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Volkswagen New Beetle: 1998 and later HVAC Control Unit - no blower after bulb replaced


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Last Post: Jun 6, 2019 3:11 AM Last Post By: ritafuller007
jpmurphy

Posts: 2
Registered: 07/25/04
HVAC Control Unit - no blower after bulb replaced
Posted: Jul 25, 2004 4:27 PM
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I replaced the light bulb in a 01' Beetle TDi today by pulling the blower speed rotary control knob out. The buld now works, but I can't get the blower to turn on. I must of broke something in the HVAC... The rotary control seems to work same as b4 but wont turn on the blower / the A/C button does not light up just as the knob is turned to the off position.
JoeBean

Posts: 4,697
Registered: 02/14/02
Re: HVAC Control Unit - no blower after bulb replaced
Posted: Jul 25, 2004 6:12 PM   in response to: jpmurphy in response to: jpmurphy
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Most likely you have a harness connector disconnected at the switch. But ensure that the fuses (S5 and S225 in particular) are ok first

Terry
jpmurphy

Posts: 2
Registered: 07/25/04
Re: HVAC Control Unit - no blower after bulb replaced
Posted: Jul 25, 2004 8:35 PM   in response to: JoeBean in response to: JoeBean
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I have the Bentley on my Jetta and A6, but non on the Beetle. I'm fixing this for a friend. Are there any easy instructions to remove the control unit in the Beetle. I have done it in the Jetta and a Passat but never a Beetle. I don't know how to get the center dash cover off.
JoeBean

Posts: 4,697
Registered: 02/14/02
Re: HVAC Control Unit - no blower after bulb replaced
Posted: Jul 26, 2004 7:28 AM   in response to: jpmurphy in response to: jpmurphy
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Attachment AOC1.gif (14.8 KB)
Attachment AOC2.gif (22.3 KB)
Attachment AOC3.gif (33.5 KB)
Attachment cont1.gif (32.7 KB)
You're referring to the controls, correct? I ask because unlike on some vehicles there is no central control module for heating and A/C on the NB.

Here's the procedure according to the Bentley:

Removing the controls does look to be a bit more of a pain than on other models (nothing new for an NB). First, remove the center air outlet console. See the attached pics. First, push the top cover up and remove it. Second, unclip the lower covers and remove the lower switch console cover after removing the screws. Then remove the screws shown in AOC3 and remove the console.

After that's done, remove the screws shown in cont1. Lift the controls with the cables out in the direction of the arrow A. If necessary, disconnect the cables to get at the electrical connectors.

Terry
1flyr

Posts: 1
Registered: 01/16/05
Re: HVAC Control Unit - no blower after bulb replaced
Posted: Jan 16, 2005 2:52 PM   in response to: jpmurphy in response to: jpmurphy
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Just found your message. Hopefully you have this fixed by now, but if not...here is my story.

When I took my 99TDI in for a recall I had the dealer repair the bulb (I had NO IDEA of how to do it!). They managed to kill the fan control ajust as you have mentioned. Told me that the WHOLE FAN/HEAT/AC CONTROL unit would have to be REPLACED, parts alone (as I reall) was around $200. Dealer insisted that it was "just a coincidence" that the controller failed immediately after they had replaced the bulb.

I started digging and found that the problem is fairly simple. If you twist the fan control knob much at all while pulling it out for bulb replacement you will bend the electrical wiper on the fan control potentiometer and disengage it from the conductors.

If your problem still exists the fix will take 2 or 3 hours, depending on your skills. If you don't have fairly advanced "fix-it" skills, you might have problems with this. If you do, then...

1) Remove the shrouding as detailed in the other response.
2) Remove the entire control unit. As I recall you might need to leave some elements attached, so you need to work carefully.
3) CAREFULLY disassemble the control unit. Work slowly, it CAN be done, but you MUST be careful or parts will fly out of the unit.
4) Isolate the fan control potentiometer. It is two semi-circular comductors, a line and a load side, with a flexible metal wiper that runs between the two, contavcting both when it is working right. You will probably find that it is bent up and it might not even be in contact with either side, certainly not both.
5) Straighten the wiper so that it makes contact to both sides through the entire control range. Hopefully the wiper will not be so mangled that you can't straighten it enough to make proper contact.
6) Put everything back together and bask in the glory of your brilliance, because it WILL (or at least certainly SHOULD) work.
7) If you have done this as a result of the dealer's incompetence as I did you may then bend the service manager's ear until he gives you some sort of refund.

In my case it was for the labor charges to replace the bulb. This was particularly sweet because when I found out what was actually involved in replacing the bulb I was LIVID about the amount charged!!

Best of luck! Hope this helps!
ritafuller007

Posts: 1
Registered: 06/06/19
Re: HVAC Control Unit - no blower after bulb replaced
Posted: Jun 6, 2019 3:11 AM   in response to: jpmurphy in response to: jpmurphy
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Thank you for the tutorial on the bulb replacement. One of the aspects of my project includes describing this process so I need to do my engineering homework on Control Unit.

Thanks for help!

Edited by: ritafuller007 on Jun 6, 2019 3:11 AM

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