Thursday, November 10, 2011

How to replace Heater core for Volkswagen Passat?

The procedure is as follows :---


Passat




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. Disconnect the heater hoses from the heater core.
  4. Discharge and recover the air conditioning system refrigerant.
  5. 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
    Raise the screwdriver (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.
  6. Remove the steering wheel by performing the following procedure:

    Place the front wheels in the straight-ahead position.
    Remove the steering wheel-to-steering column bolt.

NOTE
Two kinds of bolts are used: Standard (disconnected shortly after production) and Multi-point socket head. If equipped with a standard bolt, discard it. If equipped with a multi-point socket head bolt, it can be used up to 5 times; be sure to place a punch mark on it each time it is reused.



Remove the steering wheel from the steering column.

  1. Remove the instrument panel by performing the following procedure:

    Remove the 2 upper steering column cover screws and the cover.
    Remove the 4 lower steering column cover screws/bolt, 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 -A- pillar trim bolt cover, the -A- pillar trim-to-chassis bolts and the trim.
    At the driver-s side, remove the instrument panel-s end cover.
    Remove the 2 stowage compartment-to-instrument panel bolts, the 2 instrument panel-to-frame bolts and the stowage compartment.
    Disconnect the electrical connectors from the light switch and the headlight brightness control.
    At the steering column, slide the cover upward and place a screwdriver handle between the cover the steering column to secure it.
    Remove the 4 cover-to-instrument panel screws and the cover.
    Between the steering column and the instrument cluster, remove the 2 instrument panel insert screws and the panel.
    Disconnect the electrical connectors.
    At both sides of the steering column, remove the 2 instrument panel-to-frame bolts.
    Slide the Radio Release tool No. 3316 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. 3316, press the locating tabs (located on both sides of the radio) inward and remove them.



At the center of the instrument panel, unclip and remove the control cluster trim.
Remove the 8 center instrument panel cover-to-instrument panel bolts and the center panel; then, disconnect the electrical connector.
At the top of the center instrument panel cover opening, remove the 5 instrument panel-to-bracket bolts.
Under the left side of the glove box, remove the small piece of trim bolt and the trim.
Under the right side of the glove box, remove the lower -A- pillar trim bolt cover, the -A- pillar trim-to-chassis bolts and the trim.
Remove the 2 lower glove box bolts and open the glove box.
Remove the 5 glove box-to-instrument panel screws, disconnect the glove box light connector and remove the glove box.
At the passenger-s side of instrument panel, remove the side cover.
Remove the 4 instrument panel-to-bracket bolts and disconnect the electrical connector.
Remove the instrument cluster.

  1. Remove the ventilation ducts from the heater/air conditioning housing assembly.
  2. Remove the heater/air conditioning housing assembly-to-chassis fasteners and the assembly.
  3. Remove the heater core.
  4. Click image to see an enlarged view
    Fig. Releasing the driver-s side air bag-Passat
    Click image to see an enlarged view
    Fig. Exploded view of the instrument panel, crossmember and related components-Passat
    Click image to see an enlarged view
    Fig. Exploded view of the heater core, heater/air conditioning housing and related components-Passat
To install:
  1. Install the heater core.
  2. Install the heater/air conditioning housing assembly and the assembly-to-chassis fasteners.
  3. Install the ventilation ducts to the heater/air conditioning housing assembly.
  4. Install the instrument panel by performing the following procedure:

