Volkswagen Workshop Service and Repair Manuals

Note:

Before disconnecting battery, obtain radio code for radios with anti-theft coding.

• Plenum chamber cover
• Dust and pollen filter
• ◆ Removing => Fig.5
• Hexagon screw with shank M6x22
• ◆ 5 Nm
• Gasket

• Series resistance for fresh air blower with overheating fuse -N24-
• ◆ Removing and installing => Fig.1
• Fresh air blower -V2-
• ◆ Removing => Fig.2
• Footwell vent
• ◆ Renewing: Remove shelf on drivers' and passenger side, centre console, dash panel bracket and pedal cluster cover -23 -
• Air ducting right
• Air distributor
• ◆ Renewing: Remove centre console, dash panel bracket, central vent -12-, heating and fresh air controls -22-, remove shelf on passenger side; Loosen dash panel -20- and lift

• Right vent
• ◆ Removing => Fig. 8
• Grille
• ◆ For right vent
• Central vent
• ◆ Removing => Fig. 7
• Control panel trim
• Grilles
• ◆ For central vent
• Instrument panel trim
• ◆ Removing => Fig. 4
• Grille
• ◆ For left vent
• Air vent left
• ◆ Removing => Fig. 6

• Rear ducting
• ◆ Renewing: Remove central console, dash panel bracket, pedal cluster cover -23 -, footwell outlet -7 -
• Rear ducting seal
• ◆ Renewing: Remove central console, dash panel bracket, pedal cluster cover -23 -, footwell outlet -7 -
• Dash panel
• ◆ Removing and installing

=> General body repairs; Repair Group 70; Removing and installing dash panel

• Air ducting left
• Fresh air and heated air controls
• ◆ Removing and installing => Fig.3
• ◆ Dismantling and assembling
• ◆ Installing and adjusting cables => Page 80-14

• Pedal cluster cover
• Cables
• ◆ Renewing: First remove pedal cluster cover -23 - and foot well outlet -7 -
• ◆ Removing and installing => Page 80-14
• Intermediate piece
• ◆ With gasket
• ◆ Renewing - remove dash panel beforehand
• Air distribution housing
• ◆ With temperature flap
• ◆ With central flap
• ◆ With footwell/defrost flap
• ◆ Do not dismantle further
• ◆ Renewing: Remove dash panel and heating items -22- to 28- =>Fig. 9 ; Removing and installing heater
• ◆ Installing: => Page 80-12 dismantling and assembling heater

• Heat exchanger
• ◆ Renewing: Remove dash panel and heating items -22- to 28- =>Fig. 9 ; Removing and installing heater
• ◆ Installing: => Page 80-12 dismantling and assembling heater
• ◆ After removal renew complete coolant
• Air ducting with main shut-off flap
• ◆ Renewing: Remove dash panel and heating items -22- to 28- =>Fig. 9 ; Removing and installing heater
• ◆ Installing: ; dismantling and assembling heater
• Hexagon nut M6
• ◆ 5 Nm

→ Fig.1     Removing and installing fresh air blower series resistance with overheating fuse -N24-

Removing:

• ‒ Remove shelf on passenger side
• ‒ Pull off connections -2-
• ‒ Press retainer -arrow- down and remove series resistance -1-

Installing:

• ‒ Seal surface between series resistance -1- and air duct before installing with AMV 176 000 05.

→ Fig.2     Removing fresh air blower -V2-

• ‒ Remove shelf on passenger side
• ‒ Fold air duct cover to side.
• ‒ Push retaining clips down with a screwdriver, turn fresh air blower clockwise and remove.

→ Fig.3     Removing and installing fresh and heated air control unit

Removing:

• ‒ Pull off heating control trim panel -3-.
• ‒ Remove central vent -2- => Fig. 7 .
• ‒ Pull controls -1- with cables attached out of dash panel.

Installing:

• ‒ Secure cables to removed controls.

→ Fig.4     Removing instrument panel trim

• ‒ Carefully lever out adjustable grilles -1- with long nose pliers.
• ‒ Remove trim -2-.
• ‒ Remove 4 screws -arrows- and take out instrument panel trim housing.

→ Fig.5     Removing dust and pollen filter

•      1 -     Filter element
•      2 -     Filter housing
•      3 -     Gasket
•      4 -     Clip
•      5 -     Clip

• ‒ Remove filter element.
• ‒ Press clips -4- and -5- in direction of arrow and remove filter housing.

→ Fig.6     Removing left vent

• ‒ Remove instrument panel trim => Fig. 4 .
• ‒ Remove lighting switch.

=> Electrical system; Repair Group 96

• ‒ Remove bolt -2-.
• ‒ Remove vent housing -1-.

→ Fig.7     Removing central vent

• ‒ Remove instrument panel trim => Fig. 4 .
• ‒ Remove radio.
• ‒ Remove switch.
• ‒ Unclip control panel trim.
• ‒ Remove control -2-.
• ‒ Loosen central console -3-.
• ‒ Remove 2 screws -arrows- and take out central vent -1-.

→ Fig.8     Removing left vent

• ‒ Carefully lever out adjustable grilles -2- with long nose pliers
• ‒ Remove screw -3- and disengage locating lugs -arrows-.
• ‒ Remove vent housing -1-.

→ Fig.9     Removing and installing heater

Note:

Close evaporator connections to ensure that no coolant enters passenger compartment when removing.

Installing:

• ‒ Pre-assemble hexagon nuts on engine bulkhead.
• ‒ Tighten hexagon nut, with shank, in plenum chamber.
• ‒ Tighten engine bulkhead hexagon nuts.