VOLKSWAGEN GOLF 2004 (04) PDF Document

The fresh air blower is accessible from the footwell on the front passenger side. First, remove the heater unit baffle plate. Pull the connector off the fresh air blower, then remove the bolt for the fresh air blower. Finally, release the catch, turn the fresh air blower in the direction of the arrow, and remove it.

To remove the filter, first remove the footwell trim on the front passenger side. Remove the baffle plate from the heater unit. Release the cover in the direction of the arrow and remove the dust and pollen filter from the heater unit downwards. Install in reverse order, ensuring you observe the correct installation position of the filter.

For vehicles with a storage compartment in the centre vent trim, the rubber mat must be removed to reach the bolt. If the vehicle is equipped with Climatronic, first remove the sunlight penetration photosensor. Remove the bolt, then remove the cover (only for vehicles with Climatronic). Remove the securing bolts, remove the central vents upwards, and separate the connectors from the central vents. Install in reverse order.

Before removing the controls, set the rotary knobs to the following positions: heater control to cold, blower to 0, and vent direction to footwell. Remove the radio. If the vehicle is without a radio, remove the centre dash panel trim. Remove the bolts to remove the controls from the centre console. When disconnecting, release the connector catches.

Place a drip tray beneath the engine and clamp off the coolant hoses using appropriate hose clamps to disconnect them from the heat exchanger. Carefully blow remaining coolant out of the heat exchanger using a compressed air pistol. Depending on the engine type, you may need to remove additional parts like the charge air pipe. Loosen the bolt on the flange between the heat exchanger connections. Remove the driver side footwell trim, the left footwell vent, and the cover. Cover the carpet with waterproof foil and absorbent paper, open the pipe clamps, and pull the coolant pipes out of the heat exchanger before removing it from the heater unit.

The total capacity for refrigerant R134a depends on the air conditioner compressor installed:

Before testing, ensure the intake temperature is less than 19°C, coolant temperature is less than 80°C, passenger compartment temperature is about 20°C, battery voltage is greater than 11V, alternator load is not greater than 50%, engine speed is greater than 450 rpm, and the interior temperature knob is set to maximum. Measure the current consumption on the earth wire using a vehicle diagnostic system and a 100 A pick-up clamp. Expected values are: low heating output approximately 30 amps, medium heating output approximately 60 amps, and high heating output approximately 80 amps.

Danger of freezing injuries exists. If the refrigerant circuit has not been evacuated, refrigerant will escape. You must extract the refrigerant before opening the refrigerant circuit. If the circuit is not opened within 10 minutes after evacuation, pressure may develop in the circuit due to re-evaporation, and you must extract the refrigerant again.

The oil located in the sump of the air conditioner compressor before the system is switched on for the first time distributes itself throughout the refrigerant circuit as follows: Air conditioner compressor approximately 50%, condenser approximately 10%, suction hose approximately 10%, evaporator approximately 20%, and receiver approximately 10%.

Refrigerant oils from containers that have been open for a longer period are unusable as the oil is very hygroscopic. Opened containers must be closed immediately and made airtight. The oil must not be disposed of together with engine or gear oil.