Volkswagen Passat 2011 Instruction manual

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

List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
80 - Heating
87 - Air conditioning system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2017 Volkswagen AG, Wolfsburg D3E803125D2

Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on air conditioning systems . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 1
1.3 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Notes concerning odours in air conditioned vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Notes for vehicles with start-stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Checking cooling output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Working on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Refrigerant circuit seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Notes on control motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 Refrigerant capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 Refrigerant oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.3 Oil distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
80 - Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1 Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
87 - Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1 Overview of fitting locations - air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.1 Overview of fitting locations - components located in front section of passenger
compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 Refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.1 System overview - refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.2 Assembly overview - condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.3 Removing and installing high-pressure sender G65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.4 Removing and installing expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.5 Removing and installing condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.6 Removing and installing desiccant bag or cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.7 Removing and installing evacuating and charging valves on low and high-pressure side
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3 Air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.1 Assembly overview - pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.2 Removing air conditioning compressor from and installing on bracket . . . . . . . . . . . . . . . . 38
3.3 Removing and installing air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.4 Checking high-pressure safety valve on air conditioner compressor . . . . . . . . . . . . . . . . . . 43
3.5 Removing and installing pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4 Control motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.1 Overview of fitting locations - front control motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.2 Removing and installing temperature flap control motor V68 . . . . . . . . . . . . . . . . . . . . . . 49
4.3 Removing and installing defroster flap control motor V107 . . . . . . . . . . . . . . . . . . . . . . . . 51
4.4 Removing and installing air recirculation flap control motor V113 . . . . . . . . . . . . . . . . . . . . 53
4.5 Removing and installing left temperature flap control motor V158 . . . . . . . . . . . . . . . . . . 58
4.6 Removing and installing right temperature flap control motor V159 . . . . . . . . . . . . . . . . . . 60
4.7 Removing and installing indirect ventilation flap control motor V213 . . . . . . . . . . . . . . . . 62
4.8 Removing and installing fresh air/recirculated air, air flow flap control motor V425 . . . . . . 63
4.9 Removing and installing front air distribution flap control motor V426 . . . . . . . . . . . . . . . . 65
4.10 Removing and installing air distribution flap control motor V428 . . . . . . . . . . . . . . . . . . . . 66
4.11 Removing and installing fresh air/air recirculation, air flow flap actuator . . . . . . . . . . . . . . 67
Passat 2011 ➤ , Passat Variant 2011 ➤
Heating, air conditioner - Edition 06.2017
Contents i

5 Front heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.1 Assembly overview - heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.2 Removing and installing evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5.3 Dismantling and assembling evaporator housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5.4 Removing and installing heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.5 Dismantling and assembling heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . 78
5.6 Removing and installing air distribution housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.7 Dismantling and assembling air distribution housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.8 Checking auxiliary air heater element Z35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.9 Removing and installing auxiliary air heater element Z35 . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.10 Removing and installing evaporator temperature sensor G308 . . . . . . . . . . . . . . . . . . . . 85
5.11 Removing and installing dust and pollen filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.12 Removing and installing fresh air blower series resistor with overheating fuse N24 . . . . . . 86
5.13 Removing and installing fresh air blower V2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.14 Removing and installing fresh air blower control unit J126 . . . . . . . . . . . . . . . . . . . . . . . . 89
5.15 Removing and installing heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.16 Removing and installing condensation drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5.17 Checking condensation drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6 Air duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6.1 Assembly overview - air duct and air distribution in passenger compartment . . . . . . . . . . 95
6.2 Removing and installing centre vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
6.3 Removing and installing driver or front passenger side air vents . . . . . . . . . . . . . . . . . . . . 97
6.4 Removing and installing rear vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
6.5 Removing and installing driver side footwell vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6.6 Removing and installing front passenger side footwell vents . . . . . . . . . . . . . . . . . . . . . . . . 100
6.7 Removing and installing left or right side window vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6.8 Removing and installing rear footwell vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6.9 Removing and installing rear centre console vent duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
6.10 Removing and installing rear footwell vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
6.11 Removing and installing fresh air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
6.12 Removing and installing glove box cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
6.13 Checking forced ventilation for passenger compartment . . . . . . . . . . . . . . . . . . . . . . . . . . 105
6.14 Removing and installing forced ventilation for passenger compartment . . . . . . . . . . . . . . 106
7 Operating and display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
7.1 Overview of operating and display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
7.2 Removing and installing operating and display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
8 Other controlling and regulating components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
8.1 Removing and installing sunlight penetration photosensor G107 . . . . . . . . . . . . . . . . . . . . 122
8.2 Principle of operation of air quality sensor G238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
8.3 Removing and installing air quality sensor G238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
8.4 Removing and installing ambient temperature sensor G17 . . . . . . . . . . . . . . . . . . . . . . . . 124
8.5 Removing and installing left vent temperature sender G150 . . . . . . . . . . . . . . . . . . . . . . 125
8.6 Removing and installing right vent temperature sender G151 . . . . . . . . . . . . . . . . . . . . . . 125
8.7 Removing and installing left footwell vent temperature sender G261 . . . . . . . . . . . . . . . . 126
8.8 Removing and installing right footwell vent temperature sender G262 . . . . . . . . . . . . . . . . 126
Passat 2011 ➤ , Passat Variant 2011 ➤
Heating, air conditioner - Edition 06.2017
ii Contents

