Heating, Ventilation: Other Volkswagen Passat B6

HEAT AND FRESH AIR CONTROL, MULTI-PIN CONNECTORS

16-pin Connector is not assigned.

5-pin Connector, T5r

Scheme 3

1 - 3rd blower speed

2 - 2nd blower speed

3 - 1st blower speed

4 - 4th blower speed

5 - Terminal X

20- pin Harness Connector, T20b

3 - Fresh/Recirculating Air Door Motor -V154

6 - Fresh/Recirculating Air Door Motor -V154

8 - Rear window

11 - Heated driver seat adjuster -E94- (optional)

15 - Heated front passenger seat adjuster -E95- (optional)

16 - Heat or heat output switch -E16

18 - Terminal 30

19 - Terminal 15

20 - Terminal 31

FLEXIBLE AIR DISTRIBUTION SHAFT, CHECKING

Flexible shaft for adjusting unit of air distribution doors

Let fresh air blower run on highest speed. If air flows out of defroster vents in the Defrost position and no air flows out of footwell vents, installation of flexible shaft is correct. If this is not the case, remove flexible shaft from adapter. Place controls for hot air and fresh air onto adapter and rotate rotary knob for air distribution 1 / 2 rotation (180°). Then re-connect flexible shaft. Repeat test

Scheme 4

VENTILATION, CHECKING

Note. The stale air escapes through the vent openings in the luggage compartment trim. If the ventilation is to function properly, the ventilation openings must not be covered. The ventilation frames are located in the rear side panels, behind the bumper.

Checking

Note. The ventilation can be checked through the luggage compartment. Depending on the vehicle equipment level, it may be necessary to remove additional components.

Remove the side trim panels inside the luggage compartment.

Scheme 5

The sealing lips -1- in the ventilation frame on both sides of vehicle must be free to move and close automatically.

Removal

Remove rear bumper. Refer to Removal and Installation .

Scheme 6

Remove the vent frame -1- from the side panel.

Observe installed position.

DUST AND POLLEN FILTER

Removal

Note. There are different versions of the dust and pollen filter (without and with filter insert with activated charcoal).

Remove the partition from the heater, refer to item Removing Heater Partition .

Release cover -3- in direction of arrow.

Scheme 7

Remove dust and pollen filter downward out of heater.

Installation

Note. Note installation position of dust and pollen filter.

Install in reverse order of removal.

Scheme 8

FLEXIBLE AIR DISTRIBUTION SHAFT

Removal

Remove the glove compartment. Refer to Removal and Installation .

Scheme 9

Move the flexible shaft in to the following position

Turn the switch for air distribution control -B- enough until the locking mechanism on the shaft -D- is visible in step-up gearing -F-.

Remove controls for hot air and fresh air. Refer to HEAT AND FRESH AIR CONTROLS .

Reach into the center console and push the tab -1- in -direction of arrow- to release it.

Pull flexible shaft out of adapter -2-.

Installation

Install in reverse order of removal.

Note. When installing flexible shaft, adapter and rotary switches on controls for hot air and fresh air must have a specific position to each other, otherwise it will malfunction. Refer to FLEXIBLE AIR DISTRIBUTION SHAFT, CHECKING .

FRESH AIR BLOWER -V2

Removal

Scheme 10

Fresh Air Blower is accessible from footwell on front passenger side.

Remove the glove compartment. Refer to Removal and Installation .

Remove the partition from the heater, refer to Removing Heater Partition .

Disconnect harness connector -A- from fresh air blower.

Unscrew bolt -B- for fresh air blower (1 Nm).

Disengage the locking mechanism -2- and turn the fresh air blower -in direction of arrow- and remove it.

Installation

Install in reverse order of removal.

FRESH AIR BLOWER SERIES RESISTOR WITH FUSE -N24

Removal

Before starting repair work, perform the following

Remove the partition from the heater, refer to Removing Heater Partition .

Scheme 11

Disconnect harness connector -1- from fresh air blower series resistor with fuse.

Push the retainer in -direction of arrow- and remove the fresh air blower series resistor with fuse from the heater.

Installation

Install in reverse order of removal.

FRESH/RECIRCULATING AIR DOOR MOTOR -V154

Removal

Note. The Fresh/Recirculating Air Door Motor can only be removed without difficulty in fresh air mode stop and installed only in this position. If motor remains standing in a different position and can no longer be moved electrically into fresh air mode stop position, it can only be pulled off and removed with difficulty. Position of fresh/recirculating air door must not be changed.

