Air Door Cable: Service and Repair

NOTE:
^ A change to the control head was made during production of 1988 model 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.
- Disconnect the negative (-) terminal from the battery.
- Remove the center console. On manual transmission cars, first remove the gearshift lever knob and the gearshift boot.
- On automatic transmission cars remove the selector lever cover plate.

First Type:

Second Type:

- Depending on the center console (first type or second type), remove the retaining screws and partially remove the console. Separate any electrical connectors from behind.





- Remove the lower-left instrument panel tray by removing the screws indicated.
NOTE: On some models the tray may run the full length of the instrument panel, On models with passive restraint there may be a knee bar.
- With full-length trays it is necessary to remove two screws securing the fuse panel to the tray.

NOTE: Kneebars are held with two bolts at either end.






- Remove the control head from the instrument panel.
- 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.

Top View:

- Connect the other end of the new cable to the control head.





VACUUM CONNECTIONS
1 Black hose (vacuum source)
2 White hose (recirculation servo)
3 Red hose (defrost/floor servo)
4 Yellow hose (instrument panel top port)
5 Green hose (instrument panel side port)

- Install the cable housing retaining clip, reinstall the control head in the instrument panel, and adjust the cable.
- 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.

Long Black Cable For Instrument Panel Vent Door:

Short Black Cable For Heater/defroster Door:

Blue Cable For Blend Door:

- Push the heater box door levers in turn in the directions indicated in the images.
- Hold the levers in these positions, and install the cable housing retaining clips.

NOTE: Installation is the reverse of removal, for the remainder of the reassembly.