Heating, Ventilation (Sedan) (A5 Platform): Other Volkswagen Jetta V

HEAT AND FRESH AIR CONTROLS MULTI-PIN CONNECTORS

Special tools and workshop equipment required

1. Connector test kit Vag 1594 C

16-pin harness connector is not assigned.

5-pin harness connector, in wiring diagram T5

Scheme 61

1 - 3rd blower speed

2 - 2nd blower speed

3 - 1st blower speed

4 - 4th blower speed

5 - Terminal X

20-pin harness connector, in wiring diagram T20c

3 - Fresh/Recirculating Air Door Motor -V154

6 - Fresh/Recirculating Air Door Motor -V154

7 - Auxiliary Air Heater Control Module -J604

8 - Rear window

11 - Heated Driver Seat Control Module -J131

15 - Heated Front Passenger Seat Control Module -J132

16 - Terminal 75 Seat Heater (optional)

18 - Terminal 30

19 - Terminal 15

20 - Terminal 31

AUXILIARY AIR HEATER HEATING ELEMENT, CHECKING WITH PERIPHERY

Use the engine control module OBD to check the Auxiliary Heater Heating Element -Z35- with periphery (load signal for generator terminal DF, the Preheating Coolant, Low Heat Output Relay -J359-, the Preheating Coolant, High Heat Output Relay -J360-, the Intake Manifold Temperature Sensor -G72- and the Coolant Temperature Sensor -G62-).

AUXILIARY AIR HEATER HEATING ELEMENT, CHECKING

Special tools and workshop equipment required

1. Vehicle Diagnosis, Testing and Information System VAS 5051B with Trigger Clamp 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 left footwell vent. Refer to LEFT FOOTWELL VENT .

Remove the left footwell center console trim.

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

Scheme 62

Slight heat output approximately 30 A.

Medium heat out approximately 60 A.

Large heat output approximately 80 A.

FLEXIBLE AIR DISTRIBUTION SHAFT, CHECKING

Flexible shaft for adjusting unit of air distribution doors

Let fresh air blower run on highest speed. If air flows out of defroster vents in the Defrost position and no air flows out of footwell vents, installation of flexible shaft is correct. If this is not the case, remove flexible shaft from adapter. Place controls for hot air and fresh air onto adapter and rotate rotary knob for air distribution 1 / 2 rotation (180°). Then re-connect flexible shaft. Repeat test

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.

Remove rear bumper. Refer to Removal and Installation .

Scheme 63

The sealing lips -1- in the ventilation frame on both sides of vehicle must be free to move and close automatically.

Observe installed position.

AIR DISTRIBUTION DOOR ADJUSTER

Removing

Remove instrument panel. Refer to Removal and Installation .

Unclip flexible shaft from adapter for controls, refer to FLEXIBLE SHAFT, CLIMATIC .

Scheme 64

Unscrew bolts -1- and remove adjusting unit for air distribution doors.

Installing

The arrows on the gears must align.

Position adjusting unit for air distribution doors and tighten bolts -1-.

Note. After installing, function of air distribution doors must be checked, refer to FLEXIBLE SHAFT, CLIMATIC, CHECKING .

AIR DISTRIBUTION DOOR ADJUSTER CABLE

Removing

Remove driver side footwell trim. Refer to Removal and Installation .

Remove the left footwell vent, refer to LEFT FOOTWELL VENT .

Scheme 65

Unclip cable at adjusting unit for temperature door -2-.

Disengage locking mechanism -1- and press adjusting unit for temperature door in -direction of arrow- until it reaches stop.

Remove adjusting unit for temperature door.

Installing

Install in reverse order of removal.

Note. After installing, function of temperature door must be checked. Temperature knob on hot air and fresh air controls must be able to moved easily and without catching from cold position to warm position.

AIR GRILLE

Removing

Remove the plenum chamber cover. Refer to Removal and Installation .

Scheme 66

Remove the nuts -arrows- and the air grille.

Installing

Install in reverse order of removal.

Note. The seal must fit correctly in the air grille.

AUXILIARY AIR HEATER HEATING ELEMENT -Z35-, VEHICLES THROUGH 1K-7M 119 726

Note. Only installed on vehicles with Diesel engine without auxiliary water heater.

