Heating, Ventilation: Other Volkswagen Golf Mk7

AUXILIARY AIR HEATER HEATING ELEMENT, CHECKING

Checking with Periphery

Auxiliary Air Heater Heating Element -Z35- Periphery (load signal for generator terminal DF, Preheating Coolant, Low Heat Output Relay -J359-, Preheating Coolant, High Heat Output Relay -J360-, Intake Air Temperature (IAT) Sensor -G72-, and Engine Coolant Temperature (ECT) Sensor -G62- can be interrogated via the engine control module (ECM) self diagnosis.

Checking Auxiliary Air Heater Heating Element

Special tools and workshop equipment required

1. Vehicle Diagnosis, Testing and Information System VAS 5051B
2. Inductive pickup 100A VAS 5051B/7

Test Conditions

1. Intake temperature less than 19° C.
2. Coolant temperature less than 80° C.
3. Passenger compartment temperature approximately 20° C.
4. Battery voltage greater than 11 V.
5. Alternator load not greater than 50 % (terminal DF).
6. Engine speed greater than 450 rpm.
7. Turn the interior temperature control to maximum heating.

Test Sequence

Remove the knee airbag. Refer to Removal and Installation .

Remove the driver side footwell vent. Refer to DRIVER SIDE FOOTWELL VENT .

Remove the center console trim in the footwell.

Measure the current draw using the VAS 5051B and VAS 5051B/7 and the ground cable -arrow-.

Scheme 5

Slight heating output approx. 30A

Intermediate heating output approx. 60A

Large heating output approx. 80A

VENTILATION, CHECKING

Note. The stale air escapes through the vent openings in the luggage compartment trim. If the ventilation is to function properly, the ventilation openings must not be covered. The ventilation frames are located in the rear side panels, behind the bumper.

Checking

Note. The ventilation can be checked through the luggage compartment. Depending on the vehicle equipment level, it may be necessary to remove additional components.

Remove the luggage compartment side trim.

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

FRESH AIR BLOWER

The fresh air blower -V2- is accessible from footwell on front passenger side.

Removing

Unscrew plastic screws -2- and remove partition -1-.

Scheme 6

Disconnect the connector -A- on the fresh air blower.

Scheme 7

Remove the screw -B- on the fresh air blower (1 Nm).

Release the catch -2- and rotate the fresh air blower in -direction of arrow-.

Remove fresh air blower from heater.

Installing

Install in reverse order of removal.

FRESH AIR BLOWER SERIES RESISTOR WITH FUSE

Removing

Unscrew plastic screws -2- and remove partition -1-.

Disconnect the connector -1- on the fresh air blower series resistor with fuse.

Scheme 8

Press locking mechanism in -direction of arrow- and remove fresh air blower series resistor with fuse from heater.

Installing

Install in reverse order of removal.

DUST AND POLLEN FILTER

Removing

Unscrew plastic screws -2- and remove partition -1-.

Release cover -1- in -direction of arrow-.

Scheme 9

Remove dust and pollen filter downward out of heater.

Installing

Install in reverse order of removal. When doing this, note the following

Scheme 10

Note. Pay close attention to the installed position of the dust and pollen filter.

CENTER VENT

Special tools and workshop equipment required

1. Trim removal wedge 3409

Removing

Switch off ignition.

Remove the trim in the center of the instrument panel (Golf, from MY 2009). Refer to Removal and Installation .

Vehicles with a Storage Compartment in the Center of the Instrument Panel

Remove the radio, if equipped. Refer to Removal and Installation .

Remove the storage compartment in the center of the instrument panel (Golf, from MY 2009). Refer to Removal and Installation .

Vehicles with a Radio/Navigation System

Remove the radio/navigation system. Refer to Removal and Installation .

All Vehicles

Scheme 11

Remove the two screws -1- (1.5 Nm).

Pull out the vent in the center of the instrument panel -2- just a little.

Scheme 12

Release the four clips -arrows- on the vent -1- using the 3409

Disconnect the wiring harness for the emergency flasher switch -E3- and remove the vent from the instrument panel.

Installing

Install in reverse order of removal.

VENTS, DRIVER AND PASSENGER SIDE

Note. Removing the vents on both sides is identical.

Removing

Scheme 13

Remove side instrument panel cover. Refer to Removal and Installation .

Reach sideways into instrument panel and unclip vent -1- in direction of -arrow A- from instrument panel.

Installing

Install in reverse order of removal.

