Heater Core, Removing And Installing: Installing

Install in the reverse order of removal while noting the following:

-- Replace the seals after removing.

-- With the heater core removed, check the heater shaft for debris.

-- If necessary, remove any dirt or coolant residue.

-- If equipped, check the foam seals -2- attached to the heater core -1- for damage and replace if necessary.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

If not bonded correctly, the foam seal may curl up during insertion.

Cold air may flow past heater core if the foam seal is damaged or not installed correctly.

-- Check the heater core connection -3- and the connection -2- for the coolant pipes for damage or debris.

Fig 1: Heater Core Connections, Coolant Pipe And O-Ring Seal

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Clean and smooth the sealing surface for the gasket.

-- Coat a new seal -4- with coolant (or lightly with silicone grease) and attach it to the coolant pipe -1-.

-- Carefully slide the heater core all the way into the heater and A/C unit until stop.

-- Slide the coolant pipes into the heater core until stop.

CAUTION:

There is a risk of heater core malfunctions due to faulty seals and leaks.

- Never pinch the seals.

- Never tilt the coolant pipes.

- Slide the coolant pipes on all the way.

-- Position a new clip -5- or screw-type clamp -2- on the coolant pipe/heater core connection.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tighten the bolt -3-.

-- Check the clamp and screw-type clamp for proper seating on the heater core and the coolant pipe connections. They must not be touching the air distribution housing or any other components.

-- Fill with coolant. Refer to Cooling System/Coolant (2.0L) or Cooling System/Coolant (1.5L) .

-- Check the DTC memory and erase any displayed entries using the Vehicle Diagnostic Tester in the Guided Fault Finding function.

-- Check the heating and A/C system function.