Change Heater Core

[VW VR6]

DIY Change HEATER CORE in VW Golf MK3 VR6 with pictures:
So I decided to replace my heater core.
There are a lot of steps involved here but the work isn't difficult.
First disconnect negative or positive or both from batteries.
Remove radio/cd/tape player :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC.jpg
Carefully remove plastics around steering wheel :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/0b8d_1.jpg
Remove lower glowebox :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC1.jpg
Remove ashtray and cigarette lighter :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC2.jpg
Carefully remove plastic around heater/air-con control :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC3.jpg
When you take out there is 3 plastic clips on the top and one at the bottom. You need to remove them to disconnect all cables from switches :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC4.jpg

http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC5.jpg
Carefully with screwdriver remove two small plastics parts on the right sine from stereo, and after that unscrew two bolts :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC6.jpg
Carefully with screwdriver and fingers remove headlight euro switch and plastics with ABS and airbag lights. Disconnect all cables carefully :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC7.jpg

[VW VR6]

Remove foam under lower glowebox. There is 2 or 4 bolts:
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC8.jpg
Carefully with screwdriver remove all 4 plastics for ventilators:
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC9.jpg
On the passenger side remove 2 bolts under plastics (next to speaker) :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC10.jpg
Remove 4 bolts where is stereo :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC11.jpg
Remove tacho (2 bolts) :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/0c9c_1.jpg
Remove 4 bolts under euro light switch :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC12.jpg

[VW VR6]

Remove plastic cover around handbrake. There is 2 plustic nuts 10mm and two bolts :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC13.jpg
For easy removing plastics just remove 2 nuts 13mm for hanbrake, but first deactivate handbrake :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC14.jpg
Unclip all plastics with fingers or just a little bit help with screwdriver:
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC15.jpg
Remove 3 plastic nuts 10mm :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC16.jpg
Thre bolts for removing passenger airbag :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC17.jpg

[VW VR6]

Carefully disconect airbag. Mine connector is broken because light for airbag is on all the time :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC18.jpg
Blue one is for plastics removing around fuses and relay, and red one for dash :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC19.jpg
Now going outside to remove wipers 13mm and after that 2 pieces of plastics with screwdriver and fingers :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC20.jpg
Remove 3 nuts 10mm for easy access to nuts for dashboard :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC21.jpg
10mm nuts for dash :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC22.jpg

http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC23.jpg

http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC24.jpg

http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC25.jpg
Spy 10mm nuts under metal shield :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC46.jpg

[VW VR6]

First unclip plastic which hold polen filter, and second remove 2 plastic nuts 10mm to remove all plastic. Will be surprised how many dust and rubbish around :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC26.jpg

http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC27.jpg

http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC28.jpg
Red one is for dash and blue one for lower glowebox :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC29.jpg

Carefully take out all dashboard.
You need to unclip all plastics cable holder around stereo, and 2 connectors for left and 2 connectors for right speakers :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC30.jpg

http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC31.jpg
Blu bolts is for removing metal barrier:
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC32.jpg

http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC33.jpg

[VW VR6]

Disconnect air-con next to blower :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC34.jpg
Remove metal gold clips all around (about 10 clips) to separate heater and aircon :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC35.jpg
Unclip all cables :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC36.jpg

http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC41.jpg
Unclip vacuum hose from aircon to heater :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC37.jpg

http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC38.jpg

[VW VR6]

Remove 2 plastic nuts 10mm which hold white "BASKET" :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC39.jpg

http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC40.jpg
Remove side plastic trim for easy pull off metal bar :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC42.jpg
Pull out metal frame about 10-20cm :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC43.jpg
Go to engine bay and remove two nuts 10mm and one in the middle with allan key to disconnect aircon :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC44.jpg

http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC45.jpg

http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC47.jpg

http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC48.jpg

[VW VR6]

Remove all 3 metal clips with screwdriver and after that move little bit left or right to remove metal for adjusting heater/aircon :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC49.jpg

http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC50.jpg

http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC51.jpg

[VW VR6]

Disconnect vacuum hose from heater core from engine bay, but carefully I broke mine :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC55.jpg

http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC58.jpg
Back to car and disconnect jack on right side heater core and remove with screwdiver :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC57.jpg

http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC59.jpg

[VW VR6]

Now with screwdriver (around 4-5 bolts) separate blower from air-con.
After that take blower out slowly because is small foam gasket between blower and aircon unit.
Separate aircon unit from heater unit (small metal gold clips), there is another foam gasket - be carefully.
Take out first aircon unit (bigger one on passenger side), and after that heater unit.
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC61.jpg

[VW VR6]

Now is time to rest :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC62.jpg

http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC63.jpg

http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC64.jpg

[VW VR6]

Clean all inside car and all plastics parts.
Replace foam around heater core.
Remove old foam and clean well :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC72.jpg

http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC73.jpg

Use some foam and double sided tape :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC76.jpg

http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC77.jpg

http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC78.jpg

Finished :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC79.jpg

http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC80.jpg

[VW VR6]

Fixing broken plastic connector at heater core beetween engine bay and interior.
Old heater core and hole when should be plastic connector:
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC70.jpg
Plastics black connectors 4mm 10 pcefrom Bunnings Warehouse (around $5):
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC71.jpg
New heater core with new plastic connector :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC74.jpg

http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC75.jpg

[VW VR6]

Be carefull when order new heater core. I was order 6 months ago from Germany and send me LHD - which is a little bit different than original - plastic for hose connectors is not long enough. Now I am waiting for normal RHD from GOLF LOON.
Mine original is "Valeo" from France 1H2 819 031 A and new one 1H1 819 031 A
I already order at same time all hoses from heater core to engine and polen filter :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC65.jpg

http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC66.jpg

http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC68.jpg

[VW VR6]

Bought months ago brand new "ONIX" (with remote control) car CD MP3 Player with SD card slot and USB connection from "ALDI" for $89, and all connection for cables at back for speakers and +, - ground etc. is 100% same like VW stereo original :
http://i276.photobucket.com/albums/kk36/bokiau/VW%20VR6/Heater%20Core/HC67.jpg

[VW VR6]

Now I will have week or two off becasue waiting for GOLF LOON to send me PM when hi find new heater core for me.
Welcome to any question or sugestion.

