater (PTC) - Z115- with the
fo
en
ng
bracket and heater core cover -C- downward.

t.
yi Co
Cop py
. rig
– Remove the bolts -D-.
t
gh ht
pyri by
Vo
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by
cted agen
Prote AG.
Note
At the start of production the heater core cover is bolted with the
thread-cutting flat-head screws (M6 x 12) -D-. To remove and In‐
stall a five star bit-insert “TS30H” with TORX® bit - tamper proof
is necessity.

– Remove the heat shield -B- and bracket -C- from the High
Voltage Heater (PTC) - Z115- -D-.
AG. Volkswagen AG d
agen oes
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ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
– Clamp the coolant hoses -A and B- with Hose Clamps - Up To
wit
, is n
h re
25mm - 3094- -D-.
hole
spec
es, in part or in w
t to the co
Note
The High Voltage Heater (PTC) - Z115- -E- is designed for a spe‐
rrectness of i
cific coolant flow direction, for this reason coolant hoses must be
connected on the correct sides.
l purpos
– Remove the coolant hoses -A and B- from the connections on
nform
ercia
the High Voltage Heater (PTC) - Z115- -E-.

m
at
om
– Close the open connections for the coolant hoses on the High
ion
c
Voltage Heater (PTC) - Z115- -E- with clean plugs from the
in t
or
his
ate
do
priv
cum
or
– Remove the connectors -A- (for low voltage) and -B- (high
f
en
ng
t.
voltage cable) from the High Voltage Heater (PTC) - Z115- .
yi Co
Cop py
t. rig
– Cover the high voltage cable connector and socket on the High
gh ht
yri by
Voltage Heater (PTC) - Z115- -G- (for example with a clean
cop Vo
by lksw
cted
plug from the Engine Bung Set - VAS6122- ) to protect them
agen
Prote AG.
from debris and damage.
Remove the nut -F- (or -E-) and Ground (GND) cable -C- (or GND
cable -C- with the bracket -D-).
Installing
The heat shield -B- and the bracket -C- are bolted with thread-
cutting flat-head screws (M6 x 12) -A- on the High Voltage Heater
(PTC) - Z115- -D-. If a new High Voltage Heater (PTC) - Z115-
-D- is installed no threads are formed on the attaching points. So
that the bolts can be installed easier when installing a new High
Voltage Heater (PTC) - Z115- -D-, position the bolts -A- before
installing the High Voltage Heater (PTC) - Z115- -D- and screw
them in approximately 6 mm.

Check the contact surfaces for the GND cable -C- on the bracket
-D- and for the bracket -D- on the High Voltage Heater (PTC) -
Z115- -G- before installing and clean if necessary.
Note
The attachment points on the High Voltage Heater (PTC) - Z115-

-G- and on the bracket -D- as well as the GND cable -C- on the
nut -F- are to be checked before installing. The contact surfaces
must be clean and rust and grease-free. Otherwise service the
contact surfaces using the Contact Surface Cleaning Set -
VAS6410- .
Install the bracket -D- and GND cable -C- on the High Voltage
Heater (PTC) - Z115- -G-.
Tightening Specifications:
Nuts -E- and -F- (M6 threads) 8 Nm
– Attach the connectors -A- (for low voltage) and -B- (high volt‐
age cable) to the High Voltage Heater (PTC) - Z115- -G-.
– If necessary, fill the coolant in the coolant expansion tank for
the engine. Refer to ⇒ Rep. Gr. 19 ; Coolant System/Coolant .
– Install the coolant hose -A- on the High Voltage Heater (PTC)
- Z115- -E-.
– Carefully open the hose clamp -D- on the coolant hose -A- and
let the coolant flow into the High Voltage Heater (PTC) - Z115-
-E-.
– As soon as coolant flows out of the connection for the coolant
hose -B- on the High Voltage Heater (PTC) - Z115- -E- swag(the
en AG. V
olkswagen AG
does
High Voltage Heater (PTC) - Z115- -E- is completely by V filled with
olk not
gu
coolant), install the coolant hose -B- on the High
ris
e Voltage Heat‐
d ara
nte
er (PTC) - Z115- -E-. utho eo
r
a ac
ss
ce
le
un
pt
Note
an
d
itte
y li
rm
ab
♦ So that the High Voltage Heater (PTC) - Z115- -E- is com‐

pe
ility
ot
pletely filled with coolant, hold the connection for the coolant
wit
, is n
hose -B- as far upward as possible when the coolant is flowing

h re
hole
in.
spec
es, in part or in w
♦ When the removal and installation of the High Voltage Heater

t to the co
(PTC) - Z115- -E- is performed as described above there

should be no air in the engine coolant circuit. If, for some other
reason, there is still some air in the coolant circuit, bleed the
rrectness of i
coolant circuit. Refer to ⇒ Rep. Gr. 19 ; Coolant System/

