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How to replace heater core on 1998 VW Passat?

Its not very easy to replace heater core, and it takes lots of time and lots of parts disassembly is required.



Replacing your heater core is pretty involved. The book time is 6.6 hours plus time to evacuate and recharge the a/c. The heater case assembly has to be removed and disassembled to replace the heater core.

Here is the procedure.

First you need to remove the instrument panel.

Before beginning repairs on the electrical system:

  • Obtain the anti-theft radio security code
  • Switch off all electrical consumers
  • Switch ignition off and remove ignition key
  • Disconnect negative (-) battery terminal
  • When disconnecting and reconnecting battery terminals, observe all applicable Notes and torque specifications, as well as instructions on performing OBD program and electrical system function checks.

Instrument Panel, Removing And Installing

Removing

  • Disconnect vehicle battery.
  • Remove center console.
  • Remove driver side airbag unit.
  • Remove steering wheel.

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  • Unscrew 2 Phillips-head bolts - arrows -.
  • Remove upper trim for steering column switches - 1 -.
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    • Unscrew Phillips-head bolts - arrows -.
    • Remove hex socket head bolt - 1 -.
    • Loosen height adjustment for steering wheel - 2 -.
    • Remove lower trim for steering column switch - 3 -.


    • Remove socket head bolt - 1 -.
    • Disconnect harness connectors - arrows - from steering column switch.
    • Remove steering column switches - 2 -.

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    • Pry off cap - 1 -.
    • Remove bolts - 2 - and - 3 -.
    • Unclip lower A-pillar trim on drivers side - 4 - from sill trim and remove.

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    • Unclip cover - 1 -.
    • Remove bolts - arrows -.
    • Remove storage compartment on drivers side - 2 -.
    • Disconnect harness connectors from light switch - 3 - and from headlight beam adjuster - 4 -.

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    • Slide cover - 1 - upward and clamp using equipment (e.g. screwdriver handle) - 2 -.
    • Remove four bolts - arrows -.
    • Remove cover - 3 -.

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    • Remove two bolts - arrows -.
    • Remove instrument cluster.
    • Disconnect harness connectors.

    Radio Removal Tool 3316 is required for removing the radio.
    Radio Removal Tool 3316 consists of two equivalent individual parts.

  • Slide Radio Removal Tool 3316 into release slots - arrows - until they engage.
    • Pull radio out of instrument panel using grip rings on removal tool.

    NOTE:

    • Radio Removal Tool 3316 must not be pushed to the side or tilted during procedure.
    • To remove removal tool from radio, press in locking lugs on side of radio.
    • Disconnect harness connectors.

    Unclip trim around radio

    Remove 8 bolts - Pull out cover for center instrument panel

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    Remove five bolts

    • Disengage three clips - arrows - using flat screwdriver - 1 -.

    NOTE: The locking mechanism is located in the upper area of juncture between vent and instrument panel.

    • Keep vent - 2 - under load while doing so, to prevent disengaged clips from engaging again.
    • Pull vent - 2 - out of instrument panel and disconnect harness connector - 3 -

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    • Remove hex bolts - arrows -.
    • Disconnect harness connector - 1 -.
    • Remove instrument panel.

    • Notes
    • Observe all A/C refrigerant system safety measures.Service refrigerant system using Kent More ACR 4 or equivalent.During servicing, all couplings, fittings and related fasteners must be torqued to specifications.

    Removing

    • Discharge refrigerant system.Drain engine coolant. Remove instrument panel as described above.Remove coolant hoses at heater core.Note Installation orientation of coolant hoses -A- (inlet and outlet) in engine compartment.Clamp off both coolant hoses to heater core using 3094 hose clamps (or equivalent).Release both coolant hose clamps using suitable pliers and pull hoses off from heater core inlet and outlet.Seal off inlet and outlet at heater core to prevent coolant from escaping.Remove refrigerant lines at evaporator.
      • Remove screw -3- (15 Nm) .
      • Gently rock flange with refrigerant lines -2- up and down until they release from evaporator.
      CAUTION!Immediately plug open connections on A/C components and lines to prevent dirt and moisture contamination
      • Always replace both O-rings -1-.

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  • Carefully pull out and remove complete housing -1- from vehicle.
  • Hopefully this will help you. If you don't feel confident in your technical ability I would not recommend trying this repair.Get it done by proper garage mechanic.


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    For more car related problem troubleshooting:---

    This are the sections, you can go through and click the link to read its troubleshooting.

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    http://schematicsdiagram.blogspot.com/2011/06/car-will-not-start.html

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    ---------------

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    --------------------

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    ------------------------

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    -------------------

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    http://schematicsdiagram.blogspot.com/2011/07/how-to-replace-power-steering-rack.html

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    How to Replace a Bumper Bracket or Side Support

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    How to Replace a Washer Pump.