00 – Technical data
1 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
⇒ “1.3 Safety precautions when working on the cooling system”,
page 1
1.1 Safety precautions when working on air conditioning systems
Risk of freezing injury from refrigerant
When working on the air conditioning system, there is a risk of
highly pressurised refrigerant escaping from the system. There is
a risk of injury to the skin and parts of the body due to freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immediately
afterwards.
– If more than 10 minutes have passed since the refrigerant was
extracted, repeat the extraction process before opening the
refrigerant circuit. Pressure could build up in the refrigerant
circuit from continued evaporation.
Risk of damage to refrigerant lines
There is a risk of damage to the refrigerant lines due to rupture of
the inner foil.
– Never bend refrigerant lines to a radius less than 100 mm.
1.2 Safety measures when working on vehicles with a start/stop system
Risk of injury due to unexpected motor start
If the vehicle’s start/stop system is activated, the engine can start
unexpectedly. A message in the dash panel insert indicates
whether the start/stop system is activated.
– Deactivate start/stop system by switching off the ignition.
1.3 Safety precautions when working on the cooling system
Scalding by hot coolant
On a warm engine, the cooling system is under high pressure.
Danger of scalding by steam and hot coolant.
– Wear protective gloves.
Passat 2011 ➤ , Passat Variant 2011 ➤
Heating, air conditioner - Edition 06.2017
1. Safety information 1

– Wear protective goggles.
– Reduce excess pressure by covering cap of coolant expan‐
sion tank with cloths and opening it carefully.
Passat 2011 ➤ , Passat Variant 2011 ➤
Heating, air conditioner - Edition 06.2017
2 Rep. gr.00 - Technical data

2 General information
⇒ “2.1 Notes concerning odours in air conditioned vehicles”, page
3
⇒ “2.2 Notes for vehicles with start-stop system”, page 3
2.1 Notes concerning odours in air condi‐
tioned vehicles
♦ If the evaporator emits unpleasant odours, clean the evapo‐
rator.
♦ Volkswagen has tested and approved the ultrasound A/C
cleaner - VAS 6189A- as well as the suction feed spray-gun -
V.A.G 1538- with the appropriate spray probe.
♦ Instructions on cleaning the evaporator are supplied with the
equipment.
♦ As soon as Volkswagen approves new methods, appropriate
notes are added to the workshop manual ⇒ Air conditioning
systems with refrigerant R134a; Rep. gr. 00 ; Complaints;
Odours from the heating and air conditioning unit .
2.2 Notes for vehicles with start-stop system
The following abort conditions deactivate the start-stop-function:
♦ The start-stop system has been switched off via the start-stop
mode button.
♦ The charge status of the battery - - is insufficient to restart the
engine (starting voltage prediction).
♦ The defrost function is active.
♦ The windscreen heater function is active.
♦ The temperature set on the operating and display unit varies
by more than 8°C from the actual interior temperature.
♦ The engine speed is greater than 1200 rpm.
♦ The alternator - C- is defective, i.e. poly V-belt broken.
♦ The coolant temperature is not within specifications of 25°C -
100°C.
♦ Blower speed increase by more than 4 stages.
Passat 2011 ➤ , Passat Variant 2011 ➤
Heating, air conditioner - Edition 06.2017
2. General information 3

