Thursday, November 10, 2011

How to replace Heater core for Volkswagen New Beetle?

The procedure is as follows :---


Removal & Installation



New Beetle




NOTE
Be sure to obtain the anti-theft code for the radio.

  1. Disconnect the negative battery cable.
  2. Drain the cooling system into a clean container for reuse.
  3. Remove the driver-s side air bag by performing the following procedure:

    Release the steering column adjustment.
    Rotate the steering wheel until the spokes are vertical (90 degrees off center).
    Adjust the steering column to the completely out down position and lock the adjustment.
    At the rear of the steering wheel, insert a 7 in. (175mm) screwdriver into the hole in the hub approximately 134
    Twist the screwdriver counterclockwise (as viewed from the driver-s seat) to release the air bag clip.
    Rotate the steering wheel 180 degrees in the opposite direction and release the clip on the other side.
    Center the steering wheel with the front wheels facing straight-ahead.
    Disconnect the electrical connector and remove the air bag.
  4. Remove the steering wheel by performing the following procedure:

    Place the front wheels in the straight-ahead position.
    Disconnect the horn-s electrical connector.
    Remove the steering wheel-to-steering column bolt and discard it.
    Remove the steering wheel from the steering column.
  5. Remove the instrument panel by performing the following procedure:

    Remove the upper steering column cover screws and the cover.
    Remove the lower steering column cover screws, release the steering wheel height adjustment and remove the lower steering column switch trim.
    Remove the combination switch-to-steering column bolt, disconnect the electrical connectors and remove the combination switch.
    At the driver-s side, remove the lower instrument panel cover screws and the cover.
    At the passenger-s side of instrument panel, remove the side cover.
    At the center of the instrument panel, remove both switch assembly covers, the 4 switch assembly-to-panel screws and the switch assembly.
    Remove the 4 heater/ventilator control unit-to-instrument panel screws and move the control unit under the instrument panel with the cables attached.
    Remove the 6 glove box-to-instrument panel screws, disconnect the glove box light connector and remove the glove box.
    At the driver-s side, remove the instrument panel-s end cover and remove the 2 light switch screws.
    Rotate the light switch knob to0
    Unclip the illumination control switch and disconnect the electrical connector.
    At the steering column, remove the instrument panel trim-to-instrument panel screws and the trim.
    Remove the knee bar-to-instrument panel screws and the knee bar.
    Slide the center instrument panel cover forward out of the retainer and remove it; then, remove the 3 instrument panel-to-chassis screws.
    At the upper center of the instrument panel, lift both (left and right) plenum panel covers from the front and rear edge clips; then, move the covers toward the center and out of the A-pillar retainers.
    Unclip and remove the instrument cluster trim.
    Remove the 2 instrument cluster-to-instrument panel screws, disconnect the multi-pin electrical connector and remove the instrument cluster.
    Slide the Radio Release tool No. 3344 into the slots at both sides of the radio until they engage; then, pull the radio out of the instrument panel and disconnect the electrical connectors.

NOTE
To remove the Radio Release tool(s) No. 3344, press the locating tabs (located on both sides of the radio) inward and remove them.



If not equipped with a radio, remove the center instrument panel-s trim cover.
Remove the 2 center instrument panel-to-instrument panel screws and the center panel.
At the center of the instrument panel, remove the air duct.
At the glove box location, remove the 2 frame-to-instrument panel screws and the frame.
Remove the instrument panel-to-chassis screws and the instrument panel from the crossmember.

  1. Loosen the instrument panel crossmember-to-chassis bolts and lift the crossmember upward.
  2. Disconnect the heater hoses from the heater core.
  3. If not equipped with air conditioning, perform the following procedure:

    Partially remove the heater/ventilation housing assembly.
    Depress the retainer clips and remove the heater core from the heater housing.
  4. If equipped with air conditioning, perform the following procedure:

    Discharge and recover the air conditioning system refrigerant.
    Disconnect the refrigerant lines from the evaporator core, discard the O-rings and plug the openings to prevent contamination.
    Remove the ventilation ducts from the heater/air conditioning housing assembly.
    Remove the heater core from the heater/air conditioning housing assembly.
  5. Click image to see an enlarged view
    Fig. Releasing the driver-s side air bag-New Beetle
    Click image to see an enlarged view
    Fig. Exploded view of the instrument panel, crossmember and related components-New Beetle
    Click image to see an enlarged view
    Fig. Exploded view of the heater core, heater/ventilation housing and related components-New Beetle without air conditioning
    Click image to see an enlarged view
    Fig. Exploded view of the heater core, heater/air conditioning housing and related components-New Beetle with air conditioning
To install:
  1. If equipped with air conditioning, perform the following procedure:

    Install the heater core to the heater/air conditioning housing assembly.
    Install the ventilation ducts to the heater/air conditioning housing assembly.
    Using new O-rings, connect the refrigerant lines to the evaporator core.
  2. If not equipped with air conditioning, perform the following procedure:

    Install the heater core to the heater housing.
    Install the heater/ventilation housing assembly.
  3. Connect the heater hoses to the heater core.
  4. Lower the crossmember, install the instrument panel crossmember-to-chassis bolts and torque the bolts to 18 ft. lbs. (25 Nm).
  5. Install the instrument panel by performing the following procedure:

    Install the instrument panel and the instrument panel-to-chassis screws.
    At the glove box location, install the frame and the frame-to-instrument panel screws.
    At the center of the instrument panel, install the air duct.
    Install the center instrument panel and the 2 center panel-to-instrument panel screws.
    If not equipped with a radio, install the center instrument panel-s trim cover.
    Connect the electrical connectors and slide the radio into the instrument panel.
    Install the instrument cluster, connect the multi-pin electrical connector and install the 2 instrument cluster-to-instrument panel screws.
    Install the instrument cluster trim.
    Install both (left and right) plenum panel covers.
    Install the 3 instrument panel-to-chassis screws and the center instrument panel cover.
    Install the knee bar and the knee bar-to-instrument panel screws.
    At the steering column, install the instrument panel trim and the trim-to-instrument panel screws.
    Connect the electrical connector and install the illumination control switch.
    Connect the light switch electrical connector and install the switch.
    At the driver-s side, install the 2 light switch screws and the instrument panel-s end cover.
    Install the glove box, connect the glove box light connector and install the 6 glove box-to-instrument panel screws.
    Install the heater/ventilator control unit and the 4 heater/ventilator control unit-to-instrument panel screws.
    At the center of the instrument panel, install the switch assembly, the 4 switch assembly-to-panel screws and both switch assembly covers.
    At the passenger-s side of instrument panel, install the side cover.
    At the driver-s side, install the lower instrument panel cover and the cover screws.
    Install the combination switch, connect the electrical connectors and install the combination switch-to-steering column bolt.
    Install the lower steering column switch trim and the lower steering column cover screws.
    Install the upper steering column cover and the cover screws.
  6. Install the steering wheel by performing the following procedure:

    Install the steering wheel to the steering column.
    Install the new steering wheel-to-steering column bolt and torque it to 30 ft. lbs. (40 Nm).
    Connect the horn-s electrical connector.
  7. Connect the electrical connector and install the air bag.
  8. Refill the cooling system.
  9. Connect the negative battery cable.
  10. Evacuate, charge and leak test the air conditioning system refrigerant.
  11. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

NOTE
Be sure to obtain the anti-theft code for the radio.

  1. Disconnect the negative battery cable.
  2. Drain the cooling system into a clean container for reuse.
  3. Remove the driver-s side air bag by performing the following procedure:

    Release the steering column adjustment.
    Rotate the steering wheel until the spokes are vertical (90 degrees off center).
    Adjust the steering column to the completely out down position and lock the adjustment.
    At the rear of the steering wheel, insert a 7 in. (175mm) screwdriver into the hole in the hub approximately 1 3 / 4 in. (45mm) deep.
    Twist the screwdriver counterclockwise (as viewed from the driver-s seat) to release the air bag clip.
    Rotate the steering wheel 180 degrees in the opposite direction and release the clip on the other side.
    Center the steering wheel with the front wheels facing straight-ahead.
    Disconnect the electrical connector and remove the air bag.
  4. Remove the steering wheel by performing the following procedure:

    Place the front wheels in the straight-ahead position.
    Disconnect the horn-s electrical connector.
    Remove the steering wheel-to-steering column bolt and discard it.
    Remove the steering wheel from the steering column.
  5. Remove the instrument panel by performing the following procedure:
    NOTE
    To remove the Radio Release tool(s) No. 3344, press the locating tabs (located on both sides of the radio) inward and remove them.



