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Volkswagen Passat B6 2005 - >

(B6)

Heating system, servicing


Heating system - interior, component overview

Note :

At time of publication, all US/CDN Passat are 100%


equipped with air conditioning. Information in this
Repair Group pertains to European market vehicles
that are not equipped with air conditioning (heater
only). Information on heater controls in this Repair
Group does not apply to US/CDN vehicles. However,
this Repair Group does contain information on
heating system components that are shared with
either the Climatic or Climatronic air conditioning
systems.

Disconnect battery before removing


components marked with **

Heating system, servicing

Repair Manual, Electrical Equipment,


Repair Group 27,
.

Instrument panel **

Center vents

Removing vents 80-1,


Center vents, removing and
installing

Air duct to right side vent

Front passengers vent

Removing vents 80-1,


Driver or front passenger side
vent, removing

Controls for hot air and fresh air

With Fresh Air/Recirculating


Flap Switch E159

Also with Immediate Heating


Button E537 in vehicles with
auxiliary heater

Removing controls 80-1,


Controls for hHot air and fresh
air controls, removing and
installing

Also with Drivers Heated Seat


Adjuster E94 and Front
Passengers Heated Seat
Adjuster E95 in vehicles with
auxiliary heater

Fresh/Recirculating Air Door


Motor V154

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

. 2 39

Heating system, servicing

Right footwell vent

Fresh Air Blower V2

Removing and installing


80-1, Fresh Air Blower Series
Resistor With Fuse N24 ,
removing and installing

Heating unit partition

Removing 80-1, Fresh Air


Blower V2 , removing

Fresh Air Blower Series Resistor


With Fuse N24

Removing and installing


80-1, Right footwell vent,
removing and installing

Removing 80-1, Removing


heating unit partition

Dust and pollen filter

With activated charcoal filter

Removing and installing


80-1, Dust and pollen filter
element, removing and
installing

Connection

For rear vent air duct

To remove, center console


must be removed

Repair Manual, Body Interior, Repair


Group 68,

Rear vent air duct

Rear vent

Rear channel for right footwell

. 3 39

Heating system, servicing

Rear channel for left footwell

Removing and installing


80-1, Rear footwell channel,
removing and installing

Removing and installing


80-1, Rear footwell channel,
removing and installing

Mounting bolt

8x

Adapter for controls

Heater core

After replacing heater core,


coolant must be replaced
completely

Repair Manual, 2.0 Liter 4-Cyl. 4V


Turbo Engine Mechanical, Fuel Injection
Ignition, Engine Code(s): BPY, Repair
Group 19,
.

Left footwell vent

Removing and installing


80-1, Left footwell vent,
removing and installing

Auxiliary Air Heater Heating


Element Z35

Removing and installing


80-1, Heater core, removing
and installing

Not applicable to US/CDN

Bowden cable for temperature


flap

. 4 39

Heating system, servicing

Removing and installing


80-1, Bowden cable for
tTemperature flap Bowden
cable, removing and installing

Flexible shaft

. 5 39

Removing and installing


80-1, Flexible shaft for air
distribution, removing and
installing

Heating unit

Removing and installing


80-1, Heating unit, removing
and installing

Disassembling and
assembling 80-2, Heating
unit, disassembling and
assembling

Removing heating unit partition

- Unscrew plastic screws - 2 - and remove partition - 1 - .


Fresh Air Blower V2 , removing

Removing
Fresh Air Blower V2 is accessible from footwell on front
passenger side.
- Remove partition from heating unit

80-1, Removing

Heating system, servicing

. 6 39

heating unit partition

- Disconnect harness connector - A - from Fresh Air Blower


V2 .
- Unscrew bolt - B - for Fresh Air Blower V2 (1 Nm).
- Release locking mechanism - 2 - and rotate Fresh Air
Blower V2 in - direction of arrow - and remove.
Fresh Air Blower Series Resistor With Fuse N24 ,
removing and installing

Removing
Warning!
There is a danger of burning.
Fresh Air Blower Series Resistor With Fuse N24 may
be hot.
Let Fresh Air Blower Series Resistor With Fuse N24
cool off before removing.
First perform the following work:
- Remove partition from heating unit
heating unit partition .

