Volkswagen Passat B6 2005 - (B6) : Manual A/C System - Climatic

Volkswagen Passat B6 2005 - >
(B6)
Manual A/C system - Climatic

Heating and A/C system - interior, component overview
Note :
Disconnect battery before removing components

marked with **
Repair Manual, Electrical Equipment,

Repair Group 27,
A data plate indicates the refrigerant used and

capacity.
Instrument panel **
Center Outlet Temperature

Sensor G191
Removing and installing

87-2, Center Outlet
Temperature Sensor G191 ,
removing and installing
Center vents

80-1, Center vents, removing
and installing
Right side vent
Controls for heating and A/C

system, Climatic
With Fresh Air/Recirculating

Flap Switch E159
Also with Immediate Heating

Button E537 in vehicles with
auxiliary heater
With Rear Window Defogger

Switch E230
With Fresh Air Blower Switch

E9
Also with Drivers Heated Seat

Adjuster E94 and Front
Passengers Heated Seat
Adjuster E95 in vehicles with
auxiliary heater
With A/C Control Module

J301

87-2, Heating and A/C system
controls - Climatic, removing
and installing
Fresh/Recirculating Air Door

Motor V154
Checking: Vehicle Diagnosis,

Testing Info. System
. 2 17
VAS5051B

80-1, Fresh/Recirculating Air
Door Motor V154 , removing
and installing
Replacing: Initiate Basic

Setting using Vehicle
Diagnosis, Testing Info.
System VAS5051B 87-3,
Components, checking and
adjusting .
Right footwell vent
Fresh Air Blower V2

87-3, Evaporator Vent
removing
Heating unit partition

80-1, Fresh Air Blower Series
Resistor With Fuse N24 ,
Evaporator Vent Temperature

Sensor G263

80-1, Fresh Air Blower V2 ,
removing
Fresh Air Blower Series Resistor

With Fuse N24

80-1, Right footwell vent,
Removing 80-1, Removing

heating unit partition
Dust and pollen filter
With activated charcoal filter
. 3 17

80-1, Dust and pollen filter
element, removing and
installing
Connection
For rear vent air duct
To remove, center console

must be removed
Repair Manual, Body Interior, Repair

Group 68,
Rear vent air duct
Rear vent

80-1, Rear footwell channel,
Rear channel for left footwell

80-1, Rear vents, removing
and installing
Rear channel for right footwell

80-1, Air duct for rear vents,

Mounting bolt
8x
Adapter for controls
Auxiliary Air Heater Heating
. 4 17
Element Z35
Left footwell vent

80-1, Heater core, removing
and installing
Footwell Outlet Temperature

Sensor G192

80-1, Left footwell vent,
Heater core
Not applicable to US/CDN

87-2, Footwell Outlet
Temperature Regulator Flap

Motor V68

VAS5051B

87-2, Temperature Regulator
Flap Motor V68 , removing
and installing

adjusting .
Flexible shaft

80-1, Flexible shaft for air
distribution, removing and
installing
. 5 17
. 6 17
Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru

Volkswagen, Skoda, Seat, Audi
Heating and A/C unit

87-3, Heating and A/C unit,
Disassembling and
assembling 87-2, Heating
and A/C unit - Climatic,
assembly
Heating and A/C unit - Climatic, assembly
Temperature Regulator Flap

Motor V68

87-2, Temperature Regulator
Flap Motor V68 , removing
and installing
Bracket
Bolts
Bolts must be unscrewed to

separate air distributor and
evaporator housing.
Cover
Fresh/Recirculating Air Door

Motor V154
Housing for air entry
Disassembling and
assembling evaporator
housing 87-3, Evaporator
housing, assembly
Evaporator
Disassembling and
housing, assembly
Lower section of evaporator

housing
With recirculating air flap
Upper section of evaporator

housing

80-1, Fresh/Recirculating Air
Door Motor V154 , removing
and installing

87-5, Evaporator, removing
and installing

Sensor G263

. 7 17

removing
Connection for glove

compartment cooling
Cooling hose for glove

compartment cooling
Fresh Air Blower Series Resistor

With Fuse N24
Fresh Air Blower V2

80-1, Fresh Air Blower V2 ,
removing

installing
Cover

80-1, Fresh Air Blower Series
Resistor With Fuse N24 ,
For dust and pollen filter
Heater core

and installing
Heater core trim

Element Z35
Distribution housing
. 8 17
Heating and A/C system controls - Climatic, removing

and installing
Removing
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 center instrument panel trim
Repair Manual, Body Interior, Repair Group 68,

.
- Unscrew bolts - 2 - (4.2 x 45) and - 3 - (4.2 x 16) and

remove controls - 1 - from center console.
. 9 17
- Disengage harness connector release catch - A - by

pulling in direction or arrow - 1 - .
- Disengage harness connector release catch - B - to
connector - arrow 2 - and disconnect connector - C - .
- Disengage harness connector release catch - D - and
disconnect connector - D - .
Installing
Installation is performed in reverse order of removal, make
sure when doing so that the rotary buttons have the same
position as when removing.
Heating and A/C system controls - Climatic, electrical
connections
Special tools, testers and auxiliary items required
Test Box 105 Pin VAG1598/42
Test Adapter VAG1598/47
Template V.A.G 1598/47-2
. 10 17
Heating and A/C system controls - Climatic, multi-pin connector

assignments
20-pin harness connector, T20b

3 - Center Outlet Temperature Sensor G191
5 - High Pressure Sensor G65
7 - CAN Low
8 - CAN-High
12 - Right seat heater (optional)
13 - Left seat heater (optional)
15 - Terminal 75 seat heater (optional)
16 - A/C Compressor Regulator Valve N280
18 - Center Outlet Temperature Sensor G191
19 - Terminal 30A
20 - Terminal 31
16-pin harness connector, T16j

1 - Temperature Regulator Flap Motor V68 , warm
2 - Evaporator Vent Temperature Sensor G263
4 - Footwell Outlet Temperature Sensor G192
. 11 17
5 - Left Temperature Flap Potentiometer/Actuator G220

7 - + 5 V for Left Temperature Flap Potentiometer/Actuator
G220
8 - Ground (GND) for Footwell Outlet Temperature Sensor
G192 , Left Temperature Flap Potentiometer/Actuator
G220 and Evaporator Vent Temperature Sensor G263
9 - Fresh/Recirculating Air Door Motor V154 , open
10 - Fresh/Recirculating Air Door Motor V154 , close
11 - Temperature Regulator Flap Motor V68 , cold
5-pin harness connector, T5r

1 - 3rd blower speed
2 - 2nd blower speed
3 - 1st blower speed
4 - 4th blower speed
5 - Terminal X
Flexible shaft, removing and installing
Removing
- Remove glove compartment