Turn on the ignition and wait until the fresh/recirculating air door motor has reached its end position "fresh air mode".

Switch off the ignition.

Remove the glove compartment. Refer to Removal and Installation .

Open the retainers -B- and -C- and remove the bracket -A-.

Scheme 12

Disconnect the connector from the motor -B-.

Scheme 13

Remove the fresh/recirculating air door motor -B in direction of arrow- from intake housing.

Note. Connection between control motor toothed gears and fresh/recirculating air door is designed so that the control motor can only be removed in the "fresh air mode" position without difficulty (intake opening for recirculating air mode is sealed via the fresh/recirculating air door -A-). If motor is found in a different position and can no longer be moved, motor cannot be simply pulled off, rather it must be loosened first with great force from mounting points -C-, ensure that toothed gear -D- is not damaged when doing this.

Installation

Note. Motor as replacement part is delivered in the "fresh air mode" position, only when toothed gear -A- contacts stop -B- can it then be connected onto toothed gear of fresh/recirculating air door. If a motor was removed in a different position or activated in the removed state, it cannot be installed. If toothed gear -A- of motor does not stand at stop -B- "fresh air mode", proceed as follows

Connect the motor to the vehicle wiring harness.

Switch on the ignition.

Scheme 14

Wait until toothed gear -A- of motor reaches stop -B- "fresh air mode".

Switch off the ignition.

Reach into intake opening for recirculating air mode and move the fresh/recirculating air door -A- into the "fresh air mode" position (intake opening for recirculating air mode is closed).

Insert the motor -B- into mounts -C- in opposite direction of arrow and onto toothed gear -D-.

Scheme 15

Note. So that toothed gear on motor -A- can be slid on toothed gear of fresh/recirculating air door, short tooth -C- of motor toothed gear must align with short tooth interval -D- of toothed gear on shaft of back pressure door -D-.

After installing the control motor, install the toothed gear -1- onto the fresh/recirculation air door shaft again.

Scheme 16

Install the wiring harness so that it cannot come in contact with any moving parts (for example, the lever on the motor).

Install the bracket -A-. Make sure the guide -D- fit correctly in the air intake shroud -E- and the bracket locks into both retainers -B- and -C-.

Note. Position of motor (and of door) is no longer visible with glove compartment installed, therefore it is sensible to check its function before installing glove compartment. If both toothed gears are assembled in incorrect position, fresh/recirculating air door does not reach its two end positions or motor does not run cleanly and without hitching.

Install the parts in reverse order of removal.

Note. After installing the fresh/recirculating air door motor, the function of the recirculating air door must be checked.

Check using Vehicle Diagnosis, Testing and Information System VAS 5051B.

Replacing: perform Basic Setting using Vehicle Diagnostic, Testing and Information System VAS 5051B. Refer to CLIMATRONIC A/C SYSTEM, CHECKING AND ADJUSTING COMPONENTS .

HEATER

Special tools and workshop equipment required

1. Drip Tray For Shop Crane VAS 6208
2. Hose Clamps Up To Diameter 40 mm VAS 3093
3. Compressed air gun, commercially available

Removal

Note. To improve accessibility, additional components such as the engine cover must be removed (depending on engine version). Refer to REMOVAL AND INSTALLATION and REMOVAL AND INSTALLATION .

Remove the instrument panel. Refer to Removal and Installation .

Remove the rear channels from the right and left footwells. Refer to REAR CHANNEL, FOOTWELL .

Place VAS 6208 under the engine.

Scheme 17

Mark coolant hoses -1-.

Clamp the coolant hoses -1- using the VAS 3093 and remove the coolant hoses from the heat exchanger.

Cover the carpet inside the passenger compartment with waterproof foil and water absorbing paper.

Clear out any coolant still in the heat exchanger using a compressed air gun.

Note. When removing the bolts, make note of the lengths and location.

