Skill Level 1 - Easy VW MK4 Aluminum Blend Door Support...

Skill Level1 - Easy

Basic SkillsRequired

Proper service and repair procedures are vital to the safe, reliable operation of all motor vehicles as well as the personal safety of those performing the repairs. Standard safety procedures and precautions (including use of safety goggles and proper tools and equipment) should be followed at all times to eliminate the possibility of personal injury or improper service which could damage the vehicle or compromise its safety.

VW MK4 Aluminum Blend Door Support PinInstallation Instructions - ES3575736

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VW MK4 ALUMINUM BLEND DOOR SUPPORT PIN INSTALLATION ES#3575736

2Table of ContentsWWW.ECSTUNING.COM© 2019 ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172

The blend door in VW MK4 Golf or Jetta is responsible for adjusting the climate control temperature. This blend door pivots on a pin which is located on the bottom of the HVAC housing in the dashboard, and it is controlled by a cable which leads up to the knob on the climate control panel. The original plastic blend door pin will become brittle after years of service, and if it breaks it will render your temperature control inoperative.

Unfortunately, the OEM part is no longer available, so the Engineering Team at ECS Tuning designed a replacement part which is even better than the OEM version! Made from 6061-T6 aluminum, our blend door pin will not fail or back out like the OEM plastic version. We designed our pin with a 360° retention feature for a much more secure fit. Once fully seated our blend door pin rotates freely and is locked securely into place without worry of any future failures.

Before you begin, read through these instructions and check the required tool list to make sure you have everything you need. Thank you for looking to ECS Tuning for all your performance and repair needs, we appreciate your business!

ECS Tuning MK4 Aluminum Blend Door Support Pin

INTRODUCTION

#1: Remove the console to access & remove the original

blend door support pin

#2: Install the aluminum blend door support pin

#3: Reinstall the cable arm & reassemble the console



3WWW.ECSTUNING.COM© 2019 ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172

Installation and Safety Information .......................................................................... pg.4Removing the Center Console .................................................................................... pg.5Removing the Original Blend Door Support Pin .................................................. pg.12Installing the New Aluminum Blend Door Support Pin .................................... pg.14

ECS MK4 Blend Door Support Pin (QTY 1)M4x0.7x8mm Bolt (QTY 1)

M4 Flat Washer (QTY 1)

TABLE OF CONTENTS

KIT CONTENTS




NEVER get underneath a vehicle that is supported only by a jack, andALWAYS make sure that the vehicle is securely supported on jack stands.

• RH refers to the passenger side of the vehicle.• LH refers to the driver side of the vehicle.• Always use the proper torque specifications.• If applicable to this installation, torque specifications will be listed throughout the document and at the end as well.• Please read all of these instructions and familiarize yourself with the complete process BEFORE you begin.

• Park your car in a safe, well lit, level area.• Shut the engine off and remove the key from the ignition switch.• Make sure any remote start devices are properly disabled.• ALWAYS wear safety glasses.• Make sure the parking brake is applied until the vehicle is safely lifted and supported.• Whether lifting a vehicle using an automotive lift or a hydraulic jack, be sure and utilize the factory specified lift points.• Lifting a vehicle in an incorrect location can cause damage to the suspension/running gear.• ALWAYS support the vehicle with jack stands.• ALWAYS read and follow all safety information and warnings for the equipment you are using.

ECS Tuning cares about your health and safety, please read the following safety information. This information pertains to automotive service in general, and while it may not pertain to every job you do, please remember and share these important safety tips.

INSTALLATION NOTES

GENERAL PREPARATION AND SAFETY INFORMATION




Step 1:

Step 2: 13mm Socket & Ratchet

T20 Torx

Begin by lifting the red ashtray insert out of the shifter console, then remove the single Torx screw located underneath it.

Moving back to the armrest, remove the LH side panel by:

1. Pulling the top of it away from the armrest to release the clips (LH photo).

2. Then lift the panel upward out of the console.

Once the side panel has been removed you can access and remove the single bolt which secures the armrest to the console (RH photo). Remove this bolt, then lift the armrest and the remaining trim panel out of the center console (not shown).

REMOVING THE CENTER CONSOLE

#1: Pull the top outward slightly to release the clips

#2: Lift the panel upward and out of the center console




Step 3:

Next we need to remove the rear cupholder. Slide the cupholder rearward, then locate the two fingers inside the console which keep the cupholder from over-traveling (highlighted in RED upper photo).

Push the fingers outward slightly as you slide the cupholder out of the console (lower photo).





Step 4: Trim Removal Tool

Now we need to remove the final cover from the center console, to do this we need to pry upward gently along the front edge and pivot the cover upward (shown in the upper photo).

Once the clips have been released the panel needs to be lifted upward at an angle as shown in the bottom photo.





Step 5:

Step 6:

T20 Torx

Remove the two Torx screws from the rear of the center console.

The center console doesn’t need to be completely removed for this install, we only need to release it from the shifter console. To do this you’ll need to push the center console downward slightly to release the clips from the shifter console, then slide the center console rearward an inch or two to get it out of the way.