.
- Bring flexible shaft into the following position:
. 12 17
- Rotate rotary switch for air distribution - 1 - long enough

until locking mechanism of shaft - 2 - is visible in step-up
gearing - 3 - .
- Remove controls for heating and A/C system, Climatic
87-2, Heating and A/C system controls - Climatic, removing
and installing .
- Reach into center console and release retaining tab - 1 by pressing - in direction of arrow - .
- Pull flexible shaft out of adapter - 2 - .
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 87-2, Flexible shaft, checking .
Flexible shaft, checking
Flexible shaft for adjusting unit of air distribution flaps:

- 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.
. 13 17
. 14 17
Place controls for heating and A/C system, Climatic onto

adapter and rotate rotary knob for air distribution 1 / 2
rotation (180
test.
). Then reconnect flexible shaft. Repeat
Condensation water hose on heating and A/C unit,

checking
- Remove heating unit partition

unit partition
80-1, Removing heating
Note:
The condensation water hose - 1 - must be able to be

connected to connection of heating and A/C unit
without pre-tension.
Condensation water hose must sit securely on

connection for condensation water hose on heating
and A/C unit.
Temperature Regulator Flap Motor V68 , removing and

installing
Removing
- Remove instrument cluster

.
- Remove left footwell vent
removing and installing .
- Remove bolts - 1 - and - 3 - .

- Remove bracket - 2 - .
- Mark connector - C - to actuator motor (danger of

interchange with other connectors of same construction).
- Disconnect harness connector - C - from Temperature
Regulator Flap Motor V68 .
- Remove cover - A - .
- Unscrew securing bolts - D - and remove Temperature
Regulator Flap Motor V68 - B - .
- Disengage actuator motor lever - E - from connecting rod
-F-.
Installing
Installation is performed in the reverse order of removal,
noting the following:
- Install the wiring harness so that it cannot come in contact
with any moving parts (e.g. the actuating arm of the
actuator motor).
Note:
After installing Temperature Regulator Flap Motor
. 15 17
V68 , recirculating air door must be checked for

function.
- Checking: Vehicle Diagnosis, Testing Info. System
VAS5051B .
- Replacing: Initiate Basic Setting using Vehicle Diagnosis,
Testing Info. System VAS5051B 87-3, Components,
checking and adjusting .
Fresh/Recirculating Air Door Motor V154 , removing and
installing
Removing
- Remove Fresh/Recirculating Air Door Motor V154 801, Fresh/Recirculating Air Door Motor V154 , removing and
installing .
Center Outlet Temperature Sensor G191 , removing and
installing
Removing
Repair Manual, Electrical Equipment, Repair Group 90,

.
- Disconnect connector - 2 - at Center Outlet Temperature

Sensor G191 - 1 - .
- Rotate Center Outlet Temperature Sensor G191 - 1 - 90
and remove from instrument panel.
Installing
Installation is performed in the reverse order of removal.
. 16 17
. 17 17
Footwell Outlet Temperature Sensor G192 , removing and

installing
Removing
- Disconnect connector at Footwell Outlet Temperature

Sensor G192 - 1 - .
- Rotate Footwell Outlet Temperature Sensor G192 90
and remove from housing.
Installing
Automatic climate control system - Climatronic
. 1 47
87 - 3

Note:
Pressing the button AUTO will reverse all settings

which deviate from the automatic operation.
Deviations from automatic operation

operating instructions.
In "ECON" operation, the A/C compressor is set to

almost zero delivery. The heating and ventilation
operation continues to be controlled electronically.
Auxiliary heater (optional) is also switched off.
respective
Components, checking and adjusting
In Vehicle Diagnosis, Testing Info. System VAS5051B ,

select "Guided Fault Finding" .
After all control modules have been checked:
- Press "Go to" button
- Select "Function/component selection"
- Select "Body"
- "Heating, ventilation, air conditioning (Repair Group 01;
80 87)"
- Select "01 - On Board Diagnostic (OBD) capable
systems"
- Select "Climatronic"
- Select "Functions" :
- "Basic setting"
- "Code control module for Climatronic"
- "Check coolant output"
- "Read measuring value block"
A/C Control Head E87 , function
Display of selected interior

temperature, left side
Button for air recirculation
Press button for recirculating

air function to prevent polluted
air from entering interior.
Push button - center air

distribution
Push button - lower air

distribution
Push button - upper air

distribution
Display of selected interior

temperature, right side
Push button for defrosting
. 2 47
windshield
Push button for rear window

defroster
Rotary button for interior

temperature, left side
Blower regulator
Rotate to change blower

speeds.
Interior temperature sensor
Push button for A/C system off
Push button AUTO
Push button ECON
By pressing the AUTO

button, Climatronic maintains
the selected vehicle interior
temperature completely
automatically. With this
setting the vent air
temperature, the blower
speed and the air distribution
are controlled automatically.
By pressing the ECON

button, A/C compressor is set
to almost zero delivery. The
heating and ventilation
operation continues to be
controlled electronically.
Auxiliary heater (optional) is
also switched off.
Rotary button for interior

temperature, right side
A/C Control Head E87 with Climatronic Control Module

J255 , removing and installing
Note:
The Climatronic Control Module J255 and the A/C

Control Head E87 are one component that cannot be
disassembled.
. 3 47
Removing
- Remove center instrument panel trim

.
- Unscrew bolts - 2 - and remove A/C Control Head E87

with Climatronic Control Module J255 - 1 - from instrument
panel.
- Disconnect harness connectors from A/C Control Head
E87 .
Installing
Climatronic Control Module J255 , electrical connections
Climatronic Control Module J255 , electrical connections A, B C
multi-pin connector assignments
Test Box 105 Pin VAG1598/42
. 4 47
. 5 47

Test Adapter VAG1598/47
Template V.A.G 1598/47-2
20-pin harness connector, connector housing - A - , in

wiring diagram T20c
1 - Sunlight PhotoSensor 2 G134 or Sunlight Photo Sensor
G107 , signal
2 - High Pressure Sensor G65
3 - Sunlight PhotoSensor 2 G134 or Sunlight Photo Sensor
G107 , signal
5 - CAN-High
6 - CAN Low
7 - Indirect Ventilation Flap Motor V213
8 - Indirect Ventilation Flap Motor V213
9 - + 5V for Sunlight PhotoSensor 2 G134 or Sunlight
Photo Sensor G107
10 - Drivers Heated Seat Adjuster E94 (optional)
11 - Front Passengers Heated Seat Adjuster E95 (optional)
12 - Terminal 75 (optional)
13 - Left Vent Temperature Sensor G150
14 - Right Vent Temperature Sensor G151
15 - Indirect Ventilation Flap Motor Position Sensor G330
16 - Terminal 30a/ without auxiliary heater terminal 15
17 - Signal Ground (GND) for Sunlight Photo Sensor
G107 , Sunlight PhotoSensor 2 G134 , Left Vent
Temperature Sensor G150 , Right Vent Temperature
Sensor G151 and Indirect Ventilation Flap Motor V213
18 - A/C Compressor Regulator Valve N280

