VW Passat b4 (1994 95) Heating Air Conditioner Eng

Service
Passat 1994 ➤
Heating, air conditioner
Edition 10.1995
Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Passat 1994 ➤
Heating, air conditioner
Repair Group
01 - Self diagnosis
80 - Heating
87 - Air conditioning
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.
Passat 1994 ➤
Heating, air conditioner - Edition 10.1995
Contents
01 - Self diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1 Self diagnosis of Climatronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 Self diagnosis of Climatronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.3 Technical data of self diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.4 Test prerequisites for self diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.5 Connecting fault reader V.A.G 1551 and selecting function . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.6 Chart of functions that can be selected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.7 Interrogating fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.8 Fault table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.9 Final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1.10 Read measured value block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1.11 Erasing fault memory, ending output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
80 - Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
1 Servicing heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
1.1 Servicing heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
2 Dismantling and assembling heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
2.1 Dismantling and assembling heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
3 Installing and adjusting cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
3.1 Installing and adjusting cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
4 Dismantling and assembling heated air and fresh air controls . . . . . . . . . . . . . . . . . . . . . . . .35
4.1 Dismantling and assembling heated air and fresh air controls . . . . . . . . . . . . . . . . . . . . . . . .35
5 Servicing electronic heater controls - Thermotronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
5.1 Servicing electronic heater controls - Thermotronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
87 - Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

1 Notes on repair work to vehicles with air conditioning and on handling refrigerant . . . . . . . .42
1.1 Notes on repair work to vehicles with air conditioning and on handling refrigerant . . . . . . . .42
1.2 Safety precautions for work on vehicles with air conditioning and when handling refrigerant
R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
1.3 Service work on the air conditioner which can only be carried out in specially-equipped
workshops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
2 Air conditioner with manual controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
2.1 Air conditioner with manual controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
2.2 Servicing air conditioning and heating - Passenger compartment . . . . . . . . . . . . . . . . . . . .46
2.3 Servicing air conditioning and heating - Engine compartment . . . . . . . . . . . . . . . . . . . . . . . .55
2.4 Installing and adjusting cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
2.5 Vacuum hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
2.6 Removing and installing compressor bracket - 4 Cyl. petrol engine . . . . . . . . . . . . . . . . . .71
2.7 Removing and installing compressor bracket - 6 Cyl. petrol engine . . . . . . . . . . . . . . . . . .74
2.8 Removing and installing compressor bracket - Turbo Diesel engine . . . . . . . . . . . . . . . . . .78
3 Climatronic - air conditioner with automatic regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
3.1 Climatronic - air conditioner with automatic regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
3.2 Control and function of the control and display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
3.3 Servicing Climatronic - passenger compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
3.4 Servicing Climatronic - engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
3.5 Checking and adjusting end position of installed temperature flap positioning motor . . . . . .101
3.6 Vacuum hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Contents i
Passat 1994 ➤
ii Contents
Passat 1994 ➤
01 - Self diagnosis
1 - Self diagnosis of Climatronic

1.1 - Self diagnosis of Climatronic
Note:
Some components and functions of the Climatronic are not monitored by the self diagnosis. If after interrogating
the fault memory no fault is recognized even though there is a specific complaint, carry out further complaint
related checks.
=> Fault finding, Heating, Air Conditioning - Binder 2
Further information:
◆ Measures to correct current specific faults:
=> Technical Service Handbook
◆ Servicing Climatronic=>Page 81
◆ Servicing refrigerant system with refrigerant R134a:
=> Air conditioning with refrigerant R134a
1.2 - Function
The Climatronic control unit is supplied with information from electrical and electronic components (information
transmitters). The input signals from the information transmitters are processed in the control unit in accordance
with specifications and the output signals then control the electrical components (final controls).
The Climatronic control unit -J255- is located behind the control and display panel -E87-.
To enable fault to be rapidly detected if a component fails or there is an open circuit, the control unit is equipped
with a fault memory which can be interrogated using the fault reader V.A.G 1551.
Should a fault be detected in one of the sensors or components monitored, it is stored in the fault memory.
If a fault has been stored, the Climatronic will be switched off either partially or entirely depending on the severity
of the fault.
If a fault which has a permanent adverse effect on the operation of the Climatronic is stored to memory, the
display of the control and display panel -E87- flashes for approx. 15 seconds when the ignition is switched on.
In the case of faults that do not cause the display to flash, the Climatronic control unit can allow the Climatronic
to continue operating in emergency mode at the adjusted settings.
To commence fault finding, initiate self-diagnosis and retrieve the stored information with the fault reader V.A.G
1551.
The fault information displayed is used to refer to a fault table with notes on the possible causes for directed
repair measures.
1.1 - Self diagnosis of Climatronic 1

Passat 1994 ➤
1.3 - Technical data of self diagnosis
Memory: Non-volatile
Data output: Rapid data transfer
Final control diagnosis yes
Read measuring value block yes
1.4 - Test prerequisites for self diagnosis

◆ All fuses according to current flow diagram OK.
◆ Battery voltage OK.
1.5 - Connecting fault reader V.A.G 1551 and selecting function
-> With the ignition switched off, connect V.A.G 1551 using cable V.A.G 1551/3 to the diagnostic socket as
follows:
- Remove cover for diagnostic connections (in front of display panel right).
- Connect fault reader using cable V.A.G 1551/3.
-> Indicated on display:

V.A.G self-diagnosis HELP
1-Rapid data transfer*
2-Flash code output*
* Is displayed alternately.
Note:
If the display remains blank check V.A.G 1551 voltage supply using current flow diagram.
Notes:
◆ Additional operating information can be printed out depending on the programme by pressing the HELP key
of V.A.G 1551.
◆ The ⇒key is used for advancing the programme sequence.
◆ The PRINT key is used for switching on the printer (warning lamp in key lights up).
- Switch on ignition.
- Press key -1- for "Rapid data transfer" mode.

Rapid data transfer HELP
Enter address word XX
2 01 - Self diagnosis
Passat 1994 ➤
- Press keys -0- and -8- (08 inputs the address word of the vehicle system to be tested - "Air cond./Heating
electronics").
-> Shown in display after input of address word 08:

Rapid data transfer
Tester sends address word 08

Rapid data transfer Q
08 Air cond./Heating electronics
- Confirm entry with the Q key.
and then the display shows e.g.:
The control unit identification number is displayed:
- ->
3A0 907 044 CLIMATRONIC VXX
Vehicles up to 07.95
- ->
3A0 907 044A CLIMATRONIC VXX
Vehicles from 08.95
Note:
◆ data transfer
Rapid HELP
Control unit does not answer!
-> If one of the fault messages opposite appears in the display, the possible causes of the fault can be
printed out with the HELP key.
-> (The ignition must be switched on!)

K wire not switching to positive!
◆ data transfer
Rapid
No signal from control unit!
-> Faults have occurred at the start of or during the programme (external sources of faults?).
- ->
Rapid data transfer
Fault in communication build-up
Check diagnostic cables and also voltage supply and earth connection.
- When causes of faults have been eliminated, input address word 08 for "Air cond./Heating electronics" and
confirm with Q key.
-> Shown in display after input of address word 08:

Rapid data transfer
Tester sends address word 08
and then the following appears in the display:
The control unit identification number is displayed:
- ->
3A0 907 044 CLIMATRONIC VXX
1.5 - Connecting fault reader V.A.G 1551 and selecting function 3

Passat 1994 ➤
Vehicles up to 07.95
- ->
3A0 907 044A CLIMATRONIC VXX
Vehicles from 08.95

- Press ⇒key.
-> Indicated in display (function selection, e.g. 02 - Interrogating fault memory):

Select function XX
Note:
A list of the possible functions is printed out after pressing the HELP key:
1.6 - Chart of functions that can be selected
Page
01 - Interrogate control unit version =>Connect‐ 2
ing fault reader V.A.G 1551 and selecting
functions
02 - Interrogate fault memory 4
03 - Final control diagnosis 9
05 - Erase fault memory 16
06 - End output 16
08 - Read measured value block 12
Only the functions listed can be used at present for self diagnosis.
After pressing the ⇒key, the V.A.G 1551 programme returns to the initial position.
-> Indicated on display (function selection, e.g. 02 - Interrogating fault memory):

Select function XX
1.7 - Interrogating fault memory

- Connect V.A.G 1551 fault reader, input address word 08 "Air cond./Heating electronics" and press ⇒until
"Select function XX" appears in display => Page 2 .
-> Indicated on display (function selection):

Select function XX
- Press keys -0- and -2- (the function "Interrogate fault memory" is entered with 02).

02 - Interrogate fault memory
-> The number of stored faults or "No fault recognized" appears in the display.
X faults recognized!
Passat 1994 ➤
No fault recognized!
- Press ⇒key.
The stored faults are displayed and printed out one after the other.
- When the last fault has been displayed and printed out, eliminate faults as described in fault table ( => Page
5 ).
After the ⇒key is pressed, the programme moves to the initial position as with "No fault recognized":

Select function XX
- End output (function 06) => Page 16 .