Coolant .
l purpos
– Remove both hose clamps -D-.

nform
ercia
– Check the contact surfaces for the bracket -C-, on the High
m
a
com
Voltage Heater (PTC) - Z115- -D- and on the heat shield -B-
ion in
before attaching and clean if necessary.

r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Install the heat shield -B- and bracket -C- on the High Voltage
Heater (PTC) - Z115- -D-.
Note
The heat shield -B- and the bracket -C- are bolted with thread-
cutting flat-head screws (M6 x 12) -A- on the High Voltage Heater
(PTC) - Z115- -D-.
Tightening Specification:
Bolts -A- 8 Nm
– Install the bracket -C- with the High Voltage Heater (PTC) -
Z115- .
Bolts -A- 8 Nm
Bolts -B- 20 Nm
– Re-install are removed or loosened components.
– If necessary, fill the coolant in the coolant expansion tank for
the engine coolant circuit. Refer to ⇒ Rep. Gr. 19 ; Coolant
System/Coolant .
– Remove the Hose Clamps - Up To 25mm - 3094- and install
all removed or loosened components.
– After installing the High Voltage Heater (PTC) - Z115- switch
on the ignition and prepare the ready mode (the engine must
not run), set the A/C system to the maximum heating output
and let the A/C system run for two minutes at this setting.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co
296
by lksw
cted agen
Rep. Gr.87 - Air Conditioning Prote AG.
8 Display and Control Head

⇒ “8.1 Component Location Overview - Display and Control
Head”, page 297
. Volkswagen AG
gen AG does
⇒ “8.2 Display and Control Head, Removing and Installing”,
Vol
kswpage
a
not
301 ed by gu
ara
ris nte
ho eo
8.1 Component Location Overview
ss
au
t
- Display ra
c
and Control Head
ce
e
nl
pt
du
an
itte
⇒ “8.1.1 Component Location Overview - Display and Control
y li
erm
ab
Head, Electric-Manual Climate Control System”, page 297
ility
ot p
wit
⇒ “8.1.2 Component Location Overview - Display and Control
, is n
h re
Head, Climatronic”, page 299
hole
spec
8.1.1 Component Location Overview - Display
es, in part or in w
t to the co
and Control Head, Electric-Manual Cli‐
mate Control System
rrectness of i
l purpos
Note
nf
ercia
♦ An indicator lamp inside the controls indicates when the se‐
orm
lected function is on.
m
atio
om
n in
♦ If the lamp in the AC button does not come after the button is
or c
thi
pushed, there may be a fault in the control module. Call up the
te
sd
a
Diagnostic Trouble Code (DTC) memory using the Vehicle Di‐

iv
o
r
rp
cu
agnostic Tester . If the fault stored in the DTC memory “A/C
o
m
f
en
compressor first start not performed” is present, then is it nec‐
ng
t.
yi Co
essary to perform a basic setting and an adaptation “A/C Cop py
compressor first start” either in Guided Fault Finding or in Gui‐
t. rig
gh ht
yri by
ded Functions. op Vo
by c lksw
cted agen
Prote
AG.

page 6 .

1 - Left Seat Heating Button -

E653-
AG. Volkswagen AG d
❑ Optional agen oes
olksw not
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❑ The seat heating as 3 rise d b ara
nte
settings. A Light Emit‐utho eo
ra
ting Diode (LED) indi‐
ss a c
ce
le
un
pt
selected.
an
d
itte
y li
rm
ab
the seat heater is
pe
ility
ot
switched off.
wit
, is n
h re
2 - A/C Button
hole
spec
❑ The Air Conditioning (A/
es, in part or in w
t to the co
C) compressor is set to
almost 0 delivery when
the AC button is off.
rrectness of i
3 - Rear Window Defogger
l purpos
Button
❑ Rear window defroster
nform
remains on for 4 to 20
ercia
minutes, depending on
m
a
exterior temperature.
com
tion in
4 - Recirculating Air Mode But‐
r
te o
thi
ton
s
iva
do
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rp
cum
fo
Note
en
ng
t.
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Cop py
The recirculating air mode turns off
t. rig
gh ht
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during ignition and returns to fresh p by
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lksw
air mode.
by
cted agen
Prote AG.
5 - Immediate Heating Button

