Project 43 Removing the Air Distribution Box on a 2001 VW Beetle TDI That Won't Blow Hot Air

Overview

The  removal of the air distribution box (air box) is the Mother of interior repairs on a Beetle and all VW A4 platform vehicles. The VW manual allows eighteen (18) hours for a technician to complete the repair at a cost of $2500.00 to $3000.00 to the owner. So, let's break down why this repair is so expensive and why it can happen to any owner of a VW vehicle.

To remove the air box, the entire passenger compartment has to be disassembled, including the center console. This means that all plastic trim pieces have to be removed to access the air distribution box.

The replacement air distribution box comes from the factory as a molded assembly that contains no parts. The parts from the defective air box have to be removed; namely, evaporator, (refrigerant discharged), heater core, condenser, fan motor and blower assembly, and manual controls including cables. The replacement air box has two (2) pieces (top and bottom). The center contains screws that have to be removed to separate the top and bottom halves so that the above parts can be installed.

When parts in the assembly break, they are not serviceable. A replacement air box has to be ordered from the VW service center at a cost of approximately $800.00. A used air box can be obtained from a salvage yard that specializes in VW's and German vehicles for approximately $100.00 to $150.00. The air box that we used for this repair was bought from a local salvage yard for $100.00.

The owners complaint  is there is very little or no hot air entering the passenger compartment when the heater heater control is "ON". After disassembly, two (2) problems; namely, (1) The foam backing material on the panels of the flapper doors was rotten leaving large holes in the material covering the doors and (2) A plastic part was broken that houses the control cables.

The heater and A/C controls operate cables that open and close two (2) flapper doors controlling the selection of "HOT" or "COLD" air entering the passenger compartment. Air leaks between the doors will result in improper mixing of the air with the A/C and heater manual controls.  The air box needs to be replaced to rectify this problem.

The soft foam insulation materials used in the Beetle and all VW vehicles were designed in Germany for use in a cold climate. In Germany, or other parts of Europe, you would rarely hear of this problem. Not so in North America. Temperatures reach well over 100 degrees F in some Southern states. The foam materials used in the Beetle TDI for the insulation of the top engine cover, air box, and other applications will have a short life span when exposed to 100 degree F and higher temperatures.

When removing plastic trim be careful as it breaks very easily. Secondly, the replacement trim pieces are expensive adding unnecessary expense out of your pocket to complete the repair. Upholstery trim tools are needed for removal of trim pieces. Before attempting to remove plastic trim, a listing of Web sites that we use are listed to obtain professional and DIY trim tool kits.

Note

A screwdriver or sharp objects are not the tools of choice for removal of plastic trim pieces. The gouges and scratches that the screwdriver makes will not look pretty or very professional on the interior of your Beetle TDI.

Replacing the air distribution air box in your VW Beetle TDI is not an easy repair. On the scale of ten, it would rate at the top of the list in difficulty. With a plan and an average amount of mechanical know how, and using the repair steps provided in this procedure, you can make this repair yourself and save MONEY on professional repairs.

Repair Steps

Step 1 -Insert a battery-powered memory device in the accessory socket, located in the center console of the passenger compartment, before removing the negative cable of the battery (See Figure 43-1).

Figure 43-1 Typical Memory Keeper

Step 2 - Using the fingers, pull upward and remove the dash center insert (See Figure 43-2).

Figure 43-2 Removing Center Insert

Step 3 - Using the above step, remove the drivers-side insert.

Step 4 - Remove the passenger-side insert.

Note

The drivers-side insert houses the ECM and the passenger-side  insert is where the cabin filter and air bag is located.

Step 5 - Using a screwdriver, remove the screws securing the  floor board panel and set aside (See Figure 43-3).

Figure 43-3 Removed Floor Board Panel

Note

The below steps involve removing a number of plastic trim pieces. To keep from marring the plastic surface, trim tools are recommended to loosen and remove interior trim. Figure 43-4 shows a professional trim tool kit that was ordered from the Eastwood web site. A less expensive kit can be ordered on-line at the Harbor Freight web site.

Figure 43-4 Trim Tool Kit

Instrument Cluster Removal

Step 6 - Remove the instrument housing cover by pulling forward with the fingers (See Figure 43-5).

Figure 43-5 Removing Instrument Housing Cover

Step 7 - Using a T25 torx screwdriver, remove two (2) screws securing instrument cluster to the drivers-side assembly (See Figure 43-6).