REAR CHANNEL, FOOTWELL

Note. The procedure for removing rear channels is identical for both sides.

Removing

Remove driver or front passenger seat. Refer to Removal and Installation .

Remove center console. Refer to Removal and Installation .

Scheme 14

Lift floor carpet, unclip rear channel from floor and pull off from heater.

Installing

Install in reverse order of removal.

Note. When installing the rear channel, first slide it onto the heater -arrow- and then clip it into the floor panel.

FRONT PASSENGER SIDE FOOTWELL VENTS

Removing

Remove the glove compartment. Refer to Removal and Installation .

Scheme 15

Remove the screws -2- and then remove the footwell vent -1-.

Installing

Install in reverse order of removal.

Tighten the screw -2- to 1.5 ± 0.2 Nm.

Note. If the vehicle has glove compartment cooling, make sure the cooling hose fits correctly.

DRIVER SIDE FOOTWELL VENT

Removing

Remove the cover inside the driver side footwell. Refer to Removal and Installation .

Scheme 16

Remove the driver side storage compartment under the headlamp switch to get to the screw -2-. Refer to Removal and Installation .

Remove the screws -2- and then remove the footwell vent -1-.

Installing

Install in reverse order of removal.

Tighten the screw -2- to 1.5 ± 0.2 Nm.

HEAT EXCHANGER

Special tools and workshop equipment required

1. Drip tray for shop crane VAS 6208
2. Hose clamps up to 40 mm diameter 3093
3. Compressed air gun, commercially available

Removing

Place VAS 6208 under the engine.

Scheme 17

Clamp off the coolant hoses -1- using 3093 and disconnect the coolant hoses to the heater core.

Scheme 18

Connect a section of hose -A- onto upper connection of heater core.

Hold a container -B- under the lower connection -C-.

Using a compressed air gun, carefully blow coolant out of heater core into container -B-.

Depending on the engine, additional parts may need to be removed such as the charge air pipe.

Scheme 19

Slightly loosen (do not remove) screw -1- on connecting flange between heater core connections.

Note. By loosening the screw -1-, the coolant pipes are loosened and it is easier to remove the heater core.

Remove the knee airbag. Refer to Removal and Installation .

Remove the driver side footwell vent. Refer to DRIVER SIDE FOOTWELL VENT .

Scheme 20

Remove screws -A- and remove trim -B-.

Note. There are different versions of cover -B-. The illustration shows the version with auxiliary air heater heating element -Z35-. If the temperature door lever -C- is a position that hinders access to the upper screw -A-. Change the position of the temperature door using the controls for hot air and fresh air, on vehicles with Climatronic with operating and display unit, for example, the HI setting.

Cover carpet in area under heat exchanger with waterproof foil and water absorbing paper.

Scheme 21

Open pipe clamps -A- and disconnect coolant pipes from heater core.

Remove heater core from heater.

Installing

Install in reverse order of removal. When doing this, note the following

Scheme 22

Check seals -A- and -B- installed on heater core, only install a heater core with undamaged seals.

Note. An incorrectly glued seal can roll up into heater when sliding in the heater core. Cold air may flow past heat exchanger if seal is damaged or not properly fitted.

With the heater core removed, check heater for soiling (via heater core opening -A-).

Scheme 23

If necessary, remove dirt or coolant from heater, for example after removing leaky heater core.

Push heater core into heater.

Scheme 24

Note. Always replace the seals -1-.

Coat sealing rings -1- with coolant before installing.

Note. If pipe clamps are deformed, replace them.

Connect coolant pipes to heater core.

Pipe clamps -A- must be able to be twisted slightly when installing onto the coolant pipes.

Pipe clamps -A- must be installed as shown in the illustration.

Tighten the pipe clamps -A- to 2 Nm.

Check seating of both clamps -A- after tightening screws. They must completely enclose the flange on the heat exchanger and coolant pipe and must not come in contact with other components.

Tighten the screw -1- from the connecting flange between heater core connections to 2 Nm.

After assembling, make sure the grommet -C- fits correctly inside the plenum chamber bulkhead.

Scheme 25

Seal flange for coolant pipes to heater core -A- and for expansion valve (to evaporator) -B- at pass-through of grommet -C- with silicon adhesive sealant if necessary (to prevent water from penetrating).

Note. Sealing rings must always be replaced. After replacing heater core, coolant must be replaced completely. Refer to GENERAL INFORMATION or DRAINING AND FILLING . Check the cooling system for leaks. Pay close attention to the connections between the coolant pipes and the heat exchanger.