80-1, Removing

Heating system, servicing

- Disconnect harness connector - 1 - from Fresh Air Blower


Series Resistor With Fuse N24 .
- Press locking mechanism - in direction of arrow - and
remove Fresh Air Blower Series Resistor With Fuse N24
from heating unit.
Installing
Installation is performed in the reverse order of removal.
Dust and pollen filter element, removing and installing

Removing

- Release cover - 3 - in direction of arrow.


- Remove dust and pollen filter downward out of heating
unit.
Installing
Note:

Note installation position of dust and pollen filter


element.

Installation is performed in the reverse order of removal.

. 7 39

Heating system, servicing

. 8 39

Vents, removing

Removing and installing center vents


removing and installing

80-1, Center vents,

Remove driver or front passenger side vent


or front passenger side vent, removing

80-1, Driver

Rear footwell channel, removing and installing


Rear footwell channel, removing and installing
Right footwell vent, removing and installing
footwell vent, removing and installing
Left footwell vent, removing and installing
footwell vent, removing and installing

80-1,
80-1, Right

80-1, Left

Removing and installing air duct for rear vents


duct for rear vents, removing and installing
Removing and installing rear vents
removing and installing

80-1, Rear vents,

Center vents, removing and installing

Removing
Special tools, testers and auxiliary items required

Trim Removal Wedge 3409

80-1, Air

Heating system, servicing

. 9 39

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Volkswagen, Skoda, Seat, Audi

- Pry center vent out of instrument panel using Trim


Removal Wedge 3409 .
Disassembling and assembling center vents
Center vents, disassembling and assembling

80-1,

Installing
Installation is performed in the reverse order of removal.
Center vents, disassembling and assembling

Disassembling
- Remove center vent
installing

80-1, Center vents, removing and

- Remove panel for vent by disengaging lugs on panel arrows - .


- Pull vents - 1 - and - 2 - apart - direction of arrow Assembling
Assembly is performed in the reverse order of removal.
Driver or front passenger side vent, removing

Note:

Heating system, servicing

Vent removal on both sides is identical, only the sides


are reversed.

To prevent damage to instrument panel, use a pad


when prying out.

Removing
Special tools, testers and auxiliary items required

Trim Removal Wedge 3409

- Pry vent out of instrument panel using Trim Removal


Wedge 3409 .
Installing
Installation is performed in the reverse order of removal.
Rear footwell channel, removing and installing

Note:

Removal of rear channels on both sides is identical,


only the sides are reversed.

. 10 39

Heating system, servicing

Removing
- Remove driver or front passenger seat

Repair Manual, Body Interior, Repair Group 72,


- Remove center console

Repair Manual, Body Interior, Repair Group 68,

- Lift floor carpet, unclip rear channel from floor and pull off
from heating unit.
Installing

Installation is performed in the reverse order of removal.


Note:

When installing the rear channel, make sure that rear


channel is first slid onto heating unit - arrow - and
then clipped in to floor.

Right footwell vent, removing and installing

. 11 39

Heating system, servicing

Removing
- Remove glove compartment

Repair Manual, Body Interior, Repair Group 68,

- Unscrew securing bolt - 2 - and remove right footwell vent


-1-.
Installing
Installation is performed in the reverse order of removal.

Tightening torque for bolt 1.5 Nm

Note:

In vehicles with glove compartment cooling, make


sure cooling hose is correctly seated.

Left footwell vent, removing and installing

Removing
- Remove driver side storage compartment

Repair Manual, Body Interior, Repair Group 68,

. 12 39

Heating system, servicing

- Unscrew securing bolt - 2 - and remove left footwell vent 1-.


