Volkswagen New Beetle. Manual - part 2024

Courtesy of VOLKSWAGEN OF AMERICA, INC.

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

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Insert motor onto the fresh air/recirculating air shaft -1-. See Fig. 2 

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Turn motor in direction of -arrow A-.  

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Install mounting screw.  

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Reconnect electrical connector. 

Fig. 26: Inserting Motor Onto Fresh Air/Recirculating Air Shaft 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

HEATING AND VENTILATION CONTROLS, ASSEMBLY 

1. Heating and ventilation controls 

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With fresh air blower switch -E9-  

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With switch for fresh air blower and recirculated air -E184-  

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Removing and installing, See Heating and ventilation controls, removing and installing .  

2. Illumination filter  

3. Trim panel  

4. Fresh air control lever light -L16- 

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12V, 1.2W  

5. Rotary control 

NOTE:

If it is difficult to align and fit the motor to shaft -1-, remove fresh air 
blower -V2- and position flap/shaft as required. See Fig. 2 .

NOTE:

The following list refers to items in Fig. 27 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Heating, Ventilation - New Beetle

  

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For blower speed  

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To remove: Use pliers with suitable plastic or rubber protection on jaws  

6. Rotary control 

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For air distribution  

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To remove: Use pliers with suitable plastic or rubber protection on jaws  

7. Rotary control 

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For interior temperature  

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To remove: Use pliers with suitable plastic or rubber protection on jaws  

Fig. 27: Identifying Components Of Heating And Ventilation Controls Assembly 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

HEATING AND VENTILATION CABLES, INSTALLING AND ADJUSTING 

NOTE:

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Cable sleeve ends are color coded.  

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Check cables before installing. Replace binding or damaged cables.  

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Attach cables to removed controls first and then attach to levers at heating 
and ventilation unit.  

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All air flaps must audibly move onto end stops when turning controls.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Heating, Ventilation - New Beetle

  

Fig. 28: Installing Heating And Ventilation Cables 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

1. Central flap cable 

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From air distribution rotary control to central flap  

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Cable sleeve marking: Yellow  

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Installing and adjusting, See INSTALLING & Adjusting Central Flap Cable  

2. Footwell/defrost flap cable 

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From air distribution rotary control to footwell/defrost flap  

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Cable sleeve marking: Green  

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Removing: 

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Remove heating and ventilation controls, See Heating and ventilation controls, removing 
and installing  

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Unclip cable from controls  

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Remove steering column trim. 

See TRIM UNDER STEERING COLUMN, REMOVING . 

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Unclip cable at heating and ventilation unit.  

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Installing and adjusting, See Installing & Adjusting Footwell/Defrost Flap Cable  

3. Heating and ventilation controls 

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Removing and installing, See Heating and ventilation controls, removing and installing  

4. Temperature flap cable 

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From temperature rotary control to temperature flap  

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Cable sleeve marking: Beige  

NOTE:

The following list refers to items in Fig. 28 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Heating, Ventilation - New Beetle

  

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Installing and adjusting, See Adjusting Temperature Flap Cable  

Adjusting Temperature Flap Cable 

Cable sleeve marking: Beige 

Fig. 29: Installing Temperature Flap Cable 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Prerequisites: 

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Heating and ventilation controls are installed.  

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Connecting duct removed, See Connecting duct, removing .  

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Turn temperature rotary control knob to left onto stop.  

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Attach center wire of cable -1- to the temperature flap lever -2-. See Fig. 29 .  

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

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

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

Installing & Adjusting Footwell/Defrost Flap Cable 

Cable sleeve marking: Green 

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Heating, Ventilation - New Beetle