MK5 Heating and Ventilation System

Volkswagen Golf 5 2004-> VW Rabbit GTI 2006->
(A5)
Heating and Ventilation System

General information
Rabbit and GTI models from model year 2006 are

equipped with either the semi-automatic "Climatic" A/C
system, or the automatic "Climatronic" A/C system. The
information contained in the following section specifically
pertains to a non-A/C heating and ventilation system
offered in other markets. However, the removal and
installation procedures of air vents, air ducts and other
components described here may also apply to both the
"Climatic" and "Climatronic" systems.
Before troubleshooting or servicing, technicians must be

familiar with the functions and operation specifics of the
standard or optional heating and ventilation system or A/C
system. Always read the owners manual and review
applicable system functions.
Note:
Additional information:
Owners Manual
Self Study Program - Course Number 892503 "VW 2006

GTI Introduction"
Wiring Diagrams and Component Locations
Heating and ventilation system components in

passenger compartment, servicing
Heating and Ventilation System Page 2 / 42
Disconnect battery before removing

components marked with **
Repair Manual, Electrical Equipment,

Repair Group 27,
Instrument panel **
Center air vents
Removing and installing

80-1, Center air vents,
removing and installing
Right side window defroster air

duct
In right A-pillar
Right air vent

80-1, Right / left air vent,
Heating and ventilation controls
With Fresh Air/Recirculating

Flap Switch E159
With Immediate Heating

Button E537 where
applicable

80-1, Heating and ventilation
controls, removing and
installing
Fresh/Recirculating Air Door

Motor V154

80-1, Fresh/Recirculating Air
Door Motor V154 , removing
and installing
Right footwell air vent

80-1, Right footwell air vent,
Fresh Air Blower V2
Depending on unit
configuration, blower on
vehicle may not be exactly
as shown here

80-1, Fresh Air Blower V2 ,
Fresh Air Blower Series Resistor

With Fuse N24

80-1, Fresh Air Blower
Series Resistor With Fuse

N24 , removing and
installing
Heating and ventilation unit

partition
Removing 80-1, Heating

and ventilation unit partition,
removing
Sealing caps
Only in vehicles without air

guide to vent installed in
center console at rear
Dust and pollen filter
With activated charcoal filter

80-1, Dust and pollen filter,
Center console air duct
Connection to center
console air guide
To remove, center console

must be removed
Repair Manual, Body Interior, Repair

Group 68,
Right rear footwell air duct

80-1, Rear footwell air ducts,
Left rear footwell air duct

80-1, Rear footwell air ducts,
Screws
Qty. 8
Observe varying lengths
Heating and ventilation control

adapter

80-1, Temperature flap -
bowden cable, removing and
installing
Auxiliary Heater Heating Element

Z35
Only on models with Diesel

engine

80-1, Auxiliary Heater
Heating Element Z35 ,
Heater core
After replacing heater core,

coolant must be replaced
completely.

80-1, Heater core, removing
and installing
Left footwell air vent

80-1, Left footwell air vent,
Temperature flap bowden cable

80-1, Temperature flap -
bowden cable, removing and
installing
Air distribution control - flexible

cable

80-1, Air distribution control -
flexible cable, removing and
installing

80-1, Heating and ventilation
unit, removing and installing
Disassembly and assembly

80-1, Heating and
ventilation unit, disassembly
and assembly
Left side window defroster air

duct
In left A-pillar
Heating and ventilation unit partition, removing
- Remove screws - 2 - and partition - 1 - .

Heating and ventilation unit seal at bulkhead, installation

position
- First install seal - A - on bulkhead , then engage on

heater core.
Note:
To prevent ingress of water into vehicle interior, note

installation position.
Fresh Air Blower V2 , removing and installing
Removing:
Caution!
Switch off all electrical consumers.
Switch ignition off and remove ignition key.
Fresh Air Blower V2 is accessible from footwell on front

passenger side.
- Remove partition 80-1, Heating and ventilation unit

partition, removing
- Disconnect electrical connection - A - from Fresh Air

Blower V2 .
- Remove screw - B - (1 Nm).
- Release locking mechanism - 2 - and rotate Fresh Air

Blower V2 in direction of - arrow - and remove.
Installing
- Install in reverse order of removal.
Fresh Air Blower Series Resistor With Fuse N24 ,