- Switch off ignition and separate diagnostic connections.
Notes:
◆ If a fault was recognized:
◆ 1. Rectify fault.
◆ 2. Interrogate fault memory (function 02).
◆ 3. Erase fault memory (function 05).
1.8 - Fault table
Note:
◆ The following table lists all the faults, with the corresponding 5 digit code numbers, that can be recognized
by the Climatronic control unit -J255- and printed out by the V.A.G 1551.
◆ If a fault does not occur regularly or if the fault memory is not deleted after elimination of fault, these faults
are displayed as sporadic faults.
◆ Fault codes appear only on print-out.
◆ Fault table may also include type of fault.
◆ When repair has been carried out, the fault memory must always be interrogated again with the fault reader
V.A.G 1551 and erased.
◆ If, despite customer's complaint, no fault in Climatronic can be found, carry out "Final control diagnosis" (=>
Page 12 ). If necessary, carry out fault finding for specific complaints without self-diagnosis:
=> Fault finding, Heating, Air Conditioning - Binder 2
V.A.G 1551 printout Possible cause of fault Rectifying fault

No fault recognized If "No fault recognized" appears after performing repairs, the self diagnosis
is ended.
00522
Coolant temperature sender -G62-
Open circuit/short to positive1) Open circuit or short circuit in wires - Check -G62- using "Read measur‐
or connectors to coolant tempera‐ ing value block" => Page 12
ture sender -G62-
Short to earth1) -G62- defective - Check wires and connectors using
current flow diagram
- Renew -G62-
1) One of these read-outs is displayed in addition to relevant component.

00766
1.7 - Interrogating fault memory 5

Passat 1994 ➤

Vent temperature sender
-G152-
Open circuit/short to positive1) Short circuit or open circuit in wiring or - Check -G152- using "Read measured
connections to vent temperature send‐ value block" => Page 12
er -G152-
Short to earth1) -G152- defective - Check wires and connectors using
- Replace -G152-
1) One of these read-outs is displayed in addition to relevant component.

00281
Road speed sender -G68-1) Short circuit or open circuit in wires or - Check signal from -G22- or -G54- us‐
connectors from junction box for speed ing "Read measuring value block" =>
signal -TV13- to Climatronic control unit Page 12
Check wires and connectors using
Speed sender -G54- defective - Renew -G54-
=> Repair Group 90; Servicing dash
panel insert
Speedometer sender -G22-, defective - Renew -G22-
on gearbox (only when speedometer - => Repair Group 90; Servicing dash
G21- also malfunctions) panel insert
Cannot be checked at present This read out only appears when the final control diagnosis was carried out
before interrogation of fault memory and it is irrelevant to self diagnosis. This
fault will be erased from control unit fault memory when ignition is switched off.
1) A fault has been found with speedometer sender -G22- (vehicles with electronic speedometer sender) or
speed sender -G54- (vehicles with mechanical speedometer sender) and not from speed sender -G68-. The
fault is only recognised if 5 driving cycles take place within 4 minutes after starting engine and no speed signal
is measured.

00532
Supply voltage
Signal too large1) Alternator defective - Check supply voltage using "Read meas‐
ured value block" =>Page 12
Signal too small1) Wires or connectors to Climatronic control - Check wires and connectors to control unit
unit -J255- using current flow diagram
- Check alternator:
=> Current flow diagrams, Electrical fault
finding, Fitting locations
1) One of these messages will be displayed in addition to indication of relevant component.

00538
Reference voltage Voltage to earth at -T5/2- or -T28a/23- more
than 5.2 V (on vehicles from 08.95: more
than 5.4 V or less than 4.4 V
Signal too large1) Short circuit or open circuit in wires or con‐ - Check wires and connectors to control unit
nectors -T5/2- or -T28a/23- on Climatronic using current flow diagram
control unit -J255-
Signal too small1) Sunlight penetration photo sensor -G107- - Unplug connectors of these components
or potentiometer -G92- or potentiometer - one at a time, erase fault memory (=> Page
G112- defective or potentiometer -G113- 4 ). If the "Reference voltage" fault is no lon‐
defective ger recognised, the relevant component
must be renewed.
Passat 1994 ➤

Control unit faulty - Replace control unit if necessary

00779
Ambient temperature sensor -G17-
Open circuit/short to positive1) Short circuit or open circuit in wiring - Check -G17- using "Read measur‐
or connectors to ambient tempera‐ ing value block" => Page 12
ture sensor -G17-
Short to earth1) -G17- defective - Check wiring and connectors using
- Renew -G17-

00785
Instrument panel temperature sen‐
sor -G56-
Open circuit/short to positive1) Short circuit or open circuit in wiring - Check -G56- using "Read meas‐
or connectors to instrument panel uring value block" => Page 12
temperature sensor -G56-
Short to earth1) -G56- defective - Check wiring and connectors us‐
ing current flow diagram
- Renew -G56-

00787
Fresh air intake duct temperature
sensor -G89-
Open circuit/short to positive1) Short circuit or open circuit in wiring - Check -G89- using "Read meas‐
or connectors to fresh air intake uring value block" => Page 12
duct temperature sensor -G89-
Short to earth1) -G89- defective - Check wiring and connectors us‐
ing current flow diagram
- Renew -G89-

00792
Pressure switch for air conditioner -
F129-1)
Short circuit or open circuit in wiring - Check -F129- with "Read meas‐
or connectors to pressure switch for uring value block" => Page 12
air conditioner -F129
Refrigerant circuit incorrectly - Check wiring and connectors us‐
charged or refrigerant insufficiently ing current flow diagram
cooled
-F129- defective - Renew -F129-
1.8 - Fault table 7

Passat 1994 ➤

Cannot be checked at present This read-out appears only when the final control diagnosis was carried
out before interrogation of fault memory and pressure switch could not
be checked (e.g. when outside temperature is below 12°C). This fault
will be erased from control unit fault memory when ignition is turned off.
1) This fault cannot be recognized if outside temperature is below 12°C or -G17- and -G89- both malfunction
simultaneously.

00796
Temperature sensor blower -V42-
Dust may be blocking blower air in‐ - Carry out visual check; if necessary,
take clean -V42-
Short circuit or open circuit in wiring - Check wiring and connectors using
or connectors to temperature sensor current flow diagram
blower -V42-
-V42- defective - Renew -V42-

00797
Sunlight penetration photo sensor -
G107-
Open circuit/short to positive Open circuit or short circuit in wiring - Check -G107- using "Read meas‐
or connectors to sunlight penetra‐ uring value block" => Page 12
tion photo sensor -G107-
-G107- defective - Check wiring and connectors using
- Renew -G107-

01271
Temperature flap positioning motor -
V68-5)
or connectors to temperature flap current flow diagram
positioning motor -V68-
-V68- incorrectly adjusted - Check and adjust end position of
positioning motor -V68- with motor
installed in vehicle => Page 101
-V68- defective - Carry out final control diagnosis =>
Page 9
- Renew -V68-
1) Fault is recognized after 30 seconds at earliest.

01272
Central flap positioning motor -
V70-5)
or connectors to central flap posi‐ current flow diagram
tioning motor -V70-
-V70- defective - Carry out final control diagnosis =>
Page 9
Volkswagen Technical Site: http://vwts.ru http://vwts.info
Passat 1994 ➤

- Renew -V70-

01273
Fresh air blower -V2-
Short circuit or open circuit in wiring or con‐ - Check wiring and connectors using current
nectors to fresh air blower -V2- flow diagram
- Carry out final control diagnosis => Page
9
Blower control unit -J126- defective - Renew -J126-
-V2- defective - Renew -V2-
Air conditioner pressure switch -F129- de‐ - Replace -F129- when 12V is present at in‐
fective put, contact 2, and 5V is present at output,
contact 1

01274
Air flow flap positioning motor -
V71-1)
or connectors to air flow flap posi‐ current flow diagram
tioning motor -V71-
-V71- defective - Carry out final control => Page
9
- Renew -V71-

65535
Control unit defective Electrical interference caused by outside - Check wiring and connectors to control
sources, poor earth connections or positive unit using current flow diagram
connections to control unit -J255-
Sunlight penetration photo sensor -G107- - Unplug connectors to these components
or potentiometer -G92- or potentiometer - one at a time, delete fault memory (=> Page
G112- defective or potentiometer -G113- 4 ). If "Control unit defective" fault is no
defective longer recognized, the relevant component
must be renewed.
Control unit faulty - Replace control unit if necessary
1.9 - Final control diagnosis
Note:
◆ Final control diagnosis must be carried out with engine stationary.

.
◆ For results to be definitive, final control diagnosis must be carried out at an ambient temperature of at least
12°C as displayed on control and display panel. Operation and function of control and display panel =>Page
81
◆ Climatronic does not self-adjust during final control diagnosis.
◆ If necessary, final control diagnosis can be repeated several times.
1.8 - Fault table 9

Passat 1994 ➤
Initiating final control diagnosis
- Connect fault reader V.A.G 1551 and select Air cond./Heating electronics (address word 08) => Page 2 .

Select function XX
- Press keys -0- and -3- (03 selects "Final control diagnosis" function).

03 - Final control diagnosis
- Confirm input with Q key.

