Volkswagen Passat 2011 Workshop Manual
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Volkswagen Passat 2011 Workshop Manual

Heating, air conditioner
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Workshop Manual
Passat 2011 ➤
Passat Variant 2011 ➤
Heating, air conditioner
Edition 06.2017
Service Department. Technical Information

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Summary of Contents for Volkswagen Passat 2011

  • Page 1 Service Workshop Manual Passat 2011 ➤ Passat Variant 2011 ➤ Heating, air conditioner Edition 06.2017 Service Department. Technical Information...
  • Page 2 In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2017 Volkswagen AG, Wolfsburg D3E803125D2...

  • Page 3: Table Of Contents

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Contents 00 - Technical data ........... .
  • Page 4 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Front heater and air conditioning unit ......... .

  • Page 5: Technical Data

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 00 – Technical data Safety information (VRL010399; Edition 06.2017) ⇒ “1.1 Safety precautions when working on air conditioning sys‐ tems”, page 1 ⇒ “1.2 Safety measures when working on vehicles with a start/ stop system”, page 1...
  • Page 6 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Wear protective goggles. – Reduce excess pressure by covering cap of coolant expan‐ sion tank with cloths and opening it carefully. Rep. gr.00 - Technical data...

  • Page 7: General Information

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 General information ⇒ “2.1 Notes concerning odours in air conditioned vehicles”, page ⇒ “2.2 Notes for vehicles with start-stop system”, page 3 Notes concerning odours in air condi‐...

  • Page 8: Repair Notes

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Repair notes ⇒ “3.1 Checking cooling output”, page 4 ⇒ “3.2 Working on refrigerant circuit”, page 5 ⇒ “3.3 Refrigerant circuit seals”, page 5 ⇒ “3.4 Notes on control motors”, page 6...

  • Page 9: Working On Refrigerant Circuit

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Switch on air conditioning system via button. – Start engine. Note Start time measurement (5 minutes). – Increase engine speed to approx. 2000 rpm and hold.

  • Page 10: Notes On Control Motors

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 prevent them from being interchanged ⇒ Electronic parts catalogue . The dimensions -a- and -b- depend on the fitting location of the seal ⇒ Electronic parts catalogue .
  • Page 11 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 ♦ There are different control motors installed on the air distribu‐ tion box and air intake unit of the heater and air conditioning unit. These control motors differ in terms of electrical values (defined by the travel which is determined by the links), in terms of the links and in terms of the part number ⇒...
  • Page 12 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 3.4.2 Inserting link into the shaft of a control motor Note Up to week 45/2013 there have been different control motors ♦ available as a replacement part with pre-installed and colour- marked links (e.g.
  • Page 13 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Note The links which are available as a set are not colour-marked ♦ ⇒ Electronic parts catalogue . The achievable travel of a control motor is determined by the ♦...
  • Page 14 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 3.4.3 Activating control motor using adapter cable Note To allow for inserting a link in shaft -D- of the control motor ♦ -A-, the shaft must be set to a specific position. If shaft -D- is in a different position than the one shown in the illustration, the control motor can be activated to move the shaft to the appro‐...
  • Page 15 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 3.4.4 Locally manufacturing an adapter cable to activate control motors Procedure – Connect a wire with a cross section of 0.25 mm to each of contacts “5” and “6” of connector -A- ( flat contact housing with contact locking mechanism - 6Q0 972 706- ) ⇒...

  • Page 16: Technical Data

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Technical data ⇒ “4.1 Refrigerant capacity”, page 12 ⇒ “4.2 Refrigerant oil capacities”, page 12 ⇒ “4.3 Oil distribution”, page 13 Refrigerant capacity ⇒ “4.1.1 Capacities for refrigerant R134a, up to WEEK 44/2011”, page 12 ⇒...

  • Page 17: Oil Distribution

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Model Total capacity VCS17E; Valeo 120 ml ± 15 ml 1) This volume of refrigerant oil is contained in a replacement air conditioner com‐ pressor and corresponds to the total capacity.

  • Page 18: Heating

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 80 – Heating Heating Note At the moment, the only heating system available for the Pas‐ ♦ sat is a heating system integrated in the air conditioning sys‐...