Removing:
Caution!
Warning!
Burn danger!
Fresh Air Blower Series Resistor With Fuse N24 may

be hot.
Let Fresh Air Blower Series Resistor With Fuse N24

cool off before removing.
- First remove partition 80-1, Heating and ventilation unit

partition, removing
- Disconnect electrical connection - 1 - .
- Press locking mechanism in direction of - arrow - and

remove Fresh Air Blower Series Resistor With Fuse N24
from heating and ventilation unit.
Installing
Install in reverse order of removal.
Dust and pollen filter, removing and installing
Removing:
- Remove front passenger footwell trim - 1 - .
- Remove partition - 2 - 80-1, Heating and ventilation

unit partition, removing
- Release cover - 3 - in direction of - arrows - .
- Pull dust and pollen filter downward from heating and

ventilation unit.
Note:

Observe installation orientation of dust and pollen filter.
Installing:
Install in reverse order of removal, noting the following.
- Insert filter element into heating and ventilation unit in

direction of - arrow - .
Instrument panel air vents, removing and installing
Center air vents 80-1, Center air vents, removing and

installing
Right or left air vent 80-1, Right / left air vent, removing
and installing
Rear footwell air ducts 80-1, Rear footwell air ducts,

Right footwell air vent 80-1, Right footwell air vent,

Left footwell air vent 80-1, Left footwell air vent,

Side window defroster air vents 80-1, Side window

defroster air vents, removing and installing
Center air vents, removing and installing
Removing:
- In vehicles with Climatronic, first remove sunlight photo

sensor 87-3, Sunlight Photo Sensor G107 / Sunlight
Photo Sensor 2 G134 , removing and installing .
Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru
Volkswagen, Skoda, Seat, Audi
- Remove screw - 1 - .
- Remove cover (only in vehicles with Climatronic) - 2 - .
Note:
In vehicles without Climatronic, screws are under

trim.
- Remove screws - 1 - .
- Remove storage compartment from instrument panel.
- Remove center air vent - 2 - upward in direction of -

arrow - .
- Disconnect electrical connections from center air vents.
Installing
Right / left air vent, removing and installing
Note:
Vent removal on both sides is identical, only the

sides are reversed.
To prevent damage to instrument panel, protect

contact area with adhesive tape prior to removing
vent.
Removing:
- Pry out air vent - 1 - using appropriate tool.
- Disconnect electrical connection.
Installing
Rear footwell air ducts, removing and installing
Note:
Removal of rear channels on both sides is identical,

only the sides are reversed.
Removing:
- Remove driver or front passenger seat
Repair Manual, Body Interior, Repair Group 72,

- Remove center console
- Lift floor carpet, unclip rear channel from floor and pull off
from heating and ventilation unit - arrow - .
Installing
- Install in reverse order of removal, noting the following:
Note:
When installing rear channel, ensure channel is first

slid onto heating and ventilation unit - arrow - and
then clipped into floor.
Right footwell air vent, removing and installing
Removing:
- Remove glove compartment

- Remove screw - 2 - and remove right footwell air vent -

1- .
Installing
Note:
In vehicles with glove compartment cooling, ensure

cooling hose is correctly seated.
Left footwell air vent, removing and installing
Removing:
- Remove driver side storage compartment
- Remove screw - 2 - and remove left footwell air vent - 1

- .
Installing

Side window defroster air vents, removing and installing
Side window air vents - arrow - are installed in A-pillar

trim.
- Remove A-pillar trim on right or left
Heating and ventilation controls, removing and installing
Removing:
Caution!
Note:
Heating and ventilation controls consist of two

separable housings. Before removing controls, set
rotary control knobs to the following positions:
Heater control to "cold"
Blower control to "0"
Air flow direction control to "footwell"
- Remove radio
Repair Manual, Communication, Repair Group 91,
- Remove long screws - 2 - and short screws - 3 - and

remove controls - 1 - from center console.
- Disengage electrical connection retainer - A - by pulling

in direction or arrow - 1 - .
- Disengage electrical connection retainer - B - to

connector - arrow 2 - and Disconnect electrical
connection - C - .
- Disengage electrical connection retainer - D - and

Disconnect electrical connection - D - .
Installing
Install in reverse order of removal, ensuring rotary control

knobs have not been moved from the positions as
specified for removal.
Heating and ventilation controls, multi-pin connector

assignments
Special tools, testers and auxiliary items required

Connector test set VAG 1594 C
16-pin electrical connection is not assigned.
5-pin electrical connection -T5-
1 - 3rd blower speed