Final control diagnosis
Self test
-> Dependent upon software version alternative indication on display:

Final control diagnosis
The following tests are carried out:
◆ Read out in display of control and display panel -E87-=>Page 11

◆ Functional test of the 3 positioning motors=>Page 11
◆ Current track to fresh air blower -V2- is tested =>Page 11
◆ Current track to magnetic coupling -N25- is tested=>Page 12

Function is not recognized or cannot
⇒
be carried out at the moment!
- If "Function is not recognized or cannot be carried out at the moment" appears in display, final control
diagnosis has been concluded.
- Press ⇒ button.
Note:
After completing final control diagnosis, interrogate fault memory => Page 4
Passat 1994 ➤
Check display in control and display panel -E87-
-> Vehicles up to 07.95
-> Vehicles from 08.95
Note:
◆ All segments must appear in display. If not, renew control and display panel.
◆ After a period in excess of 20 seconds the display will change.
.
Test of positioning motors
The positioning motors:
◆ Temperature flap positioning motor -V68-

◆ Central flap positioning motor -V70-
◆ Air flow flap positioning motor -V71-
will be moved once over their complete range. The first half of the movement the motors will be fully activated,
for the rest driven in stages.
The movement will be completed in approx. 30 seconds and the following end positions attained:
Temperature flap: Warm air1)

Central flap: Defrost2)
Air flow flap: Closed3)
1) If necessary check and adjust end position of temperature flap positioning motor -V68- when installed
in vehicle => Page 101
2) Air flow to windscreen
3) The position of the air flow flap can be checked with the dust and pollen filter removed.
Note:
If when subsequently interrogating the fault memory (=> Page 4 ) no fault is recognized, even though the end
positions were not attained, then the appropriate positioning motor or the air flap must be checked for me‐
chanical damage.
Testing the current track to fresh air blower -V2-
◆ During the final control diagnosis the fresh air blower is activated with 3 different voltages. Should a fault be
detected in the fresh air blower current track, it will be stored in the fault memory.
1.9 - Final control diagnosis 11

Passat 1994 ➤
Testing the current track to magnetic coupling -N25-
◆ The current track is tested from Climatronic control unit -J255- connection T28a/15 to the air conditioner
pressure switch -F129-. Should a fault be detected, it will be stored in the fault memory.
Note:
If during the subsequent interrogation of the fault memory (=> Page 4 ) no fault is detected, even though the
magnetic coupling is not being activated during cooling operation, then check wiring from air conditioner pres‐
sure switch -F129- via -F163- (not on vehicles with 2-speed radiator fan) and -J293- to magnetic coupling using
current flow diagram.
1.10 - Read measured value block
Notes:
◆ During the function "Read measuring value block" the Climatronic regulation is in operation.
◆ There are 3 display groups each with 4 measuring values.
◆ To read off the measuring values whilst driving a 2nd mechanic is required.
- Connect fault reader V.A.G 1551 and input address word "08 Air conditioner/Heating electronics" and then
press ⇒key, until "Select function XX" is shown in display => Page 2 .

Select function XX
- Press keys -0- and -8- (08 initiates the "Read measured value block" function).

08 - Read measured value block

Read measuring value block
Input display group number XX
Passat 1994 ➤
Table of selectable display group numbers
Display group Display zone Designation

number
01 1 Measured value of
2 the ambient temper‐
3 ature sensor -G17-
4 Measured value of
fresh air duct tem‐
perature sensor -
G89-
Measured value of
dash panel temper‐
ature sensor -G56-
Vehicles up to
07.95:
Measured value of
coolant temperature
sender -G62-
Vehicles from
08.95:
Measured value of
vent temperature
sender -G152-
02 1 Speed signal from
cont. 2 speedometer send‐
3 er -G22-
4 Measured value of
sunlight penetration
photo sensor -
G107-
No display
Supply voltage
(Term.15)
03 1 No display
2 Position of air con‐
3 ditioner pressure
4 switch -F129-
A/C readiness/en‐
gine start recog‐
nized
Kick-down switch

(Specifications => Test table)
Read measured value block 1
1 2 3 4
Notes:
◆ Decoding the figures in the individual display zones => Test table Page 14 .
◆ With the printer switched on the information on the display will be printed-out.
◆ If the specifications are attained in all display zones:
- Press ⇒key.

Select function XX
Note:
After completing the "Read measured value block" function interrogate fault memory => Page 4
1.10 - Read measured value block 13

Passat 1994 ➤
Test table
Group num‐ Display Designation Test conditions V.A.G 1551 Rectifying fault
ber zone display spec‐
ification
01 1 Measured value for Displayed figure cor‐ ... °C - Check wiring and
ambient temperature responds to the ambi‐ connections accord‐
sensor -G17- ent air temperature of ing to current flow di‐
temperature sensor agram
Replace -G17-
2 Measured value of Displayed figure cor‐ ... °C - Check wiring and
fresh air intake chan‐ responds to the ambi‐ connections accord‐
nel temperature sen‐ ent air temperature of ing to current flow di‐
sor -G89- temperature sensor agram
Replace -G89-
3 Measured value of Displayed figure cor‐ ... °C - Check wiring and
dash panel tempera‐ responds to the ambi‐ connections accord‐
ture sensor -G56- ent air temperature of ing to current flow di‐
temperature sensor agram
Replace -G56-
4 Vehicles up to 07.95: Displayed figure cor‐ ... °C - Check wiring and
Measured value of responds to the tem‐ connections accord‐
coolant temperature perature of the coolant ing to current flow di‐
sender -G62- temperature sender agram
Vehicles from 08.95: Displayed figure cor‐ Replace -G62- or -
Measured value of responds to the ambi‐ G152-
air vent temperature ent temperature of the
sender -G152- air vent temperature
sender
ber zone display specifi‐
cation
02 1 Speed signal from Displayed value cor‐ ... km/h - Check wiring and
speedometer sender responds to road connections accord‐
-G22- speed ing to current flow di‐
agram
Replace -G22- (only
when the speedome‐
ter -G21- also does
not indicate road
speed)
2 Measured value for The displayed value 0..100% - Check wiring and
photo sensor for is dependent upon connections accord‐
sunlight penetration the light intensity ing to current flow di‐
-G107- agram
Replace -G107-
Dark 0%
Bright 100%
4 Supply voltage (on Displayed value cor‐ ..V - Check wiring and
Climatronic control responds to battery connections accord‐
unit, connection - voltage ing to current flow di‐
T10a/3-) agram
Check alternator
=>Current flow dia‐
grams, Electrical fault
finding, Fitting loca‐
tions
Passat 1994 ➤
ification
03 2 Switch position of air - Refrigerant circuit 101) "00" indicated on
conditioner pressure fault-free 1551:
switch -F129- Condenser cooling is 2 bar/32 bar switch
sufficient (2 bar/32 bar part open, 16 bar
switch part closed, 16 switch part open. The
bar switch part open) refrigerant circuit is
empty and must be
taken to a specialist
workshop.
Cont. - Refrigerant circuit 111) "01" indicated on
fault-free 1551:
Radiator fan in‐ 2 bar/32 bar switch
creased output stage part open, 16 bar
has switched on (2 switch part closed.
bar/32 bar switch part Condenser cooling in‐
closed, 16 bar switch sufficient (soiled); if
part closed). not the refrigerant cir‐
cuit is over-charged
and vehicle must be
taken to specialist
workshop.
1) The left figure informs of switch part 2 bar/ 32 bar switch position, the right figure informs of switch part
16 bar switch position (1 = closed, 0 = open).
Group number Display zone Designation Test conditions V.A.G 1551 dis‐ Rectifying fault
play specification
03 2 "-0" indicated on 1551:
Checking the 2 bar/32 bar
switch part is not possible at the
moment, because the tempera‐
ture switch is open. Condenser
cooling is sufficient.
Cont. "-1" indicated on 1551:
Checking the 2 bar/32 bar
switch part is not possible at the
moment, because the tempera‐
ture switch is open. Radiator fan
increased output stage has
switched on.
1.10 - Read measured value block 15

Passat 1994 ➤
ification
03 3 Air conditioner readi‐ - Climatronic switched 113) - If the engine start is
Cont. ness1)/engine start on and engine star‐ 103) not recognized,
recognized ted2): 003) check the wiring from
Climatronic switched 013) terminal X to connec‐
on and engine not tor -T28a/21- on con‐
started: trol unit.
Climatronic switched
off and engine not
started:
Climatronic switched
off and engine started:
1) Air conditioner readiness will be recognized, if voltage is present at connector -T2n/1-
2) The magnetic coupling -N25- will only be switched on when the engine start is recognized.
3) The left figure informs of whether Climatronic is switched on (1 = Climatronic on, 0 = Climatronic off); The
right figure informs of whether the engine is started (1 = Engine started, 0 = Engine not started).
Group number Display zone Designation Test conditions V.A.G 1551 Rectifying fault
display specifi‐
cation
03 4 Kick-down switch2) - Kick-down switch oper‐ 111) "10" indicated
ated (full throttle); vehi‐ 011) on 1551:
cles with automatic gear‐ 001) Check wiring
box: from automatic
Kick-down switch not op‐ gearbox control
erated; vehicles with au‐ unit -J217- to
tomatic gearbox: Climatronic
Vehicles with manual control unit -
gearbox: J255-
If necessary re‐
new control unit
-J255-
1) The left figure informs of the Kickdown switch position (1 = closed, 0 = open), the right figure informs on
gearbox type (1 = automatic gearbox, 0 = Manual gearbox). If a gearbox, other than indicated, is installed then
check wiring according to current flow diagram.
2) Test is only possible during test drive.
1.11 - Erasing fault memory, ending output
Prerequisites:
• Fault memory has been interrogated.
Erasing fault memory
- Press ⇒key.

Select function XX
- Press keys -0- and -5- (the function "Erase fault memory" is entered with 05).
Passat 1994 ➤

05 Erase fault memory

Rapid data transfer
Fault memory is erased!
-Press ⇒ key.

Select function XX
Notes:
◆ ->
Warning!
Fault memory was not interrogated
If this appears in the display, the test sequence is faulty.

◆ Follow test sequence precisely: first interrogate fault memory, if necessary eliminate faults, then erase.
Ending output
- Press keys -0- and -6- to end the output.

06 End output

Rapid data transfer Help
Enter address word XX
- Switch off ignition.