3 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
3.1 Checking cooling output
Check
– Close bonnet.
– Measure ambient temperature.
– Close doors, windows and sunroof.
– Open all dash panel vents.
– Set air conditioning system temperature to coldest setting.
– Set air distribution to chest vents.
– Hold temperature probe -2- approx. 20 mm in area shown
-3- of vents -1-.
Passat 2011 ➤ , Passat Variant 2011 ➤
Heating, air conditioner - Edition 06.2017
4 Rep. gr.00 - Technical data

– Switch on air conditioning system via A/C button.
– Start engine.
Note
Start time measurement (5 minutes).
– Increase engine speed to approx. 2000 rpm and hold.
Evaluation
After 5 minutes the temperature of the air blown out of the vents
on the “driver side” must lie within permitted tolerances depending
on the ambient temperature (see diagram).
A - Temperature of air blown out of dash panel vents on “driver
side”
B - Ambient temperature
C - Permitted tolerance range
3.2 Working on refrigerant circuit
In some countries special qualifications are required for any work
for which the refrigerant circuit needs to be opened.
Additional information
♦ For notes on repairs to vehicles with air conditioning system
and on handling refrigerant refer to ⇒ Air conditioning system
with refrigerant R134a; Rep. gr. 00 ; General information for
air conditioning system, Safety precautions for when working
on vehicles with air conditioning system and when handling
refrigerant R134a .
♦ For notes on test equipment and tools for repairs to vehicles
equipped with an air conditioning system refer to ⇒ Air con‐
ditioning system with refrigerant R134a; Rep. gr. 00 ; Test
equipment and tools .
♦ For notes on working with air conditioner service station on
vehicles equipped with an air conditioning system refer to ⇒
Air conditioning system with refrigerant R134a; Rep. gr. 00 ;
Working with air conditioner service station .
♦ For information on the conditions and the procedure for flush‐
ing with refrigerant R134a refer to ⇒ Air conditioning system
with refrigerant R134a; Rep. gr. 00 ; Clearing refrigerant circuit
of contaminants; Flushing (cleaning) refrigerant circuit with re‐
frigerant R134a .
3.3 Refrigerant circuit seals
♦ Renew seals after removal.
♦ Moisten seals with refrigerant oil before installing.
♦ Ensure proper seating of seals on the pipe or in the groove.
♦ Work in a completely clean environment. Even the smallest
contaminants, e.g. a hair, can cause leaks.
♦ Install only seals that are resistant to R134a refrigerant and its
associated refrigerant oil. These seals are marked in colour to
Passat 2011 ➤ , Passat Variant 2011 ➤
Heating, air conditioner - Edition 06.2017
3. Repair notes 5

prevent them from being interchanged ⇒ Electronic parts
catalogue .
The dimensions -a- and -b- depend on the fitting location of the
seal ⇒ Electronic parts catalogue .
3.4 Notes on control motors
⇒ “3.4.1 Notes on control motors”, page 6
⇒ “3.4.2 Inserting link into the shaft of a control motor”,
page 8
⇒ “3.4.3 Activating control motor using adapter cable”,
page 10
⇒ “3.4.4 Locally manufacturing an adapter cable to activate con‐
trol motors”, page 11
3.4.1 Notes on control motors
Note
♦ Risk of malfunction of heater or air conditioning system caused
by improperly installed control motors or links.
♦ Mark the correct allocation of the connectors to the control
motors.
♦ Always install the appropriate links to the control motors.
Passat 2011 ➤ , Passat Variant 2011 ➤
Heating, air conditioner - Edition 06.2017
6 Rep. gr.00 - Technical data

