Volkswagen New Beetle. Manual - part 2023

 

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Volkswagen New Beetle. Manual - part 2023

 

 

Flap -1- Into Retainer 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Cable color codes 

z

Footwell/defrost flap cable: green  

z

Central flap cable: yellow  

z

Temperature flap cable: beige 

{

Check and adjust cables, See Heating and ventilation cables, installing and adjusting .  

{

Connect electrical connector  

{

Fit controls into instrument panel opening and install mounting screws.  

HEATING AND VENTILATION UNIT, ASSEMBLY 

Fig. 21: Identifying Components Of Heating And Ventilation Unit 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

1. Heater core 

z

Always use new coolant after replacement  

z

Removing: 

„

Remove instrument panel. 

See INSTRUMENT PANEL, REMOVING AND INSTALLING . 

„

Loosen Instrument panel cross member. See Fig. 3 .  

„

Carefully pinch off both coolant hoses to heater core and disconnect hoses.  

NOTE:

The following list refers to items in Fig. 21 .

CAUTION: The cooling system is pressurized when the engine is warm. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Heating, Ventilation - New Beetle

  

z

Partially remove heating and ventilation unit.  

z

Press retainer clips and remove heater core.  

2. Self-tapping screw 

z

Use if retainer clips break  

3. Air distribution housing  

4. Servo motor for fresh/recirculating air door-V154- 

z

Removing and installing, See Servo motor for fresh/recirculating air door -V154-, removing 
and installing
  

5. Self-tapping screw  

6. Fresh air blower - V2- 

z

Removing see Fig. 2  

7. Cover  

8. Self-tapping screw  

9. Series resistor - N24- 

z

Removing, see Fig. 2 .  

10. Self-tapping screw  

11. Central flap lever 

z

Installing and adjusting, See Fig. 22  

12. Temperature flap lever  

13. Base plate  

14. Heater core bulkhead seal 

z

Note installation position  

z

Installing, See Fig. 23  

The central flap pinion has an adjustment mark. 

z

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

Wear gloves and other protection and carefully release system 
pressure if necessary, before performing repairs.

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Heating, Ventilation - New Beetle

  

Fig. 22: Installing Central Flap Lever 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

The seal between the heater core and the bulkhead has a positioning mark. 

z

Install the seal -1- so that the notches on the seal and the base plate -2- align -3-. 

Fig. 23: Identifying Installation Position Heater Core Bulkhead Seal 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Servo motor for fresh/recirculating air door -V154-, removing and installing 

Removing 

z

Remove glove box. 

See GLOVE BOX, REMOVING AND INSTALLING . 

z

Disconnect electrical connector -1-. See Fig. 24 

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Heating, Ventilation - New Beetle

  

z

Remove screw -3-.  

z

Swing motor -2- downwards.  

z

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

Fig. 24: Disconnecting Motor From Fresh Air/Recirculating Air Door Lever 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

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

z

Attach electrical connector -1- to flap motor -2-. See Fig. 25 .  

z

Switch on ignition.  

z

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

Fig. 25: Attaching Electrical Connector To Flap Motor

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Heating, Ventilation - New Beetle

  

 

 

 

 

 

 

 

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