- Disconnect fault reader V.A.G 1551.
1.11 - Erasing fault memory, ending output 17

Passat 1994 ➤
80 - Heating
1 - Servicing heating system

1.1 - Servicing heating system
Warning!
Always disconnect the battery earth strap before working on the electrical system.
Note:
Before disconnecting battery, obtain radio code for radios with anti-theft coding.
1 Plenum chamber cover
2 Dust and pollen filter
◆ Removing => Fig. 5
3 Hexagon screw with shank M6x22
◆ 5 Nm
18 80 - Heating
Passat 1994 ➤
4 Gasket
5 Series resistance for fresh air blower with overheating fuse -N24-
◆ Removing and installing => Fig. 1
6 Fresh air blower -V2-
7 Footwell vent
◆ Renewing: Remove shelf on drivers' and passenger side, centre console, dash panel bracket and pedal
cluster cover - 23 -
8 Air ducting right
9 Air distributor
◆ Renewing: Remove centre console, dash panel bracket, central vent -12-, heating and fresh air controls
-22-, remove shelf on passenger side; Loosen dash panel -20- and lift
1.1 - Servicing heating system 19

Passat 1994 ➤
10 Right vent
11 Grille
◆ For right vent
12 Central vent
13 Control panel trim
14 Grilles
◆ For central vent
15 Instrument panel trim
16 Grille
◆ For left vent
17 Air vent left
20 80 - Heating
Passat 1994 ➤
18 Rear ducting
◆ Renewing: Remove central console, dash panel bracket, pedal cluster cover - 23 -, footwell outlet - 7 -
19 Rear ducting seal
◆ Renewing: Remove central console, dash panel bracket, pedal cluster cover - 23 -, footwell outlet - 7 -
20 Dash panel
◆ Removing and installing
=> General body repairs; Repair Group 70; Removing and installing dash panel Removing and installing dash
panel
21 Air ducting left

22 Fresh air and heated air controls
◆ Dismantling and assembling => Page 35
◆ Installing and adjusting cables => Page 30

Passat 1994 ➤
23 Pedal cluster cover

24 Cables
◆ Renewing: First remove pedal cluster cover - 23 - and foot well outlet - 7 -
◆ Removing and installing => Page 30
25 Intermediate piece
◆ With gasket
◆ Renewing - remove dash panel beforehand
26 Air distribution housing
◆ With temperature flap
◆ With central flap
◆ With footwell/defrost flap
◆ Do not dismantle further
◆ Renewing: Remove dash panel and heating items -22- to 28- =>Fig. 9 ; Removing and installing heater
◆ Installing: => Page 28 dismantling and assembling heater
22 80 - Heating
Passat 1994 ➤
27 Heat exchanger
◆ Installing: => Page 28 dismantling and assembling heater
◆ After removal renew complete coolant
28 Air ducting with main shut-off flap
◆ Installing: =>Page 28 ; dismantling and assembling heater
29 Hexagon nut M6
◆ 5 Nm

Passat 1994 ➤
-> Fig.1 Removing and installing fresh air blower series resistance with overheating fuse -N24-
Removing:
- Remove shelf on passenger side

- Pull off connections -2-
- Press retainer -arrow- down and remove series resistance -1-
Installing:
- Seal surface between series resistance -1- and air duct before installing with AMV 176 000 05.
-> Fig.2 Removing fresh air blower -V2-

- Fold air duct cover to side.
- Push retaining clips down with a screwdriver, turn fresh air blower clockwise and remove.
24 80 - Heating
Passat 1994 ➤
-> Fig.3 Removing and installing fresh and heated air control unit
Removing:
- Pull off heating control trim panel -3-.

- Remove central vent -2- => Fig. 7 .
- Pull controls -1- with cables attached out of dash panel.
Installing:
- Secure cables to removed controls.
-> Fig.4 Removing instrument panel trim
- Carefully lever out adjustable grilles -1- with long nose pliers.
- Remove trim -2-.
- Remove 4 screws -arrows- and take out instrument panel trim housing.
-> Fig.5 Removing dust and pollen filter
1- Filter element
2- Filter housing
3- Gasket
4- Clip

Passat 1994 ➤
5- Clip
- Remove filter element.

- Press clips -4- and -5- in direction of arrow and remove filter housing.
-> Fig.6 Removing left vent
- Remove instrument panel trim => Fig. 4 .

- Remove lighting switch.
=> Electrical system; Repair Group 96
- Remove bolt -2-.

- Remove vent housing -1-.
-> Fig.7 Removing central vent
- Remove instrument panel trim => Fig. 4 .

- Remove radio.
- Remove switch.
- Unclip control panel trim.
- Remove control -2-.
- Loosen central console -3-.
- Remove 2 screws -arrows- and take out central vent -1-.
26 80 - Heating
Passat 1994 ➤
-> Fig.8 Removing left vent
- Carefully lever out adjustable grilles -2- with long nose pliers
- Remove screw -3- and disengage locating lugs -arrows-.
- Remove vent housing -1-.
-> Fig.9 Removing and installing heater
Note:
Close evaporator connections to ensure that no coolant enters passenger compartment when removing.
Installing:
- Pre-assemble hexagon nuts on engine bulkhead.

- Tighten hexagon nut, with shank, in plenum chamber.
- Tighten engine bulkhead hexagon nuts.

Passat 1994 ➤
2 - Dismantling and assembling heater

2.1 - Dismantling and assembling heater
1 Gasket
◆ Renew
2 Heat exchanger
◆ 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 Air duct with main shut-off flap
6 Series resistor -N24-
28 80 - Heating
Passat 1994 ➤
8 Air duct cover

9 Plug
10 Cables
13 Footwell vent
14 Temperature flap lever
15 Central flap lever
16 Air distribution housing
17 Intermediate piece
18 Gasket
◆ Renew
2.1 - Dismantling and assembling heater 29

Passat 1994 ➤
3 - Installing and adjusting cables

3.1 - Installing and adjusting cables
Notes:
◆ Attach cables to removed controls first and then adjust on heater levers and secure.
◆ Ends of 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 levers of flaps.
◆ When turning control knobs all flaps must be heard to contact the stops.
30 80 - Heating
Passat 1994 ➤
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
3.1 - Installing and adjusting cables 31

Passat 1994 ➤
3 Footwell/defrost flap cable

◆ From air distribution rotary control to footwell/defrost flap
◆ Black sleeve, blue marking
◆ Adjusting cable at footwell/defrost flap => Fig. 3
4 Central flap cable
◆ From air distribution rotary control to central flap
◆ Black sleeve
◆ Adjusting cable at central flap => Fig. 4
32 80 - Heating
Passat 1994 ➤
Fig.-> 1 Adjusting cable at main shut-off flap
- Install heated air and fresh air blower controls.

- Turn blower rotary control onto stop at "0" position.
- Push main shut-off flap lever onto stop (arrow) and secure cable sleeve.
-> Fig.2 Adjusting cable at temperature flap

- Turn temperature rotary control onto stop at "cold" position.
- Push temperature flap lever onto stop (arrow) and secure blue cable sleeve.
-> Fig.3 Adjusting cable at footwell/defrost flap

- Turn air distribution rotary control onto stop in defrost position.
- Push footwell/defrost flap lever onto stop -arrow- and secure black cable sleeve.

Passat 1994 ➤
-> Fig.4 Adjusting cable at central flap

- Turn air distribution rotary control onto stop in defrost position.
- Push central flap lever onto stop -arrow- and secure black cable sleeve.
-> Fig.5 Securing footwell/defrost flap cable to control
- Secure cable sleeve at blue marking -1- on control.

- Secure inner cable to upper lever.
- Adjusting cable at footwell/defrost flap => Fig. 3
34 80 - Heating
Passat 1994 ➤
4 - Dismantling and assembling heated air and fresh air controls

4.1 - Dismantling and assembling heated air and fresh air controls
1 Controls
◆ Including fresh air blower switch -E9-
2 Fresh air control light bulb -L16-
3 Light conductor
4 Cap
4.1 - Dismantling and assembling heated air and fresh air controls 35
Passat 1994 ➤
5 - Servicing electronic heater controls - Thermotronic

5.1 - Servicing electronic heater controls - Thermotronic
Warning!
Always disconnect the battery earth strap before working on the electrical system.
Notes:
◆ Before disconnecting battery, obtain radio code for radios with anti-theft coding.
◆ Remove Thermotronic controls for all tests.
◆ Use leads from adapter set V.A.G 1594 to connect up testers.
◆ Numbers 18 to 28 on the trim are references for the inside temperature. They are not test data.
36 80 - Heating
Passat 1994 ➤
5 Temperature flap control motor -V68-

◆ Check end position of control motor when installed =>Fig. 3
◆ Check resistance of control motor potentiometer -G92- when installed =>Fig. 4
6 Temperature sensor - fresh air intake duct -G89-
◆ Fitting location: in fresh air intake duct behind shelf passenger side.
◆ Check: at 25 °C, resistance should be 10 kω. Resistance decreases with increasing temperature.
◆ Removing and installing: remove cover, right, below dash panel. Turn sensor and pull out of fitting.
5.1 - Servicing electronic heater controls - Thermotronic 37

Passat 1994 ➤
7 Fresh air fan series resistor with overheating fuse -N24-

◆ Removing =>Page 80-1; Servicing heating, Fig. 1
8 Thermotronic control unit -J214-
◆ Renewing=>Fig. 2
◆ The controls are identical to those on the heater system without electronic regulation. The Thermotronic
controls also have the control unit -J214- fitted.
38 80 - Heating
Passat 1994 ➤
11 Trim for dash panel temperature sensor

12 Temperature sensor - dash panel -G56- and blower for temperature sensor -V42-
◆ Checking temperature sensor: at 25°C, resistance should be 3 kω. Resistance decreases as temperature
increases (measure between chambers 4 and 5).
13 Thermotronic wiring loom

Passat 1994 ➤
Fig.1 -> Removing dash panel temperature sensor -G56- and temperature sensor blower -V42-
Remove through the radio aperture in the instrument panel
- Remove radio.
- Pull off trim for temperature sensor.
- Release temperature sensor -G56- and blower -V42- with screwdriver (arrows) and take out through radio
aperture.
Fig.2 -> Renewing Thermotronic control unit -J214-
- Removing heating and fresh air controls => Page 25 , Fig. 3 .

