Volkswagen Cars 2000-05

Removal & Installation 1

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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.  
  3. Drain the engine coolant.
  4.  
  5. Completely remove the instrument panel.
  6.  
  7. From the engine compartment, label and remove all hoses and necessary wiring.
  8.  
  9. Remove and plug all A/C lines.
  10.  
  11. Remove and plug the coolant lines for the heater core.
  12.  
  13. 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.
  14.  
  15. On A4 and Passat models with the heater core installed into the housing:
  16.  
    1. Remove the heater box housing which contains the evaporator.
    2.  
    3. Unclip the heater core box.
    4.  
    5. Remove the heater core.
    6.  

  17. Installation is the reverse of removal. Always make sure all seals are installed properly during the installation process.
  18.  
  19. 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.
  20.  
  21. If disassembled, seal all seams of the heater box with RTV.
  22.  
  23. 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.
  24.  


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.  
  3. Remove the instrument panel.
  4.  
  5. Detach the support bracket.
  6.  
  7. From the engine compartment, label and remove all hoses and necessary wiring.
  8.  
  9. Remove and plug all A/C lines.
  10.  
  11. Remove the heater box which contains the evaporator.
  12.  
  13. Unclip the heater core box.
  14.  
  15. Remove the heater core.
  16.  
  17. Installation is the reverse of removal. Always make sure all seals are installed properly during the installation process.
  18.  
  19. Seal all seams of the heater box with RTV.
  20.  
  21. Have a MVAC certified tech evacuate and recharge the A/C system.
  22.  

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.  
  3. Drain the cooling system into a clean container for reuse.
  4.  
  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.  
  7. 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.
     

  8.  
  9. Remove the center console-to-chassis bolts and the console.
  10.  
  11. 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.
     

  12.  
  13. Loosen the instrument panel crossmember-to-chassis bolts and lift the crossmember upward.
  14.  
  15. Disconnect the heater hoses from the heater core.
  16.  
  17. 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.
     

  18.  
  19. 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

     

  20.  

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.  
  3. If not equipped with air conditioning, perform the following procedure:

    Install the heater core to the heater housing.
     
    Install the heater/ventilation housing assembly.
     

  4.  
  5. Connect the heater hoses to the heater core.
  6.  
  7. Tighten the instrument panel crossmember-to-chassis bolts.
  8.  
  9. 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.
     

  10.  
  11. Install the center console and the console-to-chassis bolts.
  12.  
  13. 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.

  14.  
  15. Connect the electrical connector and install the air bag.
  16.  
  17. Refill the cooling system.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Evacuate, charge and leak test the air conditioning system.
  22.  
  23. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  24.  

2005 Jetta



  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    Be sure to obtain the anti-theft code for the radio.

  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove facing wall in plenum chamber.
  6.  
  7. Place Drip tray for VAS6100 VAS 6208 under the engine.
  8.  
  9. Clamp off coolant hoses using hose clamps, up to 1.6 inches (40mm).
  10.  
  11. Disconnect coolant hoses to heater core.
  12.  
  13. Connect a section of hose onto upper connection of heater core.
  14.  
  15. Hold suitable container under the lower connection.
  16.  
  17. Using a compressed air gun, carefully blow coolant from heater core into container.
  18.  
  19. Remove bolt (6mm socket head) from connection flange between heater core connections. This allows the coolant pipes to move for removing the heater core.
  20.  
  21. Remove driver side footwell trim and left footwell air vent.
  22.  
  23. Remove screws and remove heater core trim.
  24.  
  25. Cover floor carpet in area below heater core with leak-proof foil and absorbent paper.
  26.  
  27. Open hose clamps and disconnect coolant pipes from heater core.
  28.  
  29. Remove heater core from heating and ventilation unit.
  30.  

To install:

  1. Install in reverse order of removal, noting the following:


    1. Check seals installed on heater core, only install a heater core with undamaged seals. An incorrectly glued seal can roll up into heating and ventilation unit when sliding in the heater core.
      NOTE
      If seal is damaged or installed incorrectly, cold air can flow past the heater core.