    Remove the upper steering column cover screws and the cover.
    Remove the lower steering column cover screws, release the steering wheel height adjustment and remove the lower steering column switch trim.
    Remove the combination switch-to-steering column bolt, disconnect the electrical connectors and remove the combination switch.
    At the driver-s side, remove the lower instrument panel cover screws and the cover.
    At the passenger-s side of instrument panel, remove the side cover.
    At the center of the instrument panel, remove both switch assembly covers, the 4 switch assembly-to-panel screws and the switch assembly.
    Remove the 4 heater/ventilator control unit-to-instrument panel screws and move the control unit under the instrument panel with the cables attached.
    Remove the 6 glove box-to-instrument panel screws, disconnect the glove box light connector and remove the glove box.
    At the driver-s side, remove the instrument panel-s end cover and remove the 2 light switch screws.
    Rotate the light switch knob to 0 , press the knob inward, rotate it clockwise; then, pull the switch outward and disconnect the electrical connector.
    Unclip the illumination control switch and disconnect the electrical connector.
    At the steering column, remove the instrument panel trim-to-instrument panel screws and the trim.
    Remove the knee bar-to-instrument panel screws and the knee bar.
    Slide the center instrument panel cover forward out of the retainer and remove it; then, remove the 3 instrument panel-to-chassis screws.
    At the upper center of the instrument panel, lift both (left and right) plenum panel covers from the front and rear edge clips; then, move the covers toward the center and out of the A-pillar retainers.
    Unclip and remove the instrument cluster trim.
    Remove the 2 instrument cluster-to-instrument panel screws, disconnect the multi-pin electrical connector and remove the instrument cluster.
    Slide the Radio Release tool No. 3344 into the slots at both sides of the radio until they engage; then, pull the radio out of the instrument panel and disconnect the electrical connectors.



    If not equipped with a radio, remove the center instrument panel-s trim cover.
    Remove the 2 center instrument panel-to-instrument panel screws and the center panel.
    At the center of the instrument panel, remove the air duct.
    At the glove box location, remove the 2 frame-to-instrument panel screws and the frame.
    Remove the instrument panel-to-chassis screws and the instrument panel from the crossmember.
  6. Loosen the instrument panel crossmember-to-chassis bolts and lift the crossmember upward.
  7. Disconnect the heater hoses from the heater core.
  8. If not equipped with air conditioning, perform the following procedure:

    Partially remove the heater/ventilation housing assembly.
    Depress the retainer clips and remove the heater core from the heater housing.
  9. If equipped with air conditioning, perform the following procedure:

    Discharge and recover the air conditioning system refrigerant.
    Disconnect the refrigerant lines from the evaporator core, discard the O-rings and plug the openings to prevent contamination.
    Remove the ventilation ducts from the heater/air conditioning housing assembly.
    Remove the heater core from the heater/air conditioning housing assembly.

    Click image to see an enlarged view
    Fig. Releasing the driver-s side air bag-New Beetle


    Click image to see an enlarged view
    Fig. Exploded view of the instrument panel, crossmember and related components-New Beetle


    Click image to see an enlarged view
    Fig. Exploded view of the heater core, heater/ventilation housing and related components-New Beetle without air conditioning


    Click image to see an enlarged view
    Fig. Exploded view of the heater core, heater/air conditioning housing and related components-New Beetle with air conditioning
To install:
  1. If equipped with air conditioning, perform the following procedure:

    Install the heater core to the heater/air conditioning housing assembly.
    Install the ventilation ducts to the heater/air conditioning housing assembly.
    Using new O-rings, connect the refrigerant lines to the evaporator core.
  2. If not equipped with air conditioning, perform the following procedure:

    Install the heater core to the heater housing.
    Install the heater/ventilation housing assembly.
  3. Connect the heater hoses to the heater core.
  4. Lower the crossmember, install the instrument panel crossmember-to-chassis bolts and torque the bolts to 18 ft. lbs. (25 Nm).
  5. Install the instrument panel by performing the following procedure:

