D.I.Y. Mk2 heater core replacement. (loads of pics...)

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Jetta2
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D.I.Y. Mk2 heater core replacement. (loads of pics...)

Post by Jetta2 » Fri Jun 08, 2007 7:03 pm

So I done a Mk2 CLI Jetta heater core replacement for Jettabug today.


Contrary to popular belief, THE DASH DOES NOT HAVE TO COME OUT.


Jettabug's CLI has aircon, but the non aircon Mk2's are easier to do as there is more space to manoeuver the heater assembly to get it out from under the dash.



So, here we go.


Tools and parts needed:

Philips head screwdriver("star" point)
10mm spanner
Thin, flat pointed screw driver (to remove clips)
Heater core
Water pump pliers (for removing clamps on water pipes)


First unscrew the gearknob and remove the shifter boot from the centre console.....

Image


Remove the screws that hold the parcel shelves in place on the driver's side and passenger's side. There are 3 screws on the top, 1 on each side of the console and 1 each side at the bottom by the door aperture.....

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Remove the screw and slide the console backwards and move it out the way. Be careful of the wires and connectors on the back.....

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Next, remove the centre air vent by unscrewing the 2 screws on the top and carefully prise the two clips up that are on the bottom inside the airvent.....

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This is what you should see.....

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With the console removed, you can see the heater assembly. Remove the 2 plastic nuts. On each side up under the dash there are airvent pipes that lead to the outer airvents. Carefully maneouver the cover off.....

Image

Image



Remove the bottom panel by undoing the 3 screws. 2 on the right and 1 on the left.....

Image

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Unclip the control cable and the clip holding the cable.....

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In the engine bay, loosen the 2 nuts and the pipes from the heater inlet and outlet.....

Image

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On the heater assembly there are 5 clips holding the heater to the aircon unit. 1 on the bottom, 2 in the front and 2 in the back. The back ones are a total **** to get off and back on again.....

Image

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With a lot of wiggling and pulling and carefully manipulating the heater assembly i will come out and then you can unclip the heater core from the assembly.....

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The old core slides out towards the top.....

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Heater core out.....

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Slide in the new core and make sure it clips in place.....

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Use the old gasket sponge from the old core and place it on the new one.....

Image

Image



Now replace the heater assembly and replace the 2 water pipes, nuts, clips, control cable, screws etc.

Refill the coolant, start car, check for leaks.

Run the car to operating temp and check everything is working 100%.

Time taken: 2,5 hours (with smoke and coffee breaks in between)
Last edited by Jetta2 on Sat Jun 16, 2007 7:35 pm, edited 1 time in total.
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Post by harley » Fri Jun 08, 2007 8:24 pm

thanks for this I need to do my too! this will really help me out :lol:
__________________________________

current: 2001 Audi A3 Quattro 1.8T
current: 1998 Yamaha FZS 600
ex: 1972 Honda Super Cub
ex: 1967 Honda SS50
ex: 1989 Yamaha TZR250
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ex: 1983 Golf GT 2.0
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Post by Jetta2 » Sun Jun 10, 2007 1:04 pm

Cool :wink:

I hope others will also find it helpful.....
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Post by 1.6carbster » Sun Jun 10, 2007 3:17 pm

Awesome thread,Ryan! This is really informative!

Moderators,make this a sticky post in the FAQ section!

Now for the big question,ryan,can you fit a cam to an 8v golfie?

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Post by Jetta2 » Sun Jun 10, 2007 3:29 pm

1.6carbster wrote:Awesome thread,Ryan! This is really informative!

Moderators,make this a sticky post in the FAQ section!

Now for the big question,ryan,can you fit a cam to an 8v golfie?



Thanks Chris :oops:



I can fit a cam, done it a few times already. Must we do yours and take pics?
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Post by 1.6carbster » Sun Jun 10, 2007 4:25 pm

Yeah Ryan, I think it'll be very cool and informative to fit a cam and take pics. I'll phone you later to arrange, but I was hoping to do it this coming weekend!