Scheme 18

1. Screw 3.5 0.5 Nm
2. Screws 4 Nm Quantity: 2
3. Cable Bracket
4. Heater Unit Removal -- Disconnect the connectors from the heater. NOTE: All cable ties opened or cut during removal must be reinstalled at the same locations during installation. -- Remove the bolts -9- and -5-. -- Remove the supports -7- and -8-. -- Remove the bolts -10- and -12- and bracket -11-. -- Remove the bolts -1- and -2- from the cable bracket -3-. NOTE: To be able to reach the bolt -1-, heater on driver side must be pulled out slightly from facing wall. When removing heat unit, make sure the two coolant pipes of the heater core do not get caught and bent or damaged on plenum chamber or noise insulation pan. Observe wiring harness, individual electrical wiring connections may get damaged when pulling on harness. -- Remove the heater. Installation Installation is carried out in the reverse order while noting the following: NOTE: A second technician is necessary to install the heater. -- When inserting heater, have the second technician guide the coolant pipes to heater core through the seal (from engine compartment), refer to «Seal Heater/Engine Compartment»(ref-460530-S29397434472012032900000) . -- Fill with coolant. Refer to «DRAINING AND FILLING»(ref-460595-S10297144382012032900000) .
5. Bracket
6. Subframe
7. Right Support
8. Left Support
9. Screws 9 1.3 Nm
10. Screws Quantity: 2 9 1.3 Nm
11. Bracket
12. Screws Quantity: 2 9 1.3 Nm

Scheme 19

Note. Note installation position of seal -A- during assembly.

Installation

Install in reverse order of removal.

HEAT EXCHANGER

Special tools and workshop equipment required

1. Drip Tray For Shop Crane VAS 6208
2. Hose Clamps Up To Diameter 40 mm VAS 3093
3. Compressed air gun, commercially available

Removal

Place VAS 6208 under the engine.

Clamp the coolant hoses -1- using the VAS 3093 and then remove them from the heat exchanger.

Connect a section of hose -A- to the upper connection on the heater core.

Hold a container -B- under the lower connection -C-.

Scheme 20

Using a compressed air gun, carefully clear out any coolant still inside the heat exchanger into the container -B-.

Scheme 21

Loosen the bolt (6 mm inner hex socket) -1- on the connection flange between the heat exchanger connections, but do not remove it.

Note. This allows the coolant pipes to move for removing the heater core.

Remove driver side footwell trim. Refer to Removal and Installation .

Remove the left footwell vent. Refer to LEFT FOOTWELL VENT .

Remove the bolts -1- (9 1.3 Nm) and -3- (1.5 Nm).

Scheme 22

Remove the heat exchanger cover -2-.

Cover the carpet the in area under heat exchanger with waterproof foil and water absorbing paper.

Open the clamps -A- (2 Nm) and remove the coolant pipes from the heat exchanger.

Scheme 23

Remove the heat exchanger from the heater.

Installation

Installation is carried out in the reverse order while noting the following

Scheme 24

Check the seals -A- and -B- on the heat exchanger for damage.

Note. An incorrectly glued seal can roll up into heater when sliding in the heater core. Cold air may flow past heat exchanger if seal is damaged or not properly fitted.

Check the heater (while the heat exchanger is removed) through the opening -A- for the heat exchanger, for dirt.

Scheme 25

Remove any dirt or coolant which has leaked out of the heater (for example, after removing a leaking heat exchanger).

Install the heat exchanger into the heater.

The sealing rings -1- must be replaced.

Scheme 26

Coat the sealing rings with coolant before installing.

Note. If hose clamps are deformed, replace them.

Attach the coolant pipes to the heat exchanger.

Hose clamps -A- must be able to be twisted slightly when installing onto the coolant pipes.

Install the clamps -A- as shown in the illustration.

Tighten hose clamps -A- to 2.0 Nm.

Check seating of both clamps -A- after tightening bolts, clamps must enclose the flange on heater core and coolant pipe completely and must not touch other components.

Tighten the connection flange bolt -1- between the heat exchanger connections to 2 Nm.

Make sure the grommet -C- fits correctly inside the plenum chamber bulkhead.

Scheme 27

Seal flange for coolant pipes to heater core -A- and for expansion valve (to evaporator, only in vehicles with A/C system) -B- at pass-through of grommet -C- with silicon adhesive sealant if necessary (to prevent water from penetrating).

Note. The seals must be replaced. If hose clamps are deformed, replace them. After replacing heater core, coolant must be replaced completely. Refer to DRAINING AND FILLING . Check coolant circuit for leaks, pay particular attention to the connection between coolant hoses and heater core. Refer to COOLANT HOSE CONNECTION DIAGRAM .

