Heating, Ventilation (Hatchback): Other Volkswagen Beetle A4

HEATING AND VENTILATION CABLES

Note. Cable sleeve ends are color coded. Check cables before installing. Replace binding or damaged cables. Attach cables to removed controls first and then attach to levers at heating and ventilation unit. All air doors must audibly move onto end stops when turning controls.

Scheme 5

1. Central door cable From air distribution rotary control to central door Cable sleeve marking: Yellow Installing and adjusting «CENTRAL DOOR CABLE»(ref-492801-S05483441742012080600000)
2. Footwell/defrost door cable From air distribution rotary control to footwell/defrost door Cable sleeve marking: Green Removing -- Remove heating and ventilation controls «HEATING AND VENTILATION CONTROLS»(ref-492801-S25861503602012080600000) -- Unclip cable from controls -- Remove steering column trim. «Removal and Installation»(ref-492720-S22323760422012080600000) -- Unclip cable at heating and ventilation unit. Installing -- Installing and adjusting «FOOTWELL/DEFROST DOOR CABLE»(ref-492801-S12001941112012080600000)
3. Heating and ventilation controls Removing and installing «HEATING AND VENTILATION CONTROLS»(ref-492801-S25861503602012080600000)
4. Temperature door cable From temperature rotary control to temperature door Cable sleeve marking: Beige Installing and adjusting «TEMPERATURE DOOR CABLE»(ref-492801-S10075046072012080600000)

HEATING AND VENTILATION

HEATING AND VENTILATION CONTROLS

Removing

Remove center instrument panel trim CENTER AIR OUTLET CONSOLE .

Remove mounting screws -arrows-.

Scheme 6

Lift out controls with cables from instrument panel in direction of -arrow A-.

Detach cables from controls.

Disconnect electrical connector.

With controls removed, check function of heating and ventilation cables as follows

Move cables in and out several times -arrow-.

Scheme 7

Replace damaged or stiff cables.

Installing

Note. Cable sleeves are color coded. All doors must audibly move onto stops when turning controls. Always check cables before installing. Replace tight or damaged cables.

Attach cable -1- to actuating arm -2- as indicated-arrow-.

Scheme 8

Press cable for footwell/defrost, cable for temperature door and cable for central door -1- into retainer -2- until it engages.

Scheme 9

Cable Color Codes

1. Footwell/defrost door cable: green
2. Central door cable: yellow
3. Temperature door cable: beige

Check and adjust cables HEATING AND VENTILATION CABLES .

Connect electrical connector

Fit controls into instrument panel opening and install mounting screws.

Scheme 10

1. Heating and ventilation unit
2. Fresh Air Blower -V2
3. Cover
4. Screws
5. Fresh air blower series resistance with fuse Fresh Air Blower Series Resistor With Fuse -N24

Removing

Remove glove box. Removal and Installation

Remove screws -4- and remove cover -3-.

Remove cover containing series resistor -5- and disconnect electrical connector.

Disconnect electrical connector from fresh air blower -2-.

Remove fresh air blower series resistor -5-.

Pull fresh air blower out downwards.

Installing

Install in reverse order of removal.

Scheme 11

Remove bolts -arrows-.

1. Tightening torque 25 Nm.

To access or remove heating and ventilation unit, lift cross member in direction of -arrow A- and support.

Note. To prevent damage to the steering column, work should be done with aid of another technician. If removed component(s) are not to be reinstalled immediately, secure the cross member to the bulkhead. Any wiring harnesses released from their retainers must be secured again at the same point, using the same method of securing.

Scheme 12

1. Bolt
2. Connecting duct
3. Rear duct
4. Retainer
5. Cover
6. Bolt

Removing

First do the following

Remove glove box. Removal and Installation

Remove steering column trim. Removal and Installation

Remove center air outlet console CENTER AIR OUTLET CONSOLE .

Remove center console. Removal and Installation

Remove retainer -4-.

Remove cover -5-.

Pull connecting piece out towards the driver side footwell -arrow A-.

Installing

Install in reverse order of removal.

DUST AND POLLEN FILTER

The filter is located in the right rear of the instrument panel under a cover.

Components of dust and pollen filter

Scheme 13

1. Frame
2. Filter element
3. Plastic nut, 2.5 Nm
4. Filter housing with seal

Removing

Push center cover -1- forward -arrow A- and lift up to remove.

Scheme 14

Remove screws -arrows-.

Scheme 15

Lift right plenum panel cover -1- and remove from clips at front and rear edge.

Pull cover -1- toward center of vehicle and out of retainer in A-pillar to remove.