    Install the instrument panel and the instrument panel-to-chassis screws.
    At the glove box location, install the frame and the frame-to-instrument panel screws.
    At the center of the instrument panel, install the air duct.
    Install the center instrument panel and the 2 center panel-to-instrument panel screws.
    If not equipped with a radio, install the center instrument panel-s trim cover.
    Connect the electrical connectors and slide the radio into the instrument panel.
    Install the instrument cluster, connect the multi-pin electrical connector and install the 2 instrument cluster-to-instrument panel screws.
    Install the instrument cluster trim.
    Install both (left and right) plenum panel covers.
    Install the 3 instrument panel-to-chassis screws and the center instrument panel cover.
    Install the knee bar and the knee bar-to-instrument panel screws.
    At the steering column, install the instrument panel trim and the trim-to-instrument panel screws.
    Connect the electrical connector and install the illumination control switch.
    Connect the light switch electrical connector and install the switch.
    At the driver-s side, install the 2 light switch screws and the instrument panel-s end cover.
    Install the glove box, connect the glove box light connector and install the 6 glove box-to-instrument panel screws.
    Install the heater/ventilator control unit and the 4 heater/ventilator control unit-to-instrument panel screws.
    At the center of the instrument panel, install the switch assembly, the 4 switch assembly-to-panel screws and both switch assembly covers.
    At the passenger-s side of instrument panel, install the side cover.
    At the driver-s side, install the lower instrument panel cover and the cover screws.
    Install the combination switch, connect the electrical connectors and install the combination switch-to-steering column bolt.
    Install the lower steering column switch trim and the lower steering column cover screws.
    Install the upper steering column cover and the cover screws.
  6. Install the steering wheel by performing the following procedure:

    Install the steering wheel to the steering column.
    Install the new steering wheel-to-steering column bolt and torque it to 30 ft. lbs. (40 Nm).
    Connect the horn-s electrical connector.
  7. Connect the electrical connector and install the air bag.
  8. Refill the cooling system.
  9. Connect the negative battery cable.
  10. Evacuate, charge and leak test the air conditioning system refrigerant.
  11. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
Removal And Installation

NOTE
Be sure to obtain the anti-theft code for the radio.

  1. Disconnect the negative battery cable.
  2. Drain the cooling system into a clean container for reuse.
  3. Remove the driver-s side air bag by performing the following procedure:

    Release the steering column adjustment.
    Rotate the steering wheel until the spokes are vertical (90 degrees off center).
    Adjust the steering column to the completely out down position and lock the adjustment.
    At the rear of the steering wheel, insert a 7 in. (175mm) screwdriver into the hole in the hub approximately 1 3 / 4 in. (45mm) deep.
    Twist the screwdriver counterclockwise (as viewed from the driver-s seat) to release the air bag clip.
    Rotate the steering wheel 180 degrees in the opposite direction and release the clip on the other side.
    Center the steering wheel with the front wheels facing straight-ahead.
    Disconnect the electrical connector and remove the air bag.
  4. Remove the steering wheel by performing the following procedure:

    Place the front wheels in the straight-ahead position.
    Disconnect the horn-s electrical connector.
    Remove the steering wheel-to-steering column bolt and discard it.
    Remove the steering wheel from the steering column.
  5. Remove the instrument panel by performing the following procedure:
    NOTE
    To remove the Radio Release tool(s) No. 3344, press the locating tabs (located on both sides of the radio) inward and remove them.



    Remove the upper steering column cover screws and the cover.
    Remove the lower steering column cover screws, release the steering wheel height adjustment and remove the lower steering column switch trim.
    Remove the combination switch-to-steering column bolt, disconnect the electrical connectors and remove the combination switch.
    At the driver-s side, remove the lower instrument panel cover screws and the cover.
    At the passenger-s side of instrument panel, remove the side cover.
    At the center of the instrument panel, remove both switch assembly covers, the 4 switch assembly-to-panel screws and the switch assembly.
    Remove the 4 heater/ventilator control unit-to-instrument panel screws and move the control unit under the instrument panel with the cables attached.
    Remove the 6 glove box-to-instrument panel screws, disconnect the glove box light connector and remove the glove box.
    At the driver-s side, remove the instrument panel-s end cover and remove the 2 light switch screws.
    Rotate the light switch knob to 0 , press the knob inward, rotate it clockwise; then, pull the switch outward and disconnect the electrical connector.
    Unclip the illumination control switch and disconnect the electrical connector.
    At the steering column, remove the instrument panel trim-to-instrument panel screws and the trim.
    Remove the knee bar-to-instrument panel screws and the knee bar.
    Slide the center instrument panel cover forward out of the retainer and remove it; then, remove the 3 instrument panel-to-chassis screws.
    At the upper center of the instrument panel, lift both (left and right) plenum panel covers from the front and rear edge clips; then, move the covers toward the center and out of the A-pillar retainers.
    Unclip and remove the instrument cluster trim.
    Remove the 2 instrument cluster-to-instrument panel screws, disconnect the multi-pin electrical connector and remove the instrument cluster.
    Slide the Radio Release tool No. 3344 into the slots at both sides of the radio until they engage; then, pull the radio out of the instrument panel and disconnect the electrical connectors.



