VW Golf HVAC Fan Failure, Fix Options & Experience

Had the same climate control issue on my 2004 VW Passat TDI. The cabin fan completely stopped working across all fan speed settings. After inspection, the root cause was a failed blower motor resistor, not the entire fan unit. The air flow problem started gradually, first losing the lower fan speeds, then complete failure. The workshop diagnostic revealed both the resistor pack and the fan speed controller needed replacement due to electrical wear. While this was not a serious mechanical issue affecting engine performance, it made the HVAC system unusable. Common failure points in these VW models include: Blower motor resistor pack, Fan speed controller unit, Wiring harness connections, Blower motor bearings The repair process involved removing the glove box to access the climate control components. Testing showed the blower motor itself was still functional, which simplified the fix. This is a fairly standard repair for VW models from that era. My recommendation would be to have a proper diagnostic done, as replacing parts without confirming the exact issue can lead to unnecessary expenses. The symptoms you describe match closely with what I experienced before the repair.

Thanks for sharing your Passat experience. My Golf had nearly identical symptoms with the blower motor. Good to know it was just the resistor pack in your case, makes me hopeful it will be a straightforward fix for my climate control system too. Quick follow up, do you recall roughly what the total repair cost was for your cabin fan issue? Also curious if you have had any other HVAC system problems since getting it fixed? Mine has been a bit inconsistent with air circulation lately so wondering if I should have them check the whole setup while they are in there.

Thanks for asking about the follow-up costs. Just had my Golf back from the mechanic last week and can confirm the heater fan is now working perfectly. The issue was indeed a defective blower motor that needed complete replacement, which came to 365€ including labor. The cabin fan now responds correctly at all speeds, and the air circulation is back to normal. The mechanic performed a full HVAC system check during the repair and found no other issues with the fan speed controller or other components. Since the fix, the climate control has been working flawlessly, no more issues with inconsistent airflow or dead spots in the fan settings. Having them check the entire system while doing the repair was definitely worth it for peace of mind. In these VW models, once the blower motor is replaced, the HVAC system typically remains reliable for many years without needing additional repairs.

I finally had my Golf back from the shop. They found a burnt blower motor just like yours. Total cost was 365€, pricey but worth it since the heater fan now works perfectly in all settings. The mechanic discovered the issue pretty quickly once they removed the glove box. While testing the air circulation system, they noted the fan speed controller was actually fine despite my initial concerns. The blower motor itself was the culprit, completely dead from electrical failure. Since the repair last week, the climate control system works like new. No more problems with inconsistent air flow or dead fan speeds. Having them do a complete HVAC check during the repair really helped identify there were no other underlying issues. Looking back, it was smart to get it fixed before winter. The whole repair process took about 3 hours, but now I have proper cabin heating again. Much better than struggling with a non-working heater fan in cold weather.