Volkswagen Front Wheel Drive 1974-1989 Repair Guide

Heater Case/Box

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REMOVAL & INSTALLATION



Without Center Console

See Figures 1, 2 and 3

  1. Disconnect the battery ground cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the windshield washer container (from its mounts) and/or the ignition coil, but only if they prevent access to the heater components under the hood.
  6.  
  7. Disconnect the two hoses from the heater core connections at the firewall.
  8.  



Click image to see an enlarged view

Fig. Fig. 1: Scirocco and Cabriolet heater box assembly



Click image to see an enlarged view

Fig. Fig. 2: Dasher heater assembly

  1. Unplug the blower fan electrical connectors. Some models are equipped with an external series resistor mounted on the heater box. Do not try to remove the wires from the resistor.
  2.  
  3. Remove the heater control knobs on the dash.
  4.  

  1. Remove the two retaining screws and remove the controls from the dash complete with brackets.
  2.  
  3. Some models have a cable attached to a lever which is operated by a round knob on the dashboard. Remove the cable from the lever.
  4.  
  5. Remove either the clips or the screws holding the heater box in place and remove the heater box with the heater controls.
  6.  

To install:
  1. When installing the new type of housing in Rabbits and Sciroccos originally equipped with the older style heater box, proceed as follows:
    1. Make a hole by cutting along the line "W".
    2.  
    3. Clip the connections after installing the new air outlet pipe and seal the joint with a suitable adhesive.
    4.  

  2.  



Click image to see an enlarged view

Fig. Fig. 3: Cut along line (W) for Rabbits and Sciroccos originally equipped with the older style heater box

  1. Mount and install the heater box (with controls) and install the retaining clips or screws.
  2.  
  3. On those models with cable operated lever, connect the cable to the lever.
  4.  
  5. Mount the controls to the dash and secure with the two retaining screws.
  6.  
  7. Install the heater control knobs.
  8.  
  9. Plug in the blower fan connectors.
  10.  
  11. Connect the hoses to the heater core at the fire wall.
  12.  
  13. Install the ignition coil and windshield washer reservoir if they were removed.
  14.  
  15. Fill the cooling system to the proper level.
  16.  
  17. Connect the negative battery cable.
  18.  

With Center Console
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Trace the heater hoses coming from the firewall and disconnect them. One leads to the back of the cylinder head and the other leads to the heater valve located above and behind the oil filter.
  6.  
  7. Detach the cable for the heater valve.
  8.  
  9. Remove the center console.
  10.  
  11. Remove the left and right covers below the instrument panel.
  12.  
  13. Pull off the fresh air/heater control knobs.
  14.  
  15. Pull off the trim plate.
  16.  
  17. Remove the screws for the controls.
  18.  
  19. Remove the center cover mounting screws and remove the cover.
  20.  
  21. Detach the right, left and center air ducts.
  22.  
  23. Remove the heater housing retaining spring.
  24.  
  25. Remove the cowl for the air plenum which is located under the hood in front of the windshield.
  26.  
  27. Remove the heater housing mounting screws and remove the heater housing. The mounting screws are under the hood where the air plenum was. Remove all the old sealing material and replace.
  28.  

To install:
  1. Mount the heater housing and install the mounting screws.
  2.  
  3. Install the air plenum cowl.
  4.  
  5. Install the heater housing retaining spring.
  6.  
  7. Connect the right, left and center air ducts.
  8.  
  9. Install the center cover.
  10.  
  11. Install the control assembly screws.
  12.  
  13. Mount the trim plate.
  14.  
  15. Install the fresh air/heater control knobs.
  16.  
  17. Install the lower left and right instrument panel covers.
  18.  
  19. Install the center console.
  20.  
  21. Connect the heater cable valve.
  22.  
  23. Connect the heater hoses.
  24.  
  25. Fill the cooling system to the proper level.
  26.  
  27. Connect the negative battery cable.
  28.  

 
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