    Install the instrument cluster.
    Install the 4 instrument panel-to-bracket bolts and connect the electrical connector.
    At the passenger-s side of instrument panel, install the side cover.
    Install the glove box, connect the glove box light connector and install the 5 glove box-to-instrument panel screws.
    Install the glove box and open the 2 lower glove box bolts.
    Under the right side of the glove box, install the lower -A- pillar trim, the -A- pillar trim-to-chassis bolts and the trim bolt cover.
    Under the left side of the glove box, install the small piece of trim and the bolt.
    At the top of the center instrument panel cover opening, install the 5 instrument panel-to-bracket bolts.
    Install the center instrument panel cover and the 8 center panel cover-to-instrument panel bolts; then, connect the electrical connector.
    At the center of the instrument panel, install the control cluster trim.
    Connect the electrical connectors and install the radio.
    At both sides of the steering column, install the 2 instrument panel-to-frame bolts.
    Connect the electrical connectors.
    Between the steering column and the instrument cluster, install the instrument panel insert and the 2 panel screws.
    At the steering column, install the cover and the 4 cover-to-instrument panel screws.
    Connect the electrical connectors to the light switch and the headlight brightness control.
    Install the stowage compartment, the 2 instrument panel-to-frame bolts and the 2 stowage compartment-to-instrument panel bolts.
    At the driver-s side, install the instrument panel-s end cover.
    At the driver-s side, install the lower -A- pillar trim, the -A- pillar trim-to-chassis bolts and the trim bolt cover.
    Install the combination switch, connect the electrical connectors and install the combination switch-to-steering column bolt.
    Install the lower steering column cover trim and the lower steering column switch trim screws/bolt.
    Install the upper steering column cover and the 2 cover screws.
  5. Install the steering wheel and the steering wheel-to-steering column bolt. Torque the standard bolt to 55 ft. lbs. (75 Nm) or the multi-point socket head bolt to 44 ft. lbs. (60 Nm).
  6. Connect the electrical connector and install the air bag.
  7. Connect the heater hoses to the heater core.
  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. Disconnect the heater hoses from the heater core.
  4. Discharge and recover the air conditioning system refrigerant.
  5. 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.
    Raise the screwdriver (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.
  6. Remove the steering wheel by performing the following procedure:
    NOTE
    Two kinds of bolts are used: Standard (disconnected shortly after production) and Multi-point socket head. If equipped with a standard bolt, discard it. If equipped with a multi-point socket head bolt, it can be used up to 5 times; be sure to place a punch mark on it each time it is reused.



    Place the front wheels in the straight-ahead position.
    Remove the steering wheel-to-steering column bolt.



    Remove the steering wheel from the steering column.
  7. Remove the instrument panel by performing the following procedure:
    NOTE
    To remove the Radio Release tool(s) No. 3316, press the locating tabs (located on both sides of the radio) inward and remove them.



    Remove the 2 upper steering column cover screws and the cover.
    Remove the 4 lower steering column cover screws/bolt, 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 -A- pillar trim bolt cover, the -A- pillar trim-to-chassis bolts and the trim.
    At the driver-s side, remove the instrument panel-s end cover.
    Remove the 2 stowage compartment-to-instrument panel bolts, the 2 instrument panel-to-frame bolts and the stowage compartment.
    Disconnect the electrical connectors from the light switch and the headlight brightness control.
    At the steering column, slide the cover upward and place a screwdriver handle between the cover the steering column to secure it.
    Remove the 4 cover-to-instrument panel screws and the cover.
    Between the steering column and the instrument cluster, remove the 2 instrument panel insert screws and the panel.
    Disconnect the electrical connectors.
    At both sides of the steering column, remove the 2 instrument panel-to-frame bolts.
    Slide the Radio Release tool No. 3316 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.



    At the center of the instrument panel, unclip and remove the control cluster trim.
    Remove the 8 center instrument panel cover-to-instrument panel bolts and the center panel; then, disconnect the electrical connector.
    At the top of the center instrument panel cover opening, remove the 5 instrument panel-to-bracket bolts.
    Under the left side of the glove box, remove the small piece of trim bolt and the trim.
    Under the right side of the glove box, remove the lower -A- pillar trim bolt cover, the -A- pillar trim-to-chassis bolts and the trim.
    Remove the 2 lower glove box bolts and open the glove box.
    Remove the 5 glove box-to-instrument panel screws, disconnect the glove box light connector and remove the glove box.
    At the passenger-s side of instrument panel, remove the side cover.
    Remove the 4 instrument panel-to-bracket bolts and disconnect the electrical connector.
    Remove the instrument cluster.
  8. Remove the ventilation ducts from the heater/air conditioning housing assembly.
  9. Remove the heater/air conditioning housing assembly-to-chassis fasteners and the assembly.
  10. Remove the heater core.