19 - Terminal 31
20 - Terminal 30a/ without auxiliary heater terminal 15
16-pin harness connector, connector housing - B - , in

wiring diagram T16i
1 - + 5V for actuator motors
2 - Left Temperature Flap Potentiometer/Actuator G220
3 - Right Temperature Flap Potentiometer/Actuator G221
4 - Defroster Flap Motor Position Sensor G135
5 - Central Flap Motor Position Sensor G112
6 - Recirculation Flap Motor Position Sensor G143
7 - Back Pressure Flap Motor Position Sensor G113
8 - Left Footwell Vent Temperature Sensor G261
9 - Right Footwell Vent Temperature Sensor G262
11 - Evaporator Vent Temperature Sensor G263
14 - Signal Ground (GND) potentiometer
16-pin harness connector, connector housing - C - , in

wiring diagram T16h
1 - Left Temperature Flap Motor V158 , cold
. 6 47
2 - Left Temperature Flap Motor V158 , warm

3 - Defroster Flap Motor V107 , closed
4 - Defroster Flap Motor V107 , open
5 - Central Air Flap Motor V70 , upper body vent
6 - Central Air Flap Motor V70 , footwell
7 - Recirculation Flap Motor V113
8 - Recirculation Flap Motor V113
9 - Air Flow Flap Motor V71 , open
10 - Air Flow Flap Motor V71 , close
11 - Right Temperature Flap Motor V159 , cold
12 - Right Temperature Flap Motor V159 , warm
15 - Fresh Air Blower Control Module J126
16 - Fresh Air Blower Control Module J126 , signal
Climatronic system - interior, component overview
Note:
Disconnect battery before removing components

marked with **

.
A data plate indicates the refrigerant used and

capacity.
. 7 47
Instrument panel **

Group 70,
Sunlight Photo Sensor G107 or

Sunlight PhotoSensor 2 G134

VAS5051B
Function: controls
temperature flap and fresh air
blow depending on light
intensity
Emergency running during
. 8 47
failure: Climatronic Control

Module J255 utilizes a fixed
value

87-3, Sunlight Photo Sensor
G107 or Sunlight
PhotoSensor 2 G134 ,
removing
Left Vent Temperature Sensor

G150

VAS5051B
Removing 87-3, Left Vent

removing
Vent for indirect ventilation
Center vents
Right Vent Temperature Sensor

G151

VAS5051B

87-3, Right Vent Temperature
Sensor G151 , removing
Air vent

80-1, Center vents, removing
and installing

80-1, Driver or front
passenger side vent,
removing
A/C Control Head E87 with

Climatronic Control Module J255
The Climatronic Control
. 9 47
Module J255 and the A/C

Control Head E87 are one
component that cannot be
disassembled.

VAS5051B

87-3, A/C Control Head E87
with Climatronic Control
Module J255 , removing and
installing

adjusting .
Air Flow Flap Motor V71

VAS5051B

87-3, Air Flow Flap Motor V71
with Back Pressure Flap
Motor Position Sensor G113 ,

adjusting .
Recirculation Flap Motor V113

VAS5051B

87-3, Recirculation Flap Motor
V113 , removing and installing

. 10 47

adjusting .
Right footwell vent

Fresh Air Blower V2 with Fresh

Air Blower Control Module J126
Note :
Fresh Air Blower Control Module J126 and Fresh Air

Blower V2 are located in one housing and therefore
cannot be replaced individually.

VAS5051B
Removing 87-3, Fresh Air

Blower V2 with Fresh Air
Blower Control Module J126 ,
removing
Harness connector

Sensor G263

VAS5051B

removing
Heating unit partition
Removing 80-1, Removing

heating unit partition
. 11 47

installing
Connection
For rear vent air duct
To remove, center console

must be removed

Group 68,
Rear vent air duct
Rear vent

Rear channel for left footwell

80-1, Rear vents, removing
and installing
Rear channel for right footwell

80-1, Air duct for rear vents,

Right Temperature Flap Motor

V159

VAS5051B
. 12 47
87-3, Right Temperature Flap

Motor V159 , removing and
installing
Right Footwell Vent Temperature

Sensor G262

VAS5051B
Removing 87-3, Right

Footwell Vent Temperature

Element Z35

Heater core
Left footwell vent

adjusting .

and installing
Left Footwell Vent Temperature

Sensor G261

VAS5051B
Removing 87-3, Left

Footwell Vent Temperature
. 13 47
Defroster Flap Motor V107

VAS5051B

87-3, Defroster Flap Motor

adjusting .
Left Temperature Flap Motor

V158

VAS5051B

87-3, Left Temperature Flap
installing

adjusting .
Central Air Flap Motor V70

VAS5051B

87-3, Central Air Flap Motor

adjusting .
. 14 47

87-3, Heating and A/C unit,
Disassembling and
assembling 87-3, Heating
and A/C unit, assembly
Indirect Ventilation Flap Motor

V213

VAS5051B
Removing 87-3, Indirect

Ventilation Flap Motor V213 ,

adjusting .
Heating and A/C unit, removing and installing
Refrigerant recycling/recovery unit Kent-Moore ACR4

(or UL approved equivalent)
A/C service station VAS 6007A illustrated for

reference only
. 15 47
Drip Tray For VAS6100 VAS6208
Hose Clamps, Up to 40 mm. 3093
Compressed air gun, standard
Removing
Note:
To improve accessibility, additional components e.g.

engine cover must be removed (depending on engine
version)
Repair Manual, 2.0 Liter 4-Cyl. 4V Turbo Engine

Mechanical, Fuel Injection Ignition, Engine Code(s): BPY,
Repair Group 10,
.
- Extract refrigerant e.g. using Refrigerant
. 16 47
. 17 47
recycling/recovery unit Kent-Moore ACR4 (or UL approved

equivalent), only then open the refrigerant circuit. Observe
notes 87-5, A/C refrigerant system, servicing .

.
- Remove rear channels for right and left footwells
Rear footwell channel, removing and installing .
80-1,
- Place Drip Tray For VAS6100 VAS6208 under the engine.
- Mark coolant hoses - 1 - to prevent interchanging the

coolant hoses.
Warning!
There is a danger of scalding.
Coolant temperature can be above 100 C with a warm
engine. Cooling system is under pressure.
If necessary, reduce pressure and temperature before
repairs.
- Clamp off coolant hoses - 1 - using Hose Clamps, Up to
40 mm. 3093 and disconnect coolant hoses to heater core.
- Connect a section of hose - A - onto upper connection.