♦ 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 ⇒ Electronic
parts catalogue . Therefore, mark position of the control mo‐
tors accordingly before removing them (risk of interchanging
the control motors).
♦ As of week 45/2013, gradual change of the control motors has
been introduced. The various links (levers, gears, etc.) for
connecting the control motors to the flaps in the heater and air
conditioning unit used to be different in colour. As of week
45/2013, the control motors are being used with links to the
various flaps of the heater and air conditioning unit in only one
colour (currently black). Thus, the links cannot be any longer
allocated via the colour. The illustration shows a temperature
flap control motor - V68- -A- with the respective link (lever)
-B-.
♦ 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. lever -B- on a temperature flap control motor
- V68- -A-) and with different part numbers. As of week
45/2013, control motors without pre-installed link and a sepa‐
rate set of links (e.g. lever -B- for a temperature flap control
motor - V68- -A-) are being gradually introduced as replace‐
ment parts ⇒ Electronic parts catalogue . The required link
can be selected from this set (depending on the respective
heater and air conditioning unit and the fitting location of the
control motor), and it can be installed to the control motor shaft
⇒ page 8 .
♦ There are different versions of the control motors without pre-
installed links -B- which are being installed or have been made
available as a replacement part as of week 45/2013. The ver‐
sion which is installed as the air recirculation flap control motor
- V113- for a heater and fresh air ventilation system or an air
conditioning system with manual controls, for example, has no
potentiometer (but limit switches instead). The control motors
with potentiometer are available with different setting ranges
(max. setting range which can be evaluated electrically of ap‐
prox. 120° or 340°) ⇒ Electronic parts catalogue . Always
make sure that the appropriate version is allocated correctly.
If a control motor with an incorrect setting range has been in‐
stalled, this may cause problems during the basic setting of
the air conditioning system and/or the operation of the heater
and air conditioning system ⇒ Vehicle diagnostic tester.
♦ After the control motor has been installed, perform the basic
setting of the air conditioning system ⇒ Vehicle diagnostic
tester.
♦ The functions “Final control diagnosis” and “Basic setting” can
be used to check the correct activation of the electric compo‐
nents of the air conditioning system (e.g. for checking whether
components have been interchanged); ⇒ Vehicle diagnostic
tester in “Guided Fault Finding” mode.
♦ Check the activation and operation of the control motor via the
operating and display unit.
Passat 2011 ➤ , Passat Variant 2011 ➤
Heating, air conditioner - Edition 06.2017
3. Repair notes 7

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. lever -B- on a temperature flap control motor
- V68- -A-) and with different part numbers. As of week
45/2013, various control motors without pre-installed link and
a separate set of links (e.g. lever -B- for a temperature flap
control motor - V68- -A-) are being introduced gradually as
replacement parts ⇒ Electronic parts catalogue . The required
link must be selected from this set, allocated correctly and in‐
serted in the new control motor.
♦ The link (e.g. lever -B-) can only be inserted and engaged in
the shaft -D- of the control motor -A- in one specific position.
♦ The links fitted in the control motors which have been installed
up to week 45/2013 (e.g. lever -B-), are engaged in shaft -D-
of the control motor. They can be levered out using, for ex‐
ample, two screwdrivers.
♦ To allow for inserting the respective link -B- into the shaft -D-
of the control motor, the shaft must be set to the position as
shown in the illustration.
Inserting link
– Remove link from removed control motor (lever it out using,
e.g., 2 screwdrivers), or select the required link from the set of
links ⇒ Electronic parts catalogue .
Note
♦
If a wrong link has been selected or installed, it may still be
possible to install the control motor. However, problems may
occur when the new control motor is adapted.
♦ The links may look quite similar in some cases. Therefore,
make sure to always select the correct version.
♦ Always insert a link which corresponds exactly to the removed
link in terms of shape.
♦ If the wrong link has been selected for a control motor, it may
still be possible to install the control motor together with the
link. However, problems may occur when the new control mo‐
tor is adapted.
♦ The various control motors all have the same shape. They can
only be distinguished by the part number. Therefore, always
make sure to use the correct version.
♦ Only install control motors which can be allocated correctly
without any doubt.
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8 Rep. gr.00 - Technical data

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
shape of the link -B- and the stop -C- on the control motor. The
position of shaft -D- of the control motor is determined via the
integrated potentiometer (or a limit switch) by the respective
control unit.
– Check position of shaft -D- of control motor -A-. Only if the shaft
is in the illustrated position, shaft -F- of the link can be inserted
and engaged without any preload.
Note
♦ If the shaft -D- of the control motor -A- is not in the illustrated
position (only in this position the link can be fitted), activate the
removed control motor so that shaft -D- is moved to the illus‐
trated position ⇒ page 10 .
♦ The link -B- must only be fitted in a position in which it engages
by applying a minimum amount of force. To allow for better
locating the correct installation position, some of the links have
an embossed contour -E- which corresponds to the contour of
the shaft mounting of control motor -D-. If the link can only be
inserted with a preload, check control motor shaft -D-. It may
be turned by 180°.
♦ Do not reuse and always renew links which show signs of
wear.
– Insert shaft of removed link or of link selected from the set of
links -F- in control motor shaft -D-, and engage it.
– Make sure that link -B- is firmly seated in control motor -A-.
– Install control motor in the appropriate position on the heater
and air conditioning unit.
Passat 2011 ➤ , Passat Variant 2011 ➤
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3. Repair notes 9