  • Page 19: Air Conditioning System

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 87 – Air conditioning system Overview of fitting locations - air con‐ ditioning system ⇒ “1.1 Overview of fitting locations - components located in front section of passenger compartment”, page 15 Overview of fitting locations - compo‐...
  • Page 20 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 ❑ Removing and installing ⇒ page 53 7 - Footwell vent on front passenger side ❑ Removing and installing ⇒ page 100 8 - Footwell trim panel, front passenger side 9 - Fresh air blower - V2- ❑...
  • Page 21 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 1.1.2 Overview of fitting locations - components inside of front passenger com‐ partment, Climatronic 1 - Dash panel ❑ Removing and installing ⇒ General body repairs, interior;...
  • Page 22 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 14 - Rear right rear footwell air ducts ❑ Removing and installing ⇒ page 102 15 - Rear vent ❑ Removing and installing ⇒ page 98 16 - Rear air duct for rear vent ❑...
  • Page 23 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 32 - Air distribution housing ❑ Dismantling and assembling ⇒ page 81 33 - Air inlet 34 - Fresh air/air recirculation, air flow flap actuator ❑ Removing and installing ⇒...

  • Page 24: Refrigerant Circuit

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Refrigerant circuit ⇒ “2.1 System overview - refrigerant circuit”, page 20 ⇒ “2.2 Assembly overview - condenser”, page 22 ⇒ “2.3 Removing and installing high-pressure sender G65 ”, page ⇒...
  • Page 25 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 9 - Receiver with dryer cartridge Note Under certain conditions, it is no ♦ longer necessary to renew the dryer cartridge each time the re‐ frigerant circuit is opened.

  • Page 26: Assembly Overview - Condenser

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Assembly overview - condenser 1 - Bolts ❑ Secure condenser to ra‐ diator ❑ 5 Nm 2 - Condenser with receiver ❑ 2 versions 3 - Radiator/cooler ❑...
  • Page 27 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 ♦ Torque wrench - V.A.G 1331- 2. Refrigerant circuit...

  • Page 28: Removing And Installing Expansion Valve

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Removing – Disconnect connector from high-pressure sender -1-. Note For reasons of clarity, right headlight is removed. CAUTION Risk of freezing injury caused by escaping pressurised refrig‐...
  • Page 29 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 ♦ Torque wrench - V.A.G 1331/- ♦ Set of plugs for engine - VAS 6122- ♦ Air conditioner service station Removing Observe notes ⇒ page 5 Applies only to vehicles with a heat shield in front of the expansion valve.

  • Page 30: Removing And Installing Condenser

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Carefully pull off expansion valve -4-. Installing – Install expansion valve in reverse order of removal, noting the following: ♦ Always renew O-rings of high-pressure refrigerant lines-3 and 5-.
  • Page 31 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 All vehicles CAUTION Risk of freezing injury caused by escaping pressurised refrig‐ erant. There is a risk of injury to the skin and parts of the body due to freezing.

  • Page 32: Removing And Installing Desiccant Bag Or Cartridge

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Remove condenser -2- upwards. Note Note installation pattern of retaining clips for stone impact protection grille. – Release fasteners -6- and remove stone impact protection grille -5-, where fitted.
  • Page 33 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Note Under certain conditions, it is not necessary to renew the re‐ ♦ ceiver with dryer/dryer cartridge every time the refrigerant circuit is opened. Refer to ELSA under ⇒ Air conditioning sys‐...
  • Page 34 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Install in reverse order of removal. During this procedure, observe the following: – First tighten bolts -4- (4.2 Nm ± 0.7 Nm) and then clip on re‐...
  • Page 35 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Remove radiator grille ⇒ General body repairs, exterior; Rep. gr. 66 ; Radiator grille/front trim; Removing and installing ra‐ diator grille . – Unscrew securing bolt -2- and remove retaining clip.
  • Page 36 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 ♦ Torque wrench - V.A.G 1331/- ♦ Air conditioner service station Without illustration ♦ Circlip pliers (commercially available) Note Under certain conditions, it is no longer necessary to renew ♦...
  • Page 37 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 CAUTION Risk of freezing injury caused by escaping pressurised refrig‐ erant. There is a risk of injury to the skin and parts of the body due to freezing.

  • Page 38: Removing And Installing Evacuating And Charging Valves On Low And High-Pressure Side

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Using long-nose pliers, pull out desiccant cartridge -1- in di‐ rection of arrow. Installing – Install dryer cartridge in reverse order of removal, noting the...
  • Page 39 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 ♦ Adapter set for service connections - T10364- ♦ Air conditioner service station Version 1 Removing – Extract refrigerant with air conditioning service station . – Unscrew protective caps -3-.
  • Page 40 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Removing CAUTION Risk of freezing injury caused by escaping pressurised refrig‐ erant. There is a risk of injury to the skin and parts of the body due to freezing.