Removing

Remove driver side footwell trim. Refer to Removal and Installation .

Remove the left footwell vent, refer to LEFT FOOTWELL VENT .

Scheme 67

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 hot and fresh air controls; on vehicles with Climatronic (e.g. Hi setting).

Remove the screws -1- from the cover -2-.

Scheme 68

Remove the screws -1- from the cover -2-.

Remove the nuts for the voltage supply -3- and the ground connection -4- (6 ±1 Nm).

Disconnect the connectors -5- from the auxiliary heater heating element.

Remove the auxiliary heater heating element from the heater.

Installing

Install in reverse order of removal.

AUXILIARY HEATER HEATING ELEMENT -Z35-, VEHICLES FROM 1K-7M 119 727

Removing

Remove driver side footwell trim. Refer to Removal and Installation

Remove the left footwell vent, refer to LEFT 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 hot and fresh air controls; on vehicles with Climatronic (e.g. Hi setting).

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

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

Remove the nut -1- 9 ±1 Nm.

Scheme 69

Loosen the retainer on the connector strip -arrow-.

Remove the bolt -2- 1.4 Nm and pull the auxiliary heater heating element out of the blower case.

Installing

Note. Make sure the ground wire is positioned correctly.

Install in reverse order of removal.

CENTER VENT

Removing

If the vehicle has Climatronic, remove the photosensor. Refer to SUNLIGHT PHOTO SENSOR -G107- OR SUNLIGHT PHOTO SENSOR 2 -G134 .

Remove the bolt -1-.

Scheme 70

If the vehicle has Climatronic, remove the cover -2-.

Note. In vehicles without Climatronic, bolts are under a trim mat.

Remove nuts -1-.

Scheme 71

Remove storage compartment from instrument panel.

Remove the center vent -2- in -direction of arrow-.

Disconnect the connectors from the center vents.

Installing

Install in reverse order of removal.

DUST AND POLLEN FILTER

Removing

Remove the trim panel from the front passenger side footwell -1-.

Scheme 72

Remove the partition -2- from the heater. Refer to REMOVING HEATER PARTITION .

Release cover -3- in direction of arrow.

Remove dust and pollen filter downward out of heater.

Installing

Install in reverse order of removal.

Scheme 73

Note. Note installation position of dust and pollen filter.

FLEXIBLE AIR DISTRIBUTION SHAFT

Removing

Remove the glove compartment. Refer to Removal and Installation .

Scheme 74

Move the flexible shaft in to the following position

Turn the switch for air distribution control -B- enough until the locking mechanism on the shaft -D- is visible in step-up gearing -F-.

Remove controls for hot air and fresh air, refer to HEAT AND FRESH AIR CONTROLS .

Scheme 75

Reach into the center console and push the tab -1- in -direction of arrow- to release it.

Pull flexible shaft out of adapter -2-.

Note. When installing flexible shaft, adapter and rotary switches on controls for hot air and fresh air must have a specific position to each other. Otherwise they will malfunction. Refer to FLEXIBLE AIR DISTRIBUTION SHAFT, CHECKING .

FRESH AIR BLOWER SERIES RESISTOR WITH FUSE -N24

Removing

Perform following work first

Remove the partition from the heater, refer to REMOVING HEATER PARTITION .

Scheme 76

Disconnect harness connector -1- from fresh air blower series resistor with fuse.

Push the retainer in -direction of arrow- and remove the fresh air blower series resistor with fuse from the heater.

Installing

Install in reverse order of removal.

FRESH/RECIRCULATED AIR DOOR MOTOR -V154

Removing

Note. Position of recirculating air door must not be changed.

Remove the glove compartment. Refer to Removal and Installation .

Scheme 77

Remove the cover -1-.

Disconnect the connector from the fresh/recirculation air door motor -2-.

Remove the fresh/recirculation air door motor -2-.

Installing

Install in reverse order of removal.

Note. After installing the fresh/recirculation air door motor, the function of the recirculating air door must be checked.

Checking using Vehicle Diagnosis, Testing & Information System VAS5051B.

