Volkswagen Golf/Jetta/Cabriole 1990-1999

Heater Core

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REMOVAL & INSTALLATION



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.  

1990-92 Golf and Jetta

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 negative battery cable.
  2.  
  3. Drain the cooling system and disconnect the heater hoses from the firewall.
  4.  
  5. Properly discharge the air conditioning system using freon recovery equipment.
  6.  
  7. Remove the gear shift knob and boot and remove the center console.
  8.  
  9. Remove the steering wheel.
  10.  
  11. Remove the knee bar from below the dashboard.
  12.  
  13. Remove the steering column support bracket and lower the column.
  14.  
  15. Pull the knobs off the heater controls and remove the control assembly and the radio.
  16.  
  17. Remove the headlight switch and switch blanks to gain access to the screws. Remove the instrument cluster and trim panel around the cluster.
  18.  
  19. Remove the glove compartment.
  20.  
  21. At the firewall, remove the plastic tray and remove the 2 nuts holding the top of the dashboard.
  22.  
  23. Remove the main fuse panel and disconnect the plugs at the back. Disconnect the ground wires.
  24.  
  25. Disconnect any remaining wiring from the dashboard and remove the 4 last screws; 1 at each end and 1 at each end of the instrument cluster area. Remove the dashboard.
  26.  
  27. Disconnect the ducts and remove the heater housing. Remove the screws and slide the heater core out of the housing.
  28.  

To install:

  1. Install the heater core and make sure the housing seals and gaskets are in good condition. Replace as necessary.
  2.  
  3. With the heater housing properly installed, install the dashboard and connect the wiring. Install the steering column bracket bolts.
  4.  
  5. Install the fuse panel and connect the wiring.
  6.  
  7. Install the glove compartment, shift boot and knob and steering wheel.
  8.  
  9. Have a MVAC certified tech evacuate and recharge the A/C system.
  10.  

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.  

 
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