HEAT EXCHANGER COOLANT PIPE

Note. The heater must be removed first in order to replace the coolant pipes leading from the engine compartment to the heat exchanger. Refer to HEATING AND A/C UNIT .

Removing

Remove the screw -1- on the connecting flange between the heat exchanger connections.

Remove screws -A- and remove trim -B-.

Open pipe clamps -A- and disconnect coolant pipes from heater core.

Installing

Coat sealing rings -1- with coolant before installing.

Insert sealing rings -1- into connection on heater core.

Note. Ensure sealing rings are installed on the proper side, as shown in the illustration. If pipe clamps are deformed, replace them.

Connect coolant pipes to heater core.

Note. Always replace the seals -1-.

Coat sealing rings -1- with coolant before installing.

Note. If pipe clamps are deformed, replace them.

Pipe clamps -A- must be able to be twisted slightly when installing onto the coolant pipes.

Pipe clamps -A- must be installed as shown in the illustration.

Tighten the pipe clamps -A- to 2 Nm.

Check seating of both clamps -A- after tightening screws. They must completely enclose the flange on the heat exchanger and coolant pipe and must not come in contact with other components.

Tighten the screw -1- from the connecting flange between heater core connections to 2 Nm.

Install the heater. Refer to HEATING AND A/C UNIT .

AUXILIARY HEATER HEATING ELEMENT

Removing

Remove the knee airbag. Refer to Removal and Installation .

Remove the driver side footwell vent. Refer to DRIVER SIDE FOOTWELL VENT .

Note. If the temperature door lever -C- is a position that hinders access to the upper screw -A-. Change the position of the temperature door using the controls for hot air and fresh air, on vehicles with Climatronic with operating and display unit, for example, the HI setting.

Disconnect battery. Refer to [For transmission(s) 0A4, 02E, 09G, 02Q] [For engine(s) CBTA, CJAA, CBUA, CCTA, CBFA] Removal and Installation .

Remove the bolts -A- from the cover -B-.

Remove the nut -1-.

Scheme 26

Loosen the connector strip locking mechanism -arrow-.

Remove the screw -2- and pull the auxiliary air heater heating element out of the blower case.

Installing

Note. Make sure the ground wire is positioned correctly.

Install in reverse order of removal.

Tighten the nut -1- to 9 ± 1 Nm and the screw -2- to 1.4 Nm.

VENTILATION VENT FRAME, SIDE PANEL

Special tools and workshop equipment required

1. Trim removal wedge 3409

Removing

Remove rear bumper. Refer to Removal and Installation .

Release the tabs -2- using the 3409 -1- and remove the vent frame -3- from the side panel.

Scheme 27

Installing

Install in reverse order of removal.

AIR INTAKE GRILLE

Removing

Remove plenum chamber cover. Refer to Removal and Installation .

Remove cover -1- from plenum chamber.

Scheme 28

Note. Air quality sensor -G238- functionality, refer to AIR QUALITY SENSOR FUNCTION .

Disconnect the connector. Then turn the air quality sensor -1- to the right and remove it.

Scheme 29

Remove the flange nuts -arrows- and remove the air intake grille upward.

Scheme 30

Installing

Install in reverse order of removal.

Note. The seal must fit correctly on the air intake grille.

Assembly sequence

Align the air intake grille on the flange.

Hold the air intake grille and tighten the side flange nuts (2.5 ± 0.4 Nm). After that, tighten the flange nut in the center.

AIR INTAKE HOUSING

Special tools and workshop equipment required

1. Vehicle Diagnosis, Testing and Information System VAS 5051B

Removing

Remove the instrument panel. Refer to Removal and Installation .

Loosen the heater and air conditioner on the right side.

Loosen the connector on the motor.

Loosen the screws -1-.

Scheme 31

Lift the air intake housing -in direction of arrow A-.

Scheme 32

Unhook the air intake housing -in direction of arrow B- from the anchoring.

Installing

Install in reverse order of removal. Make sure the housing fits correctly with the mounts -1- in the hooks -2-.

Scheme 33

Note. After installing, function of recirculation door must be checked. Initiate Basic Setting function on the motor with VAS 5051B (or succeeding model). Refer to A/C SYSTEM WITH AUTOMATIC CONTROL, CLIMATRONIC, CHECKING AND ADJUSTING COMPONENTS .