- Turn Thermotronic centre rotary control -2- past the resistance to the blue end point.
- Turn control unit pinion -1- until the marking and the pin are aligned.
- Assemble control unit -1- and controls -2-.
40 80 - Heating
Passat 1994 ➤
Fig.3 -> Checking end position of control motor -V68- when installed
- Pull 5-pin connector off control unit -J214-

- Connect cables from adapter set V.A.G 1594 to chambers 4 and 5.
- Connect to 12 V supply. Direction of rotation can be changed by reversing polarity of voltage supply.
- Move temperature flap -2- with control motor -1- from heater end position -4- to fresh air end position -3-.
- Check whether the temperature flap lever -2- reaches the stop when at the end position. If necessary, adjust
length of connecting rod -5- with temperature flap -2- on stop.
Note:
If the connecting rod has been loosened, the rotary control is to be turned to the blue mark "cold" and the
temperature flap lever must be pretensioned by pressing lightly towards cold and secured (4 clips).
Fig.4 -> Checking resistance of potentiometer -G92- for control motor -V68- when installed

- Measure resistance between chambers 1 and 2 using hand multimeter V.A.G 1526:
Fresh air end position -2-, Specification: 2 kω ±20%

Heating end position -1-, Specification: approx. 0,2 kω

Passat 1994 ➤
87 - Air conditioning
1 - Notes on repair work to vehicles with air conditioning and on handling

refrigerant
1.1 - Notes on repair work to vehicles with air conditioning and on handling refrigerant
The assemblies and pipe work system of the air conditioner are filled with refrigerant R134a (tetrafluorethane,
CF3-CH2F or CH2F-CF3).
At present the R134a refrigerant pressure vessels are labelled with the following trade names:
- H-FKW 134a
- SUVA 134a
- ARCTON 134a
These trade names may vary from country to country.
Further information:
◆ The appropriate fault finding programme can be found in, Fault finding "Heating, Air conditioner - binder 2".
◆ The valid current flow diagrams can be found in, Current flow diagrams, Electrical fault finding and Fitting
locations binder.
◆ Repairs on the air conditioner refrigerant system can be found in Workshop Manual "Air conditioner with
R12 refrigerant R134a, May 1992 ▸".
Warning!
Before working on the electrical system disconnect the battery earth strap.
Notes:
◆ A notice on the lock carrier plate in the engine compartment provides information concerning the refrigerant
and refrigerant oil used (air conditioning using R134a the refrigerant oil is a Poly-Alkylen-Glycol base with
additives).
◆ The components of the R134a refrigerant circuit are identified by labelling or by green stickers.
◆ Before disconnecting the battery, the codes for radios with anti-theft coding are to be obtained.
1.2 - Safety precautions for work on vehicles with air conditioning and when handling
refrigerant R134a
The following safety precautions must be observed for the refrigerant (in some countries additional regulations
may apply):
If it is necessary to evacuate the refrigerant circuit during repairs to the vehicle, the vehicle must be taken to a
specialist workshop!
Reason:
Only specialist workshops are equipped with suitable evacuating equipment to handle the refrigerant compe‐
tently.
Notes:
◆ It is recommended that an eye wash bottle be kept nearby. Should liquid refrigerant contact the eyes, eyes
must be thoroughly rinsed with water for approx. 15 minutes.
42 87 - Air conditioning
Passat 1994 ➤
◆ Then apply eye drops and contact a doctor immediately, even if eyes do not hurt. The doctor must be
informed that the frost bite has been caused by refrigerant R134a.
◆ If, in spite of these safety measures, refrigerant comes into contact with other body parts, these areas must
also be immediately thoroughly rinsed with cold water for at least 15 minutes.
Only work on the refrigerant circuit in well ventilated rooms. The refrigerant is not to be stored in shafts or
openings leading to cellars.
Reasons:
Refrigerant is odourless and colourless and heavier than air and therefore displaces oxygen. If, even after taking
precautions, refrigerant escapes there is a danger of asphyxiation without advance warning in poorly ventilated
rooms/pits.
Precautions:
Before working on a refrigerant circuit ensure that there are no cellar openings, pits or shafts within 5 m. Any
available extraction systems to be in operation.
Do not weld. braze or soft-solder parts of the charged air conditioner.
This also applies to welding and soldering work on the vehicle when the danger exists that parts of the air
conditioner will heat up. During paintwork, object temperatures in the drying oven or in its pre-heating zone
must not exceed 80° C.
Reason:
Heating results in high pressure in the system which may lead to pressure relief valve operating. During elec‐
trical welding invisible ultra-violet rays are produced, these penetrate hoses and breakdown the refrigerant.
Precautions:
Damaged or leaking air conditioner components are not to be repaired by soldering/welding, they must always
be renewed, first evacuate refrigerant from refrigerant circuit using refrigerant evacuation station (take vehicle
to specialist workshop).
1.2 - Safety precautions for work on vehicles with air conditioning and when handling
refrigerant R134a 43
Passat 1994 ➤
1.3 - Service work on the air conditioner which can only be carried out in specially-equipped
workshops
Note:
Only air conditioner pressure switch -F129- can be renewed in all workshops - marked with *.
1 Evacuating and charging valve

◆ Low pressure side
2 Evacuating and charging valve
◆ High pressure side
3 Air conditioner pressure switch -F129-*
◆ Pressure switch can be removed without evacuating refrigerant from system.
Passat 1994 ➤
4 Expansion valve
◆ Engine compartment right
5 Evaporator
◆ In passenger compartment
6 Compressor magnetic coupling -N25-
7 Oil filling/draining plug
8 Compressor
9 Condenser
10 Fluid container with drier
11 Sight glass
◆ Will be discontinued
1.3 - Service work on the air conditioner which can only be carried out in specially-equipped
workshops 45
Passat 1994 ➤
2 - Air conditioner with manual controls

2.1 - Air conditioner with manual controls
2.2 - Servicing air conditioning and heating - Passenger compartment
Note:
Parts marked with an * can only be serviced by specially-equipped service workshops, since refrigerant circuit
must be evacuated beforehand with extraction station V.A.G 1770 or V.A.G 1771.
1 Gasket*
◆ Renew
Passat 1994 ➤
2 Heat exchanger*
◆ Gaskets must be bonded gap-free all around.
◆ If retaining lugs do not engage when fitting, secure heat exchanger with screws.
◆ After removal replace complete coolant.
3 Connecting piece
◆ With gasket
◆ Renewing - remove dash panel beforehand
4 Evaporator housing*
◆ With evaporator
5 Air intake*
◆ With fresh and recirculating air flap
6 Series resistance -N24-
◆ Renewing => Fig. 2
2.2 - Servicing air conditioning and heating - Passenger compartment 47

Passat 1994 ➤
7 Vacuum unit for fresh and recirculating air flap*

◆ Ventilated: Fresh air operation
8 Fresh air blower switch -E9-
9 Air conditioner switch -E35-
◆ With switch for fresh/recirculating air flap -E159-
◆ With control lamp for lighting - Air conditioner switch -L43-
10 Vacuum pipe*
◆ Vacuum hose connection diagram => Page 68
◆ Removing and installation => Fig. 3
Passat 1994 ➤
12 Evaporator housing cover

◆ Renewing: First remove dash panel and footwell outlets - 32 -
13 Retaining strap
◆ Renewing: First remove dash panel and footwell outlets - 32 -
14 Air duct right
15 Air distributor
◆ Renewing: Remove centre console, dash panel bracket, central vent -13-, heating and fresh air controls
-30-, remove shelf on passenger side; loosen dash panel -26- and lift
16 Right vent
◆ Removing => Page 27 , Fig. 8

Passat 1994 ➤
17 Grille
◆ For right vent
18 Central vent
20 Grilles
◆ For central vent
21 Instrument panel trim
22 Grille
◆ For right vent
23 Air vent left
Passat 1994 ➤
24 Rear heater duct

◆ Renewing: First remove central console, dash panel bracket, pedal cluster cover - 34 -, footwell outlet
- 32 -, seats and carpet
25 Gasket
26 Dash panel
=> General body repairs; Repair Group 70; Removing and installing dash panel Removing and installing dash
panel
27 Air duct left

28 Air conditioner switch-off relay
-J365-
◆ Only on vehicles with code letters AAA, ABV, AEK, ADY and AGG
◆ Behind the central console
◆ Control number 147

Passat 1994 ➤
29 Air conditioner shut-off control unit -J314-

◆ Only on vehicles with code letters AAZ and manual gearbox
◆ Behind the centre console
30 Air conditioner magnetic coupling cut-out relay -J246-
◆ Only on vehicles with Diesel engine and automatic gearbox
31 Warm and fresh air controls
◆ With air conditioner switch -E35-
◆ Installing and adjusting cables
=> Page 64
=> Page 25 , Fig. 3
◆ Dismantling and assembling => Page 35
Passat 1994 ➤
32 Footwell outlet
◆ Renewing: Remove shelf on drivers' side and passenger side, centre console, dash panel bracket and
pedal cluster cover -33-
33 Cables
◆ Renewing: First remove pedal cluster cover - 34 - and footwell outlet - 32 -
◆ Installing and adjusting => Page 64
35 Distributor housing*
◆ With temperature flap
◆ With central flap
◆ With footwell/defrost flap
36 Vacuum pipe connection*

Passat 1994 ➤
-> Fig.1 Removing air conditioner switch -E35-
Press the switch unit (at the four locating points) against the controls and at the same time towards the buttons.
-> Fig.2 Renewing series resistance -N24-

- Remove glove box.
- Pull off connector -2- and remove screws -3-.
- Seal surface between series resistance -1- and air duct before installing with AMV 176 000 05.
-> Fig.3 Removing and installing fresh air blower -V2-