Replacing: perform a basic setting using the Vehicle Diagnosis, Testing and Information System VAS 5051B, refer to CLIMATRONIC A/C SYSTEM COMPONENTS, CHECKING AND ADJUSTING .

FRESH AIR BLOWER -V2

Removing

The fresh air blower is accessible from the front passenger side footwell.

Scheme 78

Remove the partition from the heater, refer to REMOVING HEATER PARTITION .

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

Remove the bolt -B- from the fresh air blower (1 Nm).

Open the release -2-, turn the fresh air blower in -direction of arrow- and remove it.

HEAT EXCHANGER

Special tools and workshop equipment required

1. Drip Tray For VAS 6100 VAS 6208
2. Hose Clamps Up To 40 mm VAS 3093
3. Compressed air gun, commercially available

Removing

Remove the bulkhead inside the plenum chamber. Refer to Description and Operation .

Place the VAS 6208 under the engine.

Scheme 79

Clamp off the coolant hoses -1- using the VAS 3093 and remove the coolant hoses from the heat exchanger.

Scheme 80

Connect a section of hose -A- to the upper connection on the heater core.

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

Using a compressed air gun, carefully clear out any coolant still inside the heat exchanger into the container -B-.

Scheme 81

Remove the bolt (6 mm inner hex) -1- from the connection flange between the heat exchanger connections.

Note. This allows the coolant pipes to move for removing the heater core.

Remove driver side footwell trim. Refer to Removal and Installation .

Remove the left footwell vent, refer to LEFT FOOTWELL VENT .

Scheme 82

Remove the bolts -1- and remove the heat exchanger trim.

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

Open the clamps -A- and remove the coolant pipes from the heat exchanger.

Scheme 83

Remove the heat exchanger from the heater.

Installing

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

Scheme 84

Check seals -A- and -B- on the heat exchanger for damage.

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.

Check the heater (while the heat exchanger is removed) through the opening -A- for the heat exchanger, for dirt.

Scheme 85

Remove any dirt or coolant which has leaked out of the heater (for example, after removing a leaking heat exchanger).

Install the heat exchanger into the heater.

Coat sealing rings -1- with coolant before installing.

Scheme 86

Install the seals -1- into the connection in the heat exchanger.

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

Attach the coolant pipes to the heat exchanger.

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

Hose clamps -A- must be installed as illustrated.

Tighten hose clamps -A- to 2.0 Nm.

Make sure the clamps -A- are tight after tightening the screws. They must completely enclose the flange on the heat exchanger and coolant pipe and must not come in contact with other components.

Thread the bolt -A- into the connection flange -B - and while doing this make sure bolt is actually threaded into the mounting point intended for it.

Scheme 87

Make sure the grommet -C- fits correctly inside the bulkhead.

Scheme 88

Seal flange for coolant pipes to heater core -A- and for expansion valve (to evaporator, only in vehicles with A/C system) -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. If hose clamps are deformed, replace them. After replacing heater core, coolant must be replaced completely. Refer to DRAINING AND FILLING or DRAINING AND FILLING . Check the coolant circuit for leaks. Pay attention to the connection between the coolant pipes and the heat exchanger.

HEAT AND FRESH AIR CONTROLS

Connectors for the heater and fresh air controls, refer to HEAT AND FRESH AIR CONTROLS MULTI-PIN CONNECTORS .

Removing

Note. The controls consist of two separable housings. Before removing controls, bring rotary buttons into the following position: Heater control to cold Blower to 0. Air flow direction to footwell.

Remove the radio. Refer to Removal and Installation .

If the vehicle does not have radio, remove the trim from the center of the instrument panel. Refer to Removal and Installation .

Scheme 89

Remove the bolts -2- (4.2 x 45) and -3- (4.2 x 16) and the controls -1- from the center console.

Scheme 90

Release the connector -A- by pulling it in direction of arrow -1-.

Press connector release -B- toward the connector -arrow 2- and disconnect the connector -C-.

Release the connector -D- and then disconnect it.

Note. Illustration shows Climatic version. Procedure to release the connectors is the same.

Installing

Install in reverse order of removal. Be sure install the control knobs in the same position they were in when they were removed.

