Volkswagen Cars 2000-05

Removal & Installation

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NOTE
Cable sleeve ends are color coded. Always check cables before installing, replace binding or damaged cables. Attach cables to remove controls first and then attach cables to levers. All air flaps must audibly move onto end stops when turning controls.

  1. Remove the control panel, as outlined in this section.
  2.  
  3. After removing the control panel, check that the cables move freely by moving them back and forth as shown in the illustration. Replace any cables that are damaged or hard to move.
  4.  
  5. Remove the instrument panel, as outlined in this section.
  6.  
  7. Remove the footwell air outlet .

    Click image to see an enlarged view

    Fig. After removing the control panel, check that the cables move freely by moving them back and forth (arrows)



    Click image to see an enlarged view

    Fig. View of the control cables

  8.  

To install:


NOTE
Cable sleeve ends are color coded. All air flaps must audibly move onto end stops when turning controls. Always check cables before installing. Replace binding or damaged cables.

  1. Hold the cable end at an angle and press onto the control lever.

    Click image to see an enlarged view

    Fig. Hold the cable end (1) at an angle, then press it onto the control level (2), arrow

  2.  
  3. Install the control panel.
  4.  
  5. To install and adjust the temperature flap cable, perform the following:
    1. The heating and ventilation controls must be installed and the connecting ducts removed. Refer to the illustration for details.
    2.  
    3. Turn temperature rotary control knob to left onto stop.
    4.  
    5. Attach center wire of cable (1) to the temperature flap lever (2).
    6.  
    7. Push temperature flap lever (2) to stop (arrow A) and secure the outer cable (1) with clip (3).
    8.  
    9. Turn temperature rotary control knob to left and right onto stops.
    10.  
    11. When turning the rotary control knob, both end stops must be reached.

      Click image to see an enlarged view

      Fig. Temperature flap cable installation and adjustment

    12.  

  6.  
  7. To install and adjust the footwell/defroster flap cable, perform the following:
    1. Heating and ventilation controls are installed.
    2.  
    3. Turn air distribution rotary knob to left to stop.
    4.  
    5. Attach wire end of cable (1) to temperature flap lever (3), arrow (A).
    6.  
    7. Push footwell/defroster flap lever to stop (arrow C) and attach outer cable (1) with clip (2) , (arrow B).
    8.  
    9. Turn air distribution rotary control knob to left and right to stops.
    10.  
    11. When turning the rotary control knob, both end stops must be reached.

      Click image to see an enlarged view

      Fig. Footwell/defroster flap cable installation and adjustment

    12.  

  8.  
  9. To install and adjust the central flap cable, perform the following:
    1. The central flap lever must be correctly adjustment, the heating and ventilation controls are installed and the connecting duct removed.
    2.  
    3. Turn air distribution rotary control knob to left onto stop.
    4.  
    5. Attach center wire of cable (2) to central flap lever (1).
    6.  
    7. Push central flap lever to stop (arrow A) and attach outer cable (2) with clip (3).
    8.  
    9. Turn air distribution rotary control knob to left and right onto stops.
    10.  
    11. When turning the rotary control knob both end stops must be reached.
    12.  

  10.  
  11. The remainder of installation is the reverse of the removal procedure.
  12.  


NOTE
The cable sleeve ends are color coded. Always check cables before installing, replace binding or damaged cables. Attach cables to remove controls first and then attach cables to levers. All air flaps must audibly move onto end stops when turning controls.


NOTE
The cable sleeve ends are color coded. Always check cables before installing, replace binding or damaged cables. Attach cables to remove controls first and then attach cables to levers. All air flaps must audibly move onto end stops when turning controls.

  1. Remove the control panel, as outlined in this section.
  2.  
  3. Remove heating and ventilation control panel, as outlined in this section.
  4.  
  5. Unclip the cable(s) from the control panel.
  6.  
  7. Remove the steering column trim.
  8.  
  9. Unclip cable at heating and ventilation unit.