- Hold a container - B - under the lower connection - C - .
- Using a compressed air gun, carefully blow residual
coolant out of heater core at heater core connection.
Warning!
There is a danger of ice-up.
Refrigerant may leak out if refrigerant circuit is not
discharged.
Refrigerant must be extracted before opening
refrigerant circuit.
- From the engine compartment, unscrew bolts - 1 - for
refrigerant lines - 2 - .
- Disconnect refrigerant lines from expansion valve - 3 - .

Note:
Seal all open connections.
To seal off all open connections on expansion valve,

sealing caps from a replacement expansion valve can
be used (preventing dirt and moisture from entering
. 18 47
the system).
- Cover floor carpet in vehicle interior with leak-proof foil
and absorbent paper.
Note :
Take note during removal of the length and

assignment of bolts for reinstallation
Bolt
4 Nm
Bolts
2x
4 Nm
. 19 47
Cable bracket

Removing:
- Disconnect condensation
water hose from heating
and A/C unit
87-3,
Condensation water hose
at hHeating and A/C unit condensation water hose,
checking .
- Disconnect harness
connectors from heating
and A/C unit.
Note :
All cable ties opened or cut during removal must be

reinstalled at the same locations during installation.
- Remove bolts Item - 9 from bracket Item - 5 - .

- Remove supports Item
- 7 - and Item - 8 - .
- Unscrew bolts Item 10 - and Item - 12 - and
remove bracket
Item 11 - .
- Remove bolts Item - 1 and Item - 2 - from cable
bracket Item - 3 - .
Note :
To be able to reach the bolt Item - 1 - , heating and

A/C unit on driver side must be pulled out slightly
from facing wall.
When removing heating and A/C unit, make sure the

two coolant pipes of the heater core do not get
caught and bent or damaged on plenum chamber or
sound insulation pan.
Also pay attention to wiring harness, individual wiring

connections may get damaged when pulling too
. 20 47
forcefully on wiring harness.

- Remove heating and A/C
unit.
Installing:
Installation is performed in the
reverse order of removal, noting
the following:
Note :
The assistance of a second mechanic is necessary to

install the heating and A/C unit.
- When inserting heating

and A/C unit, have the
second mechanic guide
both coolant pipes to
heater core through the
seal (from engine
compartment)
87-3, Seal
for heating and A/C unit /
engine compartment .
- Fill with coolant
Repair Manual, 2.0 Liter 4-Cyl. 4V

Turbo Engine Mechanical, Fuel Injection
Ignition, Engine Code(s): BPY, Repair
Group 19,
Bracket
Assembly carrier
Right support
Left support
Bolts
Bolts
2x
1.3 Nm
. 21 47
Bracket
Bolts
2x
1.3 Nm
1.3 Nm
Seal for heating and A/C unit / engine compartment
Note:
Note installation position of seal - A - during

assembly.
Heating and A/C unit, assembly
. 22 47
. 23 47

Central Air Flap Motor V70
Left Temperature Flap Motor

V158

87-3, Central Air Flap Motor

87-3, Left Temperature Flap
installing
Defroster Flap Motor V107

87-3, Defroster Flap Motor
Indirect Ventilation Flap Motor

V213

87-3, Indirect Ventilation Flap
installing
Intermediate piece for indirect

ventilation
Bracket
Bolts
Bolts must be unscrewed to

separate air distributor and
evaporator housing.
Cover
Recirculation Flap Motor V113
Air Flow Flap Motor V71

87-3, Recirculation Flap Motor

87-3, Air Flow Flap Motor V71
with Back Pressure Flap
Motor Position Sensor G113 ,
Housing for air entry
With fresh/recirculating air

door
With air flow flap (Climatronic)

housing
Disassembling and
housing, assembly
. 24 47
Evaporator

housing

and installing
Disassembling and
housing, assembly

Sensor G263

removing
Connection for glove

compartment cooling
Fresh Air Blower V2 with Fresh

Air Blower Control Module J126
Cannot be replaced
individually
The Fresh Air Blower Control

Module J126 and the Fresh
Air Blower V2 are combined
into one assembly.
Removing 87-3, Fresh Air

Blower V2 with Fresh Air
Blower Control Module J126 ,
removing

installing
. 25 47
Cover
For dust and pollen filter
Cooling hose for glove

compartment cooling
Heater core

and installing
Heater core trim

Element Z35
Right Temperature Flap Motor

V159

87-3, Right Temperature Flap
installing
Distribution housing
Evaporator housing, assembly
- Separate evaporator housing from heating and A/C unit

87-3, Heating and A/C unit, assembly .
- Disconnect harness connectors from heating and A/C
unit.
. 26 47

housing
Evaporator
Check insulation, it must be

completely present

and installing
Clip

housing
Bolt
Seal / insulation
Heat insulation for expansion
. 27 47
valve

and installing
Bracket

and installing
Fresh Air Blower V2 with Fresh Air Blower Control

Module J126 , removing
Fresh Air Blower V2 with Fresh Air Blower Control Module

J126 is accessible from footwell on front passenger side.
Note:
Fresh Air Blower Control Module J126 and Fresh Air

Blower V2 are located in one housing and therefore
cannot be replaced individually.

unit partition
- Disconnect harness connector from Fresh Air Blower V2

with Fresh Air Blower Control Module J126 - 1 - .
- Release locking mechanism - 2 - and rotate Fresh Air
Blower V2 with Fresh Air Blower Control Module J126 - in
direction of arrow - and remove.
Outside Air Temperature Sensor G17 removing and
installing
Removing
. 28 47
- Remove noise insulation
Repair Manual, Body Exterior, Repair Group 50,

.
- Unclip Outside Air Temperature Sensor G17 - 1 - and

disconnect harness connector.
Installing
Sunlight Photo Sensor G107 or Sunlight PhotoSensor 2
G134 , removing
Removing
Trim Removal Wedge 3409
. 29 47
- Using adhesive tape, mark dimensions "a and b" on

instrument panel.
a = 115 mm
b = 15 mm
Caution!
Panel for indirect ventilation could be damaged.
Panel is secured by a bolt under Sunlight Photo
Sensor G107 .
Lift panel max. 15 mm.
- Unclip panel at markings on right and left sides from
instrument panel using Trim Removal Wedge 3409 .
- Guide a screwdriver - 3 - with a long blade in direction of

Sunlight Photo Sensor G107 - 2 - .
- Use e.g. a wooden block - 1 - as a support underneath.
- Press screwdriver - in direction of arrow - and unclip
Sunlight Photo Sensor G107 .
- Disconnect harness connector from Sunlight Photo
Sensor G107 .
. 30 47
Installing
- Connect connector to Sunlight Photo Sensor G107 and
engage it in instrument panel.
Left Vent Temperature Sensor G150 , removing