Figure 43-6 Removing Screws to Instrument Cluster

Step 8 - Unplug the wiring harness to cluster and set aside. Figure 43-7 shows the instrument cluster being removed.

Figure 43-7 Removing Instrument Cluster

Drivers Side Dash Cover Removal

Step 9 - Using trim tool remove the drivers-side end cap to fuse panel.

Step 10 - Remove screws securing drivers-side cover (See Figure 43-8).

Figure 43-8 Removing Screws to Drivers Side Cover

Step 11 - Using a trim tool, remove the trim piece attached to steering column (See Figure 43-9).

Figure 43-9 - Removing Trim With Trim Tool

Step 12 - Remove screws securing drivers-side cover top (See Figure 43-10)

Figure 43-10 Removing Top Screws to Drivers-Side Cover

Step 13 - Remove the drivers-side cover (See Figure 43-11).

Figure 43-11 Removing Drivers Side Cover

Step 14 - Remove the head light switch.

Step 15 - Remove the connector to the light switch.

Note

The head light switch does not require a trim tool or hand tools for removal. Remove the switch by pushing in and turn the switch clockwise to the first switch position and remove (See Figure 43-12)

Figure 43-12 Removing Head Light Switch

Step 16 -Remove the wiring harness connector plug to switch (See Figure 43-13)

Figure 43-13 Removing Harness Connector to Light Switch

Step 17 - Remove the trim on the drivers-side and passenger-side to steering column.

Step 18 - Remove the screws to the head light and dimmer switch panel (See Figure 43-14)

Figure 43-14 Removing Screws to Head Light Switch Panel

Step 19 - Remove the harness connector plug from panel and set aside.

Top Dash Cover Removal

Step 20 - Remove the screws from the top cover (See Figure 43-15)

Figure 43-15 Removing Screws to Top Cover

Step 21 - Remove the top cover and set aside.

Radio Removal

Step 22 - Remove the radio from the center console (See Project 42).

Center Dash Cover Removal

Step 23 - Remove the screws securing the center cover (See Figure 43-16)

Figure 43-16 Removing Screws to Center Cover

Step 24 - Remove top screws securing center cover (See Figure 43-17).

Figure 43-17 Removing Top Screws to Center Cover

Step 25 - Remove the center cover and set aside (See Figure 43-18

Figure 43-18 Center Cover Removal

Heat and A/C Panel Removal

Step 26 - Using a phillips screwdriver, remove four (4) screws securing the heat, fan, and A/C  panel (See Figure 43-19).

Figure 43-19 Removing Screws to Heat and A/C Panel

Step 27 - Disconnect the heat and A/C  manual control cables.

Step 28 - Disconnect the harness connector to the fan switch. Figure 43-20 shows the control cables and panel removed.

Figure 43-20 Heat and A/C Switch Panel Removed.

Center Console Removal

Step 29 - Using a trim tool, remove the protective caps and remove two (2) screws in  back of console.

Step 30 - Using a flat-blade screwdriver,  press tab on back of emergency brake lever (automatic transmission) Figure (43-21).

Figure 43-21 Engaging Slot in Brake Lever Handle

Step 31 - Remove the trim from brake lever (Figure 43-22).

Figure 43-22 Remove Trim From Brake Lever

Step 32 - Using a 3/8-inch square drive ratchet and 3/8-inch square drive 13mm tall socket, remove the bolt securing the arm rest (Figure 43-23).

Figure 43-23 Removing Bolt to Arm Rest

Step 33 - Remove the cup holder (it snaps out) in the center console (Figure 43-24)

Figure 43-24 Removing Center Console Cup Holder

Step 34 - Remove protective caps (2) and screws at front of console.

Step 35 - Grasp the selector knob on the shaft and pull upward and remove knob (Figure 43-25).

Figure 43-25 Remove Selector Knob

Step 36 - Remove the console extension trim from the selector knob (Figure 43-26).

Figure 43-26 Remove Console Extension From Selector Knob

Step 37 - Remove the  the harness connector to the accessory socket of the center console (Figure 43-27).

Figure 43-27 Harness Connector to Accessory Socket

Step 38 - Remove the center console extension cover and set aside.

Drivers Side Air Bag Removal

Step 39 - Turn the steering wheel until a spoke is in a vertical position.