    If not equipped with a radio, remove the center instrument panel-s trim cover.
    Remove the 2 center instrument panel-to-instrument panel screws and the center panel.
    At the center of the instrument panel, remove the air duct.
    At the glove box location, remove the 2 frame-to-instrument panel screws and the frame.
    Remove the instrument panel-to-chassis screws and the instrument panel from the crossmember.
  6. Loosen the instrument panel crossmember-to-chassis bolts and lift the crossmember upward.
  7. Disconnect the heater hoses from the heater core.
  8. If not equipped with air conditioning, perform the following procedure:

    Partially remove the heater/ventilation housing assembly.
    Depress the retainer clips and remove the heater core from the heater housing.
  9. If equipped with air conditioning, perform the following procedure:

    Discharge and recover the air conditioning system refrigerant.
    Disconnect the refrigerant lines from the evaporator core, discard the O-rings and plug the openings to prevent contamination.
    Remove the ventilation ducts from the heater/air conditioning housing assembly.
    Remove the heater core from the heater/air conditioning housing assembly.

    Click image to see an enlarged view
    Fig. Releasing the driver-s side air bag-1998-00 New Beetle


    Click image to see an enlarged view
    Fig. Exploded view of the instrument panel, crossmember and related components-1998-00 New Beetle


    Click image to see an enlarged view
    Fig. Exploded view of the heater core, heater/ventilation housing and related components-1998-00 New Beetle without air conditioning


    Click image to see an enlarged view
    Fig. Exploded view of the heater core, heater/air conditioning housing and related components-1998-00 New Beetle with air conditioning
To install:
  1. If equipped with air conditioning, perform the following procedure:

    Install the heater core to the heater/air conditioning housing assembly.
    Install the ventilation ducts to the heater/air conditioning housing assembly.
    Using new O-rings, connect the refrigerant lines to the evaporator core.
  2. If not equipped with air conditioning, perform the following procedure:

    Install the heater core to the heater housing.
    Install the heater/ventilation housing assembly.
  3. Connect the heater hoses to the heater core.
  4. Lower the crossmember, install the instrument panel crossmember-to-chassis bolts and torque the bolts to 18 ft. lbs. (25 Nm).
  5. Install the instrument panel by performing the following procedure:

    Install the instrument panel and the instrument panel-to-chassis screws.
    At the glove box location, install the frame and the frame-to-instrument panel screws.
    At the center of the instrument panel, install the air duct.
    Install the center instrument panel and the 2 center panel-to-instrument panel screws.
    If not equipped with a radio, install the center instrument panel-s trim cover.
    Connect the electrical connectors and slide the radio into the instrument panel.
    Install the instrument cluster, connect the multi-pin electrical connector and install the 2 instrument cluster-to-instrument panel screws.
    Install the instrument cluster trim.
    Install both (left and right) plenum panel covers.
    Install the 3 instrument panel-to-chassis screws and the center instrument panel cover.
    Install the knee bar and the knee bar-to-instrument panel screws.
    At the steering column, install the instrument panel trim and the trim-to-instrument panel screws.
    Connect the electrical connector and install the illumination control switch.
    Connect the light switch electrical connector and install the switch.
    At the driver-s side, install the 2 light switch screws and the instrument panel-s end cover.
    Install the glove box, connect the glove box light connector and install the 6 glove box-to-instrument panel screws.
    Install the heater/ventilator control unit and the 4 heater/ventilator control unit-to-instrument panel screws.
    At the center of the instrument panel, install the switch assembly, the 4 switch assembly-to-panel screws and both switch assembly covers.
    At the passenger-s side of instrument panel, install the side cover.
    At the driver-s side, install the lower instrument panel cover and the cover screws.
    Install the combination switch, connect the electrical connectors and install the combination switch-to-steering column bolt.
    Install the lower steering column switch trim and the lower steering column cover screws.
    Install the upper steering column cover and the cover screws.
  6. Install the steering wheel by performing the following procedure:

    Install the steering wheel to the steering column.
    Install the new steering wheel-to-steering column bolt and torque it to 30 ft. lbs. (40 Nm).
    Connect the horn-s electrical connector.
  7. Connect the electrical connector and install the air bag.
  8. Refill the cooling system.
  9. Connect the negative battery cable.
  10. Evacuate, charge and leak test the air conditioning system refrigerant.
  11. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.


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Also see this link below for more details:---

How to replace heater core on Volkswagen Model?



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How to replace heater core on 2005 Volkswagen Jetta?


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How to replace heater core on 2005 Volkswagen Cabriolet?


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