  • Page 41: Air Conditioner Compressor

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Air conditioner compressor ⇒ “3.1 Assembly overview - pulley”, page 37 ⇒ “3.2 Removing air conditioning compressor from and installing on bracket”, page 38 ⇒ “3.3 Removing and installing air conditioner compressor”, page ⇒...

  • Page 42: Removing Air Conditioning Compressor From And Installing On Bracket

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 1 - Cover 2 - Retaining ring ❑ Remove carefully using a small screwdriver or long nose pliers (be es‐ pecially careful with the poly V-belt pulley)
  • Page 43 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 ♦ Torque wrench - V.A.G 1331- Removing – Remove noise insulation under engine ⇒ General body re‐ pairs, exterior; Rep. gr. 66 ; Noise insulation; Assembly over‐...

  • Page 44: Removing And Installing Air Conditioner Compressor

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Insert dowel sleeves -1- into air conditioner compressor. Note Ensure that dowel sleeves are properly seated and that contact surfaces are clean. Improperly fitted dowel sleeves or dirty or damaged contact surfaces can cause deviations in alignment of air conditioner compressor and engine.
  • Page 45 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Removing Observe notes ⇒ page 5 – Remove noise insulation under engine ⇒ General body re‐ pairs, exterior; Rep. gr. 66 ; Noise insulation; Assembly over‐...
  • Page 46 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Seal refrigerant lines immediately using suitable means. – Unscrew hexagon bolts (25 Nm) -5-. – Remove air conditioner compressor -4- downwards. Installing – If air conditioner compressor has been renewed, check poly- V belt for damage and renew as needed ⇒...

  • Page 47: Checking High-Pressure Safety Valve On Air Conditioner Compressor

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Checking high-pressure safety valve on air conditioner compressor Check ♦ Function: protects refrigerant circuit against excessive pres‐ sures. CAUTION Risk of freezing injury caused by refrigerant. The high-pressure safety valve releases refrigerant when the engine is running and the pressure in the refrigerant circuit is too high.

  • Page 48: Removing And Installing Pulley

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Removing and installing pulley ⇒ “3.5.1 Removing and installing pulley, Denso”, page 44 3.5.1 Removing and installing pulley, Denso Note This type of poly V-belt pulley is installed on “7SEU17C” air ♦...
  • Page 49 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 1 - Cap with circlip ❑ Remove carefully using a small screwdriver or long nose pliers (be es‐ pecially careful with the poly V-belt pulley) 2 - Drive plate 3 - Retaining ring ❑...
  • Page 50 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Remove circlip -A-. – Pull off poly V-belt pulley -B-. Installing – Renew circlip -A-. – Clean air conditioner compressor flange before fitting poly V- belt pulley –...

  • Page 51: Control Motors

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Control motors ⇒ “4.1 Overview of fitting locations - front control motors”, page 47 ⇒ “4.2 Removing and installing temperature flap control motor V68 ”, page 49 ⇒...
  • Page 52 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 1 - Temperature flap control motor - V68- ❑ With potentiometer for temperature flap control motor - G92- ❑ Removing and installing ⇒ page 49 2 - Air distribution flap control motor - V428- ❑...

  • Page 53: Removing And Installing Temperature Flap Control Motor V68

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 4.1.2 Overview of fitting locations - front control motors, Climatronic Note View -A- shows the arrangement of the control motors on the left side of the heater and air conditioning unit.
  • Page 54 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Special tools and workshop equipment required ♦ Vehicle diagnostic tester Note As of week 45/2013, control motors have been changed grad‐ ♦ ually. Comply with the notes ⇒...

  • Page 55: Removing And Installing Defroster Flap Control Motor V107

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Disconnect connector from temperature flap control motor - V68- -1-. – Remove bolts -arrows- (1.5 Nm). – Release control motor lever from connecting rod. – Remove temperature flap control motor - V68- . Pull heat ex‐...
  • Page 56 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Removing – Remove dash panel ⇒ General body repairs, interior; Rep. gr. 70 ; Dash panel; Removing and installing dash panel . – Remove footwell vent on driver side ⇒...