- Remove glove box.
- Pull off connector -1-.
- Remove clamp -3-.
- Unscrew Qty. 5 screws -arrows- and remove fresh air blower -2- downwards.
Passat 1994 ➤
2.3 - Servicing air conditioning and heating - Engine compartment
Note:
Parts marked with * can only be serviced in specially equipped Service workshops. The refrigerant must be
evacuated with Service station V.A.G 1770 or V.A.G 1771.
1 Sight glass*
2 Evacuating and charging valve*
2.3 - Servicing air conditioning and heating - Engine compartment 55

Passat 1994 ➤
4 Air conditioner pressure switch -F129-

◆ Testing => Fig. 2
◆ Removing and installing:
- Tightening torque 8 Nm
- Renew O ring seal (note Part No.).
5 Ambient temperature switch -F38-
◆ Switches off magnetic coupling -N25- at low ambient temperature (off at -1°C, on at +7°C).
7 Expansion valve*
◆ Opening must be sealed sufficiently to stop water ingress
◆ Checking insulation piece for expansion valve => Fig. 6
Passat 1994 ➤

9 Water drain valve
◆ Behind bulkhead insulation
◆ Valve lips must not be sealed with underseal
10 Heat exchanger and vacuum hose guide
11 Vacuum reservoir
◆ Insertion depth for vacuum hose: 30 mm
12 Vacuum hose
13 Non-return valve
Direction of suction indicated by arrow

Passat 1994 ➤
14 Two way valve for fresh and recirculating air flap -N63-
◆ Open when electrically connected
◆ Installing => Fig. 5
15 Radiator fan control unit -J293-
16 Thermo switch for air conditioner cut-off -F163- and thermo switch for coolant fan, 3rd speed -F165-
◆ Thermo switch for air conditioner shut-off -F163- only on vehicles with engine codes AAA, AAZ or ABV
◆ Thermo switch for coolant fan, 3rd speed -F165- only on vehicles with 3-speed fan motor
Passat 1994 ➤
◆ -F165- switch coolant fan: into 3rd speed as temperature increases (on at 112°C, off at 108°C).
◆ -F163- switches off magnetic coupling -N25- at excessively high coolant temperature (off at 119°C, on
at 112°C).
◆ Removing and installing on vehicles with engine code AAA => Fig. 1
17 Condenser*
18 Pressure relief valve*
◆ Checking => Fig. 8
19 Magnetic coupling -N25-*
20 Fluid reservoir with drier*

Passat 1994 ➤
-> Fig.1 Removing and installing thermo switch for air conditioner shut-off -F163- and thermo switch for
coolant fan, 3rd speed -F165- on vehicles with engine code AAA
Notes:
◆ Cooling system is pressurized when engine is warm. If necessary, release pressure before carrying out
repairs.
◆ Refill with coolant after installing thermo switch.
1- Clip
2- Thermostat housing
3- O ring
4- Thermo switch -F163-/-F165-, brown
5- Temperature sender switch -G2-/-F87-, yellow
6- Coolant temperature sender -G62-, blue
Passat 1994 ➤
-> Fig.2 Checking air conditioner pressure switch -F129-

◆ Visual check: Ensure that O-ring (colour: red) 10.8 mm x 1.8 mm is seated in groove
Switch part between contacts -T4a/1- and -T4a/2 of connector housing switches magnetic coupling -N25- off
when refrigerant circuit insufficiently filled or pressure too high.
- Opens below 1.2 bar and closes again above 2.4 bar (switching threshold)
- Opens above 32 bar and closes again below 24 bar (switching threshold)
- Briefly bridge circuit between chambers 1 and 2 with engine running. If the magnetic coupling -N25- switches
on, the refrigerant system is empty. Take vehicle to specialist service workshop.
Switch part between contacts -T4a/3- and -T4a/4- of connector housing switches the coolant fan -V7- to second
speed if the pressure in the refrigerant circuit increases.
- Closes above 16 bar and opens below 12.5 bar (switching threshold)
-> Fig.3 Removing and installing water drain valve
1- Bulkhead
2- Evaporator housing
3- Valve flap, shown raised

Passat 1994 ➤
4- Water drain valve
5- Hexagon key 14 mm
Removing:
- Turn valve 45° with hexagon key -5- and pull out.
Installing:
- When installing ensure lip lies downward.
-> Fig.4 Removing and installing ambient temperature switch -F38-

Installed in plenum chamber right
1 - Connector
2 - Ambient temperature switch
3 - Retainer
-> Fig.5 Installing fresh air and recirculating air flap two-way valve -N63-
1 - Cap
Check air passage slot
2 - Two-way valve (other designs possible)
Passat 1994 ➤
-> Fig.6 Checking expansion valve insulation piece
1- Insulator
2- Expansion valve
◆ The insulator prevents drop in air conditioner efficiency caused by increasing temperatures in the engine
compartment.
-> Fig.7 Removing and installing vacuum reservoir
1 - Plastic pipe
Installation depth: 30mm
2 - Rubber seal
3 - Vacuum reservoir
4 - Nut
5 - Wheel housing liner
◆ Removing and installing wheel housing liner
=> General body repairs; Repair group 66; removing and installing wheel housing liner removing and installing
wheel housing liner
-> Fig.8 Checking pressure relief valve on compressor
◆ Task: protects refrigerant circuit against over-pressure

◆ The pressure relief valve tell-tale indicates if valve has operated. An adhesive attached plate is pushed out.
In this case take vehicle to specialist workshop.

Passat 1994 ➤
2.4 - Installing and adjusting cables
Notes:
◆ First connect cables to removed controls then adjust and secure cables to levers on air conditioner.
◆ Sleeve ends of cables which are marked with a coloured line are attached to the controls.
◆ Position cable sleeves -2- and -3- at stops on the controls and then secure. Secure sleeve for cable -1-
=>Fig. 4 .
◆ Adjust cables at flap levers with the controls installed.
◆ All flaps must audibly contact stop when controls are turned.
Passat 1994 ➤
1 Footwell/defrost flap cable

◆ From air distribution rotary control knob to footwell/defrost flap
◆ Black sleeve
◆ Adjusting cable at footwell/defrost flap => Fig. 1
2 Cable for central flap
◆ From air distribution rotary control knob to centre flap
◆ Black sleeve
◆ Adjusting cable at central flap => Fig. 2
3 Temperature control flap cable
◆ From temperature rotary control knob to temperature control flap
◆ Blue sleeve
◆ Adjusting cable at temperature control flap => Fig. 3

Passat 1994 ➤
-> Fig.1 Adjusting cable at footwell/defrost flap
- Install warm and fresh air controls.

- Turn air distribution rotary control knob to stop at "defrost" position.
- Press footwell/defrost flap lever onto stop -arrow- and secure black cable sleeve.
-> Fig.2 Adjusting cable at central flap
- Install warm and fresh air blower controls.

- Turn air distribution rotary control knob onto stop at "defrost" position.
- Press central flap lever onto stop -arrow- and secure black sleeve.
-> Fig.3 Adjusting cable at temperature flap
- Install warm and fresh air blower controls.

- Turn temperature rotary control knob to stop at "cold" position.
- Press temperature flap lever onto stop -arrow- and secure blue cable sleeve.
Passat 1994 ➤
-> Fig.4 Securing footwell/defrost flap cable to control
- Secure cable sleeve at blue marking -1- on control.

- Secure inner cable to upper lever.
- Adjusting cable on footwell/defrost flap => Fig. 1

Passat 1994 ➤
2.5 - Vacuum hose connection diagram
Notes:
◆ Insertion depth of vacuum hose in vacuum reservoir: 30 mm. Overlap of vacuum hose on plastic pipe: onto
stop (approx. 15 mm)
◆ Vacuum is produced by petrol engines in the intake manifold and by Diesel engines via an exhauster

5 Reduction hose
6 Hose
3.5 x 2 x 90 mm
7 Plastic pipe
4 x 1 x 950 mm
Passat 1994 ➤
8 Plastic pipe
4 x 1 x 1030 mm
9 Foam pipe
10 Plastic pipe
4 x 1 x 490 mm
11 Vacuum reservoir
12 Cable tie
13 Non-return valve
Direction of suction indicated by arrow
14 Hose
3.5 x 2 x 40 mm
15 T-connection
16 Two way valve for fresh and recirculating air flap -N63-
2.5 - Vacuum hose connection diagram 69

Passat 1994 ➤
17 Hose
3.5 x 2 x 350 mm
18 Hose
3.5 x 2 x 245 mm
19 Hose
3.5 x 2 x 116 mm
20 Hose
3.5 x 2 x 116 mm
21 Non-return valve
Passat 1994 ➤
2.6 - Removing and installing compressor bracket - 4 Cyl. petrol engine
Note:
The compressor bracket and related components can be removed and installed without having to open the
refrigerant circuit
1 Alternator and compressor bracket

◆ Removing and installing alternator
=> Repair group 27
2 Tensioning element for tensioner

3 Hexagon nut M8
◆ 30 Nm
2.6 - Removing and installing compressor bracket - 4 Cyl. petrol engine 71

Passat 1994 ➤
4 Compressor bracket
◆ Installing:
- Insert bolts - 5 - and - 6 - 2 to 5 turns.
- Screw in bolt -6- until bracket contacts threaded bush - 7 -.
- First tighten bolt - 5 - to 45 Nm, then tighten bolt - 6 - to 45 Nm.
5 Socket head combi-bolt M10x30
◆ 45 Nm
◆ 45 Nm
7 Threaded sleeve
8 Refrigerant hoses
Passat 1994 ➤
9 Compressor
◆ Removing:
- Loosen hexagon bolt - 11 - a couple of turns and knock-back threaded sleeve - 7 - from compressor.
Then remove hexagon bolts.
10 Ribbed belt
=> Repair group 13
11 Hexagon bolt M10x112