2 - 2nd blower speed
3 - 1st blower speed
4 - 4th blower speed
5 - Terminal X
20-pin electrical connection -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 - Drivers Heated Seat Control Module J131
15 - Front Passengers Heated Seat Control Module J132
16 - Terminal 75 seat heater (optional)
18 - Terminal 30
19 - Terminal 15
20 - Ground (GND) - Terminal 31
Air distribution control - flexible cable, removing and

installing
Removing:
Caution!
- Bring flexible cable into the following position:
- Rotate air distribution rotary control knob - B - far

enough until locking mechanism of shaft - D - is visible in
gear drive - F - .
- Remove heating and ventilation controls 80-1, Heating

and ventilation controls, removing and installing
- Reach into center console and release retaining tab - 1 -

by pressing in direction of - arrow - .
- Pull cable from adapter - 2 - .
Installing:
Install in reverse order of removal, ensuring air distribution

rotary control knob has not been moved from the positions
as specified for removal.
Note:
When installing flexible cable, adapter and rotary

switches on heating and ventilation controls must be
oriented in a specific manner. Checking 80-1, Air
distribution control - flexible cable operation,
checking
Air distribution control - flexible cable operation,

checking
Check function of air distribution control flexible cable as

follows:
- Set fresh air blower to maximum speed. If air flow flows

from defroster air vents in the "Defrost" position and no air
flows from footwell air vents, installation of flexible cable is
correct. If this is not the case, remove flexible cable from
adapter. Place Heating and ventilation controls onto
adapter and rotate rotary knob for air distribution 1 2
rotation (180 ). Then reconnect flexible cable. Repeat
test.
Temperature flap - bowden cable, removing and

installing
Removing:
Caution!
- Remove heating and ventilation controls 80-1, Heating

and ventilation controls, removing and installing
- Reach into center console and disengage locking

mechanism - 1 - of Bowden cable sheath - 2 - and
remove Bowden cable sheath from mount.
- Disengage ball on bowden cable - 3 - from operating

lever.
- Remove driver side footwell trim

- Unclip bowden cable at adjusting unit of temperature

flaps - A - and unclip heating and ventilation unit - B - .
Installing
Install in reverse order of removal, noting the following:
- Ensure bowden cable is routed under hook - arrow - .
- Check whether temperature knob can be moved easily

from "cold" to "warm" .
Fresh/Recirculating Air Door Motor V154 , removing and

installing
Removing:
Caution!
Note:
Position of recirculating air door must not be

changed.
- Remove cover - 1 - .
- Disconnect electrical connection from Fresh/Recirculating

Air Door Motor V154 - 2 - .
- Remove Fresh/Recirculating Air Door Motor V154 - 2 -

from mounting.
Installing
Note:
Always check Fresh/Recirculating Air Door Motor

V154 and recirculating air door function after
replacing motor.
- Checking: Use Vehicle Diagnostic, Testing and

Information System VAS 5051/5052 in operating mode
"Guided Fault Finding"
- Replacing: Initiate Basic Setting using Vehicle

Diagnostic, Testing and Information System VAS
5051/5052 in operating mode "Guided Fault Finding" .
Heater core, removing and installing
Removing:

Drip tray for VAS6100 VAS 6208
Hose clamps, up to 40 mm. 3093
Compressed air gun, commercially available
Caution!
- Remove facing wall in plenum chamber
Repair Manual, Body Exterior, Repair Group 50,
- Place Drip tray for VAS6100 VAS 6208 under the

engine.
Warning!
Scalding danger!
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.
- Clamp off coolant hoses - 1 - using Hose clamps, up to

40 mm. 3093 and disconnect coolant hoses to heater
core.
- Connect a section of hose - A - onto upper connection of

heater core.
- Hold suitable container - B - under the lower connection

- C - .
- Using a compressed air gun, carefully blow coolant from

heater core into container - B - .
- Remove bolt (6 mm socket head) - 1 - from connection

flange between heater core connections.
Note:
This allows the coolant pipes to move for removing

the heater core.
- Remove left footwell air vent 80-1, Left footwell air

vent, removing and installing
- Remove screws - 1 - and remove heater core trim.
- Cover floor carpet in area below heater core with leak-

proof foil and absorbent paper.
- Open hose clamps - A - and disconnect coolant pipes

from heater core.
- Remove heater core from heating and ventilation unit.
Installing:
- 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 heating and

ventilation unit when sliding in the heater core.
If seal is damaged or installed incorrectly, cold air

can flow past the heater core.
- With the heater core removed, check heating and

ventilation unit for soiling (via heater core opening - A - ).
- If necessary remove dirt or coolant from heating and

ventilation unit, for example after removing leaky heater
core.
- Push heater core into the heating and ventilation unit.
- 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 hose clamps are deformed, replace them.
- Connect coolant pipes to heater core.