.
- Disconnect connector - 2 - at Left Vent Temperature

Sensor G150 .
- Rotate Left Vent Temperature Sensor G150 - 1 - 90
and remove from instrument panel.
Right Vent Temperature Sensor G151 , removing

.
. 31 47
- Disconnect connector - 1 - from Right Vent Temperature

Sensor G151 .
- Rotate Right Vent Temperature Sensor G151 - 2 - 90
and remove from air channel.
Left Footwell Vent Temperature Sensor G261 , removing

- Disconnect connector - 1 - from Left Footwell Vent

Temperature Sensor G261 .
- Rotate Left Footwell Vent Temperature Sensor G261 - 2 90 in direction of arrow and remove from housing.
Right Footwell Vent Temperature Sensor G262 , removing
- Remove right footwell vent

. 32 47
- Disconnect connector - 1 - at Right Footwell Vent

Temperature Sensor G262 .
- Rotate Right Footwell Vent Temperature Sensor G262 - 2
- 90 in direction of arrow and remove from housing.
Evaporator Vent Temperature Sensor G263 , removing

unit partition
- Disconnect connector - 2 - at Evaporator Vent

Temperature Sensor G263 - 1 - .
- Rotate Evaporator Vent Temperature Sensor G263 - 1 90 in direction of arrow and remove from housing.
Condensation water hose at hHeating and A/C unit condensation water hose, checking

unit partition
Note:
. 33 47
The condensation water hose - 1 - must be able to be

connected to connection of heating and A/C unit
without pre-tension.
Condensation water hose must sit securely on

connection for condensation water hose on heating
and A/C unit.
Actuator motors for A/C system regulation - actuator

motors, replacing
Vehicle Diagnosis, Testing Info. System VAS5051B
First perform the following work:

- Switch off all electrical consumers.
- Switch ignition off.
- Remove ignition key.
Central Air Flap Motor V70 , removing and installing
Removing
. 34 47

.
- Disconnect harness connector from Central Air Flap
Motor V70 .
- Unscrew securing bolts - 1 - and remove Central Air Flap

Motor V70 .
Installing
Note:
After installing Central Air Flap Motor V70 , central

flap must be checked for function.
Initiate "Basic Setting" function using Vehicle

Diagnosis, Testing Info. System VAS5051B 87-3,
Components, checking and adjusting .
Air Flow Flap Motor V71 with Back Pressure Flap Motor Position
Sensor G113 , removing and installing
Note:
Air Flow Flap Motor V71 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.
. 35 47
Position of fresh/recirculating air door must not be

changed.
Removing
- If necessary, switch ignition on, select operating mode
"Defrost" on A/C Control Head E87 (actuator motor is
always set to "fresh air mode" position in this operating
mode) and wait until actuator motor has reached its "fresh
air mode" end position.
- Disengage catches - D - and - E - for bracket - A - on

intake housing and remove bracket - A - .
- Remove Recirculation Flap Motor V113
87-3,
Recirculation Flap Motor V113 , removing and installing .
- Mark connector to Recirculation Flap Motor V113 (to rule
out an interchange with connector to Air Flow Flap Motor
V71 ).
. 36 47
- Remove actuator motor - A - from intake housing.

Note:
Connection between actuator motor toothed gears

and air flow flap is designed so that actuator motor
can be removed without difficulty only in the "fresh air
mode" position.
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 - B - , ensure that toothed gear - C is not damaged when doing this.
Installing
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 motor to vehicle wiring harness.

- Switch ignition on.
- Wait until toothed gear - A - of motor reaches stop - B "fresh air mode" .
. 37 47
- Before installing actuator motor, check bearing of air flow

flap in intake housing and of toothed gear - C - (air flow flap
is opened, "fresh air mode" ).
- Connect Air Flow Flap Motor V71 to vehicle wiring
harness (make sure connectors are allocated correctly).
- Reach into intake opening for recirculating air mode and

bring fresh/recirculating air door - A - into "fresh air mode"
position (intake opening for recirculating air mode is
closed).
- Insert motor - B - into mounts - C - in opposite direction of

arrow and onto toothed gear - D - .
Note:
. 38 47
So that toothed gear on motor - A - can be slid on

toothed gear of air flow flap, short tooth - C - of motor
toothed gear must align with short tooth interval - D of toothed gear on shaft of air flow flap - B - .
- After assembling actuator motor, press toothed gear - 1 again on to shaft of air flow flap.
- Install Recirculation Flap Motor V113
87-3,
Recirculation Flap Motor V113 , removing and installing .
actuator motor).
. 39 47
- Install bracket - A - , take special care when doing this,

that bracket guide - B - is inserted correctly into intake
housing mount - C - and bracket is engaged correctly in
both catches - D - and - E - .
Note:
Position of Air Flow Flap Motor V71 and of

Recirculation Flap Motor V113 (and corresponding
flaps) is no longer visible with glove compartment
installed, therefore it is advisable to check its function
before installing glove compartment.
When both toothed gears (on Air Flow Flap Motor

V71 and air flow flap) are assembled in incorrect
position, it can be detected as the air flow flap does
not reach its two end positions or motor does not run
cleanly and without hitching.
- Install all removed components in reverse order.

Note:
After installing Air Flow Flap Motor V71 , air flow flap
must be checked for function.
- Checking: Vehicle Diagnosis, Testing Info. System

VAS5051B .
- Replacing: Initiate Basic Setting using Vehicle Diagnosis,
Testing Info. System VAS5051B 87-3, Components,
checking and adjusting .
Defroster Flap Motor V107 , removing and installing
Removing

.
. 40 47


- Disconnect harness connector - C - at Defroster Flap
Motor V107 .
- Unscrew securing bolts - A - and remove Defroster Flap
Motor V107 - B - .
-D-.
Installing
Note:
After installing, function of defroster flap must be

checked.

. 41 47
Recirculation Flap Motor V113 , removing and installing
Removing

.
- Mark connector - A - if necessary (to rule out an

interchange in the event several connectors are
disconnected at the same time).
- Disconnect connector - A - .
- Disengage catches - C - and - D - for bracket - B - on

intake housing and remove bracket - B - (toward rear).
- Remove actuator motor - A - from intake housing.
Installing
. 42 47
- Check shaft of recirculation flap - C - before installing

actuator motor - A - .
- Set shaft - C - so that connecting element of actuator
motor - D - can be inserted.
- Insert actuator motor with connecting element - D - into
shaft - C - and mounts at intake housing - B - .
- Install bracket - A - , take special care when doing this,

that bracket guide - B - is inserted correctly into intake
housing mount - C - and bracket is engaged correctly in
both catches - D - and - E - .
- Install all removed components in reverse order.
Note:
After installing, function of recirculation flap must be

checked.

