[Vwpickups] replacing heater core

[Eric S]

Very good write up.

There is a shortcut to this however instead of removing the whole heater box.

Simply cut the square "cap" that holds the heater core in place where the
coolant lines enter it (using a dremel and a steady hand), slide out the
old one, slide in a new one, epoxy (or RTV if you want to make it easier
to remove next time) the plastic "cap" back on. (I call it a cap cause its
an obvious square bulge in the heater box).

If your in a hurry and lacking tools, the above shortcut is quick and
effective.

-- 
Eric
www.vintagewatercooleds.com

1981 Scirocco S (TDI swap project)
1991 Cabriolet (2.0 crossflow 8v project)
2007 Honda Fit Sport (AKA the 2007 Honda Rabbit)


Tom Bond wrote:
> Bill,
>
> Funny you should ask this question just now.  I just finished, I mean
> within the last fifteen minutes, changing the heater motor on my Rabbit
> car.
>
> I looked all over the Internet for directions and the ones I did find
> were incorrect.  Even my best VW tech bud was not exactly accurate.
>
> The way it is done is straightforward albeit time consuming.  I have a
> pretty good shop and a bunch of tools but this is a job that doesn't
> really require much.
>
>  From memory without detailed notes:
>
> Disconnect battery ground.
> Drain coolant by disconnecting the lower hose where it attached to the
> water pump. About 1 gallon.
> Remove glove box and drivers side lower panels.
> Remove drivers and passenger side air ducts that lead from the heater
> box to the outer dash vents.
> Push button on bottom of headlight switch and remove headlight switch
> knob.
> Unscrew and remove 'cold start; knob.
> Remove instrument panel bezel.
> Remove the 7mm bolts that hold the heater controls in place, move the
> heater control toward you, remove the small bolts that         hold the
> heater switch in place, remove the switch and push it back into the
> dash. Now there is enough room to move the         heater controls to
> the left, swing the right end into the dash, then slide the entire
> heater control into the dash and away from the     dash proper.
> Remove dash center vent.
> Remove radio (if equipped).
> Remove hazard switch, cigarette lighter and its lamp, and the wiring to
> the cigar lighter.
>  From under the drivers side, remove the speedo cable from the cluster.
> Remove the cluster by removing the four screws, then tilting the top
> toward you and pinching the electrical connector and
> removing the harness.
> Remove the 4 Phillips screws that are at the ends of the dash with a
> fillips tip and a 1/4" wrench, and the two 7mm bolts in the     center
> under the ash tray.
> Carefully remove the dash towards the passenger door making sure you do
> not place stress on the wiper lever and checking to     see and move the
> wiring harness off of the dash itself.
> Remove the 'knee bar' by removing the (6)  7mm bolts.
> Now your looking at the heater box itself.  By now the coolant should
> have drained and you can go back out under the hood         and
> disconnect the 5/8" heater hose where it connects at the shut-off valve
> and the factory splice just below it.
> If you have a/c, you must disconnect both supply and return lines to the
> evap.  Use two wrenches to avoid damage to the lines.
> Disconnect and remove the dash flapper and it's vacuum motor by
> releasing the rubber strap.  You may want to label which         vacuum
> lines go where.
> Disconnect the two electrical connectors to the heater box.
> Remove the two 10mm screws that hold the heater box to the chassis.
> Pull the heater box toward you to get the heater hoses         through
> the firewall and move it to the left to remove it from the vehicle.
>
> Once you have the heater box out of the vehicle, rest is
> self-explanatory.  Be sure to clean every bit of junk out of the heater
>         box while it is out and easy.
>
> The heater hoses are standard 5/8" hose you can buy anywhere.  You will
> need about 4' to finish the job.
>
> When you replace the coolant, first reconnect the hoses you
> disconnected, then remove the upper radiator hose at the radiator and
> fill the engine through the upper hose.  When it is full, reconnect the
> upper hose and refill the reserve tank.
>
> Installation is the reverse....
>
> Cheers.
>
> Tom Bond
> Kansas City
> Tomsebooks.com
>
>
>
>
>
>
> Cathy, Bill and Menace wrote:
>
>>Well, here it is Dec. in the northeast and my heater is spewing
>> antifreeze mist on my windshield...heavy sigh.  Anyone have experience
>> replacing this?  How miserable a job is this and what kind of time frame
>> are we talking about to disassemble, install and reassemble the dash and
>> heater?  I also have AC (it doesn't work but I have it).  My temperature
>> control cable is not functioning and is probably kinked and needing to be
>> replaced so I am looking for one of these if anyone has saved one.  I
>> haven't checked yet but I'm guessing that VW doesn't stock them anymore.
>> Thanks for looking.  Bill
>>_______________________________________________
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>>
>>
>
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