  • Page 57: Removing And Installing Air Recirculation Flap Control Motor V113

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Removing and installing air recirculation flap control motor - V113- ⇒ “4.4.1 Removing and installing air recirculation flap control mo‐ tor V113 , vehicles with air flow flap control motor V71 ”, page 53 ⇒...
  • Page 58 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Release catches -B- and -C- for retainer -A- on intake duct, and detach retainer -A-. – Disconnect connector from control motor -B-. – Remove air recirculation flap control motor - V113- -B- in di‐...
  • Page 59 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Switch on ignition. – Wait until gear -A- of control motor has reached stop -B- “fresh air mode”. – Switch off ignition. – Reach into intake opening for recirculated air mode and move fresh air / air recirculation flap -A- to “fresh air mode”...
  • Page 60 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Route wiring harness so that it cannot come into contact with any moving parts (e.g. actuating arm on control motor). – Install retainer -A-, paying particular attention to ensure that...
  • Page 61 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Unscrew bolts -B-. – Detach control motor -A- from mounting -D-. – Detach pin -E- of control motor from mounting of cam plate -F-. – Mark connector -C- (to prevent interchanging if several con‐...

  • Page 62: Removing And Installing Left Temperature Flap Control Motor V158

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Lever link (here pin -E-) out of control motor to be renewed (or select one link from set of links), and install link on new control motor ⇒...
  • Page 63 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Note As of week 45/2013, control motors have been changed grad‐ ♦ ually. Comply with the notes ⇒ “3.4 Notes on control motors”, page 6 , and refer to the ⇒...

  • Page 64: Removing And Installing Right Temperature Flap Control Motor V159

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Release control motor lever from connecting rod. – Remove left temperature flap actuator - V158- -C-, pull heat exchanger cover forwards slightly when doing this.
  • Page 65 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Note ♦ As of week 45/2013, control motors have been changed grad‐ ually. Comply with the notes ⇒ “3.4 Notes on control motors”, page 6 , and refer to the ⇒...

  • Page 66: Removing And Installing Indirect Ventilation Flap Control Motor V213

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Remove bolts -arrows- (1.5 Nm). – Take right temperature flap control motor - V159- -1- off heater and air conditioning unit; detach strut while doing this.

  • Page 67: Removing And Installing Fresh Air/Recirculated Air, Air Flow Flap Control Motor V425

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Separate connector on indirect ventilation flap control motor - V213- . – Remove bolts -1- (3.5 Nm). – Remove defrost intermediate piece -3- and intermediate piece for indirect ventilation mode -2- from heater and air condition‐...
  • Page 68 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Note As of week 45/2013, control motors have been changed grad‐ ♦ ually. Comply with the notes ⇒ “3.4 Notes on control motors”, page 6 , and refer to the ⇒...

  • Page 69: Removing And Installing Front Air Distribution Flap Control Motor V426

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 The fresh air/air recirculation, air flow flap control motor - V425- fits on the cam plate in one position only. Note After installation, check operation of air flow flap and air recir‐...

  • Page 70: Removing And Installing Air Distribution Flap Control Motor V428

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Loosen bolts -2- (1.5 Nm) and remove front air distribution flap control motor - V426- -B- from heater and air conditioning unit. Installing – Observe notes ⇒...

  • Page 71: Removing And Installing Fresh Air/Air Recirculation, Air Flow Flap Actuator

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 4.11 Removing and installing fresh air/air re‐ circulation, air flow flap actuator Special tools and workshop equipment required ♦ Vehicle diagnostic tester First carry out the following work: –...

  • Page 72: Front Heater And Air Conditioning Unit

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Front heater and air conditioning unit ⇒ “5.1 Assembly overview - heater and air conditioning unit”, page ⇒ “5.2 Removing and installing evaporator”, page 73 ⇒ “5.3 Dismantling and assembling evaporator housing”, page 73 ⇒...
  • Page 73 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 1 - Temperature flap control motor - V68- ❑ With potentiometer for temperature flap control motor - G92- ❑ Removing and installing ⇒ page 49 2 - Air distribution flap control motor - V428- ❑...
  • Page 74 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 19 - Dust and pollen filter ❑ Removing and installing ⇒ page 85 20 - Evaporator temperature sensor - G308- ❑ Removing and installing ⇒ page 85 21 - Heat exchanger ❑...
  • Page 75 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 1 - Defroster flap control motor - V107- ❑ With potentiometer for defroster flap control motor - G135- ❑ Removing and installing ⇒ page 51 2 - Front air distribution flap control motor - V426- ❑...
  • Page 76 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 16 - Heater and air conditioning unit wiring harness 17 - Evaporator housing - lower part ❑ Dismantling and assembling ⇒ page 73 18 - Fresh air blower - V2- ❑...