#1: Release the center console from the shift

console

#2: Slide the center console

rearward slightly




Now we need to remove the shifter console. There are two T20 Torx screws on each side, one near the front, and another toward the rear behind a small plastic cover. Use a suitable tool to pry out the plastic covers, then remove all four screws.


T20 TorxStep 7: LH side of shifter console

RH side of shifter console




Step 8:

There are two hidden clips (one of each side located near the front) which secure the shifter console to the dashboard. To release them you’ll need to push each end of the shifter console downward approximately one inch, then pull the front of the console outward approximately one inch. Perform this on both sides of the shifter console, then proceed to step 9 on the next page.


#1: Push the console downward approx. 1”

#2: Pull the console

outward approx. 1”

#1: Push the console downward approx. 1”

#2: Pull the console

outward approx. 1”




Step 9:

Step 10:

Lift the rear of the shifter console upward slightly, being mindful of the rubber shifter trim. Push the ashtray toward the dashboard to slide it out of its mounting slot.

Remove the shifter console from the vehicle as shown in the photo.


Push the ashtray forward out of the console

Remove the shifter console

Vehicles equipped with the Tipronic automatic transmission will need to pull the shift lever into the lowest range at this time.




REMOVING THE ORIGINAL BLEND DOOR SUPPORT PIN

Looking from the RH side of the console, locate the blend door support pin and lever arm (highlighted in RED in the photos on the right).

It’s worth noting that there is a vent assembly which is located directly underneath the blend door support pin. We decided to remove the vent for better visibility in next few photos, but you can perform this repair without removing it.

T20 TorxStep 1:





Now it’s time to remove the blend door support pin from the HVAC housing. Begin by removing the 7mm screw from the support pin and pull the lever arm downward. There are two different ways to proceed from here:

• If your pin has already failed or broken it will be hanging down out of the HVAC housing as shown in photo #1. Remove the pin from the housing and proceed to the next page.

• If your pin is not broken you will need to release it from the HVAC housing. There is no way to manually release the support pin clips because they are inaccessible inside the housing (shown in photo #2 below). The easiest way to remove the pin is to thread a belly pan screw (or similar) into the pin, then use a screwdriver to pry downward to pop it free (shown in photo #3 in the bottom right).

REMOVING THE ORIGINAL BLEND DOOR SUPPORT PIN

#1: BROKEN blend door support pin:

#3: UNBROKEN blend door support pins:

#2: Support pin clips:




Step 1:

INSTALLING THE NEW ALUMINUM BLEND DOOR SUPPORT PIN

There is a slot in the new blend door support pin which MUST be aligned with the blend door inside the HVAC housing (shown in the upper photo). You won’t be able to see this from below, so you’ll need to operate by feel alone.

Carefully slide the new blend door support pin into place, twisting side to side to ensure that the slot lines up with the blend door (shown in the bottom photo).

Support pin slot

Blend door

Step 2:




Step 3: Small Socket & Pry Bar

Now we need to seat the pin into place, this can be a bit tricky given how little space there is to work, and the location of the air bag control unit directly below. It is extremely important to avoid causing any damage to that air bag control unit.

Due to the space constraints we decided to place a socket on the tunnel just in front of the air bag control unit, then we used a small pry bar to lever the pin upward into the HVAC housing. You might be able to hear it click into place, but keep in mind that very little force is needed to fully seat it into place (shown in the top photo).

Give the pin a quick tug to make sure it is all the way installed, then twist it to confirm blend door operation (shown in the bottom photo).

Air bag control

unit

Small socket

Fully seated pin

Step 4:





Step 5:


Slide the lever arm onto the new pin (upper photo).

Install the supplied flat washer and bolt (lower photo) through the lever arm and into the pin. Tighten the bolt until it makes contact with the lever arm, then tighten it an additional 1/8 turn.

Your installation is complete!

Adjust the temperature control knob while watching the blend door lever and confirm that the blend door operates properly.

Reinstall the consoles in the reverse order of removal.


It’s worth noting that the top of the blend door support pin is not perfectly square, it is in fact rect-angular (see the graphic on the right). Be sure to properly align the lever arm onto the pin.

WIDE

SKINNY


These instructions are provided as a courtesy by ECS TuningProper service and repair procedures are vital to the safe, reliable operation of all motor vehicles as well as the personal safety of those performing the repairs. Standard safety procedures and precautions (including use of safety goggles and proper tools and equipment) should be followed at all times to eliminate the possibility of personal injury or improper service which could damage the vehicle or compromise its safety.

Although this material has been prepared with the intent to provide reliable information, no warranty (express or implied) is made as to its accuracy or completeness. Neither is any liability assumed for loss or damage resulting from reliance on this material. SPECIFICALLY, NO WARRANTY OF MERCHANTABILITY,

Your MK4 Blend Door Support Pin installation is complete!

FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER WARRANTY IS MADE OR TO BE IMPLIED WITH RESPECT TO THIS MATERIAL. In no event will ECS Tuning, Incorporated or its affiliates be liable for any damages, direct or indirect, consequential or compensatory, arising out of the use of this material.

Skill Level 1 - Easy VW MK4 Aluminum Blend Door Support...

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