Heater Core Removing and Installing

Heater Core, Removing And Installing

Removing:

Special tools, testers and auxiliary items required







- Drip tray for VAS6100 VAS 6208







- Hose clamps, up to 40 mm. 3093
- Compressed air gun, commercially available

CAUTION:
- Switch off all electrical consumers.
- Switch ignition off and remove ignition key.

- Remove facing wall in plenum chamber
- Place Drip tray for VAS6100 VAS 6208 under the engine.

CAUTION:
- Scalding danger.
- The cooling system is pressurized when the engine is warm. Wear gloves and other protection and carefully release system pressure if necessary before performing repairs.







- Clamp off coolant hoses - 1 - using Hose clamps, up to 40 mm. 3093 and disconnect coolant hoses to heater core.







- Connect a section of hose - A - onto upper connection of heater core.
- Hold suitable container - B - under the lower connection - C -.
- Using a compressed air gun, carefully blow coolant from heater core into container - B -.







- Remove bolt (6 mm socket head) - 1 - from connection flange between heater core connections.

NOTE: This allows the coolant pipes to move for removing the heater core.

- Remove driver side footwell trim
- Remove left footwell air vent







- Remove screws - 1 - and remove heater core trim.
- Cover floor carpet in area below heater core with leak-proof foil and absorbent paper.







- Open hose clamps - A - and disconnect coolant pipes from heater core.
- Remove heater core from heating and ventilation unit.

Installing:
Install in reverse order of removal, noting the following.







- Check seals - A - and - B - installed on heater core, only install a heater core with undamaged seals.

NOTE:
- An incorrectly glued seal can roll up into heating and ventilation unit when sliding in the heater core.
- If seal is damaged or installed incorrectly, cold air can flow past the heater core.







- With the heater core removed, check heating and ventilation unit for soiling (via heater core opening - A - ).
- If necessary remove dirt or coolant from heating and ventilation unit, for example after removing leaky heater core.
- Push heater core into the heating and ventilation unit.







- Coat sealing rings - 1 - with coolant before installing.
- Insert sealing rings - 1 - into connection on heater core.

NOTE:
- Ensure sealing rings are installed on the proper side, as shown in the illustration.
- If hose clamps are deformed, replace them.

- Connect coolant pipes to heater core.







- Hose clamps - A - must be able to be twisted slightly when installing onto the coolant pipes.
- Hose clamps - A - must be installed as shown in the illustration.
- Tighten hose clamps - A - to 2.0 Nm.
- Check seating of both clamps - A - after tightening screws, clamps must enclose the flange on heater core and coolant pipe completely and must not touch other components.







- Thread bolt - A - into connection flange - B - and while doing this ensure bolt is actually threaded into the mounting point intended for it.







- Check position of grommet - C - in bulkhead for proper seating.
- Seal flange for coolant pipes to heater core - A - and for expansion valve (to evaporator, only in vehicles with A/C system) - B - at grommet pass-through - C - with silicon adhesive sealant if necessary (to prevent water from penetrating).

NOTE:
- Sealing rings must always be replaced.
- If hose clamps are deformed, replace them.
- After replacing heater core, coolant must be replaced completely.
- Check coolant circuit for leaks, pay particular attention between coolant hoses and heater core.