Remove screws -arrows- and remove right closeout panel -1-.

Scheme 16

Remove rubber grommet -1-.

Scheme 17

Press tabs of filter housing in direction of -arrow-.

Remove filter element with frame in upward direction -arrow A-.

Installing

Scheme 18

Guide frame -1- into first slot on left and right sides of new filter element.

Press frame with filter into housing -2- and engage retainers.

SIDE WINDOW AIR OUTLETS

Note. To prevent damage to air outlets, use needle nose pliers with suitable plastic or rubber protection on jaws.

Carefully remove air outlet -1- with needle nose pliers.

Scheme 19

SIDE AIR OUTLETS

Carefully remove air outlet -1- with needle nose pliers as indicated.

Scheme 20

CENTER AIR OUTLET CONSOLE

First do the following

Remove radio Removal and Installation

Push center cover -1- forward -arrow A- and lift up to remove.

Unclip covers -2-.

Scheme 21

Remove lower switch console cover -1- (remove screws).

Remove screws -arrows-.

Scheme 22

Remove center air outlet console.

DEFROSTER AIR OUTLET PANEL

First do the following

Remove radio Removal and Installation .

Remove center air outlet console CENTER AIR OUTLET CONSOLE .

Remove plenum panel covers -1- and -2- Removal and Installation .

Remove closeout panels -3- and -4

Remove spreader rivets -6- and lift out panel -5- from bulkhead clips.

Scheme 23

1. Plenum panel cover Driver side
2. Plenum panel cover Passenger side
3. Closeout panel Driver side
4. Closeout panel Passenger side
5. Defroster air outlet panel
6. Spreader rivets

Scheme 24

The central door pinion has an adjustment mark.

Install the lever so that the notches on the lever and the pinion align -arrows-.

FRESH/RECIRCULATING AIR DOOR MOTOR

Removing

Remove glove box. Removal and Installation

Disconnect electrical connector -1-.

Scheme 25

Remove screw -3-.

Swing motor -2- downwards.

Disconnect motor -2- from fresh air/recirculating air door lever.

Installing

Replacement motors are supplied with operating levers in the "recirculating air" position. To ease installation, first do the following

Attach electrical connector -1- to door motor -2-.

Scheme 26

Switch on ignition.

Operate button for fresh air/recirculating air and observe lever position.

When the center position is reached, quickly disconnect the electrical connector.

Insert motor onto the fresh air/recirculating air shaft -1-.

Scheme 27

Note. If it is difficult to align and fit the motor to shaft -1-, remove Fresh Air Blower -V2-, remove Fresh Air Blower -V2- FRESH AIR BLOWER and position door/shaft as required.

Turn motor in direction of -arrow A-.

Install mounting screw.

Reconnect electrical connector.

TEMPERATURE DOOR CABLE

Cable sleeve marking: Beige

Installing, prerequisites

1. Heating and ventilation controls are installed.
2. Connecting duct removed «CONNECTING DUCT»(ref-492801-S07842865882012080600000) .

Adjusting

Scheme 28

Turn temperature rotary control knob to left onto stop.

Attach center wire of cable -1- to the temperature door lever -2-.

Push temperature door lever -2- onto stop -arrow A- and secure outer cable -1- with clip -3-.

Turn temperature rotary control knob to left and right onto stops.

When turning the rotary control knob both end stops must be reached.

FOOTWELL/DEFROST DOOR CABLE

Cable sleeve marking: Green

Prerequisite

Heating and ventilation controls are installed.

Installing and adjusting

Scheme 29

Turn air distribution rotary knob to left onto stop.

Attach end of cable -1- to the temperature door lever -3-, arrow -A-.

Press footwell/defrost door lever onto stop arrow -C- and attach outer cable -1- with clip -2-, arrow -B-.

Turn air distribution rotary control knob to left and right onto stops.

When turning the rotary control knob both end stops must be reached.

CENTRAL DOOR CABLE

Cable sleeve marking: Yellow

Prerequisite

1. Central door lever correctly adjusted «CENTRAL DOOR LEVER»(ref-492801-S37389304472012080600000) .
2. Heating and ventilation controls are installed.
3. Connecting duct removed «CONNECTING DUCT»(ref-492801-S07842865882012080600000) .

Installing and adjusting

Scheme 30

Turn air distribution rotary control knob to left onto stop.

Attach center wire of cable -2- to the central door lever -1-.

Press footwell/defrost door lever onto stop arrow -A- and attach outer cable -2- with clip -3-.

Turn air distribution rotary control knob to left and right onto stops.

When turning the rotary control knob both end stops must be reached.