VW Golf Mk5 2004 Heating, air conditioning - Workshop Manual

1.1 Passenger compartment heating......Page 5
1.3.1 Removing......Page 7
1.5 Removing vents......Page 8
1.5.3 Removing right or left vent......Page 9
1.5.7 Installing......Page 10
1.6.1 Removing......Page 11
1.7.1 Pin assignment for multi-pin connectors on back of controls for heated and fresh air......Page 12
1.8.1 Removing......Page 13
1.9.1 Removing......Page 14
1.10.2 Installing......Page 15
1.11.1 Removing......Page 16
1.11.2 Installing......Page 18
1.12.1 Removing......Page 19
1.13.2 Checking auxiliary air heater element -Z35-......Page 20
1.13.5 Removing and installing......Page 21
1.15.1 Removing......Page 22
1.16 Removing and installing heater unit......Page 23
1.16.1 Removing......Page 24
2.1 Assembly overview – heater unit......Page 27
2.2.1 Removing......Page 28
2.3.2 Assembling......Page 29
2.5.2 Installing......Page 30
1 Notes on repair work to vehicles with air conditioning and on handling refrigerant......Page 32
2.1 Air conditioning and heating - passenger compartment......Page 33
2.2 Dismantling and assembling heater and air conditioner unit “Climatic”......Page 35
2.4.1 Pin assignment for multi-pin connectors on back of controls for heating and air conditioning “Climatic”......Page 37
2.5.2 Checking......Page 39
2.8.1 Removing......Page 40
2.8.2 Installing......Page 41
2.9.1 Removing......Page 42
2.11.1 Removing......Page 43
2.11.2 Installing......Page 44
3 Air conditioning system with automatic regulation “Climatronic”......Page 45
3.1 Procedure for checking and adjusting components......Page 46
3.2 Function of operating and display unit for Climatronic air conditioning system -E87-......Page 47
3.3.2 Installing......Page 48
3.4.1 Pin assignment for multi-pin connectors A, B and C on back of Climatronic control unit -J255-......Page 49
3.5 Climatronic - passenger compartment......Page 51
3.6 Dismantling and assembling heater and air conditioner unit “Climatronic”......Page 54
3.7 Assembly overview - evaporator housing......Page 56
3.8.2 Installing......Page 57
3.10.1 Removing......Page 58
3.12.1 Removing......Page 59
3.13 Function of air quality sensor -G238-......Page 60
3.14.1 Removing......Page 61
3.15 Removing left vent temperature sender -G150- and right vent temperature sender -G151-......Page 62
3.18 Renewing control motors for air conditioning regulation......Page 63
3.20.1 Removing......Page 64
3.21.1 Removing......Page 65
3.22.2 Installing......Page 66
3.23.2 Installing......Page 67
3.24.2 Installing......Page 68
3.25.2 Installing......Page 69
3.26.2 Installing......Page 70
4.1 Engine codes: AZV, BDK, BJB, BKC, BKD, BLS, BMM, BMN, BRM, BRU, BVB, BXE, BXF and BXJ......Page 71
4.2 Engine codes: BCA, BUD......Page 73
4.3 Engine codes: BLG, BMY......Page 75
4.4 Engine codes: BAG, BKG, BLF, BLN, BLP and CAX......Page 77
4.5 Engine codes: AXW, AXX, BGU, BHY, BLR, BLX, BLY, BPY, BSE, BSF, BVX, BVY, BVZ, BWA, BYD, CAWB, CBFA and CCTA......Page 79
4.6 Engine codes: BGP, BGQ, BTK, CBTA and CBUA......Page 81
4.7 Engine codes: BUB, CBRA......Page 83
5 Repair work on refrigerant circuit which may be performed only in appropriate workshops by specially trained mechanics......Page 86
5.1 Testing equipment and tools......Page 87
5.2 Removing and installing heater and air conditioning unit......Page 88
5.2.1 Removing......Page 89
5.3 Renewing components of refrigerant circuit......Page 92
5.5 Removing and installing receiver with dryer......Page 96
5.5.1 Removing......Page 97
5.6.1 Removing......Page 98
5.7 Assembly overview - poly V-belt pulley (air conditioner compressor from “Denso”)......Page 101
5.8.2 Installing......Page 103
5.11 Expansion valve, function and removing......Page 104
5.13 Removing and installing condenser......Page 107
5.14.1 Installing......Page 110
5.14.2 Removing evacuating and charging valve, low-pressure side and high-pressure side......Page 111
6.2.1 Oil distribution......Page 113