◆ 45 Nm
◆ 25 Nm
13 Tensioner

Passat 1994 ➤
2.7 - Removing and installing compressor bracket - 6 Cyl. petrol engine
Note:
Compressor and related parts can be removed and installed without having to open refrigerant circuit
1 Alternator, compressor and P.A.S. vane pump bracket

◆ Removing:
- First remove alternator, compressor - 8 - and P.A.S. vane pump
- Removing and installing alternator
=> Electrical system; Repair Group 27; Removing and installing alternator Removing and installing alternator
Passat 1994 ➤
- Removing and installing P.A.S. vane pump
=> Repair Group 48; Removing and installing P.A.S. vane pump, vehicles with 128 kW engine Removing and
installing P.A.S. vane pump, vehicles with 128 kW engine
◆ Installing:
- First, fit "fitted bolts" - 3 - and -12-.
2 Washer 8.4x16x1.6
3 Fitting bolt M8x28
◆ 25 Nm
◆ 25 Nm
◆ 25 Nm
◆ 25 Nm

Passat 1994 ➤
7 Refrigerant hoses
8 Compressor
◆ Removing:
- First remove front bumper
=> General body repairs; Repair Group 63; Servicing bumpers Servicing bumpers
- Loosen bonnet lock carrier and pull forward

- Remove headlight housing
=> Electrical system; Repair Group 94; Servicing headlights Servicing headlights
- Remove double ribbed belts - 9 -

- Remove alternator
=> Electrical system; Repair Group 27; Removing and installing alternator Removing and installing alternator
Passat 1994 ➤
- Loosen hexagon bolts - 10 - a couple of turns and knock-back threaded sleeves from compressor. Then
remove hexagon bolts.
9 Double ribbed belts

◆ Removal and installing
=> 6-cylinder injection engine, Mechanics; Repair Group 13; Removing and installing ribbed belts Removing
and installing ribbed belts

◆ 45 Nm
◆ 25 Nm
12 Fitted bolt M8x20
◆ 25 Nm
13 Washer 8.4x16x1.6

Passat 1994 ➤
2.8 - Removing and installing compressor bracket - Turbo Diesel engine
Engine codes AAZ and 1Z
The compressor bracket and related components can be removed and installed without having to open the
refrigerant circuit
1 Hexagon bolt M8 x 22
◆ 25 Nm
2 Alternator and compressor bracket
◆ Removing:
- First remove alternator - 4 - and compressor - 9 -.
◆ 25 Nm
Passat 1994 ➤
4 Alternator
◆ Removal and installing
=> Electrical system; Repair group 27; Removing and installing alternator Removing and installing alternator
5 Tensioning element for tensioner

6 Socket head bolt M8 x 22
◆ 25 Nm
◆ Qty. 3
7 Hexagon nut M8
◆ 30 Nm
◆ Qty. 4
◆ 25 Nm
2.8 - Removing and installing compressor bracket - Turbo Diesel engine 79

Passat 1994 ➤
9 Compressor
◆ Removing:
- Loosen hexagon bolt - 11 - a couple of turns and knock-back threaded sleeve from compressor. Then
remove hexagon bolts.
10 Ribbed belt
=> Repair group 13

◆ 45 Nm
◆ Qty. 2
12 Tensioner
◆ Removing:
- First loosen M6 x 16 socket head bolt on tensioning roller tensioning element and knock-back tensioning
roller with rubber hammer.
Passat 1994 ➤
3 - Climatronic - air conditioner with automatic regulation

3.1 - Climatronic - air conditioner with automatic regulation
3.2 - Control and function of the control and display unit
1 - Blower speed indicator

Displays a medium speed in automatic operation -7-, independent of actual blower speed.
2 - Ambient temperature indicator
Ambient temperature is measured by ambient temperature sensor -G17-. In event of failure, temperature
sensor in fresh air intake duct -G89- takes over the function. If both temperature sensors fail, "--" appears
in the display.
If road speed drops to below 5 km/h, the value displayed will not change. The actually measured value
is not displayed as this is affected by heat from the engine at low speeds.
3 - Windscreen defrost indicator
4 - Air recirculation indicator
5 - Air flow direction indicator
6 - Selected interior temperature

7 - Vehicles up to 07.95:
Display "AUTO" (automatic operation) or "OFF" (system off)
Vehicles from 08.95:
"AUTO" (automatic operation) or "ECON" (compressor only switched off)
8 - "Automatic operation" button
9 - "Blower speed higher" button
10 - "Blower speed lower" button
(the system is also switched off with this button)
11 - "Defrost windscreen" button
12 - "Air recirculation" button
13 - "Air flow to upper body" button
14 - "Air flow to foot well" button
15 - Celsius/Fahrenheit selector button
3.1 - Climatronic - air conditioner with automatic regulation 81

Passat 1994 ➤
16 - "Warmer" button
17 - "Colder" button
18 - Vehicles up to 07.95:
OFF button for " System on/off"
Vehicles from 08.95:
ECON button for "Switching compressor on/off"
Notes:
◆ The automatic operation of the Climatronic can be influenced with buttons 9 - 14.
◆ When deviating from automatic operation the display "AUTO" -7- will disappear; the control of the Climatronic
continues to function under the programmed restrictions.
◆ Returning to automatic operation is only possible by pressing button -8-.
◆ On vehicles from 08.95 the Climatronic can only be completely switched off with button 10.
◆ In ECON operation only the compressor is switched off, the heating and ventilation operation continues to
be controlled electronically.
Passat 1994 ➤
3.3 - Servicing Climatronic - passenger compartment
Notes:
◆ Parts marked * can only be serviced in specially equipped Service workshops, as the refrigerant must be
◆ Removing and installing components without item numbers =>Page 46
1 Climatronic relay -J254-

2 Heating and air conditioning fuse -S23-
◆ Only installed in vehicles up to 07.95
3.3 - Servicing Climatronic - passenger compartment 83

Passat 1994 ➤
3 Sunlight penetration photo sensor -G107-

◆ Tasks: controls temperature flap and fresh air blower depending on light intensity
◆ In event of failure: control unit -J255- assumes fixed value
◆ Checking: self diagnosis using V.A.G 1551
4 Double vacuum unit - foot well/defrost flap
5 Air intake*
◆ With fresh air and recirculating air flap and air flow flap
Passat 1994 ➤
6 Fresh air intake duct temperature sender -G89-*

◆ Task: temperature sensor controls temperature flap and fresh air blower depending on temperature
◆ In event of failure: ambient temperature sensor -G17- takes over task. If both sensors are defective,
operation continues assuming value of +10°C. Air recirculation is not possible. Control and display unit
-E87- reads: "--"
◆ Removing: first remove air flow flap positioning motor - 7 -.

Passat 1994 ➤
7 Air flow flap positioning motor -V71-*

◆ Checking: Self diagnosis using V.A.G 1551
◆ Removing: first remove dash panel and complete air conditioner
8 Valve block bracket
9 Valve strip -N53-
◆ If no current is flowing in the valve strip, no vacuum is created
◆ Removing and installing=> Fig. 5
10 Blower control unit -J126-
◆ Task: precisely controls fresh air blower speed depending on voltage
Passat 1994 ➤

◆ Removing: first remove dash panel and complete air conditioner
◆ Removing=> Page 54 , Fig. 3
13 Central vent
14 Climatronic control unit -J255-

Passat 1994 ➤
15 Control and display unit -E87-

◆ Operation and function => Page 81
16 Dash panel temperature sensor trim
17 Dash panel temperature sensor -G56- with temperature sensor fan -V42-
◆ Task: Temperature sensor controls temperature flap and fresh air blower in dependence on temperature
◆ In event of -G56- failure: continued operation assuming value of +24°C
Passat 1994 ➤
18 Air distributor
◆ Removing => Fig. 49 , item 15
19 Air conditioner switch-off relay -J365-
◆ Only on vehicles with ADY and AEK engines up to 07.95
20 Central vent vacuum unit
◆ Removing: Remove dash panel insert, rotate, pull out

Passat 1994 ➤
21 Central flap positioning motor -V70-

22 Temperature flap positioning motor -V68-
◆ Checking and adjusting end position of installed positioning motor =>Page 101
◆ Removing: first remove central console and footwell vent (removing footwell vent) =>Page 53 , item
32 )
Passat 1994 ➤
23 Front vent temperature sender -G152-

◆ Only installed in vehicles from 08.95
◆ Function: Controls the air distribution defrost/footwell and the fresh air blower speed dependent upon
the vent temperature.
◆ Emergency running in event of front vent temperature sender-G152- failure: Continued operation as‐
suming value of +80°C
◆ Removing and installing=> Fig. 7
24 Distributor and evaporator housing*
◆ With heat exchanger
◆ with evaporator
25 Vacuum pipe

Passat 1994 ➤
-> Fig.1 Removing Climatronic control unit -J255- and control and display unit -E87-
- Lever out control and display unit from below with screwdriver (arrows -A-)
Note:
Control and display unit cannot be levered out from above as this could damage the display.
- Release connectors and pull off.

- Press control unit clips (arrows -B-) together.
- Remove control unit.
-> Fig.2 Renewing blower control unit -J126-

- Remove glove compartment.
- Pull off connector -2- and remove screw -3-.
- Seal area between series resistor -1- and air duct with AMV 176 000 05 before fitting.
Passat 1994 ➤
-> Fig.3 Removing dash panel temperature sensor -G56- and temperature sensor blower -V42-
Remove through the radio aperture in the Climatronic instrument panel

- Remove radio.
- Remove temperature sender trim.
- Release temperature sensor -G56- and blower -V42- with a screwdriver (arrows) and take out through radio
aperture.
-> Fig.4 Removing and installing central flap positioning motor -V70-
1- Central flap positioning motor
2- Intermediate gear
3- Central flap bearing
Removing:
- First remove central console and footwell vent.
Installing:
For correct setting of central flap markings (arrows) must be aligned.
-> Fig.5 Removing and installing valve strip -N53-

1- Valve strip
2- Vacuum hose, white
3- Vacuum hose, red

Passat 1994 ➤
4- Vacuum hose, green
5- Vacuum hose, black
6- Vacuum hose, yellow
7- Valve block bracket
8- Connector
Removing:

- Remove glove compartment.
- Pull off vacuum hoses and connections.
- Unscrew valve block -arrow-.
Installing:
- Use valve block 357 907 533 as replacement part.