    2.  
    3. Push heater core into the heating and ventilation unit.
    4.  
    5. Coat sealing rings with coolant before installing.
    6.  
    7. Insert sealing rings into connection on heater core.
    8.  
    9. Ensure sealing rings are installed with the chamfered end facing the heater core.
    10.  
    11. If hose clamps are deformed, replace them.
    12.  
    13. Connect coolant pipes to heater core.
    14.  
    15. Hose clamps must be able to be twisted slightly when installing onto the coolant pipes. Tighten hose clamps to 1.5 ft. lbs. (2 Nm).
    16.  
    17. Check seating of both clamps after tightening screws, clamps must enclose the flange on heater core and coolant pipe completely and must not touch other components.
    18.  
    19. Thread bolt into connection flange and while doing this ensure bolt is actually threaded into the mounting point intended for it.
    20.  
    21. Check position of grommet in bulkhead for proper seating.
    22.  
    23. Seal flange for coolant pipes to heater core and for expansion valve (to evaporator, only in vehicles with A/C system) at grommet pass-through with silicon adhesive sealant if necessary (to prevent water from penetrating).
      NOTE
      Sealing rings must always be replaced. If hose clamps are deformed, replace them.

    24.  

  2.  
  3. After replacing heater core, coolant must be replaced completely.
  4.  
  5. Check coolant circuit for leaks, pay particular attention between coolant hoses and heater core.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Evacuate, charge and leak test the air conditioning system refrigerant.
  10.  
  11. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  12.  

Cabriolet



It is necessary to remove the instrument panel and to discharge the air conditioning system. Have a MVAC certified tech recover the A/C system refrigerant.

  1. Disconnect the battery cable.
  2.  
  3. Remove the steering wheel. Tilt the shelf downward, remove the screws and remove the shelf.
  4.  
  5. From the driver's side, remove the instrument panel cover-to-instrument panel screws, pry out the clips and pull the cover downward.
  6.  
  7. Remove the shift knob and pull the boot out of the console.
  8.  
  9. From the driver's side, remove the instrument panel cover-to-instrument panel screws, pry out the clips and pull the cover downward.
  10.  
  11. From the passenger's side, remove the shelf-to-instrument panel screws and the shelf. Pry out the lower instrument panel cover-to-instrument panel clips and pull the cover from the guides.
  12.  
  13. At the console, remove the screws and pull the lower part of the console rearward.
  14.  
  15. From the heater/fresh air control, remove the knobs and trim.
  16.  
  17. From the upper part of the console, remove the screws and pull the upper part of the console out slightly. Detach the electrical connectors from the console and remove the upper console pan.
  18.  
  19. At the upper part of the instrument cluster, remove the instrument cluster trim screws and the trim. Remove the instrument cluster (center) screw and tip the cluster forward. Pull off the vacuum hose and multi-point connector from the instrument cluster. Disconnect the speedometer cable from the instrument cluster.
  20.  
  21. From the instrument panel, push the switch forward (out of the panel), pull the air ducts from the side vents.
  22.  
  23. Detach the electrical connectors from the ashtray housing and the wiring harness from the instrument panel.
  24.  
  25. Open the glove box and remove the screws from the center, left and right sides.
  26.  
  27. Pull out the heater/fresh air control, pry off the E-clip and disconnect the flap cable. Remove the control.
  28.  
  29. Remove the instrument panel-to-chassis screws and clips. Remove the instrument panel from the vehicle.
  30.  
  31. Drain the cooling system.
  32.  
  33. Disconnect the hoses from the heater core.
  34.  
  35. Discharge the air conditioning system into freon recovery equipment.
  36.  
  37. Detach the vacuum connectors from the fresh air box.
  38.  
  39. Disconnect the cables as required from the evaporator housing. Remove the retaining bolts, the heater core hoses, the evaporator inlet and outlet hoses and cap or plug the openings immediately.
  40.  
  41. Remove the heater assembly from the vehicle. Remove the screw and lift the heater core out of the housing.
  42.  
  43. Install the heater core into the housing and fit the housing into the vehicle. Connect the heater hoses and the air conditioner lines.
  44.  
  45. Position the instrument panel into the vehicle and install the screws and clips.
  46.  
  47. Install the heater/fresh air control, connect the flap control and the E-clip.
  48.  
  49. Install the glove box and secure with the screws.
  50.  
  51. Connect the wiring harness to the instrument panel.
  52.  
  53. Connect the speedometer cable, vacuum hose and multi-point connector to the instrument cluster. Install the instrument cluster and trim.
  54.  
  55. Install the upper console pan and connect the electrical connectors.
  56.  
  57. Install the heater controls, knobs and trim.
  58.  
  59. At the passenger's side, install the instrument panel cover and the shelf.
  60.  
  61. At the driver's side, install the instrument panel cover.
  62.  
  63. Install the shelf and tilt it upward. Install the steering wheel.
  64.  
  65. Have a MVAC certified tech evacuate and recharge the A/C system.
  66.  