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‐
priate position.
♦ The control motor shaft -D- does not have a limit stop. Thus,
it will turn continuously on a control motor with integrated po‐
tentiometer, if a voltage is applied to contacts 5 and 6 of the
connector on the control motor. Therefore, voltage should only
be applied to a removed control motor, if the link -B- is fitted
or to move the shaft -D- to the appropriate position, if it is not
possible to fit the link.
♦ If the link -B- cannot be inserted in the control motor without
any preload, the shaft -D- may be in the wrong position.
Move control motor shaft to the appropriate position.
– Connect adapter cable ⇒ page 11 to control motor -A-.
Note
Instead of the adapter cable, a test lead from the auxiliary meas‐
uring set - V.A.G 1594/C- may also be used to connect contacts
“5” and “6” in the connector of control motor -A- via a 5-A fuse to
a 12-V battery.
– Connect one of the wires of the adapter cable via a 5-A fuse
to the positive terminal of a 12-V battery.
– Connect the remaining wire of the adapter cable (e.g. using a
test lead from the auxiliary measuring set - V.A.G 1594/C- )
briefly to the negative terminal of the 12-V battery.
• Activate the control motor in such a way that shaft -D- is moved
to the position shown in the illustration with the minimum pos‐
sible travel.
– Observe direction of rotation of control motor shaft -D-. If shaft
turns into wrong direction, change polarity of wires.
– As soon as control motor shaft -D- is in appropriate position,
interrupt activation of control motor.
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Heating, air conditioner - Edition 06.2017
10 Rep. gr.00 - Technical data

3.4.4 Locally manufacturing an adapter cable
to activate control motors
Procedure
–Connect a wire with a cross section of 0.25 mm2 to each of
contacts “5” and “6” of connector -A- ( flat contact housing with
contact locking mechanism - 6Q0 972 706- ) ⇒ Electronic
parts catalogue .
– Connect a commercially available banana coupling -B- to oth‐
er end of each wire.
Note
The banana couplings -B- can be used to connect the wires (e.g.
using test leads from the auxiliary measuring set - V.A.G 1594/
C- ) to a 12-V power source (e.g. a 12-V battery).
Passat 2011 ➤ , Passat Variant 2011 ➤
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3. Repair notes 11

4 Technical data
⇒ “4.1 Refrigerant capacity”, page 12
⇒ “4.2 Refrigerant oil capacities”, page 12
⇒ “4.3 Oil distribution”, page 13
4.1 Refrigerant capacity
⇒ “4.1.1 Capacities for refrigerant R134a, up to WEEK 44/2011”,
page 12
⇒ “4.1.2 Capacities for refrigerant R134a, as of WEEK 45/2011”,
page 12
4.1.1 Capacities for refrigerant R134a, up to WEEK 44/2011
Total capacity
600 ± 25 grammes
4.1.2 Capacities for refrigerant R134a, as of WEEK 45/2011
Total capacity
550 ± 15 grammes
Note
A tolerance of ± 15 g is permissible although not indicated on the
identification plate.
4.2 Refrigerant oil capacities
Note
♦ Refrigerant oils from containers which have been open for a
longer period of time are unusable.
♦ Refrigerant oil is very hygroscopic. Therefore, opened con‐
tainers must be closed immediately after use to stop ingress
of moisture.
Air conditioner compressor
manufacturer
Part number of refrigerant oil
Delphi, Mahle, Sanden -G 052 154 A2-
Denso -G 052 300 A2-
Model Total capacity1)
11PXE14; Sanden 75 ml ± 10 ml
PXE14; Sanden 110 ml ± 10 ml
PXE16; Sanden 110 ml ± 10 ml
SD7V16; Sanden 110 ml ± 10 ml
6SEU14C; Denso 90 ml ± 10 ml
DH5; Mahle/Delphi 110 ml ± 10 ml
Passat 2011 ➤ , Passat Variant 2011 ➤
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12 Rep. gr.00 - Technical data

