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Replacing and Adjusting Heater Control Cables

The three cables that control the heating and ventilation system are identified by their color and length. The long black cable controls the door for the instrument panel vents, the short black cable controls the heater/defroster door, and the blue cable controls the temperature blend door. If a cable or the control head is replaced, the cables should be adjusted.

NOTE-

A change to the control head was made during production of 1988 models, on Golfs from VIN JB 048 306 and on Jettas from VIN JW 163 297. The temperature lever of the new control head has two pivot points instead of one. In addition, a longer temperature blend door cable is used. The new-style control head is interchangeable with the old style head, but the longer cable must be used. The longer cable can be used with early-style control heads.

Fig. 4-5. Exploded view of ventilation control head showing removal of control levers.

Replace control cables by first removing the center console and the lower instrument panel trays as described in 4.1 Instrument Cluster and Instrument Panel. Next, remove the control head from the instrument panel as shown in Fig. 4-5 above. Release the cable housing retaining clips on the heater box and control head, and then pull the cable off of the door control lever. Connect the new cable to the door lever, but do not install the cable housing retaining clip on the heater box. Connect the other end of the new cable to the control head as shown in Fig. 4-18, install the cable housing retaining clip, reinstall the control head in the instrument panel, and adjust the cable as described below. The remainder of installation is the reverse of removal.

Fig. 4-18. Control cables installed on control head. View is from top. 1 is long black cable, 2 is short black cable. Arrows indicate correct clip installation. Turn head over for installation of blue cable.

To adjust control cables, remove all of the cable housing retaining clips on the heater box. Push the levers in the control head all the way to the left. Push the heater box door levers in turn in the directions indicated in Fig. 4-19, Fig. 4-20, and Fig. 4-21, hold the levers in these positions, and install the cable housing retaining clip.

Fig. 4-19. Long black cable for instrument panel vent door being adjusted. Arrow shows direction to push lever during adjustment.

Fig. 4-20. Short black cable for heater/defroster door being adjusted. Arrow shows direction to push lever during adjustment.

Fig. 4-21. Blue cable for blend door being adjusted. Arrow shows direction to push lever during adjustment.

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