Step 40 - Extend the steering column to its full position by pulling toward the body.

Step 41 - Using a hook flat-blade screwdriver insert the blade into a hole of the dashboard side of steering wheel (See Figure 43-28).

Figure 43-28 Using Screwdriver to Disengage Clip to Air Bag

Step 42 - Feel with the screwdriver for a clip (there are two) that secures the air bag assembly to the steering wheel.

Step 43 - Using the screwdriver, pull "UP" to press back spring clip and release the locking lug of air bag assembly.

Step 44 - Turn the steering wheel back 1/2 turn (180 degrees).

Step 45 - Repeat the same procedure  and release the locking lug on the opposite side of the steering wheel.

Step 46 - Turn the steering wheel to a straight ahead position.

Step 47 - Disconnect the harness connector from the air bag assembly.

Step 48 - Remove the air bag assembly and set aside with the padding side facing "UP".

Note

Patience is needed to find the air bag locking lugs as they cannot be seen with the eyes. When the lugs are located, a lot of pressure is needed to disengage the clips.

Steering Wheel Removal

Step 49 - Using a 3/8-inch square drive ratchet and 3/8-inch square drive 1/2-inch square drive tall socket with 12mm multi-point socket, remove the bolt securing the steering wheel to the steering column (See Figure 43-29). Figure 43-30 shows the steering wheel bolt removed.

Figure 43-29 Removing Steering Wheel Bolt

Figure 43-30 Steering Wheel Bolt Removed

Step 50 - Using a 3/8-inch square drive ratchet and 3/8-inch square drive T25 torx socket, remove three (3) screws attached to the securing plate.

Step 51 - Remove the securing plate and set aside.

Step 52 - Remove steering wheel by grasping the wheel with two (2) hands and pull toward the body. Figure 43-31 shows the steering wheel removed.

Figure 43-31 Steering Wheel Removed

Step 53 - Remove the spring and slip ring by releasing lugs.

Step 54 - Unplug the harness connector.

Note

For steering wheel to be straight, the center punch mark on the steering wheel must align with the center punch mark on the steering column.

Step 55 - Remove two (2) screws securing the upper steering column trim (See Figure 43-32). Figure 43-33 shows the trim caps and steering wheel removed.

Figure 43-32 Removing Steering Column Trim

 

Figure 43-33 Steering Wheel Removed

Glove Box Removal

Step 56 - Using a trim tool, remove the protective caps on the drivers-side and passenger-side of the vehicle. Figure 43-34 show the protective caps being removed. Figure 43-35 shows the trim caps removed.

Figure 43-34 Removing Glove Box Protective Caps

Figure 43-35 - Glove Box Hand Rail Caps Removed

Step 57 - Using a screwdriver with a T30 socket, remove the hand rail to the glove box and set aside.

Step 58 - Using a screwdriver with a T25 socket, remove the top screws to the glove box (Figure 43-36)

Figure 43-36 Removing Glove Box Top Screws

Step 59 - Using a screwdriver with a T25 socket, remove the screws at the bottom of glove box (Figure 43-37).

Figure 43-37 - Removing Glove Box Bottom Screws

Step 60 - Using a trim tool, remove the passengers-side end caps to access the screws to remove the glove box (Figure 43-38).

Figure 43-38 Removing Passenger-Side End Cap

Step 61 - Remove screws to access and remove wiring connector plug to glove box (Figure 43-39).

Figure 43-39 Removing Connector Plug

Step 62 - Remove glove box and set aside.

Passenger Side Air Bag Removal

Step 63 -Using a screwdriver with a T25 socket, remove the top screws securing the passenger-side dash panel (See Figure 43-40).

Figure 43-40 Removing Passenger Side Panel

Step 64 - Using a screwdriver with a T25 bit, remove the bottom screws securing the panel. Figure 43-41 shows the screws being removed from the passenger-side panel.

Figure 43-41 Removing Screws to Passenger Side Panel

Step 65 - Remove the panel and set aside.

Step 66 - Unplug the connector plug to the wiring harness.

Step 67 - Using a screwdriver with a T30 socket, remove four (4) screws securing the air bag assembly to the dash (See Figure 43-42).

Figure 43-42 Removing Air Bag Assembly

Air Distribution Box Removal

Step 68 - Using a screwdriver with a T30 socket, remove two (2) screws securing the glove box bracket (See Figure 43-43).

