You are correct there is a short cut. remove the wiper arms and cowl cover. This will expose the upper portion of the HVAC box. remove the screws and remove the two covers. You will need a t20 torx probably 8in in length to reach the back screws. I'll see if I can dig up some info on this procedure to post as it is a bit awkward the first time around. I recommend replacing the fresh air flap and recirculation flap together.

 

We love short cuts! I'm all ears.


For what its worth, the shop manual says you can access the fresh air flap motor from the driver's side footwell area. Need to remove some trim panels from the under dash area.


Not so for the recirc flap motor.

 

http://www.ebay.com/itm/131841591917?_trksid=p2055119.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT
Does it look anything like this supposedly 2005 GT part? The graphic in my shop manual doesn't really match this photo.

 

my bentley only cools when it's on the freeway or it isn't too hot outside, my mercedes cools no matter what the temperature is outside, considering i live in texas it gets as hot as 116 degrees and it's super humid, i took the car to get the A/C service and no difference, it only cools when the sun goes down or car is parked under a shade or better yet at night, glad to hear i'm not the one with this problem.

 

I have the same issue living in the desert of Utah. But the dealership says my recirculation flap actuator/motor is not working (per their code scan) and this is not an uncommon problem. Thus the outside 105 degree air is constantly flowing in and trying to be cooled.


You should notice that on any car the HVAC will automatically go into recirculation mode when it is super hot or super cold outside. You may think it is but can't tell the recirc flap isn't working.


I'm anxious to fix it. Awaiting DIY instructions.


You may have the same problem and don't know it. Suggest you have the dealer or someone else with the proper VW/Bentley/Scoda/Audi scan tool run a diagnostic.

 

So just because the HVAC is blowing hard it doesn't mean it's working properly ???

 

Correct. The fan speed is not an indicator. Well you do want the fan working and the system fully charged with 134a refrigerant. Sounds like you have both of those covered.


If the recirc flap does not work you are constantly trying to cool very hot outside air. If the recirc flap does work you will be recirculating the inside air and re-cooling the already cooled air. Thus the air will get colder and colder.

 

Gotcha, is this the part that needs to be replaced or is it the whole thing from up above ???

 

That's it pretty much it. Except I believe the recirc flap motor has a different part number than the fresh air flap motor shown in that ebay ad.


There could be slight differences in mounting or where on the motor the electrical connector plugs in.

 

summer is almost gone here in texas, so i guess i'll worry about it next year, just sucks when i'm stuck in traffic and i have a hot date sitting in the passenger seat, you would think the A/C is ice cold since it's a bentley, thanks for the help bud.

 

Sorry for the late response life has been crazy. Attached is the TSI for the HVAC motors.

 

Been in Europe so its taken me a while to get back to you.


Thank you for digging up this tech info for me.


Not 100% sure what it all means. Seems like I need to look up some other BINs for various parts of the procedure.


As per a previous post a new actuator was for sale ebay for a princely sum of $190 plus shipping. Does anyone know the VW part number so we can seek a more reasonable price?


As you and the instructions say, both fresh air and recirc motors should be replaced at once. Hate to pay $400 just for two small parts.

 

After reading the instructions I'm still not sure I want to DIY the replacement HVAC flap control motors. Nevertheless I purchased two today from my local VW dealership.


As the instructions say, Bentley recommends that you replace the fresh air and recirculating air flap control motors at the same time. I have confirmed the they are the same part number 4D0-820-511. No crossover part number needed to order from VW or Audi.


From an ebay ad referred to earlier, it appears the Bentley price is about $220 each. The dealership is selling on ebay for $190, plus shipping I believe. The VW price is $178.33 plus tax. I got mine with a military discount for $151.58 plus tax.


I gather there are not too many left to be bought. One will be shipped from the VW warehouse and one from another dealership in Wisconsin. So if you want to get two you might order now.


I am considering taking the replacement instructions to the service manager at the VW dealership and seeing if they would be interested in doing the work and at what cost. Although I replaced the spark plugs and one ignition coil myself as well as two horns, the flap motor procedure looks a bit intimidating. The Bentley dealership, with a $175/hr labor rate, quoted me $1268 to replace the recirc flap motor. That included the part cost. Not sure what they would add to replace the fresh air flap motor at the same time. It couldn't add more than 15 minutes to the job but I believe the labor rate books that dealerships use still do not account for doing two activities at once. For example if you wanted brake pads replaced and tires rotated at the same time you will pay to have the wheels taken off and remounted twice as that activity is included in the hourly time estimate for both jobs.

 

I researched and printed out every bit of instruction from the shop manual CD related to replacing the fresh air and recirc air flap motor controllers and took that info into the VW dealer. Reviewed it with their head mechanic and he thinks its a 2-3 hour job. I'm sure it would take me 2-3 times that long so I have an appointment to have them replace both parts, which arrived yesterday.


I don't know their labor rate but it is probably around $85/hr or so. Bentley's is $175 and they quoted 3.85 hours for the labor. So it must be quite a savings having the VW dealer do it. I just don't feel like doing it myself.


SURPRISE SURPRISE!!!!
I opined earlier when it was really hot or really cold outside with the HVAC set on AUTO the fresh air flap would close and the recirc flap would open. Thus the recirculated cabin air would heat or cool more quickly. This is how it works on every other car I've had in the past 15 years. But I found out today this in not how the Bentley HVAC is programmed. (at least not for my 2008 and earlier)


Researching the shop manual today I read up on the functioning of the HVAC system. It says the only time it will go into recirc mode is if pollution is detected. It will then shut out the pollution by closing the fresh air flap and recirculate the cabin air.


So if you want to heat or cool your car more quickly you need to manually hit the Recirc button. To go back to normal mode you have to turn it off manually. What a pain, but at least we now know why the AC takes so long to cool.


Some of you may still have a Recirc flap motor that works. If so you can use the manual procedure described above. But some of us need to replace the motor first. If you are not sure what category you are in you should get a scan for faults in the HVAC system.

 

Got the fresh air and recirc air control motors replaced at the local VW dealer. Total cost $758 with parts. Bentley dealer quote $1265. Both estimated 3.5 hours labor.


Works great now but they scratched my bonnet. Probably while removing or reinstalling the wiper arms. So they have readily agreed to pay to have the bonnet repainted for $565.


Car was going into the paint shop next week anyway to have the rocker panels and front bumper refinished. After that car will be in like new condition. I will get Clearbra installed on the rockers and bumper to prevent any future little dings. Wheel well flaps just wouldn't look right.