Volkswagen Passat 1995 Operating instructions

Heating & Air Conditioning
80 - Heating, Ventilation
Heating and ventilation system
Heating and ventilation system, assembly
Heating and ventilation unit, assembly
Heating and ventilation cables, installing and adjusting
Heating and ventilation controls, assembly
87 - Air conditioning
A/C refrigerant system, notes
Safetymeasures
A/C refrigerant R-134a, properties
Basics when working on A/C refrigerant system R-134a
Manual A/C
Heating and A/C components in passenger compartment, servicing
Heating and A/C cables, installing and adjusting
Heating and A/C components in engine compartment, servicing
Vacuum hose layout
A/C clutch -N25- (Sanden), servicing (compressor removed)
Compressor bracket, removing and installing
4-cyl. gasoline engine
4-cyl. TDI engine
6-cyl. engine
A/C refrigerant system
A/C refrigerant system, identification
A/C refrigerant system, component overview
A/C refrigerant system, servicing
Expansion valve, removing
Condensor, removing
Heating and A/C unit, removing and assembly
A/C refrigerant system, replacing components
A/C refrigerant system pressures and temperatures, checking
A/C refrigerant system, testing with pressure gauges
A/C refrigerant system, discharging
A/C refrigerant system, flushing with compressed air and nitrogen
A/C refrigerant system, evacuating and recharging

A/C refrigerant system, troubleshooting
Compressor noisy
A/C refrigerant system pressures, checking
A/C refrigerant system cooling performance, checking
A/C refrigerant system, checking for leaks
A/C refrigerant system, capacities
Refrigerant R-134a, capacity
Refrigerant (PAG) oil R-134a, capacity
Refrigerant (PAG) oil R-134a, identification
Refrigerant (PAG) oil R-134a, distribution