for Parking/Auxiliary Heater
ON/OFF or OFF Button for
Heating and Air Conditioning
ON/OFF
❑ Depending on the equipment level
❑ OFF button is pressed, the A/C does not work. There is no heating or ventilation.
6 - Right Seat Heating Button - E654-
❑ Optional
❑ The seat heating as 3 settings. An LED indicates which setting is selected.
❑ If no LED is illuminated, the seat heater is switched off.
7 - Air Distribution Control Knob
8 - Air Distribution Display
9 - Blower Speed Control Knob
❑ To the left: decreases the blower speed
❑ To the right: increases the blower speed
10 - Blower Speed Display
11 - Temperature Control Knob
❑ To the left: lower the temperature
❑ To the right: increases the temperature
12 - Temperature Setting Display

8.1.2 Component Location Overview - Display

and Control Head, Climatronic
AG. Volkswagen AG d
agen oes
Note Volksw not
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d by ara
ise nte
r
♦ An indicator lamp insideutthe controls indicates when the se‐
ho eo
ra
lected function is on. sIn
s addition to this, whenever a button or
a c
a control is selected, the function will briefly appear in the radio
ce
e
nl
pt
or radio/navigation system display.
du
an
itte
y li
erm
♦ To change from °C and °F in the radio or radio/navigation sys‐
ab
ility
tem display, go to the main menu in the instrument cluster. Call
ot p
wit
up the main menu with the rocker switch in the windshield
, is n
h re
wiper lever. Select settings, units and temperature .
hole
spec
♦ If a new Heater and A/C Controls - EX21- with Climatronic
es, in part or in w
t to the co
Control Module - J255- was installed, perform the Guided
Fault Finding or Guided Functions, the basic setting and adap‐
tation “Air Conditioning (A/C) compressor first start”.
rrectness of i
l purpos

page 6 .
nf
ercia
o
♦ If the lamp in the AC button does not come after the button is
rm
m
atio
pushed, there may be a fault in the control module. Call up the
om
n in
Diagnostic Trouble Code (DTC) memory using the Vehicle Di‐
or c
agnostic Tester . If the DTC memory entry “A/C compressor
thi
te
sd
a
first start not performed” is present, then is it necessary to

iv
o
r
rp
cu
perform a basic setting and an adaptation “A/C compressor
o
m
f
first start” either in Guided Fault Finding. en

ng
t.
yi Co
op py
♦ Pressing the button AUTO will reverse all settings which devi‐ t. C rig
gh ht
ate from the automatic operation. pyri by
Vo
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by c lksw
cted agen
♦ If there are differences from automatic operation, see the cor‐ Prote AG.
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 6 .

1 - Left Temperature Display

❑ Shows the set tempera‐
ture for the driver side.
2 - Left Seat Heating Button -
E653-
❑ Optional
selected.
the seat heater is
switched off.
3 - Windshield Air Distribution
Button
❑ The LED turns on when AG. Volkswagen AG d
the system is active. agen oes
olksw not
byV gu
ara
d
4 - Center Air Distribution But‐orise nte
ton aut
h eo
ra
s c
❑ Air distribution to the up‐s
ce
le
per body via the center

un
pt
an
d
vents
itte
y li
rm
ab
❑ The LED turns on when
pe
ility
the system is active.
ot
wit
, is n
h re
5 - Lower Air Distribution But‐
hole
spec
ton
es, in part or in w
❑ Air distribution into the

t to the co
footwell.
❑ The LED turns on when rrectness of i
l purpos
6 - Air Recirculation Button

❑ The LED turns on when
nform
ercia
❑ Manual and automatic recirculating air mode.

m
a
com
ti
❑ Press the button for recirculating air function to prevent polluted air from entering interior.
on in
r
te o
thi
Recirculating air is switched on automatically under the following conditions:

s
iva
do
r
rp
• When the windshield washer system is operated,

um
fo
en
ng
t.
yi
• When the Air Quality Sensor - G238- is activated.
Co
Cop py
ht. rig
• When the reverse gear is engaged (this function is only active for two minutes after the engine is started).
rig ht
py by
co Vo
by lksw
cted
• Blower speed on the Heater and A/C Controls - EX21- off
agen
Prote AG.
• Heater and A/C Controls - EX21- “OFF”.

