Removing and installing air distribution flap actuator: VW Polo 6R

🧭 Before you start

Fits: VW Polo 6R (2009–2014)

Don't miss

• During installation, it is possible to see lever pin (1) through a hole in lower gear wheel of actuator.
• Check function of actuator.It must be possible to move all flaps to their end positions easily and smoothly.The actuator has no limit stop. It should be possible to rotate it several turns of 360°.

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Remove heater unit .
2. Remove securing bolts (1).
3. Release fastener (2), and swing actuator out of distribution box in direction of (arrow).
4. Lock actuator gear wheels. To do so, turn gear wheels until marks (arrows) engage in one another.
5. Insert an M6 bolt (2) into the opening of the lower gear wheel and the actuator (1) whilst in this position.

6. Position footwell vent flap lever (1) downwards.
7. Position dash panel vent flap lever (2) downwards.
8. Position defroster flap lever (3) so that the defroster flap is fully open.
9. Insert locked actuator (5) at an angle into the three openings of the distribution box.
10. Guide actuator onto distribution box so that pins of levers (1) and (2) engage in corresponding track of actuator (5).
11. Guide retaining pin (3) into respective opening of actuator (5). [Note: During installation, it is possible to see lever pin (1) through a hole in lower gear wheel of actuator.]
12. Lock actuator (5).
13. Remove bolt (4). [Note: Check function of actuator.It must be possible to move all flaps to their end positions easily and smoothly.The actuator has no limit stop. It should be possible to rotate it several turns of 360°.]
14. Remove actuator and repeat installation, as described.
15. Secure actuator with bolts (1 Nm). — 1 Nm (0.7 lb-ft)

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