Volkswagen Front Wheel Drive 1974-1989 Repair Guide

Evaporator Core

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REMOVAL & INSTALLATION



See Figure 1

Procedures for discharging and servicing the air conditioning system are described in General Information And Maintenance . If a refrigerant recovery/recycling machine is not available, this job should be done at the dealer or a shop that has this equipment.

  1. Drain the cooling system and discharge the air conditioning system into a recovery/recycling machine. Disconnect the negative battery cable.
  2.  
  3. If equipped, remove the console.
  4.  
  5. Remove the instrument panel pad.
  6.  
  7. Remove the radio and the glove box.
  8.  
  9. Remove the dash completely. Unplug the wiring/vacuum connections and disconnect the speedometer cable.
  10.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the evaporator mounting on Golf and Jetta models

  1. Disconnect the cables from the evaporator housing. Remove the retaining bolts, heater core hoses and the evaporator inlet and outlet hoses. Cap or plug the hoses immediately.
  2.  
  3. Remove the evaporator housing from the vehicle. Separate the halves of the evaporator housing, then remove the evaporator.
  4.  

To install:
  1. After assembling the evaporator housing, install it into the vehicle and complete the installation in the reverse of the removal procedure.
  2.  
  3. Connect the battery cable.
  4.  
  5. Fill the cooling system. Evacuate and recharge the air conditioning system.
  6.  

 
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