7 - Right Seat Heating Button - E654-
❑ Optional
❑ The seat heating as 3 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 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
AG. Volkswagen AG d
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❑ In automatic mode the Climatronic maintains theoselected oes automatically. The air
lksw not
temperature, the blower speed and the air distribution
ed byV are adjusted automatically.gu
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15 - SETUP Button utho eo
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❑ Pressing the SETUP button calls up the climate control menu for adjustment for example of the recircu‐
ce
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un
lating air mode, and default functions.
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16 - Blower Control
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❑ By turning the knob, the blower speed can be individually adjusted.
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❑ If the blower speed is manually adjusted, the function AUTO is automatically deactivated.
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17 - High Blower Speed
t to the co
❑ 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
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❑ Depending on the equipment level
s
❑ When the OFF button is activated, the Climatronic does not work. There is no heating or ventilation.
s o
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19 - Max Defrost Button
form
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❑ Air sucked in from the outside is directed to the windshield if installed causing the recirculating air mode
atio
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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 (34.7 °
thi
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20 - Rear Window Defogger Button

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❑ The selected temperature will be shown in the display.
8.2 Display and Control Head, Removing

and Installing
⇒ “8.2.1 Display and Control Head, Removing and Installing,
Electric-Manual Climate Control System and Climatronic”,
page 301
8.2.1 Display and Control Head, Removing

and Installing, Electric-Manual Climate
Control System and Climatronic

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- .
page 6 .
Removing
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The image shows a vehicle with Climatronic. Removingssand in‐
a ac
stalling on vehicles with an electric-manual climate control system
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is identical.
an
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ab
ility
– Unclip the trim -1- from the display and control head at the
ot p
points indicated -arrows- with the Trim Removal Wedge -
wit
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3409- in direction of -arrow A-.
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– Push the display and control head in the direction of the in‐
n
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strument panel to release the expanding rivets.

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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

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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- .

9 Additional Components for Control

and Regulation
⇒ “9.1 Sunlight Photo Sensor G107 , Removing and Installing”,
page 303
⇒ “9.2 Air Quality Sensor G238 , Removing and Installing”, page
304
⇒ “9.3 Function of Air Quality Sensor G238 ”, page 305
⇒ “9.5 A/C Humidity Sensor G260 , Removing and Installing”,
page 307
⇒ “9.6 Left Vent Temperature
gen AG Sensor G150
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⇒ “9.7 RightorisVent
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Temperature Sensor G151 , Removing
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tee and
Installing”,
au thpage 308 or
a
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⇒ “9.8 Footwell Vent Temperature Sensor G192 , Removing and
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9.1 Sunlight Photo Sensor - G107- , Remov‐

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Removing
rrectness of i
– Unclip Sunlight Photo Sensor -1- in direction of -arrow- out of

the instrument cluster.
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– Disconnect the connector.

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9.2 Air Quality Sensor - G238- , Removing

and Installing
⇒ “9.2.1 Air Quality Sensor G238 , Removing and Installing”,
page 304
9.2.1 Air Quality Sensor - G238- , Removing

and Installing
Note
♦ 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.
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♦ Do not install a sensor that has been kept, for example,
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Do not store removed sensors in areas wheres athey can come
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into contact with solvents, fuels and certain chemical compo‐
s c
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sitions (fluids or vapors).

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⇒ “6.3 Fresh Air Intake Cover, Removing and Installing”, page
t to the co
274 .
– Release the securing tab -2- downward.
rrectness of i
– 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

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they can come into contact with solvents, fuels, and certain chem‐
a
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ical compositions (fluids or vapors).

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– Check the Diagnostic Trouble Code (DTC) memory and erase Prote AG.

♦ Bulkhead; overview - plenum chamber cover. Refer to ⇒ Body
Exterior; Rep. Gr. 50 ; Bulkhead; Overview - Plenum Chamber
Cover .

9.2.2 Air Quality Sensor - G238- , Removing

and Installing, RHD
Note
♦ The Air Quality Sensor - G238- is installed at the left front on

the intake air grille in the plenum chamber.
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‐
sitions (fluids or vapors).
♦ The Air Quality Sensor - G238- is only installed on vehicles
with climatronic.
Removing lkswage es n
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– Remove the freshoris air intake cover. Refer to tee
⇒ “6.3 Freshau Air Intake Cover, Removing and Installing”, page
th or
ac
274 . ss
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– Release the securing tab -2- downward.

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– Pull the Air Quality Sensor - G238- -1- in the

-direction of the arrow-.
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ical compositions (fluids or vapors).