  • Page 77: Removing And Installing Evaporator

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Removing and installing evaporator Note The refrigerant must be extracted beforehand, with the air ♦ conditioning service station . Releasing refrigerant into the environment is a punishable of‐...

  • Page 78: Removing And Installing Heater And Air Conditioning Unit

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Disconnect connectors from heater and air conditioning unit. 1 - Evaporator housing - lower part 2 - Evaporator ❑ Check insulation. It must be complete.
  • Page 79 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 ♦ Hose clamps to 25 mm - 3094- ♦ Drip tray for workshop hoist - VAS 6208- ♦ Set of plugs for engine - VAS 6122- ♦...
  • Page 80 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Applies only to vehicles with a heat shield in front of the expansion valve. – Unscrew nut -1- (4.5 Nm) and bolt -4- (2.5 Nm). – Release clips -2-, and remove heat shield -3-.
  • Page 81 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Push a piece of hose -A- and -B- onto both connections to heat exchanger. – Hold a container -C- under hose from lower connection -B-.

  • Page 82: Dismantling And Assembling Heater And Air Conditioning Unit

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Remove module bracket -5-. – Remove bolts (9 Nm) -7- and -8- from bracket for heater and air conditioning unit -6-. – Disconnect all connectors from heater and air conditioning unit -1-.
  • Page 83 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 ♦ Drip tray for workshop hoist - VAS 6208- ♦ Hose clamps to 25 mm - 3094- ♦ Commercially available compressed air pistol ♦ Set of plugs for engine - VAS 6122- ♦...

  • Page 84: Removing And Installing Air Distribution Housing

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Remove heater and air conditioning unit ⇒ page 74 – Remove heat exchanger ⇒ page 89 – Separate evaporator housing from heater and air conditioning unit ⇒...

  • Page 85: Dismantling And Assembling Air Distribution Housing

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Note The refrigerant must be extracted beforehand, with the air ♦ conditioning service station . Releasing refrigerant into the environment is a punishable of‐ ♦ fence.
  • Page 86 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 ♦ Set of plugs for engine - VAS 6122- ♦ Air conditioner service station Note ♦ Evacuate refrigerant circuit using air conditioner service sta‐ tion before opening refrigerant circuit.

  • Page 87: Checking Auxiliary Air Heater Element Z35

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Installing – Install in the reverse order of removal. When doing this, note the following: – Shafts and flaps -arrows- must engage in their respective guides.

  • Page 88: Removing And Installing Auxiliary Air Heater Element Z35

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Removing and installing auxiliary air heater element - Z35- Note Installed only in vehicles with diesel engines without supple‐ ♦ mentary heater. Checking (with vehicle diagnostic tester ): Heating, ventilation, ♦...

  • Page 89: Removing And Installing Evaporator Temperature Sensor G308

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Disconnect connector for auxiliary air heater element - Z35- -1-. CAUTION Risk of burns on metal surfaces of auxiliary air heater element. The heater elements may become very hot.

  • Page 90: Removing And Installing Fresh Air Blower Series Resistor With Overheating Fuse N24

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Removing – Remove plastic bolts -2- and remove footwell trim panel -1- on front passenger side. – Release cover -3- in direction of -arrow-. – Remove dust and pollen filter from heater unit downwards.

  • Page 91: Removing And Installing Fresh Air Blower V2

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Pull connector -1- off fresh air blower series resistor with over‐ heating fuse - N24- . – Press locking device in -direction of arrow- and pull fresh air blower series resistor with overheating fuse - N24- out of heat‐...
  • Page 92 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Disconnect connector -2- from fresh air blower - V2- -1-. – Release catch -arrow A- and turn fresh air blower - V2- -1- in -direction of arrow-.

