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DESCRIPTION & OPERATION Heating and ventilation system is a blend type system. A heater control valve is not used. Coolant flows unrestricted through heater core. Interior temperature is regulated by a blend door which controls amount of air flowing through heater core. Blend door is operated by a cable connected to temperature control knob. Three knobs are used to control blower speed, air temperature, and air distribution. Fresh air blower has 4 speeds. Blower motor resistor is located on blower motor housing. ADJUSTMENTS MAIN SHUTOFF FLAP CABLE Install heater control panel. Adjust blower control knob to stop at position “0″. Connect main shutoff flap cable (Black sleeve) to main shutoff flap lever. Push lever in direction of arrow until it stops. See Fig. 1. Hold lever in this position, and install cable retaining clip. TEMPERATURE FLAP CABLE Install heater control panel. Adjust temperature control knob to full cold. Connect temperature flap cable (Blue sleeve) to temperature flap lever. Push lever in direction of arrow until it stops. See Fig. 2. Hold lever in this position, and install cable retaining clip. Fig. 2: Adjusting Temperature Flap Cable Courtesy of Volkswagen United States, Inc. FOOTWELL/DEFROST FLAP CABLE Install heater control panel. Adjust airflow distribution knob to defrost position (against stop). Connect footwell/defrost flap cable (Black sleeve) to footwell/defrost flap lever. Push lever in direction of arrow until it stops. See Fig. 3. Hold lever in this position, and install cable retaining clip. Fig. 3: Adjusting Footwell/Defrost Flap Cable

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All Vehicles 1. Remove the RH lower instrument panel insulator. 2. If equipped, remove the dealer installed air filter and brackets. 3. Remove the passenger side scuff plate. 4. Remove the passenger side kick panel. 1. Position aside the weatherstrip. 2. Remove the passenger side kick panel. 5. Disconnect and detach the electrical connector. 6. Position back the carpet. EATC Vehicles 7. Disconnect the aspirator tube and remove the screw. 8. Remove the aspirator tube extension. 1. Remove the screws. 2. Remove the aspirator tube extension. All Vehicles 9. Disconnect the electrical connector. 10. Remove the screws and remove the blower motor. 11. Remove the wheel from the blower motor. 1. Remove the clip. 2. Remove the blower wheel. 12. To install, reverse the removal procedure.

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C1 CHECK BLOWER MOTOR SUPPLY VOLTAGE Gain access to the blower motor control connector. Turn ignition switch to the ON position. Using a voltmeter, check voltage at Circuit 687 (GY/Y) at motor connector. Is voltage 10 volts or more? Yes GO to C4. No GO to C2. C2 CHECK CIRCUIT 687 (GY/Y) FOR SHORT Remove blower Fuse 30A at primary junction block. Using an ohmmeter connected to a known good ground, connect second lead to Circuit 687 (GY/Y) at A/C blower motor. Measure resistance. Is resistance 5 ohms or less? Yes SERVICE Circuit 687 (GY/Y) for short. REPLACE fuse. RESTORE vehicle. RETEST system. No GO to C3. C3 CHECK CIRCUIT 687 (GY/Y) FOR OPEN Disconnect A/C blower motor control. Connect a jumper wire to Circuit 687 (GY/Y) at blower motor control connector. Connect other end to a known good ground. Using an ohmmeter connected to a known good ground, connect second lead to Circuit 687 (GY/Y). Measure resistance. Is resistance 5 ohms or less? Yes GO to C4. No SERVICE Circuit 687 (GY/Y) for open. RESTORE vehicle. RETEST system. C4 CHECK BLOWER MOTOR SPEED CONTROL GROUND Gain access to A/C blower motor speed control as outlined. Using an ohmmeter connected to a known good ground, connect second lead to Circuit 57 (BK) at A/C blower motor speed control connector, J1-2. Measure resistance. Is resistance 5 ohms or less? Yes

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SYMPTOM The blower motor does not work at all. PROBABLE CAUSE Poor connection at the blower motor caused by tension on the wiring harness. CORRECTIVE ACTION Install a blower motor sub harness. REPAIR PROCEDURE 1. Remove the glove box and cover: • 1999–03 3.2 TL: See page 20-66 of the 1999–03 3.2 TL Service Manual. • 2001–03 3.2 CL: See page 20-64 of the 2001–03 3.2 CL Service Manual. • Online, enter keyword GLOVE, and select Glove Box Removal/Installation from the list. 2. Disconnect the brown 7P connector (C202) from the main harness. Remove the YEL/BLK wire terminal from cavity 3 of connector C202. Cut off the terminal, and tape the remaining end of the wire to the harness. NOTE: If necessary, refer to the terminal replacement section of the appropriate ETM for how to properly remove a terminal from a connector.

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1. Disconnect the electrical connector (3). 2. Remove the blower motor resistor mounting screws (1). 3. Remove the blower motor resistor (2) from the blower case. 2. Install the blower motor resistor mounting screws (1). Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Connect the electrical connector (3). Removal Procedure (C60) 1. 2. 3. 4. 5. Remove the A/C control relay bracket with the relay. Remove the blower resistor harness. Remove the stud from the IP, if necessary. Remove the blower motor resistor mounting screw. Cut the access cover from the case. Cut all four sides of the cover in order to remove the three attaching screws. Use a sharp utility knife in order to cut the case. Make the cuts straight and clean. The access cover must be reinstalled and is visible to the customer.