PASSAT B6 C3 2006 Thermal fuse (Heater fan resistor fuse) replacement

This is what I did when my 1.2.3 positions on my fan heater stopped working. Position 4 still work as it worked before. The model is 2006 with climatic cooling system:

First step- check the fuse on the right side next the driving wheel on the side facing the driver door.

 

If the fuse is gone replaced and try again. If you are lucky that is it, if not the next step is to remove and to check the thermal fuse. Fortunately the place is easy accessible and you don’t need any special tools to do so. It is placed on the passenger’s side under the glove box next on the left side to climatic filter.

First remove the plastic (pressed Styrofoam) cover held by two plastic screws.

Here is the resistor connected to the mains:

Once removed you can check with multimeter if the fuse is gone:  

To make sure the rest of the resistor is fine, simply make a bypass with wire.

THE IGNITION KEY MUST BE REMOVED from the dashboard to prevent your car from any unexpected electrical faults!!!

Be sure the resistor is hinging in the air and it is not attached to any plastic parts of the interior. Then put the key, and try if the vent is spinning when the switch is on 1.2 or 3 position.

Do not leave the car in this state. You can burn the car down as the resistor is developing extremely high temperature. Once tested don’t touch the resistor as it can burn your skin. Hold the white plastic instead!!!!!!

If so simply buy new thermal resistor online or from Maplin. Make sure it is working on temperature 220-240 °C.

Next step is to remove the old and solder the new fuse. Make the contacts perfectly clean as they are make of iron and it is tricky to be soldered easily.

Once that is done move back the resistor on your car and test it.

Don’t forget the resistor gets very HOT!!!

So far it is working on my car and hopefully it will last longer. The interesting fact is the resistor has been replaced at spring at 2007, probably this is a common fault for B6

NOTE:

The material it is not a tutorial but simple example how I fixed my car. If you are not sure you can do this, please look for assistance.

© The author of this material is NOT responsible for any damages, system and electrical problems caused by following his examples!!!!

Viliivanov 2012