Installing
Installation is performed in the reverse order of removal.

Tightening torque for bolt 1.5 Nm

Air duct for rear vents, removing and installing

Removing
- Remove center console

Repair Manual, Body Interior, Repair Group 68,


.
- Remove center armrest

Repair Manual, Body Interior, Repair Group 68,

- Remove mounting bolts - 1 - .

. 13 39

Heating system, servicing

- Remove air duct for rear vents - 2 - from center console.


Installing
Installation is performed in the reverse order of removal.

Tightening torque for bolts 1.5 Nm

Rear vents, removing and installing

Removing
- Remove rear trim

Repair Manual, Body Interior, Repair Group 68,

- Unscrew bolts - 1 - and unhook vent.


Installing

- Guide vent into tabs of panel - arrows - Tighten bolts - 1 - lightly.

. 14 39

Heating system, servicing

- Check function of control - 1 - .


If it functions:

- Tighten bolts - 1 - to 1.5 Nm.


If it does not function:

- Loosen bolts - 1 - and align vent until the control


functions.
- Tighten bolts - 1 - to 1.5 Nm.
- Reinstall rear panel.
Controls for hHot air and fresh air controls, removing and

. 15 39

Heating system, servicing

installing

Removing
Note:

The controls consist of two separable housings.


Before removing controls, bring rotary buttons into
the following position:

Heater control to "cold"

Blower to "0"

Air flow direction to "footwell"

- Remove center instrument panel trim

Repair Manual, Body Interior, Repair Group 68,


.

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


remove controls - 1 - from center console.

. 16 39

Heating system, servicing

- Disengage harness connector release catch - A - by


pulling - in direction or arrow 1 - .
- Disengage harness connector release catch - B - to
connector - arrow 2 - and disconnect connector - C - .
- Disengage harness connector release catch - D - and
disconnect connector - D - .
Installing
Installation is performed in reverse order of removal, make
sure when doing so that the rotary buttons have the same
position as when removing.
Harness connectors at controls for hot air and fresh air
controls

Special tools, testers and auxiliary items required

Test Box 105 Pin VAG1598/42

Test Adapter VAG1598/47

Template V.A.G 1598/47-2

Terminal assignment of multi-pin harness connector at rear side


of controls for hot air and fresh air

16-pin harness connector is not assigned.

. 17 39

Heating system, servicing

5-pin harness connector, T5r


1 - 3rd blower speed
2 - 2nd blower speed
3 - 1st blower speed
4 - 4th blower speed
5 - Terminal X

20-pin harness connector, T20b


3 - Fresh/Recirculating Air Door Motor V154
6 - Fresh/Recirculating Air Door Motor V154
8 - Rear window
11 - Drivers Heated Seat Adjuster E94 (optional)
15 - Front Passengers Heated Seat Adjuster E95 (optional)
16 - Heater/Heat Output Switch E16
18 - Terminal 30
19 - Terminal 15
20 - Terminal 31
Flexible shaft for air distribution, removing and installing

. 18 39

Heating system, servicing

Removing
- Remove glove compartment

Repair Manual, Body Interior, Repair Group 68,


.
- Bring flexible shaft into the following position:

- Rotate rotary switch for air distribution - B - long enough


until locking mechanism of shaft - D - is visible in step-up
gearing - F - .
- Remove controls for hot air and fresh air 80-1, Controls
for hHot air and fresh air controls, removing and installing .

- Reach into center console and release retaining tab - 1 by pressing - in direction of arrow - .
- Pull flexible shaft out of adapter - 2 - .
Installing
Installation is the reverse of removal.
Note:

. 19 39

Heating system, servicing

When installing flexible shaft, adapter and rotary


switches on controls for hot air and fresh air must
have a specific position to each other, otherwise it will
malfunction 80-1, Flexible shaft for air distribution,
checking .