- Hose clamps - A - must be able to be twisted slightly

when installing onto the coolant pipes.
- Hose clamps - A - must be installed as shown in the

illustration.
- Tighten hose clamps - A - to 2.0 Nm.
- Check seating of both clamps - A - after tightening

screws, clamps must enclose the flange on heater core
and coolant pipe completely and must not touch other
components.
- Thread bolt - A - into connection flange - B - and while

doing this ensure bolt is actually threaded into the
mounting point intended for it.
- Check position of grommet - C - in bulkhead for proper

seating.
- Seal flange for coolant pipes to heater core - A - and for

expansion valve (to evaporator, only in vehicles with A/C
system) - B - at grommet pass-through - 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 applicable engine
repair manual Rep. Gr. 19).
Check coolant circuit for leaks, pay particular

attention between coolant hoses and heater core.
Auxiliary Heater Heating Element Z35 , removing and

installing
Note:
Heating element only installed on models with Diesel

engine.
Removing:
Caution!
Warning!
Burn danger!
Auxiliary Heater Heating Element Z35 may be hot.
Before removing Auxiliary Heater Heating Element Z35

let it cool off.


- Remove screws - 1 - from cover - 2 - .
- Remove mounting nut for voltage supply - 3 - and for

Ground (GND) connection - 4 - .
- Disconnect electrical connections - 5 - from Auxiliary

Heater Heating Element Z35 .
- Remove element from heating and ventilation unit.
Removing:
Ventilation system, checking
Note:
Stale interior air escapes via ventilation openings in

the luggage compartment trim.
If the ventilation is to function properly the ventilation

openings must not be covered.
Ventilation frames are located in rear side panels,

behind bumper.
Checking
- Remove rear bumper

- The sealing lips - 1 - in the ventilation frame on both

sides of vehicle must be free to move and close
automatically.
- Note installation position.
Intake air grille, removing and installing
Removing:
- Remove plenum chamber cover
- Remove nuts - arrows - and remove intake air grille

upward.
Installing
Install in reverse order of removal, noting the following.
Note:
Seal must be seated correctly on intake air grille.
Heating and ventilation unit, removing and installing
Preparation:
Drip tray for VAS6100 VAS 6208
Hose clamps, up to 40 mm. 3093
Compressed air gun, commercially available
Caution!
Note:
To improve accessibility, additional components e.g.

engine cover must be removed (depending on

engine version).
- Remove instrument panel
- Remove facing wall in plenum chamber
- Remove left and right rear footwell channels 80-1,

Rear footwell air ducts, removing and installing
- Place Drip tray for VAS6100 VAS 6208 under the

engine.
- Mark coolant hoses - 1 -
Warning!
Scalding danger!
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.
- Clamp off coolant hoses - 1 - using Hose clamps, up to

40 mm. 3093 and disconnect coolant hoses to heater
core.
- Using a compressed air gun, carefully blow residual

coolant from heater core at heater core connection.
- Cover floor carpet in vehicle interior with leak-proof foil

and absorbent paper.
Note :
Take note during removal of the length and

assignment of screws for re-installation
Bolt
4 Nm
Screws
Qty. 2
4 Nm
Cable bracket
Removing:
- Disconnect electrical
connections from heating
and ventilation unit.
Note :
All cable ties opened or cut during removal must be

reinstalled at the same locations during installation.
- Remove screws Item -

6 - from bracket Item - 5
- .
- Remove supports Item

- 8 - and Item - 9 - .

10 - and Item - 12 - and
remove bracket Item -
11 - .

1 - and Item - 2 - from
cable bracket Item - 3 - .
Note :
To be able to reach the bolt Item - 1 - , heating

and ventilation unit on driver side must be pulled out
slightly from facing wall.
When removing heat unit, ensure the two coolant

pipes of the heater core do not get caught and bent
or damaged on plenum chamber or sound insulation
pan.
Also pay attention to wiring harness, individual wiring

connections may get damaged when pulling too
forcefully on wiring harness.
- Remove heating and

ventilation unit.
Installing:
Install in reverse order of

removal, noting the following:
Note :
Assistance of a second mechanic is necessary to

install heating and ventilation unit.
- When inserting heating

and ventilation unit, have
second mechanic guide
both coolant pipes to
heater core through the
seal (from engine
compartment) 80-1,
seal at bulkhead,
installation position .
- Fill with coolant.
Bracket
Screws
8 Nm
Assembly carrier
Right support
Left support
Screws
Qty. 2
8 Nm
Bracket
Screws
Qty. 2
8 Nm
Heating and ventilation unit seal at bulkhead, installation

position
- First install seal - A - on bulkhead , then engage on

heater core.
Note:
To prevent ingress of water into vehicle interior, note

installation position.
Heating and ventilation unit, disassembly and assembly

Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru
Volkswagen, Skoda, Seat, Audi
Temperature flap adjusting unit