Left Temperature Flap Motor V158 , removing and installing
Removing
. 43 47

.


- Disconnect harness connector - C - at Left Temperature
Flap Motor V158 .
- Remove cover for heater core - A - .
- Unscrew securing bolts - D - and remove Left
Temperature Flap Motor V158 - B - .
-F-.
Installing
. 44 47

actuator motor).
Note:
After installing Left Temperature Flap Motor V158 ,

temperature flap must be checked for function.

Right Temperature Flap Motor V159 , removing and installing
Removing

.
- Remove right footwell vent
- Disconnect harness connector from Right Temperature

Flap Motor V159 .
- Unscrew securing bolts - 1 - and remove Right

Temperature Flap Motor V159 .
- Unhook brace - 2 - from Right Temperature Flap Motor
V159 .
. 45 47
Installing
Note:
After installing Right Temperature Flap Motor V159 ,

temperature flap must be checked for function.

Indirect Ventilation Flap Motor V213 , removing and installing
Removing

.
- Disconnect harness connector from Indirect Ventilation

Flap Motor V213 - 3 - .
- Remove bolts - 1 - .
- Disconnect Indirect Ventilation Flap Motor V213 - 3 - from
intermediate piece for indirect ventilation flap - 2 - .
Installing
Note:
After installing Indirect Ventilation Flap Motor V213 , it

must be checked for function.
. 46 47

. 47 47
A/C compressor bracket
. 1 10
87 - 4

A/C compressor bracket - 4-cylinder engine, removing
and installing
Torque Wrench 5-50Nm VAG1331
Note :
The auxiliary component bracket for A/C compressor

and ancillary parts can be removed and installed
without opening the refrigerant circuit.
To remove the ribbed belt:

Group 13,
. 2 10

Cylinder collar bolt M1045
Alignment bore
2.0L Turbo FSI-engine: 40

Nm

Nm

Nm
Nm
A/C compressor
Hex bolts M8100
3x
25 Nm
Alignment bore

Nm

87-5, A/C compressor,

Nm
Dowel sleeves
2x
Ensure proper seating

between auxiliary component
bracket and A/C compressor
Auxiliary component bracket for

A/C compressor
No. on auxiliary component
bracket 06F 903 143 E/F
Removing
- Remove generator
Repair Manual, Electrical Equipment,

Repair Group 27,
- Loosen A/C compressor,
unscrew hex-bolts - 6 - .
. 3 10
Remove A/C compressor

from auxiliary component
bracket and secure to body
with appropriate material
(e.g. welding wire) 87-4,
Securing A/C compressor
to body
- Unscrew bolts - 1 - to - 4 and - 7 - and - 8 - and
remove auxiliary
component bracket - 10 from cylinder block.
Installing
Always observe tightening torque of mounting

bolts:
- Tighten cylinder collar

bolt, items - 1 - (alignment
bore), - 7 - (alignment
bore) , - 4 - , - 8 - , - 3 - and
- 2 - in succession.
Securing A/C compressor to body
If A/C compressor is removed and refrigerant circuit not

opened, A/C compressor must be secured to body using
appropriate material, a welding wire for example.
Make sure that coolant hoses remain on A/C compressor
without tension for this.
Note:
. 4 10
When installing the belt ensure it is correctly seated

in the ribbed belt pulley.
Last, install ribbed belt over ribbed belt pulley of A/C

compressor.
Ribbed belt pulley, removing and installing

Ribbed belt pulley - Zexel, removing and installing
A/C compressor
Zexel
Clean flange before sliding

ribbed belt pulley on
Ribbed belt pulley
. 5 10
. 6 10
Removing
Topic 87-4
To loosen and tighten bolt,

hold ribbed belt pulley firmly
in place using a standard
band wrench (with webbing).
Circlip
Replace
Install on proper side, beveled

insertion edge faces away
from compressor (install flat
side facing compressor)
Overload safeguard
Bolted to ribbed belt pulley
Guarantees ribbed belt pulley

will continue to turn if A/C
compressor locks up
To loosen and tighten bolts,

Hex bolt
Replace
To loosen and tighten bolt,

Before screwing in, clean off

old bolt locking compound
from thread on A/C
compressor shaft.
Insert bolt with locking fluid D

000 600 A2 .
20 Nm
Socket head bolt
3x
5 Nm
Removing ribbed belt pulley

Note:
A/C compressor must not be removed to replace the

ribbed belt pulley.
To loosen and tighten bolts, hold ribbed belt pulley

firmly in place using a standard band wrench (with
webbing).
- Remove ribbed belt
Repair Manual, 2.0 Liter 4-Cyl. 4V Turbo Engine

Mechanical, Fuel Injection Ignition, Engine Code(s): BPY,
Repair Group 13,
- Remove bolts - arrows - .

- Remove bolt - 1 - .
. 7 10
. 8 10
- Remove circlip - 1 - .
- Remove ribbed belt pulley - 2 - from A/C compressor.
Installing
Before screwing in, clean off old bolt locking

compound from thread on A/C compressor shaft.
Clean A/C compressor flange before sliding ribbed

belt pulley on.
Install circlip on proper side, beveled insertion edge

faces away from compressor (install flat side facing
compressor)
Hex bolt
Item - 5 - must be replaced
Ribbed belt pulley - Sanden, removing and installing
Note :
A/C compressor must not be removed to replace the

ribbed belt pulley.
To loosen and tighten bolts, hold ribbed belt pulley

firmly in place using a standard band wrench (with
webbing).
Removing ribbed belt

Group 13,
Hex nut
Replace
To loosen and tighten hex

nut, hold ribbed belt pulley
firmly in place using a
standard band wrench (with
webbing).
Insert hex nut with locking

fluid D 000 600 A2 .
25 Nm
Bolt
To loosen and tighten hex

nut, hold ribbed belt pulley
firmly in place using a
standard band wrench (with
webbing).
. 9 10
3x
4.5 Nm
Overload safeguard
Bolted to ribbed belt pulley.
Guarantees ribbed belt pulley

will continue to turn if A/C
compressor locks up.
To loosen and tighten bolts,

Washer
Circlip
Replace
Install on proper side, beveled

insertion edge - A - faces
away from A/C compressor
(install flat side facing A/C
compressor)
Ribbed belt pulley
Clean A/C compressor flange

before sliding on pulley.
A/C compressor
Sanden
Clean flange before sliding

ribbed belt pulley on.
. 10 10
A/C refrigerant system, servicing
. 1 21
87 - 5

Information for performing repair work on A/C

refrigerant circuit and on handling refrigerant
Repair Manual, Refrigerant R134a - Servicing, Repair

Group 00,
.
Information on tools for repairing A/C refrigerant

circuit

Group 00,
.
Note:
Refrigerant must be extracted beforehand using e.g.

