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Home >> Volkswagen >> 2005 >> Passat Wagon 4Motion (3B6) L4-1.8L Turbo (AWM) >> Repair and Diagnosis >> Heating and Air Conditioning >> Service and Repair >> Climatronic Components In Passenger Compartment, Servicing

Climatronic Components In Passenger Compartment, Servicing



Climatronic Components In Passenger Compartment, Servicing







CAUTION: Before beginning repairs on the electrical system:
- Obtain the anti-theft radio security code.
- Switch off all electrical consumers.
- Switch ignition off and remove ignition key.
- Disconnect negative (-) battery terminal.
- When disconnecting and reconnecting battery terminals, observe all applicable Notes and torque specifications, as well as instructions on performing OBD program and electrical system function checks.

NOTE:
- System components identified with * must only be serviced or replaced after discharging refrigerant system. Use Kent Moore ACR4 or equivalent.
- System components identified with ** must only be serviced or replaced after disconnecting vehicle battery.

1. Clip
- Lift out with screwdriver
2. Dust and pollen filter
- Vehicles from 10.00, replacing.
3. Air intake housing
4. Sunlight photo sensor -G107-
- Function: Controls temperature flap and fresh air blower speed depending on light intensity
- In event of failure: Climatronic control module -J255- assumes fixed value
- Checking, use VAS 5051/5052 in mode "Guided Fault Finding".
5. Defroster air outlet
- Removing and installing:
6. Side window air outlet
7. Instrument panel interior temperature sensor -G56- with interior temperature sensor fan -V42-
- Climatronic control module -J255-, A/C control head -E87- and instrument panel interior temperature sensor -G56- with interior temperature sensor blower -V42- are integrated into a single unit and cannot be serviced separately.
- Function: Temperature sensor controls temperature flap and fresh air blower speed dependant on temperature measurement of interior air.
- In event of -G56- malfunction, operation continues using assumed value of 24 degrees C (75 degrees F)
- Checking, use VAS 5051/5052 in mode "Guided Fault Finding".
- Replacing and adjusting: Code Climatronic control module, function 07 and then set Basic Setting, function 04 using VAS 5051/5052 in mode "Guided Fault Finding".
8. A/C control head -E87-
- Climatronic control module -J255-, A/C control head -E87- and instrument panel interior temperature sensor -G56- with interior temperature sensor blower -V42- are integrated into a single unit and cannot be serviced separately.
- Functions
- Checking, use VAS 5051/5052 in mode "Guided Fault Finding".
9. Air outlets
- Center and side air outlets, removing (early prod.) , see Fig.2
- Center air outlet, removing (later prod.) removing, see Fig. 3
- Side air outlets, removing (later prod.), see Fig. 4
10. Inst. panel cross member**
- Always follow installation instructions for bolt, see Fig. 7
11. Defroster duct**
- Replacing:
- Remove instrument panel
- Loosen cross member -10-.
- Always follow installation instructions for bolt, see Fig. 7
12. Evaporator water drain guide
13. Fresh air intake duct temperature sensor -G89-
- Function: Temperature sensor controls temperature flap and fresh air blower speed dependant on temperature measurement of intake air.
- Sensor -G17- value is used if -G89- malfunctions.
- Checking, use VAS 5051/5052 in mode "Guided Fault Finding".
- Replacing:

- Remove glove box
- Reach behind heat/A/C unit from below.
- Turn sensor 90 degrees and pull out.
- Lubricate seal -15- with oil when installing.

NOTE: If unable to access and remove sensor as described above, proceed as follows:

- Remove instrument panel
- Loosen cross member -10-.
- Always follow installation instructions for bolt , see Fig. 7

14. Evaporator vent temperature sensor -G263-
- Vehicles from 10.00 only
- Checking, use VAS 5051/5052 in mode "Guided Fault Finding".
- Replacing

- Remove glove box
- Reach behind heating and A/C unit from below.
- Turn sensor 90 degrees and pull out.
- Lubricate seal -15- with oil when installing.

15. Gasket
- Lubricate with oil when installing.

CAUTION: Area around dust and pollen filter and air intake housing must be free from debris, leaves etc. before reaching into housing. Debris entering heating and A/C unit will block evaporator water drain and cause subsequent (water) damage.