- Connect up vacuum hose according to colour coding on connection pipes.
-> Fig.6 Removing and installing double vacuum unit
1- Vacuum hose, green

2- Vacuum hose, yellow
3- Double vacuum unit
4- Retainer
5- Lever for footwell/defrost flap
Removing:
- First remove dash panel and heating and air conditioning unit
-> Fig.7 Removing and installing front vent temperature sender -G152-
- Remove front left footwell trim

- Pull connector -1- off front vent temperature sender -G152- -2-
Passat 1994 ➤
- Turn front vent temperature sender -G152- -2- by 90° and remove
3.4 - Servicing Climatronic - engine compartment
Note:
Parts marked with * can only be serviced in specially equipped Service workshops. The refrigerant must be
1 Sight glass*

Passat 1994 ➤
4 Air conditioner pressure switch -F129-

◆ Removing and installing:
- Tightening torque 8 Nm
- Renew O ring seal (note Part No.).
6 Expansion valve*
◆ Checking insulation piece for expansion valve => Fig. 6
8 Water drain valve
◆ Behind bulkhead insulation
◆ Removing and installing => Page 61 , Fig. 3
Passat 1994 ➤
9 Coolant temperature sender -G62-

◆ Only installed in vehicles up to 07.95
◆ Task: coolant temperature sender controls air distribution defrost/footwell and fresh air blower speed
depending on temperature
◆ In event of -G62- failure : operation continues assuming a value of +125°C
◆ Removing and installing on vehicles with engine code ABF => Fig. 8
10 Heat exchanger and vacuum hose guide
11 Vacuum reservoir
◆ Insertion depth for vacuum hose: 30 mm
◆ Removing and installing => Page 63 , Fig. 7
3.4 - Servicing Climatronic - engine compartment 97

Passat 1994 ➤
12 Vacuum hose
13 Non-return valve
◆ Arrow points in direction of vacuum
14 Radiator fan control unit -J293-
15 Thermo switch for air conditioner cut-off -F163- and thermo switch for coolant fan, 3rd speed -F165-
◆ Thermo switch for air conditioner shut-off -F163- only on vehicles with engine codes AAA, ABV or AAZ
◆ Thermo switch for coolant fan, 3rd speed -F165- only on vehicles with 3-speed fan motor
Passat 1994 ➤
◆ -F165- switch coolant fan: into 3rd speed as temperature increases (on at 112°C, off at 108°C).
◆ -F163- switches off magnetic coupling -N25- at excessively high coolant temperature (off at 119°C, on
at 112°C).
◆ Removing and installing on vehicles with engine code AAA => Page 60 , Fig. 1
16 Condenser*
17 Pressure relief valve*
◆ Checking => Page 63 , Fig. 8
18 Magnetic coupling -N25-*

Passat 1994 ➤
19 Fluid reservoir with drier*

20 Ambient temperature sensor -G17-
◆ Function: temperature sensor controls temperature flap and fresh air blower, depending on temperature
◆ In event of failure: fresh air intake duct temperature sensor -G89- takes over task. If both sensors are
defective, operation continues assuming a value of +10°C. Air recirculation not possible. Control and
display unit -E87- indicates: "--"

Passat 1994 ➤
-> Fig.8 Removing and installing coolant temperature sender -G62- on vehicles with engine code ABF
Notes:
◆ Cooling system is pressurized when engine is warm. If necessary, release pressure before carrying out
repairs.
◆ Refill with coolant after installing thermo switch.
1- Clip
2- Connection
3- O ring
4- Coolant temperature sender -G62-
5- Connector
3.5 - Checking and adjusting end position of installed temperature flap positioning motor
- Remove footwell vent => Page 46 , item 32

- Move temperature flap -2- with control motor -1- from heater end position -4- to fresh air end position -3-.
- Check whether the temperature flap lever -2- reaches the stop at the end position. If necessary, adjust length
of connecting rod -5- with temperature flap -2- on stop.
Checking:
By reversing polarity of 12V voltage, positioning motor must move to both end positions.

Passat 1994 ➤
3.6 - Vacuum hose connection diagram
Vacuum hoses in passenger compartment
Notes:
◆ Plug vacuum hoses onto valve strip and vacuum hoses to the stop.
◆ Vacuum hose connections in engine compartment => Page 105
1 Valve block -N53-

◆ Connections for vacuum hoses colour-coded
2 Central vent vacuum unit
◆ Remove dash panel insert

Passat 1994 ➤
3 Vacuum unit for footwell/defrost flap

◆ Remove dash panel
4 Vacuum unit for fresh and recirculating air flap
◆ Remove dash panel, air distributor housing and evaporator housing, but first evacuate refrigerant circuit
5 Vacuum hose, white
◆ From valve strip -N53- to fresh air and air recirculation flap vacuum unit
6 Vacuum hose, black
◆ From vacuum reservoir in engine compartment to valve strip -N53-
7 Vacuum hose, red
◆ From valve block -N53- to centre vent vacuum unit

Passat 1994 ➤
8 Vacuum hose, green

◆ From valve strip -N53- to vacuum unit for footwell/defrost flap
9 Vacuum hose, yellow
◆ From valve strip -N53- to vacuum unit for footwell/defrost flap

Passat 1994 ➤
Vacuum hoses in engine compartment
Notes:
◆ Insertion depth of vacuum hose in vacuum reservoir: 30 mm. Overlap dimension of vacuum hose on plastic
pipe: onto stop (approx. 15 mm)
◆ Vacuum hose connections in passenger compartment => Page 102
◆ Vacuum is produced by petrol engines in the intake manifold and by Diesel engines via an exhauster.
1 Reducing hose
◆ Vacuum hose to valve strip -N53- (in passenger compartment)
2 Plastic pipe
4 x 1 x 540 mm

Passat 1994 ➤
3 Plastic pipe
4 x 1 x 950 mm
4 Plastic pipe
4 x 1 x 1030 mm
5 Foam pipe
6 Plastic pipe
◆ 4 x 1 x 490 mm
7 Vacuum reservoir
8 Cable tie
9 Non-return valve
Stamped-on arrow indicates direction of suction
10 Hose
3.5 x 2 x 40 mm
11 T-connection

Passat 1994 ➤
12 Hose
3.5 x 2 x 245 mm
13 Hose
3.5 x 2 x 160 mm
14 Hose
3.5 x 2 x 116 mm
15 Non-return valve

VW Passat b4 (1994 95) Heating Air Conditioner Eng

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Service

Service Department. Technical Information

87 - Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

1 - Self diagnosis of Climatronic

=> Fault finding, Heating, Air Conditioning - Binder 2

◆ Measures to correct current specific faults:

=> Technical Service Handbook

=> Air conditioning with refrigerant R134a

1.1 - Self diagnosis of Climatronic 1

1.3 - Technical data of self diagnosis

1.4 - Test prerequisites for self diagnosis

1.5 - Connecting fault reader V.A.G 1551 and selecting function

-> Indicated on display:

-> Indicated on display:

-> Shown in display after input of address word 08:

-> Indicated on display:

- Confirm entry with the Q key.

and then the display shows e.g.:

The control unit identification number is displayed:

Vehicles from 08.95

-> (The ignition must be switched on!)

-> Shown in display after input of address word 08:

and then the following appears in the display:

The control unit identification number is displayed:

1.5 - Connecting fault reader V.A.G 1551 and selecting function 3

Vehicles from 08.95

-> Indicated in display (function selection, e.g. 02 - Interrogating fault memory):

1.6 - Chart of functions that can be selected

-> Indicated on display (function selection, e.g. 02 - Interrogating fault memory):

1.7 - Interrogating fault memory

-> Indicated on display (function selection):

-> Indicated on display:

- Confirm entry with the Q key.

-> Indicated on display (function selection):

- End output (function 06) => Page 16 .

1.8 - Fault table

=> Fault finding, Heating, Air Conditioning - Binder 2

V.A.G 1551 printout Possible cause of fault Rectifying fault

1) One of these read-outs is displayed in addition to relevant component.

V.A.G 1551 printout Possible cause of fault Rectifying fault

1.7 - Interrogating fault memory 5

V.A.G 1551 printout Possible cause of fault Rectifying fault

1) One of these read-outs is displayed in addition to relevant component.

V.A.G 1551 printout Possible cause of fault Rectifying fault

V.A.G 1551 printout Possible cause of fault Rectifying fault

1) One of these messages will be displayed in addition to indication of relevant component.

V.A.G 1551 printout Possible cause of fault Rectifying fault

V.A.G 1551 printout Possible cause of fault Rectifying fault

1) One of these messages will be displayed in addition to indication of relevant component.

V.A.G 1551 printout Possible cause of fault Rectifying fault

1) One of these messages will be displayed in addition to indication of relevant component.

V.A.G 1551 printout Possible cause of fault Rectifying fault

1) One of these messages will be displayed in addition to indication of relevant component.

V.A.G 1551 printout Possible cause of fault Rectifying fault

1) One of these messages will be displayed in addition to indication of relevant component.

V.A.G 1551 printout Possible cause of fault Rectifying fault

1.8 - Fault table 7

V.A.G 1551 printout Possible cause of fault Rectifying fault

V.A.G 1551 printout Possible cause of fault Rectifying fault