80-1, Temperature flap
adjustment unit, removing
and installing
Bracket
Cover
Fresh/Recirculating Air Door

Motor V154
Checking: Vehicle
Diagnostic, Testing and
Information System VAS
5051/5052

80-1, Fresh/Recirculating Air
Door Motor V154 , removing
and installing
Replacing: Initiate Basic

Setting using Vehicle
Diagnostic, Testing and
Information System VAS
5051/5052 in operating
mode "Guided Fault
Finding" .
Air intake housing
With recirculating air flap
Fresh Air Blower V2

80-1, Fresh Air Blower V2 ,
Fresh Air Blower Series Resistor

With Fuse N24

80-1, Fresh Air Blower
Series Resistor With Fuse
N24 , removing and
installing
Dust and pollen filter

80-1, Dust and pollen filter,
Cover
For dust and pollen filter
Heater core

80-1, Heater core, removing
and installing
Heater core trim
Auxiliary Heater Heating Element

Z35
With Auxiliary Air Heater

Control Module J604
Only installed on vehicles

with Diesel engine

80-1, Auxiliary Heater
Heating Element Z35 ,
Air distribution housing
Air distribution flap adjustment

unit

80-1, Air distribution flap
adjustment unit, removing
and installing
Air distribution flap adjustment unit, removing and

installing
Removing:
Caution!
- Remove instrument panel
- Unclip flex cable 80-1, Air distribution control - flexible

cable, removing and installing
- Remove screws - 1 - and remove adjustment unit.
Installing
- Arrows on toothed gears must align with each other.
- Position adjustment unit and tighten screws - 1 - .
Note:
After installing, check air distribution flap function

80-1, Air distribution control - flexible cable,
Temperature flap adjustment unit, removing and

installing
Removing:

- Unclip cable at adjusting unit for temperature flap - 2 - .
- Disengage locking mechanism - 1 - and press adjusting

unit for temperature flap in direction of - arrow - until it
reaches stop.
- Remove adjustment unit.
Installing
Note:
After installing, check temperature flap function as

follows: Temperature rotary control knob must be
able to move easily and without catching from "cold"
to "warm" position.

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What are the main components of the heating and ventilation system described?

What are the main components of the heating and ventilation system described?

What steps are involved in removing and installing different HVAC components?

What steps are involved in removing and installing different HVAC components?

Volkswagen Golf 5 2004-> VW Rabbit GTI 2006->

Heating and Ventilation System

Rabbit and GTI models from model year 2006 are

Before troubleshooting or servicing, technicians must be

Self Study Program - Course Number 892503 "VW 2006

Wiring Diagrams and Component Locations

Heating and ventilation system components in

Disconnect battery before removing

Repair Manual, Electrical Equipment,

Center air vents

Removing and installing

Right side window defroster air

Right air vent

Removing and installing

Heating and ventilation controls

With Fresh Air/Recirculating

With Immediate Heating

Removing and installing

Fresh/Recirculating Air Door

Removing and installing

Right footwell air vent

Removing and installing

Fresh Air Blower V2

Removing and installing

Fresh Air Blower Series Resistor

Removing and installing

Series Resistor With Fuse

Heating and ventilation unit

Removing 80-1, Heating

Only in vehicles without air

Dust and pollen filter

With activated charcoal filter

Removing and installing

Center console air duct

To remove, center console

Repair Manual, Body Interior, Repair

Right rear footwell air duct

Removing and installing

Left rear footwell air duct

Removing and installing

Observe varying lengths

Heating and ventilation control

Removing and installing

Auxiliary Heater Heating Element

Only on models with Diesel

Removing and installing

After replacing heater core,

Removing and installing

Left footwell air vent

Removing and installing

Temperature flap bowden cable

Removing and installing

Air distribution control - flexible

Removing and installing

Heating and ventilation unit