Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 540

List of Workshop Manual Repair Groups

Repair Group

00 - General, Technical Data
80 - Heating, Ventilation
87 - Air Conditioning

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.

Service

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2016 Volkswagen AG, Wolfsburg

D4B804111B6

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Contents

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

1

1

Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

1.1

Heater and A/C Unit Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

2

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

2.1

Odors in Vehicles with A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

2.2

Vehicles with Start/Stop System General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

2.3

Repairing Vehicles Equipped with A/C and Handling Refrigerants . . . . . . . . . . . . . . . . . .

4

2.4

Type Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

3

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

3.1

Handling Refrigerant Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

3.2

Start/Stop System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

4

Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

4.1

Refrigerant Circuit, Specialized Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

5

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

5.1

Refrigerant R134a Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

5.2

Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

5.3

Oil Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

80 - Heating, Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

1

Component Location Overview - Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

1.1

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

9

1.2

Component Location Overview - Components Inside Front Passenger Compartment . . . . 10

2

Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.1

Component Location Overview - Front Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.2

Temperature Regulator Door Motor V68 with Temperature Regulator Door Motor Position

Sensor G92 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.3

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

2.4

Air Distribution Door Motor V428 with Position Sensor Air Distribution Door Motor Position

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

3

Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.1

Overview - Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.2

Fresh Air Blower V2 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.3

Fresh Air Blower Control Module J126 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 19

3.4

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

3.5

Heater, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.6

Heater, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.7

Auxiliary Heater Heating Element Z35 with Auxiliary Air Heater Control Module J604 ,

Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.8

Auxiliary Heater Heating Element Z35 with Auxiliary Air Heater Control Module J604 ,

Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.9

Heater Core, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.10 Partition, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4

Air Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.1

Overview - Air Routing and Air Distribution in Passenger Compartment . . . . . . . . . . . . . . 21

4.2

Driver Side Footwell Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.3

Front Passenger Side Footwell Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 21

4.4

Rear Footwell Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.5

Fresh Air Intake, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.6

Fresh Air Intake Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.7

Air Intake Duct, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.8

Passenger Compartment Forced Air Extraction, Checking . . . . . . . . . . . . . . . . . . . . . . . . 22

4.9

Passenger Compartment Forced Air Extraction, Removing and Installing . . . . . . . . . . . . 22

4.10 Air Guide for the Defrost Air Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 22

4.11 Air Guide for Center Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5

Display and Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5.1

Overview - Display and Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5.2

Display and Control Head, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

6

Additional Components for Control and Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

6.1

Outside Air Temperature Sensor G17 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 25

87 - Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1

Component Location Overview - A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1.1

Component Location Overview - Components Outside of Passenger Compartment . . . . 26

1.2

Component Location Overview - Components Inside Front Passenger Compartment . . . . 29

2

Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2.1

System Overview - Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2.2

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

2.3

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

2.4

Expansion Valve, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

2.5

Condenser, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.6

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

2.7

Refrigerant Lines with Inner Heat Exchanger, Removing and Installing . . . . . . . . . . . . . . 52

2.8

Low Pressure Side Refrigerant Line Balance Weight, Removing and Installing . . . . . . . . 54

2.9

Evacuating and Charging Valve, Removing and Installing, Low and High Pressure Side . . 55

3

A/C Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

3.1

Overview - A/C Compressor Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

3.2

Overview - Belt Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

3.3

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

3.4

A/C Compressor, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

3.5

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

3.6

Belt Pulley, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

4

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

4.1

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

4.2

Overview - Attachments for Heater and A/C Unit and Air Intake Housing . . . . . . . . . . . . . . 77

4.3

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

4.4

Overview - Air Distribution Housing Doors and Partitions . . . . . . . . . . . . . . . . . . . . . . . . . . 81

4.5

Heater and A/C Unit, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

4.6

Heater and A/C Unit, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

4.7

Air Distribution Housing, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

4.8

Heater and A/C Unit Bracket, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

4.9

Evaporator, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

4.10 Fresh Air Blower Control Module J126 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 91

4.11 Dust and Pollen Filter, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

4.12 Fresh Air Blower V2 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

4.13 Auxiliary Heater Heating Element Z35 with Auxiliary Air Heater Control Module J604 ,

Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

4.14 Auxiliary Heater Heating Element Z35 with Auxiliary Air Heater Control Module J604 ,

Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

4.15 Heater Core, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

4.16 Heater Core Coolant Pipes, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

4.17 Evaporator Temperature Sensor G308 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 108

4.18 Condensation Water Drain, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

4.19 Condensation Water Drain, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

4.20 Partition, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
5

Air Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

5.1

Overview - Air Routing and Air Distribution in Passenger Compartment . . . . . . . . . . . . . . 113

5.2

Fresh Air Intake, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

5.3

Fresh Air Intake Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

5.4

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

5.5

Driver Side Footwell Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

5.6

Front Passenger Side Footwell Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 117

5.7

Rear Footwell Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

5.8

Rear Center Console Vent Air Guide Channel, Removing and Installing . . . . . . . . . . . . . . 118

5.9

Passenger Compartment Forced Air Extraction, Checking . . . . . . . . . . . . . . . . . . . . . . . . 119

5.10 Passenger Compartment Forced Air Extraction, Removing and Installing . . . . . . . . . . . . 119

5.11 Air Guide for Defrost Air Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 120

5.12 Air Guide for Center Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
6

Display and Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

6.1

Component Location Overview - Display and Control Head . . . . . . . . . . . . . . . . . . . . . . . . 122

6.2

Display and Control Head, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

7

Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

7.1

Component Location Overview - Front Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

7.2

Temperature Regulator Door Motor V68 with Temperature Regulator Door Motor Position

Sensor G92 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

7.3

Defroster Door Motor V107 with Defroster Door Motor Position Sensor G135 , Removing and

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

7.4

Recirculation Door Motor V113 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 134

7.5

Left Temperature Door Motor V158 with Left Temperature Door Potentiometer/Actuator

G220 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

7.6

Right Temperature Door Motor V159 with Right Temperature Door Potentiometer/Actuator

G221 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

7.7

Fresh Air/Recirculating Air/Back Pressure Door Motor V425 with Fresh Air/Recirculating Air/

Back Pressure Door Motor Position Sensor G644 , Removing and Installing . . . . . . . . . . 140

7.8

Front Air Distribution Door Motor V426 with Air Distribution Door Motor Position Sensor

G642 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

7.9

Air Distribution Door Motor V428 with Position Sensor Air Distribution Door Motor Position

Sensor G645 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

7.10 Air Distribution Door Adjuster, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
8

Additional Components for Control and Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

8.1

Sunlight Photo Sensor G107 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 150

8.2

Air Quality Sensor G238 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

8.3

Function of Air Quality Sensor G238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

8.4

Outside Air Temperature Sensor G17 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 153

8.5

A/C Humidity Sensor G260 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

8.6

Left Vent Temperature Sensor G150 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 153

8.7

Right Vent Temperature Sensor G151 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 154

8.8

Footwell Vent Temperature Sensor G192 , Removing and Installing . . . . . . . . . . . . . . . . 155

9

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

10

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