    Click image to see an enlarged view

    Fig. 1 - Central flap cable (yellow), from air distribution rotary control to central flap 2 - Footwell/defrost flap cable (green), from air distribution rotary control to footwell/defrost flap 3 - Heater and A/C control panel 4 - Temperature flap cable (beige), from temperature rotary control to temperature flap

  10.  

To install:

  1. To install and adjust the temperature flap cable (refer to illustration):
    1. The heating and ventilation control panel must be installed and the connecting duct removed .
    2.  
    3. Turn temperature rotary control knob to left onto stop.
    4.  
    5. Attach the center wire of cable (1) to the temperature flap lever (2).
    6.  
    7. Push the temperature flap lever (2) onto stop (arrow A) and secure the outer cable (1) with the clip (3).
    8.  
    9. Turn temperature rotary control knob to left and right onto stops.
    10.  
    11. When turning the rotary control knob both end stops must be reached.

      Click image to see an enlarged view

      Fig. Installing and adjusting the temperature flap cable

    12.  

  2.  
  3. To install and adjust the footwell/defrost flap cable (refer to illustration):
    1. The heating and ventilation control panel must be installed and the connecting duct removed .
    2.  
    3. Turn the air distribution rotary knob to left onto stop.
    4.  
    5. Attach the end of cable (1) to the temperature flap lever (3), (arrow A).
    6.  
    7. Press footwell/defrost flap lever onto stop arrow (C) and attach the outer cable (1) with the clip (2), (arrow B). Turn the air distribution rotary control knob to left and right onto stops.
    8.  
    9. When turning the rotary control knob both end stops must be reached.

      Click image to see an enlarged view

      Fig. Installing and adjusting the footwell/defrost flap cable

    10.  

  4.  
  5. To install and adjust the central flap cable (refer to illustration):
    1. The central flap lever must be correctly adjusted . The heating and ventilation control panel must be installed and the connecting duct removed .
    2.  
    3. Turn air distribution rotary control knob to left onto stop.
    4.  
    5. Attach center the wire of cable (2) to the central flap lever (1).
    6.  
    7. Press the footwell/defrost flap lever onto stop (arrow A) and attach the outer cable (2) with clip (3).
    8.  
    9. Turn the air distribution rotary control knob to left and right onto stops.
    10.  
    11. When turning the rotary control knob both end stops must be reached.

      Click image to see an enlarged view

      Fig. Installing and adjusting the central flap cable

    12.  

  6.  


NOTE
The cable sleeve ends are color coded. Always check cables before installing, replace binding or damaged cables. Attach cables to remove controls first and then attach cables to levers. All air flaps must audibly move onto end stops when turning controls.


NOTE
The cable sleeve ends are color coded. Always check cables before installing, replace binding or damaged cables. Attach cables to remove controls first and then attach cables to levers. All air flaps must audibly move onto end stops when turning controls.

  1. Remove the control panel, as outlined in this section.
  2.  
  3. Remove the instrument panel, as outlined in this section.
  4.  
  5. Remove the footwell air outlet.
  6.  
  7. Disconnect the cable for the central flap or temperature flap from the heating and A/C unit.
    1. To remove the footwell/defrost cable, perform the following:
    2.  
    3. Remove driver side shelf.
    4.  
    5. Unclip cable from the heating and A/C unit.
      NOTE
      When installing the footwell/defrost cable, attach the cable to heating and A/C unit first.

    6.  

  8.  
  9. Installation is the reverse of the removal procedure. Refer to the accompanying illustrations.

    Click image to see an enlarged view

    Fig. Control cables-1 - Central flap cable, sleeve marking: black, 2 - Temperature flap cable, sleeve marking: red. 3 - When attaching the inner cable do not press end of wire (arrow) against the lever.



    Click image to see an enlarged view

    Fig. Central flap cable, from the air distribution rotary to the central flap (1), footwell/defrost flap cable, from air distribution rotary to the footwell defrost flap (2), control panel (3) and temperature flap cable, from temperature rotary control to temperature flap (4)

  10.  

 
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