Fox



  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Disconnect the heater inlet hoses at the firewall.
  6.  
  7. Inside the vehicle, remove the center console side panels. Disconnect the temperature control cables at the heater case.
  8.  
  9. Remove the left and right air distribution ducts.
  10.  
  11. In the engine compartment, remove the cowl cover and remove the air distribution housing cover.
  12.  
  13. Inside the vehicle, remove the lower housing retaining clips and remove the housing.
  14.  


NOTE
On vehicles equipped with A/C the heater box also contains the A/C system evaporator mounted in the lower housing cover. When removing the lower cover on these models lay the cover and evaporated aside WITHOUT disconnecting the refrigerant lines.

  1. Remove the bolts retaining the heater case and remove the case.
  2.  
  3. Remove the clips holding the case together and split the case, the heater core can now be removed.
  4.  

To install:

  1. Insert the heater core into the case, then reassemble it.
  2.  
  3. Install the case into the vehicle. Attach the lower heater case cover to the heater case. Install the air distribution ducts and the control cables.
  4.  
  5. Install the center console side panels. Reconnect the heater inlet hoses. Install the air distribution housing cover and the cowl.
  6.  
  7. Fill the cooling system to the proper level.
  8.  

Golf




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

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system into a clean container for reuse.
  4.  
  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.  
  7. 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.
     

  8.  


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.



Remove the steering wheel from the steering column.
 

  1. Remove the center console-to-chassis bolts and the console.
  2.  
  3. Remove the instrument panel by performing the following procedure:

    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.
     

  4.  


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 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 to0
 
Unclip the illumination control switch and disconnect the electrical connector.
 
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.  
  3. Disconnect the heater hoses from the heater core.
  4.  
  5. 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.
     

  6.  


NOTE
If the retainer clips break, use a self-tapping screw to hold the heater core in place.

  1. 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.
     

  2.  


    Click image to see an enlarged view

    Fig. Releasing the driver-s side air bag-Golf



    Click image to see an enlarged view

    Fig. Exploded view of the center console and related components-Golf



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel, crossmember and related components-Golf



    Click image to see an enlarged view

    Fig. Exploded view of the heater core, heater/ventilation housing and related components-Golf without air conditioning



    Click image to see an enlarged view

    Fig. Exploded view of the heater core, heater/air conditioning housing and related components-Golf 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.  
  3. If not equipped with air conditioning, perform the following procedure:

    Install the heater core to the heater housing.
     
    Install the heater/ventilation housing assembly.
     

  4.  
  5. Connect the heater hoses to the heater core.
  6.  
  7. Tighten the instrument panel crossmember-to-chassis bolts.
  8.  
  9. 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.
     

  10.  
  11. Install the center console and the console-to-chassis bolts.
  12.  
  13. 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).
  14.  


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.

  1. Connect the electrical connector and install the air bag.
  2.  
  3. Refill the cooling system.
  4.  
  5. Connect the negative battery cable.
  6.  
  7. Evacuate, charge and leak test the air conditioning system.
  8.  
  9. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  10.  


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

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system into a clean container for reuse.
  4.  
  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.  
  7. 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.
     

  8.  
  9. Remove the center console-to-chassis bolts and the console.
  10.  
  11. 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.
     