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♦ Bulkhead; overview - plenum chamber cover. Refer to ⇒ Body
Exterior; Rep. Gr. 50 ; Bulkhead; Overview - Plenum Chamber
Cover .
9.3 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.
♦ At an outside temperature between approximately +2 °C (35.6
°F) and approximately -5 °C (23 °F), the change over to recir‐
culating air mode only occurs at a sharp increase of pollutant
concentration, during which the compressor is switched on si‐
multaneously.
♦ At an outside temperature less than approximately -5 °C (23 °
F), the system still only changes to recirculation mode when
there is a strong increase in the level of pollutants. However,
it only switches on for approximately 15 seconds and the A/C
compressor does not switch on. If the concentration decrea‐
ses, the A/C system switches to the fresh air mode.
♦ “Automatic recirculating air mode” can be switched off at any
time. If the function is active, the A/C compressor is switched
on with a request for “automatic recirculating air mode” and
also when the outside air temperature is below 2 °C (35.6 °F).
If the temperature is below -5 °C (23 °F), it is not possible to
use the A/C compressor.
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♦ If the vehicles has “automatic recirculating air mode”,Vtheolks A/C
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♦ To ensure that the A/C system does not operate ss constantly in c
the recirculating air mode in areas with a consistently higher
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for less than 12 minutes given uniform ambient air pollution. If
t to the co
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.
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♦ A certain amount of time is required for repositioning of the air
l purpos
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
nf
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taken in with the fresh air into the passenger compartment until
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the door can be closed. For this reason, a dust and pollen filter
atio
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is installed with a charcoal layer. A filter that is saturated with

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pollutants is no longer effective and needs to be replaced.

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♦ In order to avoid frequent shifting of the recirculated air/fresh

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not allow for immediate shifting (the sensor does not send a
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♦ In order to avoid frequent shifting of the recirculating air/fresh
air door, the requirement from the sensor for “Automatic air
recirculation” mode remains for at least 25 seconds (minimum
duration period), even if the pollutant concentration is so far
reduced that recirculating air mode is no longer necessary.
♦ If the A/C compressor is switched off (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”.
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.
9.4 Outside Air Temperature Sensor -

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– Remove the radiator
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Body Exterior; Rep. Gr.
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66 ; Radiator Grille/Front Trim; Radiator Grille, Removing and

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

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♦ Overview - Radiator Grille. Refer to ⇒ Body Exterior; Rep. Gr.

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66 ; Radiator Grille/Front Trim; Overview - Radiator Grille .

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The A/C Humidity Sensor - G260- and the Rain/Light Recognition Prote AG.
Sensor - G397- are one component and are vehicle-specific.
– Removing and Installing. Refer to ⇒ Electrical Equipment;
Rep. Gr. 92 ; Windshield Wiper System; Rain/Light Recogni‐
tion Sensor, Removing and Installing .
Note
The diagnosis occurs via the Vehicle Electrical System Control

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


Removing
Note
♦ Only for vehicles with Climatronic. For vehicles with heater or

electronic-manually regulated A/C system the openings on the
air guide channels are closed with plugs.
♦ The illustration shows RHD. The procedure is identical.
– 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
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– Replace the seal -3- if it is damaged or faulty.

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An incorrectly installed vent temperature sensor causes flow-

spec
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♦ Instrument panel; instrument panel side cover removing and
nform
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installing. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Instrument

m
Panel; Instrument Panel Side Cover, Removing and Installing .

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9.7 Right Vent Temperature Sensor -

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Note
♦ 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.
♦ The illustration shows RHD. The procedure is identical.

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– Remove the instrument panel side cover.uthRefer
o to ⇒ Body or
Interior; Rep. Gr. 70 ; Instrument Panel;ssInstrument
a Panel Side ac
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– Turn the vent temperature sensor -1- in direction of -arrow-
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the “Guided Fault Finding” function. Prote AG.
♦ 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 .
9.8 Footwell Vent Temperature Sensor -

Removing
Note
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.

page 276 .