HEAT AND FRESH AIR CONTROLS

Removal

Note. The controls consist of two separable housings. Before removing controls, bring rotary buttons into the following position: Heater control to cold Blower to "0" Air flow direction to footwell

Remove the trim from the center of the instrument panel. Refer to Removal and Installation .

Scheme 28

Remove the screws (1.5 Nm) -2- (4.2 x 45 mm) and -3- (4.2 x 16 mm) and remove the heating and ventilation controls -1-.

Pull the connector -A- in -direction of arrow 1- to disconnect it.

Scheme 29

Press connector release -B- toward the connector -arrow 2- and disconnect the connector -C-.

Disconnect the connector -D-.

Installation

Installation is performed in reverse order of removal, make sure when doing so that the rotary buttons have the same position as when removing.

INTAKE AIR GRILLE

Removal

Remove the plenum chamber cover. Refer to Description and Operation .

Remove the cover -1-.

Scheme 30

Only for vehicles with an Air quality sensor -G238-. Refer to AIR QUALITY SENSOR -G238 .

Remove the nuts -3- (2.5 Nm) and air grille -2-.

Installation

Install in reverse order of removal.

Note. The seal must fit correctly in the air grille.

TEMPERATURE DOOR RELEASE CABLE

Removal

Remove controls for hot air and fresh air. Refer to HEAT AND FRESH AIR CONTROLS .

Carefully pull out adapter for controls.

Reach in the center console and loosen the retainer -1- on the cable grommet -2- and then remove the grommet from the mount.

Scheme 31

Loosen the ball on the cable -3- from the lever -4-.

Remove driver side footwell trim. Refer to Removal and Installation .

Scheme 32

Unclip Bowden cable at adjusting unit of temperature doors -A- and unclip heater -B-.

Installation

Install in reverse order of removal. When doing this, make sure that Bowden cable lies under the hook -arrow-.

Note. When installing flexible shaft, adapter and rotary switches on controls for hot air and fresh air must have a specific position to each other, otherwise it will malfunction. Refer to FLEXIBLE AIR DISTRIBUTION SHAFT, CHECKING .

Make sure the temperature control moves easily from cold to warm.

CENTER VENT

Removal

Special tools and workshop equipment required

1. Trim Removal Wedge 3409
2. Special Hook 3370

Insert the 3409 between the center vent and instrument panel.

Scheme 33

Insert the 3370 between the center vent and instrument panel.

Scheme 34

Remove the center vent from the instrument panel using the 3370.

Center Vent, disassembling and assembling, refer to CENTER VENTS .

Installation

Installation is carried out in the reverse order while noting the following

First insert the top of the center vent -arrows A- into the instrument panel.

Scheme 35

Pay attention to the alignment -arrow B- on the instrument panel when installing the center vents.

DRIVER AND PASSENGER SIDE

Special tools and workshop equipment required

1. Trim Removal Wedge 3409

Note. Removal of the vents on both sides is identical, but one is a mirror image of the other. To prevent damage to instrument panel, use a pad when prying out.

Removal

Pry the vent out of the instrument panel using the 3409.

Scheme 36

Installation

Install in reverse order of removal.

LEFT FOOTWELL VENT

Remove the trim panel and cover inside the driver footwell. Refer to Removal and Installation .

Scheme 37

Unscrew securing bolt -2- and remove left footwell vent -1-.

Installation

Install in reverse order of removal.

1. Screw tightening specification: 1.5 Nm

RIGHT FOOTWELL VENT

Removing

Remove partition from heater, refer to Removing Heater Partition .

Remove the glove compartment. Refer to Removal and Installation .

Scheme 38

Unscrew securing bolt -2- and remove right footwell vent -1-.

Installation

Install in reverse order of removal.

1. Screw tightening specification: 1.5 Nm

Note. If the vehicle has glove compartment cooling, check the cooling hose to make sure it is installed correctly.

REAR CHANNEL, FOOTWELL

Note. Removal of rear channels on both sides is identical, only the sides are reversed.

Removal

Remove driver or front passenger seat. Refer to Removal and Installation .

Remove center console. Refer to Removal and Installation .

Scheme 39

Lift floor carpet, unclip rear channel from floor and pull off from heater.

Installation

Install in reverse order of removal.

Note. When installing the rear channel, ensure the rear channel is first slid onto heater -arrow- and then clipped in to floor.

REAR VENT AIR DUCT

Removal

Remove center console. Refer to Removal and Installation .