  12.  
  13. Loosen the instrument panel crossmember-to-chassis bolts and lift the crossmember upward.
  14.  
  15. Disconnect the heater hoses from the heater core.
  16.  
  17. 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.
     

  18.  
  19. 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-Golf



    Click image to see an enlarged view

    Fig. Exploded view of the center console and related components-Golf



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel, crossmember and related components-Golf



    Click image to see an enlarged view

    Fig. Exploded view of the heater core, heater/ventilation housing and related components-Golf without air conditioning



    Click image to see an enlarged view

    Fig. Exploded view of the heater core, heater/air conditioning housing and related components-Golf with air conditioning

     

  20.  

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.  
  3. If not equipped with air conditioning, perform the following procedure:

    Install the heater core to the heater housing.
     
    Install the heater/ventilation housing assembly.
     

  4.  
  5. Connect the heater hoses to the heater core.
  6.  
  7. Tighten the instrument panel crossmember-to-chassis bolts.
  8.  
  9. 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.
     

  10.  
  11. Install the center console and the console-to-chassis bolts.
  12.  
  13. 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.

  14.  
  15. Connect the electrical connector and install the air bag.
  16.  
  17. Refill the cooling system.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Evacuate, charge and leak test the air conditioning system.
  22.  
  23. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  24.  

Golf And Jetta



Removal And Installation

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

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system into a clean container for reuse.
  4.  
  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.  
  7. 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.
     

  8.  
  9. Remove the center console-to-chassis bolts and the console.
  10.  
  11. 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.
     

  12.  
  13. Loosen the instrument panel crossmember-to-chassis bolts and lift the crossmember upward.
  14.  
  15. Disconnect the heater hoses from the heater core.
  16.  
  17. 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.
     

  18.  
  19. 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-Golf and Jetta



    Click image to see an enlarged view

    Fig. Exploded view of the center console and related components-Golf and Jetta



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel, crossmember and related components-Golf and Jetta



    Click image to see an enlarged view

    Fig. Exploded view of the heater core, heater/ventilation housing and related components-Golf 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-Golf and Jetta with air conditioning

     

  20.  

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.  
  3. If not equipped with air conditioning, perform the following procedure:

    Install the heater core to the heater housing.
     
    Install the heater/ventilation housing assembly.
     

  4.  
  5. Connect the heater hoses to the heater core.
  6.  
  7. Tighten the instrument panel crossmember-to-chassis bolts.
  8.  
  9. 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.
     

  10.  
  11. Install the center console and the console-to-chassis bolts.
  12.  
  13. 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.

  14.  
  15. Connect the electrical connector and install the air bag.
  16.  
  17. Refill the cooling system.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Evacuate, charge and leak test the air conditioning system.
  22.  
  23. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  24.  

Gti And Jetta




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

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system into a clean container for reuse.
  4.  
  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.  
  7. 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.
     

  8.  


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.



Remove the steering wheel from the steering column.
 

  1. Remove the center console-to-chassis bolts and the console.
  2.  
  3. Remove the instrument panel by performing the following procedure:

    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.
     

  4.  


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 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 to0
 
Unclip the illumination control switch and disconnect the electrical connector.
 
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.  
  3. Disconnect the heater hoses from the heater core.
  4.  
  5. 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.
     

  6.  


NOTE
If the retainer clips break, use a self-tapping screw to hold the heater core in place.

  1. 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.
     

  2.  


    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.  
  3. If not equipped with air conditioning, perform the following procedure:

    Install the heater core to the heater housing.
     
    Install the heater/ventilation housing assembly.
     

  4.  
  5. Connect the heater hoses to the heater core.
  6.  
  7. Tighten the instrument panel crossmember-to-chassis bolts.
  8.  
  9. 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.
     

  10.  
  11. Install the center console and the console-to-chassis bolts.
  12.  
  13. 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).
  14.  


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.

  1. Connect the electrical connector and install the air bag.
  2.  
  3. Refill the cooling system.
  4.  
  5. Connect the negative battery cable.
  6.  
  7. Evacuate, charge and leak test the air conditioning system.
  8.  
  9. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  10.  

 
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