HEATER UNIT

Special tools and workshop equipment required

1. Drip Tray For VAS 6100 VAS 6208
2. Hose Clamps Up To 40 mm VAS 3093
3. Compressed air gun, commercially available

Removing

Note. To improve accessibility, additional components e.g. engine cover must be removed (depending on engine version). Refer to ENGINE COVER/UPPER AIR FILTER HOUSING , ENGINE COVER or ENGINE COVER/UPPER AIR FILTER HOUSING .

Remove instrument panel. Refer to REMOVAL AND INSTALLATION .

Remove the bulkhead inside the plenum chamber. Refer to DESCRIPTION AND OPERATION .

Remove the rear channels from the right and left footwells. Refer to REAR FOOTWELL CHANNEL .

Place the VAS 6208 under the engine.

Mark the coolant hoses -1-.

Clamp off the coolant hoses -1- using the VAS 3093 and remove the coolant hoses from the heat exchanger.

Using a compressed air gun, carefully blow residual coolant out of heater core at heater core connection.

Cover the carpet inside the passenger compartment with waterproof foil and water absorbing paper.

Note. On removal, note down bolt lengths and assignment for installation later.

Scheme 91

1. Screw 4 Nm
2. Screws 4 Nm Quantity: 2
3. Cable Bracket
4. Heater Unit Removing -- Disconnect the connectors from the heater. NOTE: All cable ties opened or cut during removal must be reinstalled at the same locations during installation. -- Remove the bolts from the bracket, refer to "Screws" in item 6 and "Bracket" in item 5 . -- Remove the supports, refer to "Right Support" in item 8 and "Left Support" in item 9 . -- Remove the bolts, refer to "Screws" in item 10 , "Screws" in item 12 and "Bracket" in item 11 . -- Remove the bolts, refer to "Screw" in item 1 , "Screws" in item 2 and "Cable Bracket" in item 3 . NOTE: To be able to reach the bolt heater on driver side must be pulled out slightly from the bulkhead, refer to "Screw" in item 1 . When removing heat unit, make sure the two coolant pipes of the heater core do not get caught and bent or damaged on plenum chamber or noise insulation pan. Also pay attention to wiring harness, individual wiring connections may get damaged when pulling too forcefully on wiring harness. -- Remove the heater. Installing Install in reverse order of removal. When doing this, note the following: NOTE: A second technician is necessary to install the heater. -- A second technician should guide both coolant pipes (from inside the engine compartment) into the heat exchanger as the heater is being installed, refer to «SEAL BETWEEN HEATER AND ENGINE COMPARTMENT»(ref-479481-S39513882692012061300000) . -- Fill with coolant. Refer to «DRAINING AND FILLING»(ref-479567-S10974463242012061300000) or «DRAINING AND FILLING»(ref-479574-S30062936622012061300000) .
5. Bracket
6. Screws 8 Nm
7. Subframe
8. Right Support
9. Left Support
10. Screws 8 Nm Quantity: 2
11. Bracket
12. Screws 8 Nm Quantity: 2

SEAL BETWEEN HEATER AND ENGINE COMPARTMENT

Note. Note installation position of seal -A- during assembly.

LEFT FOOTWELL VENT

Removing

Remove the driver side storage compartment. Refer to Removal and Installation .

Scheme 92

Unscrew securing bolt -2- and remove left footwell vent -1-.

Installing

Install in reverse order of removal.

RIGHT OR LEFT VENT

Note. Removal of the vents on both sides is identical, but one is a mirror image of the other. To prevent damage to instrument panel, use a pad when prying out.

Removing

Pry out vent -1- using an appropriate tool.

Scheme 93

Disconnect the connector from the vent.

Installing

Install in reverse order of removal.

REAR FOOTWELL CHANNEL

Note. Removal of rear channels on both sides is identical, only the sides are reversed.

Removing

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

Remove center console. Refer to Removal and Installation .

Scheme 94

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

Installing

Note. When installing the rear channel, ensure the rear channel is first slid onto heater -arrow- and then clipped in to floor.

Install in reverse order of removal.

RIGHT FOOTWELL VENT

Removing

Remove the glove compartment. Refer to Removal and Installation .