Flexible shaft for air distribution, checking

Flexible shaft for adjusting unit of air distribution flaps:


- Let fresh air blower run on highest speed. If air flows out
of defroster vents in the "Defrost" position and no air flows
out of footwell vents, installation of flexible shaft is correct.
If this is not the case, remove flexible shaft from adapter.
Place controls for hot air and fresh air onto adapter and
rotate rotary knob for air distribution 1 / 2 rotation (180 ).
Then reconnect flexible shaft. Repeat test.
Bowden cable for tTemperature flap Bowden cable,
removing and installing

Removing
- Remove controls for hot air and fresh air 80-1, Controls
for hHot air and fresh air controls, removing and installing .
- Carefully pull out adapter for controls.

- Reach into center console and disengage locking


mechanism - 1 - of Bowden cable sleeve - 2 - and remove
Bowden cable sleeve from mount.
- Disengage ball on Bowden cable - 3 - from operating
lever - 4 - .
- Remove driver side footwell trim

Repair Manual, Body Interior, Repair Group 68,

. 20 39

Heating system, servicing

- Unclip Bowden cable at adjusting unit of temperature flap


- A - and unclip heating unit - B - .
Installing

Installation is performed in the reverse order of removal.


When doing this, make sure that Bowden cable lies under
the hook - arrow - .
Note:

When installing flexible shaft, adapter and rotary


switches on controls for hot air and fresh air must
have a specific position to each other, otherwise it will
malfunction 80-1, Flexible shaft for air distribution,
checking .

- Check whether temperature knob can be moved easily


from "cold" to "warm" .
Fresh/Recirculating Air Door Motor V154 , removing and
installing

Removing
Note:

. 21 39

Heating system, servicing

. 22 39

Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru


Volkswagen, Skoda, Seat, Audi

Fresh/Recirculating Air Door Motor V154 can only be


removed without difficulty in "fresh air mode stop" and
installed only in this position. If motor remains
standing in a different position and can no longer be
moved electrically into "fresh air mode stop" position,
it can only be pulled off and removed with difficulty.

Position of fresh/recirculating air door must not be


changed.

- Switch on ignition and wait until Fresh/Recirculating Air


Door Motor V154 has reached its end position "fresh air
mode" .
- Switch ignition off.
- Remove glove compartment

Repair Manual, Body Interior, Repair Group 68,


.

- Disengage catches - B - and - C - for bracket - A - on


intake housing and remove bracket - A - .

Heating system, servicing

- Disconnect harness connector from actuator motor - B - .


- Remove Fresh/Recirculating Air Door Motor V154 - B in
direction of arrow - from intake housing.
Note:

Connection between motor toothed gears and


fresh/recirculating air door is designed so that the
motor can only be removed in the "fresh air mode"
position without difficulty (intake opening for
recirculating air mode is sealed via the
fresh/recirculating air door - A - ).

If motor is found in a different position and can no


longer be moved, motor cannot be simply pulled off,
rather it must be loosened first with great force from
mounting points - C - , ensure that toothed gear - D is not damaged when doing this.

Installing
Note:

Motor as replacement part is delivered in the "fresh


air mode" position, only when toothed gear - A contacts stop - B - can it then be connected onto
toothed gear of fresh/recirculating air door. If a motor
was removed in a different position or activated in the
removed state, it cannot be installed.

If toothed gear - A - of motor does not stand at stop B - "fresh air mode" , proceed as follows:

- Connect motor to vehicle wiring harness.


- Switch ignition on.
- Wait until toothed gear - A - of motor reaches stop - B -

. 23 39

Heating system, servicing

"fresh air mode" .


- Switch ignition off.

- Reach into intake opening for recirculating air mode and


bring fresh/recirculating air door - A - into "fresh air mode"
position (intake opening for recirculating air mode is
closed).