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


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


    Click image to see an enlarged view
    Fig. Exploded view of the heater core, heater/air conditioning housing and related components-Passat
To install:
  1. Install the heater core.
  2. Install the heater/air conditioning housing assembly and the assembly-to-chassis fasteners.
  3. Install the ventilation ducts to the heater/air conditioning housing assembly.
  4. Install the instrument panel by performing the following procedure:

    Install the instrument cluster.
    Install the 4 instrument panel-to-bracket bolts and connect the electrical connector.
    At the passenger-s side of instrument panel, install the side cover.
    Install the glove box, connect the glove box light connector and install the 5 glove box-to-instrument panel screws.
    Install the glove box and open the 2 lower glove box bolts.
    Under the right side of the glove box, install the lower -A- pillar trim, the -A- pillar trim-to-chassis bolts and the trim bolt cover.
    Under the left side of the glove box, install the small piece of trim and the bolt.
    At the top of the center instrument panel cover opening, install the 5 instrument panel-to-bracket bolts.
    Install the center instrument panel cover and the 8 center panel cover-to-instrument panel bolts; then, connect the electrical connector.
    At the center of the instrument panel, install the control cluster trim.
    Connect the electrical connectors and install the radio.
    At both sides of the steering column, install the 2 instrument panel-to-frame bolts.
    Connect the electrical connectors.
    Between the steering column and the instrument cluster, install the instrument panel insert and the 2 panel screws.
    At the steering column, install the cover and the 4 cover-to-instrument panel screws.
    Connect the electrical connectors to the light switch and the headlight brightness control.
    Install the stowage compartment, the 2 instrument panel-to-frame bolts and the 2 stowage compartment-to-instrument panel bolts.
    At the driver-s side, install the instrument panel-s end cover.
    At the driver-s side, install the lower -A- pillar trim, the -A- pillar trim-to-chassis bolts and the trim bolt cover.
    Install the combination switch, connect the electrical connectors and install the combination switch-to-steering column bolt.
    Install the lower steering column cover trim and the lower steering column switch trim screws/bolt.
    Install the upper steering column cover and the 2 cover screws.
  5. Install the steering wheel and the steering wheel-to-steering column bolt. Torque the standard bolt to 55 ft. lbs. (75 Nm) or the multi-point socket head bolt to 44 ft. lbs. (60 Nm).
  6. Connect the electrical connector and install the air bag.
  7. Connect the heater hoses to the heater core.
  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. Disconnect the heater hoses from the heater core.
  4. Discharge and recover the air conditioning system refrigerant.
  5. 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.
    Raise the screwdriver (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.
  6. Remove the steering wheel by performing the following procedure:
    NOTE
    Two kinds of bolts are used: Standard (disconnected shortly after production) and Multi-point socket head. If equipped with a standard bolt, discard it. If equipped with a multi-point socket head bolt, it can be used up to 5 times; be sure to place a punch mark on it each time it is reused.



    Place the front wheels in the straight-ahead position.
    Remove the steering wheel-to-steering column bolt.



    Remove the steering wheel from the steering column.
  7. Remove the instrument panel by performing the following procedure:
    NOTE
    To remove the Radio Release tool(s) No. 3316, press the locating tabs (located on both sides of the radio) inward and remove them.



    Remove the 2 upper steering column cover screws and the cover.
    Remove the 4 lower steering column cover screws/bolt, 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 -A- pillar trim bolt cover, the -A- pillar trim-to-chassis bolts and the trim.
    At the driver-s side, remove the instrument panel-s end cover.
    Remove the 2 stowage compartment-to-instrument panel bolts, the 2 instrument panel-to-frame bolts and the stowage compartment.
    Disconnect the electrical connectors from the light switch and the headlight brightness control.
    At the steering column, slide the cover upward and place a screwdriver handle between the cover the steering column to secure it.
    Remove the 4 cover-to-instrument panel screws and the cover.
    Between the steering column and the instrument cluster, remove the 2 instrument panel insert screws and the panel.
    Disconnect the electrical connectors.
    At both sides of the steering column, remove the 2 instrument panel-to-frame bolts.
    Slide the Radio Release tool No. 3316 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.



