Thursday, November 10, 2011

How to replace heater core on Volkswagen Model?


Removal & Installation


This procedure is basically for all the models of Volkswagen.
You can check your VW model and read the details:---

NOTE
The recovery of the air conditioning system refrigerant must be performed before the heater core can be removed. Have a MVAC certified tech recover the A/C system refrigerant.

  1. Disconnect the negative battery cable.
  2. Drain the engine coolant.
  3. Completely remove the instrument panel.
  4. From the engine compartment, label and remove all hoses and necessary wiring.
  5. Remove and plug all A/C lines.
  6. Remove and plug the coolant lines for the heater core.
  7. On Passat models using a heater core that is not completely surrounded by the air box housing, remove the self tapping screws if installed, then slide the heater core out of the housing.
  8. On A4 and Passat models with the heater core installed into the housing:
    1. Remove the heater box housing which contains the evaporator.
    2. Unclip the heater core box.
    3. Remove the heater core.
  9. Installation is the reverse of removal. Always make sure all seals are installed properly during the installation process.
  10. On Passat models using a heater core that is not completely surrounded by the air box housing, install the heater core with a self adhesive seal installed along the top of the fins on the side of the heater core that is near the inlet and outlet spigots and around the end of the heater core spigot housing to seal the heater core in the housing. If the heater core fit is slightly loose, secure it to the housing with self-tapping screws.
  11. If disassembled, seal all seams of the heater box with RTV.
  12. The balance of the installation is in reverse order of removal making sure to have a MVAC certified technician evacuate and recharge the A/C system.

NOTE
Consult the under hood label for the correct refrigerant type and amount installed in the system. The R134A type of refrigerant was introduced as standard equipment in the 1993 models.

1993-99 Golf, Jetta, And Cabrio




NOTE
The recovery of the air conditioning system refrigerant must be performed before the heater core can be removed. Have a MVAC certified tech recover the A/C system refrigerant.

  1. Drain the engine coolant.
  2. Remove the instrument panel.
  3. Detach the support bracket.
  4. From the engine compartment, label and remove all hoses and necessary wiring.
  5. Remove and plug all A/C lines.
  6. Remove the heater box which contains the evaporator.
  7. Unclip the heater core box.
  8. Remove the heater core.
  9. Installation is the reverse of removal. Always make sure all seals are installed properly during the installation process.
  10. Seal all seams of the heater box with RTV.
  11. Have a MVAC certified tech evacuate and recharge the A/C system.

2002-05 Gti And 2002-04 Jetta




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.
    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.
  4. Remove the steering wheel by performing the following procedure:
    NOTE
    The Multi-point socket head bolt 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.
  5. Remove the center console-to-chassis bolts and the console.
  6. 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 upper steering column cover screws and the cover.
    Remove the 3 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 passenger-s side of instrument panel, remove the side cover.
    Remove the 7 glove box-to-instrument panel screws, disconnect the glove box light connector and remove the glove box.
    At the driver-s side, remove the both lower instrument panel cover screws and the covers.
    Remove the DLC-to-bracket screws.
    At the driver-s side, remove the 6 sound damper panel-to-instrument panel screws and the panel.
    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 pane (above the radio), unclip and remove the switches and disconnect the electrical connectors.
    Unclip and remove the Climatronic control (heater control) trim.
    Remove the 4 Climatronic control (heater control)-to-instrument panel screws and the control; then, disconnect the electrical connector.
    Remove the 5 center reinforcement-to-chassis screws and the reinforcement.
    At the driver-s side, remove the 3 footwell cover screws and the cover.
    Remove the 2 instrument cluster-to-instrument panel screws, disconnect the multi-pin electrical connector and remove the instrument cluster.
    At the upper center of the instrument panel, unclip the photo sensor and disconnect the electrical connector.
    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.
    Remove the instrument panel-to-chassis screws and the instrument panel from the crossmember.
  7. Loosen the instrument panel crossmember-to-chassis bolts and lift the crossmember upward.
  8. Disconnect the heater hoses from the heater core.
  9. If not equipped with air conditioning, perform the following procedure:
    NOTE
    If the retainer clips break, use a self-tapping screw to hold the heater core in place.



    Partially remove the heater/ventilation housing assembly.
    Depress the retainer clips and remove the heater core from the heater housing.
  10. 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-GTI and Jetta


    Click image to see an enlarged view
    Fig. Exploded view of the center console and related components- GTI and Jetta


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


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


    Click image to see an enlarged view
    Fig. Exploded view of the heater core, heater/air conditioning housing and related components- GTI and Jetta 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. Tighten the instrument panel crossmember-to-chassis bolts.
  5. Install the instrument panel by performing the following procedure:

    Install the instrument panel and the instrument panel-to-chassis screws.
    Connect the electrical connectors; then, install the light switch knob and the illumination control switch.
    At the upper center of the instrument panel, connect the electrical connector and install the photo sensor.
    Install the instrument cluster, connect the multi-pin electrical connector and install the 2 instrument cluster-to-instrument panel screws.
    At the driver-s side, install the footwell cover and the 3 cover screws.
    Install the center reinforcement and the 5 reinforcement-to-chassis screws.
    Connect the electrical connector; then, install the Climatronic control (heater control) and the 4 control-to-instrument panel screws.
    Install the Climatronic control (heater control) trim.
    At the center of the instrument pane (above the radio), Install the switches and connect the electrical connectors.
    Connect the electrical connectors and install the radio.
    At the driver-s side, install the sound damper panel and the 6 panel-to-instrument panel screws.
    Install the DLC-to-bracket screws.
    At the driver-s side, install the both lower instrument panel covers and the cover screws.
    Install the glove box, connect the glove box light connector and install the 7 glove box-to-instrument panel screws.
    At the passenger-s side of instrument panel, install the side cover.
    Install the combination switch, connect the electrical connectors and install the combination switch-to-steering column bolt.
    Install the lower steering column cover, the 3 lower steering column cover screws and the lower steering column switch trim.
    Install the upper steering column cover and the cover screws.
  6. Install the center console and the console-to-chassis bolts.
  7. Install the steering wheel and the steering wheel-to-steering column bolt. Torque the multi-point socket head bolt to 44 ft. lbs. (60 Nm).
    NOTE
    The Multi-point socket head bolt can be used up to 5 times; be sure to place a punch mark on it each time it is reused.
  8. Connect the electrical connector and install the air bag.
  9. Refill the cooling system.
  10. Connect the negative battery cable.
  11. Evacuate, charge and leak test the air conditioning system.
  12. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.


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For car AC related and Heater related solutions. You can refer the options mentioned below:---

Car AC Blows Warm Air ?


How to test AUTO AC pressure?


AUTO Air Conditioning Troubleshooting?



AUTO A/C COOLING PROBLEM?


Fixing refrigerant leak?


How to locate Car AC Refrigerant leak?


CAR AC INTERMITTENT COOLING?


What causes INTERMITTENT COOLING on Car AC system?


Car AC making Noise?


BAD ODOR ON CAR AIR CONDITIONER?



How to Recharge Car's Air Conditioner

http://repairhelpcenter.blogspot.com/2011/10/how-to-recharge-cars-air-conditioner.html

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