80-1
Heating and
ventilation system
Heating and ventilation
system, assembly
CAUTION!
Obtain the anti-theft radio
security code.
Switch the ignition off.
Disconnect the battery
Ground(GND) strap.
After reconnecting
battery, re-
code andcheck
operation of anti-theft
radio. Also check
operation of clock and
power windows according
to Repair Manual and/or
Owner's Manual.
1- Plenum chamber cover
2- Dust and pollenfilter
Removing Fig. 5
3- Hex screw with shank
M6x22
5 Nm (44 in lb)
4- Gasket
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80-2
5-
Fresh Air Blower
Series Resistance with
Fuse -N24-
Removing and
installing Fig. 1
6- Fresh air blower -V2-
Removing Fig. 2
7- Footwell outlet
Replacing: Remove
shelf on drivers' and
passenger side, center
console, instrument
panel bracket and
pedal cluster cover -
23 -
8- Airduct
9- Airdistribution duct
Replacing center outlet
-12-
, heating and fresh
air controls -22-,
remove shelf on
passenger side;
Loosen instrument
panel -20- and lift
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80-3
10 -
Right air outlet
Removing Fig. 8
11 - Grille
For right air outlet
12 - Center air outlet
Removing Fig. 7
13 - Control panel trim
14 - Grilles
For center outlet
15 - Instrument panel trim
Removing Fig. 4
16 - Grille
For left air outlet
17 - Left air outlet
Removing Fig. 6
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80-4
Repair Manual, Body
Exterior, Interior, Repair Group
70; Removing and installing
instrument panel
18 - Rear duct
Replacing: Remove
console, instrument
panel bracket, pedal
cluster cover - 23 -,
footwell outlet - 7 -
19 - Rear duct seal
Replacing: Remove
console, instrument
panel bracket, pedal
cluster cover - 23 -,
footwell outlet - 7 -
20 - Instrument panel
Removing and
installing
21 - Left air duct
22 -
Heating and ventilation
controls
Removing and
installing Fig. 3
Assembly Page 80-
21
Installing and adjusting
cables Page 80-15
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80-5
23 -
Pedal cluster cover
24 -
Heating and ventilation
cables
Replacing: First
remove pedal cluster
cover - 23 - and foot
well outlet - 7 -
Removing and
installing Page 80-
15
25 - Intermediate duct
With gasket
Replacing - remove
instrument panel first
26 -
Heating and ventilation
unit
Contains:
Heater core
Temperature flap
Center flap
Footwell/defrost flap
Do not disassemble
further
Assembly Page 80-
12
Removing: Remove
instrument panel
&items -22- to 28-
Fig. 9
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80-6
27 -
Heater core
Replacing Page 80-
12
Always replace coolant
after
removal/replacement.
28 - Airduct with main
shut-off flap
Replacing: Remove
instrument panel and
items -22- to 28-
Fig. 9
Installing: Page 80-
12
29 - Hex nut M6
5 Nm (44 in lb)
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80-7
Removing:
Installing:
Fig. 1
Fresh Air Blower Series Resistance with
Fuse -N24-, removing
-Remove shelf on passenger side
-Pull off connections -2-
-Press retainer -arrow- down and remove series
resistor -1-
-Seal surface between series resistor -1- and air
duct before installing with AMV 176 000 05.
Fig. 2 Fresh Air Blower -V2-, removing
-Shelf on right side, remove
-Move air duct cover to side.
-Push retaining clips down with a screwdriver, turn
fresh air blower clockwise and remove.
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80-8
Removing:
Installing:
Fig. 3 Heating and ventilation controls,
removing and installing
-Heater control trim panel -3-, pull off
-Central outlet -2- Fig. 7 , remove
-Heater controls -1-
with cables attached, pull out of
instrument panel.
-Secure cables to removed controls.
Fig. 4 Instrument panel trim, removing
-Carefully lift and remove adjustable grilles -1- with
long nose pliers.
-Remove trim -2-.
-Remove 4 screws -arrows- and take out
instrument panel trim housing.
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80-9
Fig. 5 Dust and pollenfilter, removing.
1 - Filter element
2 - Filter housing
3 - Gasket
4 - Clip
5 - Clip
-Filter element, remove.
-Press clips -4- and -5- in direction of arrow and
remove filter housing.
Repair Manual, Electrical Equipment, Repair
Group 96
Fig. 6 Left air outlet, removing
-Instrument panel trim Fig. 4 , remove.
-Light switch, remove.
-Bolt -2-, remove.
-Vent housing -1-, remove.
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80-10
Fig. 7 Center air outlet, removing
-Instrument panel trim Fig. 4 , remove.
-Radio, remove.
-Switch, remove.
-Remove control panel trim.
-Control -2-
, remove
-Center console -3-, loosen
-Remove 2 screws -arrows- and take out central
outlet -1-.
Fig. 8 Left air outlet, removing
-Carefully lift and remove adjustable grilles -2- with
long nose pliers
-Remove screw -3- and disengage locating tabs -
arrows-.
-Vent housing -1-, remove
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80-11
Note:
Close evaporator connections to ensure that no
coolant enters passenger compartment when
removing.
Installing:
Fig. 9 Heating and ventilation unit installing
-Pre-assemble hex nuts on engine bulkhead.
-Tighten hex nut with shank, in plenum chamber.
-Tighten engine bulkhead Hex nuts.
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80-12
Heating and ventilation
unit,assembly
Repair Manual, Body-
Interior, Repair Group 70
CAUTION!
The cooling system is
pressurized when the engine
is warm. Wear gloves and
other protection and
carefully release system
pressure if necessary, before
performing repairs.
1- Gasket
Replace
2- Heater core
Always replace coolant
after
removal/replacement
Replacing:
-
Remove instrument
panel.
-
Carefully pinch off
both coolant hoses
to heater core and
disconnect hoses.
-
Seal off heater core
to prevent coolant
from running out.
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80-13
-
Partially remove heating and
ventilation unit.
-Press retainer clips and
remove heater core.
Gaskets must be glued,
free of gaps all around.
If catches do not engage
when installing, then secure
heat exchanger with
screws.
3- Clip
4- Gasket
5- Airduct with main
shut-off flap
Do not disassemble
further
6- Fresh Air Blower
Series Resistance with
Fuse -N24-
7- Fresh air blower -V2-
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80-14
8-
Airduct cover
9- Plug
10 - Cables
11 - Fresh air and heated
air controls
12 - Pedal cluster cover
13 - Footwell outlet
14 - Temperature flap lever
15 - Center flap lever
16 - Airdistribution
housing
Do not disassemble
further
17 - Intermediate piece
18 - Gasket
Always replace
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80-15
Heating and ventilation
cables, installing and
adjusting
Notes:
Attach cables to removed
controls first and then
adjust on heater levers and
secure.
Endsof sleeves on cables,
which are marked with a
stripe of paint, must be
secured to the controls.
Position sleeves of cables -
1-, -2- and -4- at stops on
the controls and then
secure. Secure sleeve for
cable -3- Fig. 5 .
With controls installed,
adjust cables at flap levers.
When turning control knobs
all flaps must be heard to
contact the stops.
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80-16
1-
Main shut-off flap cable
From blower rotary
control to main shut-
off
flap
Black sleeve, white
marking
Adjusting cable at
main shut-off flap
Fig. 1
2- Temperature flap cable
From temperature
rotary control to
temperature flap
Blue sleeve, white
marking
Adjusting cable at
temperature flap
Fig. 2
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