Model Total capacity1)
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.
4.3 Oil distribution
The oil, which is located in the sump of the air conditioner com‐
pressor before the air conditioner system is switched on for the
first time, distributes itself through the refrigerant circuit as follows:
♦ Air conditioner compressor approx. 50%
♦ Condenser approx. 10%
♦ Suction hose approx. 10%
♦ Evaporator approx. 20%
♦ Receiver approx. 10%
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4. Technical data 13

80 – Heating
1 Heating
Note
♦
At the moment, the only heating system available for the Pas‐
sat is a heating system integrated in the air conditioning sys‐
tem.
♦ For information on repairs, refer to
⇒ g r.87 “Air conditioning system”, page 15 .
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14 Rep. gr.80 - Heating

87 – Air conditioning system
1 Overview of fitting locations - air con‐
ditioning system
⇒ “1.1 Overview of fitting locations - components located in front
section of passenger compartment”, page 15
1.1 Overview of fitting locations - compo‐
nents located in front section of passen‐
ger compartment
⇒ “1.1.1 Overview of fitting locations - components in front pas‐
senger compartment, air conditioning system with electrical/man‐
ual controls”, page 15
⇒ “1.1.2 Overview of fitting locations - components inside of front
passenger compartment, Climatronic”, page 17
1.1.1 Overview of fitting locations - components in front passenger compartment,
air conditioning system with electrical/manual controls
1 - Dash panel
❑ Removing and installing
⇒ General body repairs,
interior; Rep. gr. 70 ;
Dash panel; Removing
and installing dash pan‐
el .
2 - Centre vent
❑ Removing and installing
⇒ page 96
3 - Side vent
❑ Removing and installing
⇒ page 97
4 - Operating and display unit
for front air conditioning sys‐
tem - E87- with air conditioning
system control unit - J301-
❑ Function ⇒ page 108
❑ Removing and installing
⇒ page 118
5 - Air distribution flap control
motor - V428-
❑With potentiometer for
air distribution flap con‐
trol motor - G645-
❑ Checking: vehicle diag‐
nostic tester
❑ Removing and installing
⇒ page 66
6 - Air recirculation flap control
motor - V113-
❑ With potentiometer for
air recirculation flap
control motor - G143-
❑ Checking: vehicle diagnostic tester
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1. Overview of fitting locations - air conditioning system 15

❑ 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-
❑Removing and installing ⇒ page 87
10 - Fresh air blower series resistor with overheating fuse - N24-
❑Removing and installing ⇒ page 86
11 - Dust and pollen filter
❑Removing and installing ⇒ page 85
12 - Rear right rear footwell air ducts
❑Removing and installing ⇒ page 102
13 - Rear vent
❑Removing and installing ⇒ page 98
14 - Rear air duct for rear vent
❑Removing and installing ⇒ page 104
15 - Front air duct for rear vent
❑Removing and installing ⇒ page 103
16 - Rear left rear footwell air ducts
❑Removing and installing ⇒ page 102
17 - Condensate drain hose with valve
❑Removing and installing ⇒ page 93
❑Checking ⇒ page 94
18 - Heater unit connecting piece ▶ rear air duct vent
❑Cap installed on models with no rear vents.
19 - Heat exchanger
❑ Removing and installing ⇒ page 89
20 - Temperature flap control motor - V68-
❑With potentiometer for temperature flap control motor - G92-
❑ Checking: vehicle diagnostic tester
❑ Removing and installing ⇒ page 49
21 - Auxiliary air heater element - Z35-
❑Removing and installing ⇒ page 84
22 - Footwell vent on driver side
❑Removing and installing ⇒ page 99
23 - Heater and air conditioning unit
❑Removing and installing ⇒ page 74
❑Dismantling and assembling ⇒ page 78
24 - Evaporator temperature sensor - G308-
❑Removing and installing ⇒ page 85
Passat 2011 ➤ , Passat Variant 2011 ➤
Heating, air conditioner - Edition 06.2017
16 Rep. gr.87 - Air conditioning system