VW Passat & Audi A4 1990-2000

Control Cables

Print

REMOVAL & INSTALLATION
1990-97 Passat Models

Install the cable ends marked with a white or blue band to the control head assembly. The cables must be attached to the control head before connection to the system air flaps.

  1. Remove the climate control head from the center dash assembly to access the control head cable ends.
  2.  
  3. Remove the lower dash panels as necessary to access the cable lever arms.
  4.  
  5. Attach the airflow distribution cable (cable 2) to the airflow distribution knob's lower control lever.
  6.  

This cable can be identified as follows:



Operates the mode/central air flap
 
Cable has a black sleeve and is 25.0 inches (634 mm) long
 
Cable is marked with a white band
 

  1. Press the cable's sleeve against the control head stop and install the retaining clip.
  2.  
  3. Attach the temperature control/air blend cable (cable 3) to the air temperature knob's control lever.
  4.  

This cable can be identified as follows:



Operates the temperature control/air blend cable air flap
 
Cable has a blue sleeve and is 21.0 inches (535 mm) long
 
Cable is marked with a white band
 

  1. Press the cable's sleeve against the control head stop and install the retaining clip.
  2.  
  3. Attach the airflow distribution cable (cable 1) to the airflow distribution knob's upper control lever.
  4.  

This cable can be identified as follows:



Operates the footwell/defroster air flap
 
Cable has a black sleeve and is 37.5 inches (954 mm) long
 
Cable is marked with a blue band
 

  1. Install the cable such that the blue band is over the retaining clip mount and install the retaining clip directly over the blue band.
  2.  
  3. Install the climate control head.
  4.  
  5. Set the air flow distribution knob to defrost.
  6.  
  7. Connect the longest airflow cable (cable 1) to the footwell/defroster flap lever on the heater's air box.
  8.  
  9. Press and hold the flap's lever toward the retaining clamp perch and install the cable retaining clip.
  10.  
  11. Set the airflow distribution knob to the Vent position.
  12.  
  13. Connect the short airflow cable (cable 2) to the central/mode flap's lever.
  14.  
  15. Pull and hold the mode flap's lever away from the retaining clamp perch and install the cable retaining clip. Check the operation of both air flaps making sure they can be heard contacting their stops.
  16.  
  17. Set the temperature control knob to full cold.
  18.  
  19. Connect the blue-sleeved cable (cable 3) to the air blend/temperature flap's lever.
  20.  
  21. Pull and hold the mode flap's lever away from the retaining clamp perch and install the cable retaining clip. Check the operation of the air blend/temperature flap making sure it can be heard contacting the stops.
  22.  



Click image to see an enlarged view

Fig. Side view of the control head and cable location. 1. Footwell/defrost flap cable-2. Air distribution cable-3. Temperature control flap cable



Click image to see an enlarged view

Fig. Footwell/defrost flap cable location and adjustment



Click image to see an enlarged view

Fig. Center flap cable location and adjustment



Click image to see an enlarged view

Fig. Temperature flap cable location and adjustment

 
label.common.footer.alt.autozoneLogo