– 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.
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10 Special Tools
♦ Refrigerant Sockets - T10364-
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10. Special Tools 311

♦ Torque Wrench 1783 - 1/4" Drive Ratchet - VAS6234-
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10. Special Tools 313

11 Revision History
Re Dat Job Type Feedback # Notes Editor
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Cautions & Warnings
Please read these WARNINGS and CAUTIONS before proceeding with maintenance
and repair work. You must answer that you have read and you understand these
WARNINGS and CAUTIONS before you will be allowed to view this information.
•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
wholly or in part by any of the extensive warranties issued by Volkswagen.
•= 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 andgsometimes these

AG. Volkswagen AGchanges, both in parts and specifications,
a en does
are made applicable to earlier models. Therefore,
olkswpart numbers listed in this nomanual
t gu are for reference only. Always
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check with your authorized Volkswagen iretailer
sed parts department for the latest information.
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•= Any time the battery has been on an automatic transmission disconnected
be necessary to
ss vehicle, it willc
ce
le
reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).
un
pt
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•= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support
ab
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a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
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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
es, in part or in w
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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
become inoperable, even if the correct code is used in a later attempt.
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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
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
l purpos
starting the vehicle while you are under it.

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

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•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
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•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
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goggles, gloves and other protective clothing whenever the job requires working with harmful substances. C py
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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
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machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe
AG.
injury could result.
•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
new parts where indicated, and any other time it is deemed necessary by inspection.
Page 1 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled
fuel or oil.
•= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.
Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.
•= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be
crushed by heavy parts.
•= 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
repairs.
•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
once, but do not store the oily rags, which can ignite and burn spontaneously.
•= Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque
listed.
•= 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
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automotive chemical refrigerants. yV
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•= Before doing any electrical welding on vehicles
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h equipped with anti-lock brakes (ABS), disconnect
or
a
the battery
sa
negative terminal (ground strap) and the sABS control module connector. c
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•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase
itte
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system pressure and may cause the system to burst.

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•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
h re
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Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
spec
components is not separately fused, disconnect the control module connector(s).

es, in part or in w
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•= 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.
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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
l purpos
should test, disassemble or service the airbag system.

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Page 2 of 3
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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.
I have read and I understand these Cautions and Warnings.
AG. Volkswagen AG d
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Service

Service Department. Technical Information

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Copyright © 2014 Volkswagen AG, Wolfsburg D4B804B254B

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

1 Component Location Overview - Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

1.1 Component Location Overview - Components Outside of Passenger Compartment . . . . 63

1.2 Component Location Overview - Components Inside Front Passenger Compartment . . . . 67

2.1 Component Location Overview - Front Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Sensor G92 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

3.1 Overview - Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

3.2 Fresh Air Blower V2 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

3.4 Dust and Pollen Filter, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

3.5 Heater, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

3.6 Heater, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

4.5 Fresh Air Intake, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

2.14 Refrigerant Line with Restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

2.15 Condenser/Evaporator Refrigerant Line, Removing and Installing . . . . . . . . . . . . . . . . . . 142

2.16 Condenser/A/C Compressor Refrigerant Line, Removing and Installing . . . . . . . . . . . . . . 144

2.17 A/C Compressor/Evaporator Refrigerant Line, Removing and Installing . . . . . . . . . . . . . . 146

6.2 Fresh Air Intake, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

6.3 Fresh Air Intake Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

6.4 Air Intake Duct, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

6.5 Driver Side Footwell Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

6.7 Rear Footwell Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

7 Coolant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

9.2 Air Quality Sensor G238 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304

00 – General, Technical Data

1.1 Handling Refrigerant Safety Precau‐

– If the refrigerant was extracted more than 10 minutes in the ab

frigerant again. The refrigerant circuit pressure comes from

Risk of Destroying the Refrigerant Lines.

Destroying the refrigerant lines by ripping in the inner foil is pos‐

– Never bend the refrigerant lines to a radius smaller than r =

1.2 Start/Stop System Safety Precautions

There Is A Risk of Injury From the Engine Starting Unexpectedly.

The engine can start unexpectedly on vehicles with an activated

Start/Stop System. A visible message appears in the instrument

cluster indicating whether the Start/Stop System is activated.

– Deactivate the Start/Stop System: Turn off the ignition.

The high voltage system is under high voltage. Death or serious

– Have the high voltage system de-energized by a qualified per‐

and the high voltage cables.

1.5 Cooling System Safety Precautions

There Is A Risk of Burning from Hot Coolant

The cooling system is under pressure when the engine is warm.

There is a risk of scalding from hot steam and coolant.

1.6 Parking/Auxiliary Heater Safety Precau‐

2 Rep. Gr.00 - General, Technical Data

– Only switch on the parking/auxiliary heater in closed areas

er. Parking/auxiliary heater malfunctions due to air in the parking/

auxiliary heater fuel supply are possible.

– Fill the fuel extraction tube with fuel.

heater components are possible, as well as the risk of fire and

2.1 Heater and A/C Unit Identification

2.1.1 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

Correct allocation must be observed when replacing components.