PS: I pay in beers!! :wink:

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Post by Jetta2 » Sun Jun 10, 2007 4:33 pm

:wink:
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Post by GolfII GTi King » Mon Jun 11, 2007 3:09 pm

Nice one!
This forum should have a DIY section for each model.
i.e MKI, MkII,....
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Post by EX-DOHCTOR » Mon Jun 11, 2007 3:58 pm

Nice one!
This forum should have a DIY section for each model.
i.e MKI, MkII,....
Do you have any idea how huge something like that would be?

Let's start with the Mk1's shall we?

GT
GTi
Chico
Shuttle
Sport
Deco
Designa
CTi
Life
.Com
Velociti
Citi-R

Eish - am I leaving any out? :?
Last edited by EX-DOHCTOR on Mon Jun 11, 2007 7:29 pm, edited 1 time in total.
2014 - VW Jetta 6 - 1.6 TDi DSG - Moonrock Silver.
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MK1 Build Register: http://www.vwclub.co.za/forum/viewtopic ... 1&t=192835

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Post by GolfII GTi King » Mon Jun 11, 2007 4:04 pm

Not in so much detail.
E.g. Velo, life and .com all fall under MKI.
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Post by EX-DOHCTOR » Mon Jun 11, 2007 7:31 pm

Lol, I know mate, just being volkak :lol:
2014 - VW Jetta 6 - 1.6 TDi DSG - Moonrock Silver.
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Post by bru-tom » Tue Jun 12, 2007 8:12 am

very nice DIY jetta2 :wink: :lol: it takes lank time to put together a DIY like that, thanks for sharing :wink:

i agree with the others that mentioned that we should have a DIY section too :D
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Post by Jetta2 » Tue Jun 12, 2007 8:57 am

Thanks Bru :wink:


I have a few more DIY's coming up.

Mk2 steering rack replacement (thanks Meox)
Mk2 gearbox and clutch replacement......
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Post by megesh » Tue Jun 12, 2007 9:00 am

cool thanks alot man will def use it!
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Post by Jetta2 » Tue Jun 12, 2007 9:15 am

megesh wrote:cool thanks alot man will def use it!

Sweet brother :wink:
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Post by GolfII GTi King » Tue Jun 12, 2007 10:11 am

I have printed out your DIY already and put it in file along with Macman's 2.0l conversion. Awaiting your other DIY's!
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Post by Jetta2 » Tue Jun 12, 2007 10:21 am

Cool stuff :wink:


The Mk2 steering rack jobby will be posted on Thursday night.

The 8 valve cam swop will be posted on Saturday afternoon(Carbster's Mk1)

The gearbox swop will be next week sometime.
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Post by GolfII GTi King » Tue Jun 12, 2007 10:24 am

Coooool!!
I will be doing a MP9 conversion to one of my MKII K-jets soon.
Will try and capture it all on camera and post it as well.
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Post by bru-tom » Tue Jun 12, 2007 10:31 am

Jetta2 wrote:Cool stuff :wink:


The Mk2 steering rack jobby will be posted on Thursday night.

The 8 valve cam swop will be posted on Saturday afternoon(Carbster's Mk1)

The gearbox swop will be next week sometime.
hectic, will be interesting to see how you change a cam in an 8v, maybe i will chanhe my cam myself then, cheers dude :wink:
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Post by Wazzsta » Tue Jun 12, 2007 12:28 pm

Ryan, that is a brilliant thread and thank u for the effort put into taking the pics and go thru it step by step, i am sure this will be helpful to many :wink:
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Post by Jetta2 » Tue Jun 12, 2007 12:31 pm

Wazzsta wrote:Ryan, that is a brilliant thread and thank u for the effort put into taking the pics and go thru it step by step, i am sure this will be helpful to many :wink:

Thanks Wazzstaaaaaaaaaaaaaaa :lol:


I try help out fellow enthusiasts as much as I can. Loads more DIY's in the pipeline..... :wink:
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Post by Jetta2 » Sun Jun 17, 2007 8:35 pm

@ Moderators.

Can you please make these DIY's sticky?

Or how about a DIY section on the BB?

Please :wink:
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