Yup, as mentioned above, definitely sounds like a dead fan/blower resistor. Had this exact problem before and posted here about it and was given the same advice. Truthfully, I was skeptical at first till I finally found the wire diagram and confirmed the symptoms schematically. (This was on a Mk4 Jetta).
Yep, although it is no doubt the resister gone bad there is often a reason the resister heat protector "fuse" fails. I replaced a couple years ago in the 2001 until one day the smoke spewed out of the dash vents and the blower fan motor suddenly screeched to a stop. When the fan motor bearings (and or windings/brushes) wear out and cause extra amp draw from excess drag it can overheat the resistor. Eventually the motor is toast. Replace the resistor or heat protector "fuse" and see how much time it buys you.
Thanks for all of the replies. I have the resistor out which is attached to a plastic cover. Resistor is pretty dark and cracked. Appears to be made on to the plastic cover. Does any one know if the new/replacement part is just the resistor or does it come on a new plastic cover?
Hello, I was not able to find any info about this repair, so I decide to make tutorial. Cars what have this type of blower as per my knowledge: VW New Beetle 98 - 2003 VW Golf 2000 - 2009 VW Jetta 1999 - 2007 Worn out brushes are very often cause of not working fan. PDF is on the link for...