Figure 43-43 Removing Screws to Glove Box Bracket

Note

The steering column lower trim was previously removed in Step 55.

Step 69 - Once all of the interior dash piece parts have been removed, the air box can be accessed. Figure 43-44 shows the interior dash piece parts removed.

Figure 43-44 View of Interior Compartment Stripped

Step 70 - Remove the bolts securing the instrument panel cross member. Figure 43-45 shows the location of bolts securing the cross member.

Figure 43-45 Location of Cross Member Bolts

Step 71 - Discharge and recycle the refrigerant in the A/C system. Figure 43-46 shows the evaporator removed from the Beetle air distribution box.

Figure 43-46 Evaporator Removed From Beetle TDI

 

Step 72 - Using wrenches, remove the connectors to the low and high side of the refrigerant metering valve.

Warning

Wear safety glasses to protect the eyes when discharging the A/C system.

Step 73 - Drain or pinch off with hose pinch pliers the coolant hoses to the heater core.

Warning

The cooling system is pressurized when the engine is warm.  Wear safety glasses and protective gloves when working around the cooling system.

Step 74 - Remove the manual control cables to the heater and A/C selector switches. Figure 43-47 shows the manual control cables being removed.

Figure 43-47 Removing Manual Control Cables

Step 75 -Tilt and lift the cross member in an "UP" direction.

Step 76- Remove the air distribution box and set aside (See Figure 43-48).

Figure 43-48 Air Distribution Box Removed From Beetle

Note

The air distribution box is heavy. Seek the services of a helper for proper removal.

Step 77 - Using hand tools, remove the screws securing the top and bottom halves of the air distribution box. Figure 43-49 shows the top and bottom halves being removed. 

Figure 43-49 Air Distribution Box Top and Bottom Halves Being Removed

Note

The Air Distribution Box houses the condenser, evaporator, heater core, flapper door, manual control cables, and blower motor. Each component has to be removed from the defective air distribution box and reinstalled in the replacement air box.

Step 78 -Remove the condenser. Figure 43-50 shows the condenser removed from the air box.

Figure 43-50 Condenser Removed

Step 79 - Remove the A/C evaporator (See Figure 43-51).

Figure 43-51 A/C Evaporator Removed

Step 80 - Remove the heater core (See Figure 43-52).

Figure 43-52- Heater Core Removed

Step 81 - Remove the manual A/C and heater control cables (See Figure 43-53).

Figure 43-53 Manual Control Cables Removed

Step 82 - Remove the fan motor and blower assembly (See Figure 43-54).

Figure 43-54 Fan Motor and Blower Assembly

Step 83 - Install the replacement air distribution box in the reverse order from which it was removed.

Finishing Up

Step 84 - Install the replacement air distribution box.

Step 85 - Install the high and low-side connections to the A/C metering valve that were previously removed.

Step 86 - Install the inlet and outlet hoses to the heater core.

Step 87 - Connect the manual control cables to the A/C and heater selector switches.

Step 88 - Connect the wiring harness connectors to the fan motor and blower assembly.

Step 89 - Install all trim pieces and screws to the drivers-side, passenger-side and control panel in the reverse order from which they were removed.

Step 90 - Install and top off the coolant tank with anti-freeze.

Step 91 - Evacuate the A/C system.

Step 92 - Recharge the A/C system with the proper charge listed in the owners manual, Bentley, or factory service manual.

Step 93 - Remove the memory keeper from the accessory socket.

Step 94 - Install the Vag Com scan tool and check for resetting air bags and trouble codes.

Step 95 - Check the A/C and all controls for proper operation.

Step 96 - Road test the vehicle.

Tools and Equipment

Memory keeper

Phillips screwdriver

#2 phillips bit

Flat-blade screwdriver

Trim tool kit

T25 torx screwdriver

Radio grip hooks (2)

3/8-inch square drive ratchet

3/8-inch square drive 13mm tall socket

Hook flat-blade screwdriver

3/8-in square drive 1/2-inch square drive tall socket

12mm multi-point socket

3/8-inch square drive T25 torx socket

T30 torx screwdriver

Hose clamp pliers

Pinch-off pliers

A/C refrigerant gauges

R-134 refrigerant

G-12 VW coolant

Vag Com scan tool

Safety glasses

Protective gloves