16. Air flow flap motor -V71-**
- Also operates fresh and recirculating air flap
- Checking or use VAS 5051/5052 in mode "Guided Fault Finding".
- Replacing and adjusting:
- Initiate Basic Setting, function 04 using VAS 5051/5052 in mode "Guided Fault Finding".
17. Fresh air blower -V2-
- Checking, use VAS 5051/5052 in mode "Guided Fault Finding".
18. Control module for fresh air blower -J126-
- Function: Controls fresh air blower speed with variable voltage signal.
- Checking, use VAS 5051/5052 in mode "Guided Fault Finding".
19. Air outlet for glove box
- Removing and installing, see Fig. 2
20. Temperature regulator flap motor -V68- **
- Checking, use VAS 5051/5052 in mode "Guided Fault Finding".
- Replacing and adjusting:
- Initiate Basic Setting, function 04 using VAS 5051/5052 in mode "Guided Fault Finding".
21. Central air flap motor -V70-
- Checking, use VAS 5051/5052 in mode "Guided Fault Finding".
- Removing, installing and adjusting
- Replacing and adjusting:
- Initiate Basic Setting, function 04 using VAS 5051/5052 in mode "Guided Fault Finding".

NOTE: A modified flap (with cut-out at top) was introduced 11.98. This design allows air flow to footwell to be blocked.

22. Climatronic control module -J255-
- Climatronic control module -J255-, A/C control head -E87- and instrument panel interior temperature sensor -G56- with interior temperature sensor blower -V42- are integrated into a single unit and cannot be serviced separately.
- Checking, use VAS 5051/5052 in mode "Guided Fault Finding".
23. Climatronic Control Module - A/C Control Head trim
24. Center trim
25. Sender for outlet temperature, center -G191-
- Function: Controls center air distribution and fresh air blower speed, dependent on air outlet temperature measurement.
- Checking, use VAS 5051/5052 in mode "Guided Fault Finding".
26. Center air outlet duct **
27. Heating and A/C unit *, **
Contains:
- Heater core
- Evaporator
- Removing/assembly.
28. Sender for outlet temperature, floor outlet -6192-
- Function: Controls air distribution to defrost/footwell and fresh air blower speed dependant on outlet temperature measurement.
- In event of malfunction, operation continues using assumed value of 80 degrees C (176 degrees F)
- Checking, use VAS 5051/5052 in mode "Guided Fault Finding".
- Removing and installing, see Fig. 1.
29. Footwell/defroster flap motor -V85- **
- Checking, use VAS 5051/5052 in mode "Guided Fault Finding".
- Replacing and adjusting:
- Initiate Basic Setting, function 04 using VAS 5051/5052 in mode "Guided Fault Finding".
30. Heater core *, **
- Removing and installing, heating and A/C unit assembly.
- Always use new coolant after replacement
31. Left rear duct
- Right is mirror image
32. Lower duct
33. Upper duct
34. Footwell air outlet **
- Replacing:
- Remove instrument panel
- Remove instrument panel cross member -10-
- Always follow installation instructions for bolt, see Fig. 7
- Remove upper duct.
- Carefully lift heating and A/C unit.
- Remove footwell air outlet.
35. Instrument panel cross member left side support securing bolt
- Always follow installation instructions for bolt, see Fig. 7
36. Relay

First Speed Coolant Fan Control (FC) relay -J279-
- Vehicles from 10.00: Control number 373

Second Speed Coolant Fan Control (FC) Relay -J280-
- Vehicles from 10.00: Control number 370

Coolant Fan Afterrun Relay -J397-
- TDI - PD only (where applicable)
- Control number 373

Component locations.

37. A/C clutch relay -J44-
- For A/C Clutch -N25-
- Not for W8 engine
- Control number 267
Component locations.
38. Instrument panel **
- Removing and installing:







Fig. 1 Sender for outlet temperature, floor outlet -G192-, removing and installing

Removing
- Remove driver side shelf
- Disconnect electrical connector from sender -G192-
- Rotate sender -2-, 90 degrees -arrow- and remove from housing -1-.

Installing
- Lubricate rubber seal on footwell sender -G192- with oil when installing.







Fig. 2 Air outlet for glovebox, removing and installing

Removing
- Remove glove box
- Remove securing screw -5-.
- Pull air outlet -4- out from guides on heating and A/C unit -2-
- Pull off hose -1-

Installing
- Replace seal -3- if damaged.
When installing, ensure that locking lugs engage in guides on heating and A/C unit -arrows-.







Fig. 3 Sender for outlet temperature, center-G191-, removing and installing

Removing
- Remove radio
- Remove Climatronic control module -J255-
- Remove center trim
- Disconnect electrical connector -2- from sender -G191-
- Rotate sender -1-, 90 degrees -arrow A- and remove from housing -3-.

Installing
- Install in reverse order of removal, being sure to coat seal lightly with oil.







Fig. 4 Sunlight photo sensor -G107-, removing
- Carefully lift sender -1- at side with small screwdriver.
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