- Insert motor - B - into mounts - C - in opposite direction of


arrow and onto toothed gear - D - .
Note:

So that toothed gear on motor - A - can be slid on


toothed gear of fresh/recirculating air door, short
tooth - C - of motor toothed gear must align with short
tooth interval - D - of toothed gear on shaft of back
pressure flap - D - .

. 24 39

Heating system, servicing

- After assembling actuator motor, press toothed gear - 1 again on to shaft of fresh/recirculating air door.
- Install the wiring harness so that it cannot come in contact
with any moving parts (e.g. the actuating arm of the
actuator motor).

- Install bracket - A - , take special care when doing this,


that bracket guide - D - is inserted correctly into intake
housing mount - E - and bracket is engaged correctly in
both catches - B - and - C - .
Note:

Position of motor (and of flap) is no longer visible with


glove compartment installed, therefore it is sensible
to check its function before installing glove
compartment.

When both toothed gears are assembled in incorrect


position, it can be detected as the fresh/recirculating
air door does not reach its two end positions or motor
does not run cleanly and without hitching.

- Install all removed components in reverse order.


Note:

. 25 39

Heating system, servicing

After installing Fresh/Recirculating Air Door Motor


V154 , recirculating air door must be checked for
function.

- Checking: Vehicle Diagnosis, Testing Info. System


VAS5051B
- Replacing: Initiate Basic Setting using Vehicle Diagnosis,
Testing Info. System VAS5051B 87-3, Components,
checking and adjusting .
Heater core, removing and installing

Special tools, testers and auxiliary items required

Drip Tray For VAS6100 VAS6208

Hose Clamps, Up to 40 mm. 3093

Compressed air gun, standard

Removing
- Place Drip Tray For VAS6100 VAS6208 under engine.

. 26 39

Heating system, servicing

Warning!
There is a danger of scalding.
Coolant temperature can be above 100 C with a warm
engine. Cooling system is under pressure.
If necessary, reduce pressure and temperature before
repairs.

- Clamp off coolant hoses - 1 - using Hose Clamps, Up to


40 mm. 3093 and disconnect coolant hoses to heater core.

- Connect a section of hose - A - onto upper connection of


heater core.
- Hold a container - B - under the lower connection - C - .
- Using a compressed air gun, carefully blow coolant out of
heater core into container - B - .

. 27 39

Heating system, servicing

. 28 39

- Unscrew bolt - 1 - out of connection flange between


heater core connections.
Note:

This allows the coolant pipes to move for removing


the heater core.

- Remove driver side footwell trim

Repair Manual, Body Interior, Repair Group 68,


.
- Remove left footwell vent
removing and installing .

80-1, Left footwell vent,

- Remove screws - 1 - and remove heater core trim.


- Cover floor carpet in area below heater core with leakproof foil and absorbent paper.

Heating system, servicing

- Open hose clamps - A - and disconnect coolant pipes


from heater core.
- Remove heater core from heating unit.
Installing
Installation is the reverse of removal, noting the following:

- Check seals - A - and - B - installed on heater core, only


install a heater core with undamaged seals.
Note:

An incorrectly glued seal can roll up into heating unit


when sliding in the heater core.

If seal is damaged or installed incorrectly, cold air can


flow past the heater core.

. 29 39

Heating system, servicing

- With the heater core removed, check heating unit for


soiling (via heater core opening - A - ).
- If necessary remove dirt or coolant from heating unit, for
example after removing leaky heater core.
- Push heater core into the heating unit.

- Sealing rings - 1 - must be replaced.


- Coat O-rings with coolant before installing.
Note:

If hose clamps are deformed, replace them.

- Connect coolant pipes to heater core.

. 30 39

Heating system, servicing

- Hose clamps - A - must be able to be twisted slightly


when installing onto the coolant pipes.
- Hose clamps - A - must be installed as shown in the
illustration.
- Tighten hose clamps - A - to 2.0 Nm.
- Check seating of both clamps - A - after tightening bolts,
clamps must enclose the flange on heater core and coolant
pipe completely and must not touch other components.