    At the center of the instrument panel, unclip and remove the control cluster trim.
    Remove the 8 center instrument panel cover-to-instrument panel bolts and the center panel; then, disconnect the electrical connector.
    At the top of the center instrument panel cover opening, remove the 5 instrument panel-to-bracket bolts.
    Under the left side of the glove box, remove the small piece of trim bolt and the trim.
    Under the right side of the glove box, remove the lower -A- pillar trim bolt cover, the -A- pillar trim-to-chassis bolts and the trim.
    Remove the 2 lower glove box bolts and open the glove box.
    Remove the 5 glove box-to-instrument panel screws, disconnect the glove box light connector and remove the glove box.
    At the passenger-s side of instrument panel, remove the side cover.
    Remove the 4 instrument panel-to-bracket bolts and disconnect the electrical connector.
    Remove the instrument cluster.
  8. Remove the ventilation ducts from the heater/air conditioning housing assembly.
  9. Remove the heater/air conditioning housing assembly-to-chassis fasteners and the assembly.
  10. Remove the heater core.

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


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


    Click image to see an enlarged view
    Fig. Exploded view of the heater core, heater/air conditioning housing and related components-1998-00 Passat
To install:
  1. Install the heater core.
  2. Install the heater/air conditioning housing assembly and the assembly-to-chassis fasteners.
  3. Install the ventilation ducts to the heater/air conditioning housing assembly.
  4. Install the instrument panel by performing the following procedure:

    Install the instrument cluster.
    Install the 4 instrument panel-to-bracket bolts and connect the electrical connector.
    At the passenger-s side of instrument panel, install the side cover.
    Install the glove box, connect the glove box light connector and install the 5 glove box-to-instrument panel screws.
    Install the glove box and open the 2 lower glove box bolts.
    Under the right side of the glove box, install the lower -A- pillar trim, the -A- pillar trim-to-chassis bolts and the trim bolt cover.
    Under the left side of the glove box, install the small piece of trim and the bolt.
    At the top of the center instrument panel cover opening, install the 5 instrument panel-to-bracket bolts.
    Install the center instrument panel cover and the 8 center panel cover-to-instrument panel bolts; then, connect the electrical connector.
    At the center of the instrument panel, install the control cluster trim.
    Connect the electrical connectors and install the radio.
    At both sides of the steering column, install the 2 instrument panel-to-frame bolts.
    Connect the electrical connectors.
    Between the steering column and the instrument cluster, install the instrument panel insert and the 2 panel screws.
    At the steering column, install the cover and the 4 cover-to-instrument panel screws.
    Connect the electrical connectors to the light switch and the headlight brightness control.
    Install the stowage compartment, the 2 instrument panel-to-frame bolts and the 2 stowage compartment-to-instrument panel bolts.
    At the driver-s side, install the instrument panel-s end cover.
    At the driver-s side, install the lower -A- pillar trim, the -A- pillar trim-to-chassis bolts and the trim bolt cover.
    Install the combination switch, connect the electrical connectors and install the combination switch-to-steering column bolt.
    Install the lower steering column cover trim and the lower steering column switch trim screws/bolt.
    Install the upper steering column cover and the 2 cover screws.
  5. Install the steering wheel and the steering wheel-to-steering column bolt. Torque the standard bolt to 55 ft. lbs. (75 Nm) or the multi-point socket head bolt to 44 ft. lbs. (60 Nm).
  6. Connect the electrical connector and install the air bag.
  7. Connect the heater hoses to the heater core.
  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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How to replace Heater core for Volkswagen New Beetle?



This procedures will help you out.
Thanks.


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