  • Page 93: Removing And Installing Fresh Air Blower Control Unit J126

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Remove fresh air blower - V2- -1- from heater unit. Installing NOTICE Improper handling may damage the fresh air blower. Imbalance leading to customer complaints may occur during operation.
  • Page 94 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 ♦ Hose clamps to 25 mm - 3094- ♦ Set of plugs for engine - VAS 6122- ♦ Drip tray for workshop hoist - VAS 6208- ♦...
  • Page 95 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Clamp off coolant hoses -1- using hose clamps up to 25 mm - 3094- and disconnect coolant hoses to heat exchanger. – Push a piece of hose -A- and -B- onto both connections to heat exchanger.
  • Page 96 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Open hose clips -A- (2 Nm), and pull coolant pipes out of heat exchanger. – Remove heat exchanger from heater unit. Installing Installation is carried out in the reverse order. When installing, note the following: –...

  • Page 97: Removing And Installing Condensation Drain

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – During assembly, hose clips -A- must turn easily on coolant pipes. – Hose clips -A- must be secured as shown in the diagram. – Tighten hose clips -A- to 2.0 Nm.

  • Page 98: Checking Condensation Drain

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Pull condensate drain hose -1- off heater and air conditioning unit and body. Installing – Install condensate drain hose -1- in reverse order of removal, noting the following: ♦...

  • Page 99: Air Duct

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Air duct ⇒ “6.1 Assembly overview - air duct and air distribution in pas‐ senger compartment”, page 95 ⇒ “6.2 Removing and installing centre vent”, page 96 ⇒...

  • Page 100: Removing And Installing Centre Vent

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 1 - Side air duct and left side vent ❑ To remove, dash panel must be removed 2 - Footwell vent on driver side ❑ Removing and installing ⇒...

  • Page 101: Removing And Installing Driver Or Front Passenger Side Air Vents

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 ♦ Removal wedge - 3409- Removing – Unclip centre vent -1- from dash panel starting at bottom -arrows A- then at top -arrows B- using wedge - 3409- .

  • Page 102: Removing And Installing Rear Vents

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Note Removal of the right side is described. Removal of the left side is similar. Removing – Remove side trim ⇒ General body repairs, interior; Rep. gr.

  • Page 103: Removing And Installing Driver Side Footwell Vents

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Guide vents into tabs of trim -arrows-. – Lightly tighten bolts -1-. – Check function of controls -1-. If OK: – Tighten bolts -1- to 1.5 Nm.

  • Page 104: Removing And Installing Front Passenger Side Footwell Vents

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 ♦ Removal wedge - 3409- Removing – Remove driver side footwell trim ⇒ General body repairs, in‐ terior; Rep. gr. 68 ; Compartments/covers; Overview of fitting locations - compartments/covers .

  • Page 105: Removing And Installing Left Or Right Side Window Vents

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Removing – Remove plastic bolts -2- and remove footwell trim panel -1- on front passenger side. – Remove glove compartment ⇒ General body repair, interior; Rep. gr. 68 ; Compartments/covers .

  • Page 106: Removing And Installing Rear Footwell Vent

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Installing – Install A-pillar trim ⇒ General body repairs, interior; Rep. gr. 70 ; Trims, interior; Removing and installing A-pillar trim . Removing and installing rear footwell...

  • Page 107: Removing And Installing Rear Centre Console Vent Duct

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Installing – Fit air ducts (angled at approx. 45°) on heater and air condi‐ tioning unit, then guide towards floor. – Clip air ducts onto floor.

  • Page 108: Removing And Installing Rear Footwell Vent

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Pull front air duct for rear vent off rear air duct for rear vent. Installing – Install front air duct for rear vent in reverse order of removal.

  • Page 109: Removing And Installing Glove Box Cooling

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Remove cover -1-. – Remove air quality sensor - G238- (where fitted) ⇒ page 124 – Unscrew securing nuts -3- and remove inlet duct -2- upwards.

  • Page 110: Removing And Installing Forced Ventilation For Passenger Compartment

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 ♦ Removal wedge - 3409- Note The stale air escapes via ventilation outlets in the luggage ♦ compartment trim. If the ventilation is to work properly, the vent openings must ♦...
  • Page 111 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Removing – Remove rear bumper ⇒ General body repairs, exterior; Rep. gr. 63 ; Rear bumper; Removing and installing rear bumper . – Unclip ventilation outlet -1- from side panel using removal wedge - 3409- .