- Thread bolt - A - into connection flange - B - and while


doing this make sure bolt is actually threaded into the
mounting point intended for it.

. 31 39

Heating system, servicing

- Check position of grommet - C - in bulkhead for proper


seating.
- Seal flange for coolant pipes to heater core - A - and for
expansion valve (to evaporator, only in vehicles with A/C
system) - B - at pass-throughs of grommet - C - with silicon
adhesive sealant if necessary (to prevent water from
penetrating).
Note:

Sealing rings must always be replaced.

If hose clamps are deformed, replace them.

After replacing heater core, coolant must be replaced


completely

Repair Manual, 2.0 Liter 4-Cyl. 4V Turbo Engine


Mechanical, Fuel Injection Ignition, Engine Code(s): BPY,
Repair Group 19,
.

Check coolant circuit for leaks, pay particular


attention to connection between coolant hoses and
heater core.

Ventilation, checking

Note:

The stale air escapes via ventilation openings in the


luggage compartment trim.

If the ventilation is to function properly the ventilation


openings must not be covered.

Ventilation frames are located in rear side panels,


behind bumper.

Checking
- Remove rear bumper

. 32 39

Heating system, servicing

Repair Manual, Body Exterior, Repair Group 63,


.

- The sealing lips - 1 - in the ventilation frame on both sides


of vehicle must be free to move and close automatically.
- Note installation position.
Intake air grille, removing and installing

Removing

- Unscrew mounting nuts - arrows - and remove intake air


grille upward.
Installing
Installation is performed in the reverse order of removal.
Note:

Seal must be seated correctly on intake air grille.

Heating unit, removing and installing

Special tools, testers and auxiliary items required

. 33 39

Heating system, servicing

Drip Tray For VAS6100 VAS6208

Hose Clamps, Up to 40 mm. 3093

Compressed air gun, standard

Removing
Note:

To improve accessibility, additional components e.g.


engine cover must be removed (depending on engine
version)

Repair Manual, 2.0 Liter 4-Cyl. 4V Turbo Engine


Mechanical, Fuel Injection Ignition, Engine Code(s): BPY,
Repair Group 10,
.
- Remove instrument cluster

. 34 39

Heating system, servicing

. 35 39

Repair Manual, Body Interior, Repair Group 70,


.
- Remove rear channels for right and left footwells
Rear footwell channel, removing and installing .

80-1,

- Place Drip Tray For VAS6100 VAS6208 under the engine.

- Mark coolant hoses - 1 - .


Warning!
There is a danger of scalding.
Coolant temperature can be above 100 C with a warm
engine. Cooling system is under pressure.
If necessary, reduce pressure and temperature before
repairs.
- Clamp off coolant hoses - 1 - using Hose Clamps, Up to
40 mm. 3093 and disconnect coolant hoses to heater core.
- Using a compressed air gun, carefully blow residual
coolant out of heater core at heater core connection.
- Cover floor carpet in vehicle interior with leak-proof foil
and absorbent paper.
Note :

Take note during removal of the length and


assignment of bolts for reinstallation

Heating system, servicing

Bolt

3.5

0.5 Nm

Bolts

2x

4 Nm

Cable bracket

Heating unit
Removing:
- Disconnect harness
connectors from heating
unit.
Note :

. 36 39

Heating system, servicing

All cable ties opened or cut during removal must be


reinstalled at the same locations during installation.

- Remove bolts Item - 9 from bracket Item - 5 - .


- Remove supports Item
- 7 - and Item - 8 - .
- Unscrew bolts Item 10 - and Item - 12 - and
remove bracket
Item 11 - .
- Remove bolts Item - 1 and Item - 2 - from cable
bracket Item - 3 - .
Note :

To be able to reach the bolt Item - 1 - , heating unit


on driver side must be pulled out slightly from facing
wall.

