Heater core replacement. with A/C

[82MK1Rabbit]

1982 Rabbit MK-1

I hope I was right when I took the entire dash cluster out of the car to get to the heater core box. If I'm not right, I'd rather not know that I didn't have to. There were two bolts that held the box in tight into the firewall area and the held the top of the box in. The box won't come out any further, as there are two hard wired tubes going into the top passenger side of the box.

Anyway, I'm guessing that these two tubes run into the evaporator, or the condenser, which sits right in front of what appears to be the heater core. One of the tubes is a little smaller than the other one, and it runs to a cylindrical canister in the front passenger side behind the front grill. The larger tube runs to the a/c compressor.

Is it safe to disconnect these lines? or should I get someone that is A/C knowledgeable to help me disconnect the lines, and to help me change the heater core out?

So far, this has been a HUGE pain trying to get to this heater core



Thanks in advance

[amesghali]

I don't think you need to disconnect the A/C lines to replace the Heater core. If you disconnected them, you release the Freon charge and would have to recharge it.

Getting to the heater core is crazy. You have disassemble the whole dash and cluster. But here is a trick if you're willing to do some minor damage to the core enclosure.

The heater core inlet and outlet lines come in on the driver side of the enclosure.

Using a Dremel tool or even a utility knife (maybe heat the blade - get creative), cut out the side of the enclosure.
You will expose the heater core connection lines. remove the lines and slide out the heater core.
Slide in the new core. Connect the lines.
Replace the plastic section that you cut out. seal it using the aluminum tape that is used for sealing duct work.
Get a can of black paint and touch up the repair.

This would save you all the headache of removing the dash.

Good luck!

[briano1234]

I don't think you need to disconnect the A/C lines to replace the Heater core. If you disconnected them, you release the Freon charge and would have to recharge it.

Getting to the heater core is crazy. You have disassemble the whole dash and cluster. But here is a trick if you're willing to do some minor damage to the core enclosure.


The heater core inlet and outlet lines come in on the driver side of the enclosure.

Using a Dremel tool or even a utility knife (maybe heat the blade - get creative), cut out the side of the enclosure.
You will expose the heater core connection lines. remove the lines and slide out the heater core.
Slide in the new core. Connect the lines.
Replace the plastic section that you cut out. seal it using the aluminum tape that is used for sealing duct work.
Get a can of black paint and touch up the repair.

This would save you all the headache of removing the dash.

Good luck!

Winner winner chicken dinner............................................ ..................
step by step 1:
http://www.driversfound.com/scirocco...dy/heatercore/
step by step 2
http://forums.vwvortex.com/showthread.php?1149945

Now I did this to my green cabby, and it was a real beatch getting the core back in place, you have to rock it.
To cover the core hole, I used a piece of black plastic about a 1/8 inch larger than the hole that I cut and filed for the correct profile. I then fitted it to the heater box a and drilled 3 small pilot holes 2 in front and one in the back I made damn sure the holes cleared the new core. I then used sand paper to get the exact profile. I used black RTV on the sides, then using car trim screws, the type with the concave washers, I screwed it on the cover. I then hit the plastic with 2000 grit and polished to match the case. It turned out really really well, and looks factory.

Didn't see the thread soon enough to get a picture of the coverlet, but it was up to the hose cover and notched there.