[VW VR6]

Finded brand new one from UK at e-bay.
Going tomorrow to complete job.

[Jmac]

Brings back memories Boris, good work, and im sure the masses will find your effort with the piccies informative, ill thank you from everyone for taking the effort mate
Cheers
Jmac:banana:

[Golf Loon]

Yup, nice work Boris on the pics.
Hope you get it back together alright.

[Mrk_Mickey]

Mate I'm very impressed! Nobody has put up a DIY yet so I'm glad you have. If I can get around about a week or so when my car doesn't need to be used I think I might have a go!

[Lorenz]

Nice write up mate, very easy to follow and informative. Im sure quite a few people will find it rather useful :)

[vwthunder]

Wow well done, good to see you taking the time, looks like a big job

Will feel good when it is back together knowing you have done it yourself and saved many $$$ doing it

:woot:

[Jmac]

Nice write up mate, very easy to follow and informative. Im sure quite a few people will find it rather useful :)

Absolutely good on that man. I would love to do write ups i get the camera ready many times but get into it get filthy and its all over and i think to myself ill do it next time, same happens again.
I have a VR motor here to do a how to cyl leak test and chains thats been sitting for a long time now, one of these days:rolleyes:
Jmac

[VW VR6]

That will be very good help Jmac.

[Mrk_Mickey]

Absolutely good on that man. I would love to do write ups i get the camera ready many times but get into it get filthy and its all over and i think to myself ill do it next time, same happens again.
I have a VR motor here to do a how to cyl leak test and chains thats been sitting for a long time now, one of these days:rolleyes:
Jmac

Mate I know how you feel haha. I've written two or three write-ups on some things before, but the amount of times I've kicked myself for not making the effort to wrap a towel around my hands to keep the camera clean...hahah.

[VW VR6]

Anyone in Brisbane - Gold Coast - Sunshine Coast who need help PM me and I will help you about heater core for FREE FREE FREE.
I just need transport because don't have licence................

[vwvinny]

Thanx champ! i got my new heater core today, when i get the time im gonna give it a go!
wish me luck guys...lol

[Tim]

Nice writeup.
What a horrible job to have to do!

[Ben J]

looks like this will be very helpfull if i end up getting a vr with a broken heatercore...

Wondering where one would buy a heatercore though? Found a US site which has them for $85US shipped, but if its LHD that makes a difference?

[Mrk_Mickey]

looks like this will be very helpfull if i end up getting a vr with a broken heatercore...

Wondering where one would buy a heatercore though? Found a US site which has them for $85US shipped, but if its LHD that makes a difference?

Gap sell them, I reckon ECS might, mjm perhaps, probably ebay UK, or maybe tooley's here...

[Ben J]

Gap sell them, I reckon ECS might, mjm perhaps, probably ebay UK, or maybe tooley's here...

Alright thanks.

feel quite stupid asking, but have been wondering for a while what gap is?

[AusScare]

Alright thanks.

feel quite stupid asking, but have been wondering for a while what gap is?

German Auto Parts (http://www.germanautoparts.com/)

[karmen]

my head is spinnin

[The_Hawk]

They are available in Australia, when I had mine done a few years back the part was only $80 - $100 (off the top of my head)... it's the labour that cost me :P

[jono0309]

Back to car and disconnect jack on right side heater core and remove with screwdiver :
http://www.vwwatercooled.com.au/forums/

http://www.vwwatercooled.com.au/forums/

hey man,

is the first pic just a clip that holds the wires into place or is that a connector? because I cannot find a connector to fit there and the heater box does not have a plug in port

and for picture two,

where is this located? The bottom of the heater box?

---------- Post added at 07:52 PM ---------- Previous post was at 06:47 PM ----------

Any help is greatly appreciated, I am stuck on this as I dont want to go any further to find out I need a plug to install.
I have photos of my heater box and I cant seem to see an adapter...Look here at the tutorial picture above and then look at this...same angle, same side, etc...but this one has a connector with wires going to it and my heater box doesnt seem to have this? :S

http://i208.photobucket.com/albums/bb202/Jono0309/379397_10150497847923092_502873091_10628057_473486 321_n.jpg

[Onslo]

Having a go at one tonight. My question is, it looks possible to leave the aircon connected and to separate the heater in the car. Is this possible? I can't seem to find what holds the heater box in place to the firewall. Must be some screws in a hidden place?

[Umai Naa!!]

Great write-up!

Going to have a practice run on this wreck I've got. I can't see it being much different, if at all, to a VR6.

[VR28LT]

^nah exactly the same

[Umai Naa!!]

Thought as much!

[Onslo]

Hey Umaii. please let me know how you go and if it looks like you can avoid removing the AC. I would like to try and separate the heater and AC in the car and not have to discharge the AC.

[Umai Naa!!]

Way ahead of you!

Although I've already dumped the gas out to salvage the compressor and condensor, it'd be a good thing to establish whether you can do it with the evaporator still hooked up. Perseverance will be the key here!