When removing heat unit, make sure the two coolant


pipes of the heater core do not get caught and bent
or damaged on plenum chamber or sound insulation
pan.

Also pay attention to wiring harness, individual wiring


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

- Remove heating unit.


Installing:
Installation is performed in the
reverse order of removal, noting
the following:
Note :

The assistance of a second mechanic is necessary to


install the heating unit.

- When inserting heating


unit, have the second
mechanic guide both

. 37 39

Heating system, servicing

coolant pipes to heater


core through the seal (from
engine compartment)
80-1, Seal for heating unit /
engine compartment .
- Fill with coolant

Repair Manual, 2.0 Liter 4-Cyl. 4V


Turbo Engine Mechanical, Fuel Injection
Ignition, Engine Code(s): BPY, Repair
Group 19,

Bracket

Assembly carrier

Right support

Left support

Bolts

1.3 Nm

Bolts

2x

Bracket

Bolts

2x

1.3 Nm

1.3 Nm

. 38 39

Heating system, servicing

Seal for heating unit / engine compartment

Note:

Note installation position of seal - A - during


assembly.

. 39 39

Heating unit, disassembling and assembling

. 1 5

Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru


Volkswagen, Skoda, Seat, Audi

Heating unit, disassembling and assembling


Heating unit, disassembling and assembling

Adjusting unit for temperature


flap

Removing and installing


80-2, Adjusting unit for air
distribution flaps adjusting
unit, removing and installing

Bracket

Cover

Fresh/Recirculating Air Door


Motor V154

Heating unit, disassembling and assembling

Checking: Vehicle Diagnosis,


Testing Info. System
VAS5051B

Removing and installing


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

Replacing: Initiate Basic


Setting using Vehicle
Diagnosis, Testing Info.
System VAS5051B 87-3,
Components, checking and
adjusting .

Housing for air entry

With fresh air/recirculating air


door

Heating unit

Fresh Air Blower V2

Fresh Air Blower Series Resistor


With Fuse N24

Removing and installing


80-1, Dust and pollen filter
element, removing and
installing

Cover

Removing and installing


80-1, Fresh Air Blower Series
Resistor With Fuse N24 ,
removing and installing

Dust and pollen filter

Removing and installing


80-1, Fresh Air Blower V2 ,
removing

For dust and pollen filter

Heater core

. 2 5

Heating unit, disassembling and assembling

Removing and installing


80-1, Heater core, removing
and installing

Heater core trim

Auxiliary Air Heater Heating


Element Z35

Not applicable to US/CDN

Distribution housing

Adjusting unit for air distribution


flaps

Removing and installing


80-2, Adjusting unit for air
distribution flaps adjusting
unit, removing and installing

Adjusting unit for air distribution flaps adjusting unit,


removing and installing

Removing
- Remove left footwell vent
removing and installing .

80-1, Left footwell vent,

- Unclip flexible shaft from adapter for controls


80-1,
Flexible shaft for air distribution, removing and installing .

- Unscrew bolts - 1 - and remove adjusting unit for air


distribution flaps.
Installing
- Arrows on toothed gears must align with each other.

. 3 5

Heating unit, disassembling and assembling

- Position adjusting unit for air distribution flaps and tighten


bolts - 1 - .
Note:

After installing, function of air distribution flap must be


checked.

Adjusting unit for tTemperature flap adjusting unit,


removing and installing

Removing

- Unclip cable at adjusting unit for temperature flap - 2 - .


- Disengage locking mechanism - 1 - and press adjusting
unit for temperature flap - in direction of arrow - until it
reaches stop.
- Remove adjusting unit for temperature flap.
Installing
Installation is performed in the reverse order of removal.
Note:

After installing, function of temperature flap must be

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Heating unit, disassembling and assembling

checked. Temperature knob on hot air and fresh air


controls must be able to be moved from "cold"
position to "warm" position easily and without
catching.

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