Heating and Ventilation System, Servicing
Heating And Ventilation System, Servicing
CAUTION:
Before beginning repairs:
- Switch off all electrical consumers.
- Switch off ignition.
- Remove ignition key from ignition switch.
1. Side window air outlet
- Removing see Fig. 1
2. Air outlets
- Golf and Jetta have different types
3. Defroster air outlet
4. Heating and ventilation controls
- With fresh air blower switch -E9-
- With fresh air/recirculating flap switch -E159-
- Cables, installing and adjusting.
5. Intermediate duct
6. Instrument panel cross member
- Loosening and tightening see Fig. 5
7. Dust and pollen filter
- With activated charcoal filter
- Removing and installing see Fig. 4
8. Servo motor for fresh/recirculating air door -V154-
9. Fresh air blower -V2-
- Removing see Fig. 3
10. Fresh air blower series resistance with fuse -N24-
- See Fig. 3, Fresh air blower -V2-, removing and installing
11. Heating and ventilation unit
- Removing:
- Remove instrument panel
- Loosen instrument panel cross member see Fig. 5
- Carefully pinch off both coolant hoses to heater core and disconnect hoses.
- Seal off heater core to prevent coolant from running out
CAUTION: The cooling system is pressurized when the engine is warm. Wear gloves and other protection and carefully release system pressure if necessary, before performing repairs.
- Locate and remove fasteners for heating and ventilation unit at bulkhead.
- Remove heating and ventilation unit.
12. Center trim
13. Footwell air outlet
- Passenger's side only
14. Rear footwell air duct
15. Gasket
16. Connecting duct
- With driver's side footwell air outlet
- Removing see Fig. 6
17. Cables
18. Heater core
- Always replace coolant after removal/replacement
- Replacing
19. Heater core/bulkhead seal
- Installation position see Fig 2
20. Defroster duct
- Replacing:
- Remove and install instrument panel.
- Loosen instrument panel cross member see Fig. 5
- Installation position see Fig. 2
Fig. 1 Side window air outlet, removing
- Carefully pull out using needle nose pliers
Fig. 2 Defroster duct, installation position
- Attach defroster duct -2- to heater unit.
- At the same time position defroster duct -2- in instrument panel cross member -1-.
Fig. 3 Fresh air blower -V2-, removing
1. Heater unit
2. Fresh air blower -V2-
3. Cover
4. Screws
5. Fresh Air Blower Series Resistance With Fuse -N24-
Removing
- Remove glove box.
- Disconnect electrical connector for fresh air blower series resistance with fuse -N24.
- Disconnect electrical connector for heater fan.
- Remove resistor for fresh air blower.
- Remove fresh air blower downward.
Fig. 4 Dust and pollen filter, removing and installing
1. Air deflector
2. Frame
3. Dust and pollen filter element
4. Plastic nut, 2.5 Nm (22 in. lb)
5. Filter housing
Removing
With plenum cover removed:
- Depress tabs at front edge of frame -2-.
- Lift and pull out filter element with frame to front.
Installing
- Assemble filter element to frame
- Insert so that pins fit into into filter housing -5-.
- Clip frame into place.
Fig. 5 Instrument panel cross member, loosening and tightening
- Remove bolts -arrows-
- Tightening torque: 25 Nm (18 ft. lb.)
- To access or remove heating unit and surrounding parts, lift cross member in direction of arrow -A- and support.
NOTE:
- To avoid damage to the steering column, have a second technician assist.
- If removed components are not to be re-installed immediately, secure cross member to the bulkhead.
- Any wiring harnesses released from their retainers must be secured again at the same point, using the same retainers.
Fig. 6 Connecting duct, removing
1. Bolt
2. Air duct connector
3. Rear footwell duct
4. Bracket
5. Cover
6. Bolt
First do the following:
- Remove glove box
- Remove steering column cover.
Removing
- Remove bracket -4-.
- Remove cover -5-.
- Remove duct in direction of footwell -arrow -A-.