Volkswagen Workshop Service and Repair Manuals

Removing and installing dash panel cross member Removing –  Remove dash panel → Chapter. –  Remove footwell vent on driver side → Heating, air conditioning; Rep. gr.80. –  Separate steering column from cross member → Running gear, axles, steering; Rep. gr.48. –  Remove wiper arms → Electrical system; Rep. gr.92. –  Remove plenum chamber cover → General body repairs, exterior; Rep. gr.50. –  Loosen wiper frame with linkages and wiper motor → Electrical system; Rep. gr.92.

–  Unscrew bolt -1- (20 Nm) in plenum chamber on driver side.

–	Lever out the two spreader pins -3- upwards.

–	Pull out both spreader rivets -2- and -4-.

–	Remove intermediate piece -1- from heater and air conditioning unit.

–	If fitted, separate connector from temperature sender -arrow-.

–	Remove intermediate piece -5- from heater and air conditioning unit.

–	Unscrew 2 bolts -1- (5 Nm).

–	Remove 2 bolts -2-.

–	Remove bolt -3-.

When installing, first install bolt -3- (5 Nm) and then 2 bolts -2- (5 Nm).

–	Remove bolt -2- (20 Nm).

–	Unscrew 2 bolts -3- (9 Nm) and remove support -1-.

–	Remove bolt -1- (9 Nm).

Bolt -1- is installed against direction of normal travel!

–	Push retaining hook -arrow- on both sides of adjusting element -3- inwards and detach strut -2- from cross member.

t	A wiring harness is routed between the strut -2- and the dash panel cross member.

t	When removing from the dash panel cross member, the adjusting element -3- and the strut -2- remain in the vehicle.

–	Remove bolt -1- (20 Nm).

–	Unscrew 2 bolts -2- (20 Nm).

If you release or remove and install electrical cables, produce sketches or take photos. This guarantees installation in the original position.

–	Unclip 10 wiring harness fasteners -arrows- from cross member.

–	Pull cross member into vehicle interior until 3 bolts -1- are accessible.

–	Unscrew 3 bolts -1- (4.5 Nm).

The 3 bolts -1- are installed against the direction of normal travel.

–  On vehicles with seat heating, unclip seat heating control unit -1-. –  With aid of second mechanic, carefully lift cross member out of vehicle. Installing –  Install in reverse order of removal.