(or UL approved equivalent). A/C service station VAS
6007A illustrated for reference only.
The previously used service stations can still be used

catalog V.A.G tools.
To prevent the ingress of damp air, all components of
the refrigerant circuit which have been opened must

be sealed with suitable plugs.
The color coding of O-rings for the R134a refrigerant

circuits has been discontinued. Colored and black Orings are used.
Threaded connections of refrigerant circuit must be

coated with polyethylene glycol (PEG) VW material
no. 294440 before installing.
Under certain conditions, the dryer cartridge must no

longer be replaced after each time refrigerant circuit
is opened

Group 00,
replacing components.
A/C refrigerant system components, replacing
Warning!
discharged.
. 2 21
A/C compressor
Manufacturers identification
for Sanden: PXE16
Manufacturers identification
for Zexel: DSC17E
Pay attention to notes for

installing A/C compressor
87-5, A/C Compressor,
installation notes

87-5, A/C compressor,
Condenser

87-5, Condenser, removing
and installing
. 3 21
Fluid reservoir with dryer

cartridge
Note :

is opened
Repair Manual, Refrigerant R134a Servicing, Repair Group 00,

Fluid reservoir with dryer cartridge is installed on right

or left side on condenser, depending on engine
version.

87-5, Fluid reservoir with
dryer cartridge, removing and
installing
High Pressure Sensor G65
Removing
87-5, Removing
Bracket
Evacuating and charging valve
High pressure side
Environmentally hazardous
draining of refrigerant is an
offense punishable by law.
Capacities
87-6, Capacities
Retaining bracket
Evacuating and charging valve
Low pressure side
Environmentally hazardous
draining of refrigerant is an
offense punishable by law.
. 4 21
Function and removal

87-5,
Expansion valve, removal and
function
Hex nut
87-6, Capacities
Expansion valve
Capacities
20 Nm
Bracket
Removing High Pressure Sensor G65
Note:
For better depiction, right headlight is removed.
- Disconnect harness connector from high pressure sensor

-1-.
- Unscrew High Pressure Sensor - 2 - from connection of
refrigerant line.
Note:
Replace O-ring
High Pressure Sensor G65 - 2 - may also be installed

on a different side in the vicinity of the condenser,
depending on the engine version.
. 5 21
Fluid reservoir with dryer cartridge, removing and

installing
Note:

is opened

Group 00,

version.

Not illustrated
Seeger ring pliers (commercially available)
Removing
equivalent), only then open the refrigerant circuit. Observe
notes 87-5, A/C refrigerant system components,
replacing .
- Bring the lock carrier into service position
. 6 21
. 7 21

.
- Unscrew mounting bolts for cooler - arrows - .
- Push cooler in direction of engine until cover bolt - arrow is accessible.

- Unscrew cover bolt 1.2 Nm
0.3 Nm
- Screw in one cylinder bolt (M5) into thread of sealing cap.

Warning!
discharged.
- Press sealing cap downward and remove Seeger ring.
- Using pliers on the cylinder bolt - 2 - , pull out sealing cap

- 1 - straight in direction of arrow.
- Pull out dryer cartridge - 1 - in direction of arrow using

needle-nose pliers.
Installing
Tightening torque of plastic nut on fluid reservoir with dryer
cartridge is 1.2 Nm 0.3 Nm
A/C compressor, removing and installing
. 8 21

Removing
recycling/recovery unit Kent-Moore ACR4
(or UL approved equivalent), only then
open the refrigerant circuit. Observe
notes 87-5, A/C refrigerant system
components, replacing .
- Remove noise insulation beneath
engine
Repair Manual, Body Exterior, Repair

Group 50,
.
- Remove ribbed belt

Group 13,
.
- Disconnect harness connector to A/C
Compressor Regulator Valve N280
- Unscrew bolts (22 Nm 1 Nm) - 1 from A/C compressor and disconnect
refrigerant lines from A/C compressor.
. 9 21
- Unscrew hex bolts - 2 - and remove A/C

compressor.
Installing
Note:
Make sure alignment bushings - 3 - are seated

correctly.
Pay attention to notes for installing A/C compressor

87-5, A/C Compressor, installation notes .
Pressure relief valve on A/C compressor - pressure relief

valve, checking
Function: protects refrigerant circuit against

excessive pressures
. 10 21
Warning!
Pressure relief valve will drain refrigerant when engine
is running and there is excessive pressure in
Turn engine off.
Checking pressure relief valve on A/C compressor (Sanden)
The pressure relief valve - arrow - has triggered

when refrigerant oil is found in the immediate vicinity.
In this case, refer to

Group 00,
.
Warning!
Pressure relief valve will drain refrigerant when engine
is running and there is excessive pressure in
Turn engine off.
. 11 21
Checking pressure relief valve on A/C compressor (Denso)
The pressure relief valve - arrow - has triggered

when refrigerant oil is found in the immediate vicinity.
In this case, refer to

Group 00,
.
Expansion valve, removal and function

Note:
. 12 21
. 13 21


(or UL approved equivalent).


Bolts
10
2x
1 Nm
Refrigerant lines on expansion

valve
O-ring
13.7 mm; 2.5 mm
Expansion valve
Removing:
- Extract refrigerant e.g.

using Refrigerant
recycling/recovery unit
Kent-Moore ACR4 (or UL
approved equivalent).
- Remove bolts Item - 1 and disconnect refrigerant
lines Item - 2 - from
expansion valve.
- Unscrew bolts Item - 8
- and remove expansion
valve.
O-ring
14 mm; 1.82 mm
Coat with refrigerant oil when

installing
O-ring
10.8 mm; 1.82 mm
Coat with refrigerant oil when

installing
O-ring
9.5 mm; 2.5 mm
Cylindrical combination bolt
Function
5 Nm
. 14 21
. 15 21
The expansion valve atomizes the streaming

refrigerant and controls the flow quantity so that the
vapor is gaseous only at the evaporator outlet,
depending on the heat transmission.
Evaporator, removing and installing
- Remove A/C unit

and installing .
87-3, Heating and A/C unit, removing
- Disassemble A/C unit 87-3, Heating and A/C unit,

assembly , vehicles with Climatic 87-2, Heating and A/C
unit - Climatic, assembly .
- Disassemble evaporator housing
housing, assembly .
87-3, Evaporator
- Remove evaporator - A - from lower section of evaporator

housing.
Note:
Before inserting the evaporator, check condensation

water drain and clean drain if necessary.
Before inserting evaporator, clean evaporator

housing and the evaporator if necessary.
- When inserting evaporator - A - into lower section of

evaporator housing and when assembling both housing
halves, make sure the seal - F - is not damaged.
- Check seal - F - (it must be glued all around) before

inserting evaporator.
- Place bracket - C - and seal / insulation - B - onto
connecting pipe of evaporator - D - and - E - .
- Insert evaporator - A - into lower section of evaporator
housing as shown in the illustration.
Note:
After assembling both housing halves, check seal /

insulation -B- for correct seating at pass-through for
both refrigerant lines -D- and -E-.
Check seating of bracket - C - on both refrigerant

lines - D - and - E - for correct seating.
If heat protection insulation - B - is missing or not

installed correctly, it can cause reduced performance
of the A/C system (change of adjusted control
characteristics of expansion valve due to radiant
heat).
Condenser, removing and installing
. 16 21

Note:

(or UL approved equivalent).