Scheme 95

Unscrew securing bolt -2- and remove right footwell vent -1-.

Installing

Install in reverse order of removal.

Note. If the vehicle has glove compartment cooling, check the coolant hose to make sure it is secure.

SIDE WINDOW VENTS

The side vents -arrow- are located in the A-pillar trim.

Scheme 96

Remove the A-pillar trim. Refer to Removal and Installation .

TEMPERATURE DOOR RELEASE CABLE

Removing

Remove controls for hot air and fresh air, refer to HEAT AND FRESH AIR CONTROLS .

Scheme 97

Reach in the center console and loosen the retainer -1- on the cable grommet -2-. Remove the grommet.

Loosen the ball on the cable -3- from the lever.

Remove driver side footwell trim. Refer to Removal and Installation .

Scheme 98

Unclip Bowden cable at adjusting unit of temperature doors -A- and unclip heater -B-.

Installing

Install in reverse order of removal. When doing this, make sure that Bowden cable lies under the hook -arrow-.

Check whether the temperature control can be moved easily from cold to warm.

Scheme 99

1. Adjusting Unit For Temperature Door Removing and installing, refer to «AIR DISTRIBUTION DOOR ADJUSTER CABLE»(ref-479481-S07027344322012061300000) .
2. Bracket
3. Cover
4. Fresh/Recirculating Air Door Motor -V154- Checking, use: Vehicle Diagnosis, Testing and Information System VAS 5051B. Removing and installing, refer to «FRESH/RECIRCULATION AIR DOOR MOTOR -V154- / -V425»(ref-479480-S00137793822012061300000) . Replacing: perform a basic setting using Vehicle Diagnosis, Testing and Information System VAS 5051B, refer to «CLIMATRONIC A/C SYSTEM COMPONENTS, CHECKING AND ADJUSTING»(ref-479480-S31898758052012061300000) .
5. Housing For Air Entry With recirculating air door.
6. Heater Unit
7. Fresh Air Blower -V2- Removing and installing, refer to «FRESH AIR BLOWER -V2»(ref-479481-S34009433552012061300000) .
8. Fresh Air Blower Series Resistor With Fuse -N24- Removing and installing, refer to «FRESH AIR BLOWER SERIES RESISTOR WITH FUSE -N24»(ref-479481-S07696597442012061300000) .
9. Dust and Pollen Filter Removing and installing, refer to «DUST AND POLLEN FILTER»(ref-479481-S03204578932012061300000) .
10. Cover For dust and pollen filter.
11. Heat Exchanger Heat Exchanger, removing and Installing, refer to «HEAT EXCHANGER»(ref-479481-S22104988452012061300000) . Heat Exchanger, Jetta from MY 11, removing and installing, refer to . After replacing heater core, replace all the coolant. Refer to «DRAINING AND FILLING»(ref-479567-S10974463242012061300000) or «DRAINING AND FILLING»(ref-479574-S30062936622012061300000) .
12. Heater Core Trim
13. Auxiliary Heater Heating Element -Z35- Vehicles Through 1K-7M 119 726 With Auxiliary Air Heater Control Module -J604- Checking: with Vehicle Diagnosis, Testing and Information System VAS 5051 (or succeeding model), under Heating, Ventilation and Air Conditioning; OBD-Capable Systems; Auxiliary Heating; Electrical Components. Removing and installing, refer to «AUXILIARY AIR HEATER HEATING ELEMENT -Z35-, VEHICLES THROUGH 1K-7M 119 726»(ref-479481-S23443805962012061300000) . Vehicles From 1K-7M 119 726 A 3-stage Auxiliary Heater Heating Element -Z35- is installed here; it is controlled by each motor control module via relays. Only installed on vehicles with Diesel engine without auxiliary heater. Removing and installing, refer to «AUXILIARY HEATER HEATING ELEMENT -Z35-, VEHICLES FROM 1K-7M 119 727»(ref-479481-S29575686282012061300000) .
14. Air Distribution Housing
15. Adjusting Unit For Air Distribution Doors Removing and installing, refer to «AIR DISTRIBUTION DOOR ADJUSTER»(ref-479481-S37879901852012061300000) .