Remove the center armrest. Refer to Removal and Installation .

Remove nuts -1-.

Scheme 40

Remove the rear vent air duct -2- from the center console.

Installation

Install in reverse order of removal.

1. Screw tightening specification: 1.5 Nm

REAR VENT

Removal

Remove the rear trim. Refer to Removal and Installation .

Remove the screws -1- and unhook the vent.

Scheme 41

Installation

Install the vent into the loops on the trim -arrows-.

Tighten the screws -1-.

Make sure the open/close thumbwheel -1- works correctly.

Scheme 42

If the open/close thumbwheel works

Tighten the screws -1- to 1.5 Nm.

If the open/close thumbwheel does not work

Loosen the screws -1- and adjust the vents until the open/close thumbwheel.

Tighten the screws -1- to 1.5 Nm.

Install the rear trim.

CENTER VENTS

Disassembly

Removing the center vents. Refer to CENTER VENT .

Press the tabs -arrows- and remove the vent trim.

Scheme 43

Separate the vents -1- and -2- in -direction of arrow-.

Assembly

Assemble in reverse order.

Scheme 44

1. Adjusting Unit For Temperature Door Removing and installing, refer to «AIR DISTRIBUTION DOOR ADJUSTER»(ref-460530-S29942931742012032900000) .
2. Bracket
3. Cover
4. Fresh/Recirculating Air Door Motor -V154- Check using Vehicle Diagnosis, Testing and Information System VAS 5051B. Removing and installing, refer to «FRESH/RECIRCULATING AIR DOOR MOTOR -V154»(ref-460530-S27804433942012032900000) . Replacing: perform Basic Setting using Vehicle Diagnostic, Testing and Information System VAS 5051B. Refer to «CLIMATRONIC A/C SYSTEM, CHECKING AND ADJUSTING COMPONENTS»(ref-460602-S08419284092012032900000) .
5. Housing For Air Entry With fresh/recirculation air door.
6. Heater Unit
7. Fresh Air Blower -V2- Removing and installing, refer to «FRESH AIR BLOWER -V2»(ref-460530-S25591634172012032900000) .
8. Fresh Air Blower Series Resistor With Fuse -N24- Removing and installing, refer to «FRESH AIR BLOWER SERIES RESISTOR WITH FUSE -N24»(ref-460530-S12233790562012032900000) .
9. Dust and Pollen Filter Removing and installing, refer to «DUST AND POLLEN FILTER»(ref-460530-S32585915782012032900000) .
10. Cover For dust and pollen filter.
11. Heat Exchanger Removing and installing, refer to «HEAT EXCHANGER»(ref-460530-S33155149692012032900000) .
12. Heater Core Trim
13. Auxiliary Heater Heating Element -Z35- Not applicable to the US or Canada
14. Junction Box
15. Adjusting Unit For Air Distribution Doors Removing and installing, refer to «AIR DISTRIBUTION DOOR ADJUSTER»(ref-460530-S29942931742012032900000) .

AIR DISTRIBUTION DOOR ADJUSTER

Removal

Remove the left footwell vent. Refer to LEFT FOOTWELL VENT .

Unclip flexible shaft from adapter for controls. Refer to FLEXIBLE AIR DISTRIBUTION SHAFT .

Scheme 45

Unscrew bolts -1- and remove adjusting unit for air distribution doors.

Installation

The arrows on the gears must align.

Position adjusting unit for air distribution doors and tighten bolts -1-.

Note. After installing, function of air distribution door must be checked.

AIR DISTRIBUTION DOOR ADJUSTER LINKAGE

Removal

Unclip cable at adjusting unit for temperature door -2-.

Scheme 46

Disengage the catch -1- and press adjusting unit for temperature door -in direction of arrow- until it reaches stop.

Remove adjusting unit for temperature door.

Installation

Install in reverse order of removal.

Note. After installing, function of temperature door must be checked. Temperature knob on hot air and fresh air controls must be able to moved easily and without catching from cold position to warm position.

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

1. Hose Clamps Up To Diameter 40 mm VAS 3093
2. Trim Removal Wedge 3409
3. Special Hook 3370
4. Test Box V.A.G 1598/42
5. Adapter Cable V.A.G 1598/47
6. Template V.A.G 1598/47-2
7. Drip Tray For Shop Crane VAS 6208
8. Compressed air gun, commercially available