  • Page 112: Operating And Display Unit

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Operating and display unit ⇒ “7.1 Overview of operating and display unit”, page 108 ⇒ “7.2 Removing and installing operating and display unit”, page Overview of operating and display unit ⇒...
  • Page 113 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 button ❑ If button is deacti‐ vated, air conditioner compressor will be set to almost zero delivery. 2 - Heated rear window button ❑ Depending on ambient temperature, rear win‐...
  • Page 114 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 7.1.2 Overview of control and display unit, air conditioning system with electric/man‐ ual controls, up to week 21/2012 Note A warning lamp in the instrument panel controls will indicate ♦...

  • Page 115: Overview Of Control And Display Unit, Air Conditioning System With Electric And Manual Controls, As Of Week 22/2012

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 9 - Rotary knob for setting temperature ❑ Anticlockwise: lowers temperature ❑ Clockwise: increases temperature 10 - Heated driver seat regulator - E94- (optional) ❑ The seat heater has 3 heat settings. Current setting is shown by LED.

  • Page 116: Overview Of Operating And Display Unit, Climatronic Up To Week 44/2011

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 button ❑ If the button is de‐ activated, the air condi‐ tioner compressor will be set to almost zero de‐ livery. 2 - Heated rear window button ❑...
  • Page 117 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 1 - Max. defrost function button ❑ Depressing this button causes the control unit to select settings to clear the windscreen as quickly as possible. function button AUTO ❑...
  • Page 118 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Blower speed on operating and ♦ display unit for Climatronic air conditioning system - E87- is switched off. Operating and display unit for ♦ Climatronic air conditioning sys‐...

  • Page 119: Overview Of Operating And Display Unit, Climatronic Up To Week 21/2012

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 7.1.5 Overview of operating and display unit, Climatronic up to week 21/2012 1 - Left temperature indicator ❑ Indicates temperature setting on driver side. 2 - Left seat heating button ❑...
  • Page 120 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 ❑ If the button is deactivated, the air conditioner compressor will be set to almost zero delivery. If the button is activated, heating and ventilation mode will continue to be controlled electronically.

  • Page 121: Overview Of Operating And Display Unit, Climatronic From Week 22/2012

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 7.1.6 Overview of operating and display unit, Climatronic from week 22/2012 1 - Left temperature indicator ❑ Indicates temperature setting on driver side. 2 - Left seat heating button ❑...

  • Page 122: Removing And Installing Operating And Display Unit

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 ❑ If the button is deactivated, the air conditioner compressor will be set to almost zero delivery. If the button is activated, heating and ventilation mode will continue to be controlled electronically.
  • Page 123 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 ♦ Removal wedge - 3409- Removing – Remove radio trim ⇒ General body repairs, interior; Rep. gr. 70 ; Dash panel; Removing and installing mounting frame for radio/navigation system .
  • Page 124 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 ♦ Removal wedge - 3409- Note The Climatronic control unit - J255- and the operating and dis‐ ♦ play unit for Climatronic air conditioning system - E87- are a single component which cannot be dismantled.
  • Page 125 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 – Remove bolts -arrows- (1.5 Nm) from operating and display unit for front air conditioning system - E87- -1-. – Disconnect connectors on operating and display unit for front air conditioning system - E87- -1-.

  • Page 126: Other Controlling And Regulating Components

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Other controlling and regulating com‐ ponents ⇒ “8.1 Removing and installing sunlight penetration photosensor G107 ”, page 122 ⇒ “8.2 Principle of operation of air quality sensor G238 ”, page 122 ⇒...
  • Page 127 Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Climatronic control unit actuates the air conditioning system de‐ pending on the degree, type and concentration of pollutant. The air quality sensor - G238- requires approx. 30 seconds to become operational once the ignition has been switched on.

  • Page 128: Removing And Installing Air Quality Sensor G238

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Note The air quality sensor - G238- is a highly sensitive electronic component which could be destroyed by direct contact with sol‐ vents, fuels and certain chemical compounds. Never install sen‐...

  • Page 129: Removing And Installing Left Vent Temperature Sender G150

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Removing – Unhook retaining lug -arrow A- from retainer. – Pull ambient temperature sensor - G17- -1- out of retainer downwards in -direction of arrow-. – Pull ambient temperature sensor - G17- out forwards through centre air intake grille.

  • Page 130: Removing And Installing Left Footwell Vent Temperature Sender G261

    Passat 2011 ➤ , Passat Variant 2011 ➤ Heating, air conditioner - Edition 06.2017 Removing and installing left footwell vent temperature sender - G261- Special tools and workshop equipment required ♦ Vehicle diagnostic tester Removing – Remove footwell vent on driver side ⇒...

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