First perform the following work:

- Switch off all electrical consumers.
- Remove ignition key.
equivalent).
Note:
Environmentally hazardous draining of refrigerant is

an offense punishable by law.
- Remove bumper
. 17 21
. 18 21

- Bring lock carrier into service position

- Disconnect refrigerant lines from condenser (12
and seal.
Bolt
5 Nm
4x
Air duct
Clipped on to condenser
1 Nm)
Installation position:
Fluid reservoir with dryer

cartridge
Note :

is opened
Repair Manual, Refrigerant R134a Servicing, Repair Group 00,


version.

87-5, Fluid reservoir with
dryer cartridge, removing and
installing
Sealing strip
Adhere upper sealing strips

onto 3rd lamella row from top
of condenser before installing.
Adhere lower sealing strips

onto 3rd lamella row from
bottom of condenser before
installing.
Water cooler
Mount for fan
Bolts
4x
5 Nm
Charge air cooler
. 19 21
Condenser
Secured to water cooler with

4 bolts.
A/C Compressor, installation notes

Installing
- Only start engine after refrigerant circuit has been

assembled.
- After installing a new A/C compressor or fresh refrigerant
oil has been filled into compressor (e.g. after blowing
through the A/C system), turn ribbed belt pulley of A/C
compressor 10 rotations by hand before starting the
engine. This prevents damage to the A/C compressor.
- If possible, only start engine with refrigerant circuit
recharged.
Note:
The A/C compressor is always driven by the ribbed

belt pulley (no A/C clutch):
If an A/C compressor locks-up the overload

safeguard for the A/C compressor shaft is triggered.
An indication that the A/C compressor has locked-up
is deformations/bumps on the ribbed belt pulley, but
these are not always easy to detect. Another indicator
is abraded rubber material in the area of the ribbed
belt pulley.
The A/C compressor is equipped with a protected oil

supply, this prevents A/C compressor damage in the
event that the system is empty. This means that
approx. 40 to 50 cm 3 of refrigerant oil remains in the
A/C compressor.
The engine should only be started when the

refrigerant circuit is completely and properly installed.
For example; if the refrigerant lines are not connected
to A/C compressor, when the engine is running the
A/C compressor may heat up (via internal heat
generation) so much that the A/C compressor will be
damaged.
. 20 21
A/C Compressor Regulator Valve N280 is not

activated when the refrigerant circuit is empty and the
A/C compressor idles with the engine.
If it is necessary to start the engine with a discharged

refrigerant circuit:
Refrigerant circuit must be fully assembled.
At least 1/4 of the prescribed refrigerant oil must be in

the A/C compressor.
Engine speed should not increase above 2500 RPM.
The engine should only run as long as absolutely

necessary.
Note the following when starting engine for first time

after charging refrigerant circuit:
- Start engine with A/C compressor switched off ( "ECON"
mode) and wait until the idling speed stabilizes.
- Open instrument panel vents.
- Select temperature preset "Lo" on A/C Control Head E87 .
- Now switch A/C compressor on ( "Auto" mode) and allow
engine to run for 5 minutes at idling speed.
. 21 21
Capacities
. 1 2
87 - 6
Capacities
Refrigerant R134a
A/C compressor
Manufacturer
Total capacity
PXE16
Sanden
600 + 25 grams
DSC17E
Zexel
600 + 25 grams
Refrigerant oil
The special refrigerant oil (for use with refrigerant circuits

R134a only) is no longer obtainable on the
refrigerant/machine oil market.
Refrigerant oil can be obtained using following part No.; for:
PXE16- Sanden
G 052 154 A2
DSC17E- Zexel
G 052 200 A2
Model
Production
Total capacity 1)
1K0 820 803 G Sanden
As of 12.04
110 cm 3
10 cm 3
1K0 820 803 L Zexel
As of 12.04
120 cm 3
15 cm 3
1) This
quantity of refrigerant oil is in a replacement

compressor and equates to the total capacity.
Important information:
The refrigerant oil is very hygroscopic, therefore opened

containers must be closed immediately after use to stop
ingress of moisture.
Refrigerant oil, because of its chemical properties, must not
be disposed of together with engine oils or transmission
oils.
Oil distribution
The oil, which is located in the sump of the A/C compressor

before initially switching on the air conditioner system, is
distributed through the refrigerant circuit as follows:
A/C compressor approx. 50%
Condenser approx. 10%
Suction hose approx. 10%
Capacities
. 2 2
Evaporator approx. 20%
Fluid reservoir approx. 10%

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Volkswagen Passat B6 2005 - >

Manual A/C system - Climatic

Disconnect battery before removing components

Repair Manual, Electrical Equipment,

A data plate indicates the refrigerant used and

Manual A/C system - Climatic

Center Outlet Temperature

Removing and installing

Removing and installing

Right side vent

Controls for heating and A/C

With Fresh Air/Recirculating

Also with Immediate Heating

With Rear Window Defogger

With Fresh Air Blower Switch

Also with Drivers Heated Seat

With A/C Control Module

Removing and installing

Fresh/Recirculating Air Door

Checking: Vehicle Diagnosis,

Manual A/C system - Climatic

Removing and installing

Replacing: Initiate Basic

Right footwell vent

Fresh Air Blower V2

Removing and installing

Heating unit partition

Removing and installing

Evaporator Vent Temperature

Removing and installing

Fresh Air Blower Series Resistor

Removing and installing

Removing 80-1, Removing

Dust and pollen filter

With activated charcoal filter

Manual A/C system - Climatic

Removing and installing

For rear vent air duct

To remove, center console

Repair Manual, Body Interior, Repair

Rear vent air duct

Removing and installing

Rear channel for left footwell

Removing and installing

Rear channel for right footwell

Removing and installing

Removing and installing

Adapter for controls

Auxiliary Air Heater Heating

Manual A/C system - Climatic

Left footwell vent

Removing and installing

Footwell Outlet Temperature

Removing and installing

Not applicable to US/CDN

Removing and installing

Temperature Regulator Flap

Checking: Vehicle Diagnosis,