VOLKSWAGEN JETTA 2011 (02) PDF Document

Remove the plastic bolts and take off the baffle plate.

First, insert the seal between the heater unit and the engine compartment in the bulkhead and then attach it to the heat exchanger. It is important to observe the installation position to prevent water from entering the vehicle interior.

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, remove the bolt for the fresh air blower, then release the catch, turn the fresh air blower in the direction of the arrow, and remove it.

Be aware that the fresh air blower series resistor can be hot and cause burn injuries. Always let it cool off before attempting to remove it.

Remove the footwell cover 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.

First, switch off the ignition. Remove the centre trim of the dash panel. If fitted, remove the radio or radio navigation system. Move the steering wheel to the lowest position and adjust the reach so the steering wheel is as far into the passenger compartment as possible. Release the gap cover using a removal wedge 3409, then remove the bolt. Use the removal wedge to release the clips for the centre vent and pull out the dash panel insert trim with the centre vent slightly. Release the clips for the left vent and the fasteners for the dash panel insert trim using the wedge, then remove the dash panel insert trim with the centre and left vents, disconnecting the wiring harness for the hazard warning light switch.

Release the upper and lower clips of the right vent using a removal wedge 3409, pull the vent out slightly, and remove the right dash panel vent from the dash panel.

Before removing the controls, set the heater control to cold, the blower to 0, and the vent direction to footwell.

Remove the radio. For models without a radio trim, remove the centre part of the dash panel. Remove the mounting bolts and remove the controls from the centre console. Release the connector catch by pulling it, push the connector catch towards the connector to remove it, and release the remaining connector catches to remove the connectors.

Run the fresh air blower at the highest speed. If air flows out of the defroster vent in the defrost position and no air flows out of the footwell vent, the flexible shaft is correctly installed.

Remove the controls for fresh and heated air. Reach into the centre console and release the locking lug of the Bowden cable sleeve and take it out of the mounting. Release the ball of the Bowden cable from the operating lever. Remove the driver side footwell trim, then unclip the Bowden cable from the control unit for the temperature flap and the heater unit.

The position of the air recirculation flap must not be changed.

First, disconnect the battery to avoid a short circuit. Remove the driver side footwell trim and the left footwell vent. If the temperature flap lever blocks access to the upper bolt, change the temperature flap position at the controls. Remove the cover bolts, remove the securing nut for the voltage supply and the earth connection, disconnect the connector, and pull the auxiliary air heater element out of the heater unit.

Test conditions include: intake temperature less than 19 degrees Celsius, coolant temperature less than 80 degrees Celsius, passenger compartment temperature about 20 degrees Celsius, battery voltage greater than 11 V, alternator load not greater than 50%, engine speed greater than 450 rpm, and the interior temperature knob set to the maximum temperature.

Remove the plenum chamber cover, remove the securing nuts, and remove the air intake grille upwards.

Before removing, set the heater control to cold, the blower to 0, and the vent direction to footwell. Remove the radio or the centre part of the dash panel. Remove the bolts to take the controls out of the centre console, release the connector catches, and remove the connectors.

Turn the AC compressor poly V-belt pulley 10 revolutions by hand before starting the engine to prevent damage to the compressor. Only start the engine after the refrigerant circuit has been assembled, and if possible, only start the engine when the refrigerant circuit is full.

The oil distributes itself as follows:

Air conditioner compressor: approx. 50%

Condenser: approx. 10%

Suction hose: approx. 10%

Evaporator: approx. 20%

Receiver: approx. 10%