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-washer-pump.html

    How to Replace a Grille

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    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-power-steering-hose.html

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    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-tailgate.html

    How to Replace a Soft Top

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-soft-top.html

    How to Replace a Carburetor

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-carburetor.html

    ­

    How to Replace a Bumper Trim

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-bumper-trim.html

    How to Replace Trunk Strut

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-trunk-strut.html

    How to Replace a Front End Cover

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-front-end-cover.html

    How to Replace a Front Pipe

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-front-pipe.html

    How to Replace an Antenna Mast

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-antenna-mast.html

    How to Replace a Side Marker Light Assembly

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-side-marker-light.html

    How to Install a Carpet on car?

    http://schematicsdiagram.blogspot.com/2011/08/how-to-install-carpet-on-car.html

    How to Replace a Spoiler

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-spoiler.html

    How to Replace a Mirror Glass on car?

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-mirror-glass-on-car.html

    How to Replace a Step Bumper?

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-step-bumper.html

    How to Replace a Door Lock

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-door-lock.html

    How to Replace a Throttle Body

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-throttle-body.html

    How to Replace a Throttle Position Sensor

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-throttle-position-sensor.html

    How to Replace a Grille Insert

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-grille-insert.html

    How to Replace a Fan Shroud Assembly

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-fan-shroud-assembly.html

    How to Replace an Engine Splash Shield

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-engine-splash-shield.html

    How to Replace a Turn Signal Light Assembly

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-turn-signal-light.html

    How to Replace a Headlight Assembly

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-headlight-assembly.html

    How to Replace a Park Light Assembly

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-park-light-assembly.html

    How to Replace an Expansion Tank

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-expansion-tank.html

    How to Replace an Exhaust System

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-exhaust-system.html

    How to Replace a Fender Trim

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-fender-trim.html

    How to Replace a Headlight Door

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-headlight-door.html

    How to Replace a Fan Shroud

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-fan-shroud.html

    How to Replace a Harmonic Balancer

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-harmonic-balancer.html

    How to Replace a Header Panel

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-header-panel.html

    How to Replace a Fuel Tank

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-fuel-tank.html

    How to Replace a Fuel Tank Cap

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-fuel-tank-cap.html

    How to Replace a Distributor

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-distributor.html

    How to Replace an EGR Valve

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-egr-valve.html

    How to Replace an Oxygen Sensor

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-oxygen-sensor.html

    How to Replace an Ignition Wire Set

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-ignition-wire-set.html

    How to Replace a Tail Light

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-tail-light.html

    How to Replace a Door Handle

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-door-handle_18.html

    How to Replace a Hood Strut

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-hood-strut.html

    How to Replace Tail Light Assembly

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-tail-light-assembly.html

    How to Replace a Front Bumper

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-front-bumper.html

    How to Replace a Fuel Pump Assembly

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-fuel-pump-assembly.html

    How to Replace an Axle Assembly

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-axle-assembly.html

    How to Replace a Tailgate Handle

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-tailgate-handle.html

    How to Replace a Wheel Hub Assembly

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-wheel-hub-assembly.html

    How to Replace a Control Arm

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-control-arm.html

    How to Replace a Window Regulator with Motor

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-window-regulator-with.html

    How to Replace a Headlight

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-headlight.html

    How to Check the Brake Fluid Level

    http://schematicsdiagram.blogspot.com/2011/08/how-to-check-brake-fluid-level.html

    How to Replace a Parking Brake Switch

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-parking-brake-switch.html

    How to Replace a Blower Motor Resistor

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-blower-motor-resistor.html

    How to replace frost plug on car?

    http://howtobyme.blogspot.com/2011/08/how-to-replace-frost-plug-on-car.html

    Horn stopped working?

    http://howtobyme.blogspot.com/2011/08/horn-stopped-working.html

    How to clean egr valve on Isuzu Amigo?

    http://howtobyme.blogspot.com/2011/08/how-to-clean-egr-valve-on-isuzu-amigo.html

    Cruise control stopped working?

    http://howtobyme.blogspot.com/2011/08/cruise-control-stopped-working.html

    Car is stuck in park and the shift will not move?

    http://howtobyme.blogspot.com/2011/08/car-is-stuck-in-park-and-shift-will-not.html

    How to change the outer door weather strip?

    http://howtobyme.blogspot.com/2011/08/how-to-change-outer-door-weather-strip.html

    Car slows down when it gets hotter?

    http://howtobyme.blogspot.com/2011/08/car-slows-down-when-it-gets-hotter.html

    Warning lights on and speedometer died?

    http://howtobyme.blogspot.com/2011/08/warning-lights-on-and-speedometer-died.html

    Car won't rev past 1900 rpms?

    http://howtobyme.blogspot.com/2011/08/car-wont-rev-past-1900-rpms.html

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