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92 GTI heater core replacement



 
 
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  #1  
Old December 27th 07, 04:28 AM posted to rec.autos.makers.vw.watercooled
Tobin Fricke
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Posts: 7
Default 92 GTI heater core replacement

I am working on replacing the heater core of my '92 GTI (automatic, 8v).
Some questions:

- Where are the top instrument panel nuts? They're labeled "A" on the
diagram 70-A039 in the Bentley book (page 13-8), which explains that they
are located in the air plenum in the engine compartment. I've removed the
"drip tray" in the engine compartment but don't see any promising bolts,
unless perhaps something is hiding behind the windshield-wiper motor.

- How can I remove the drive selector/gear shift? It would be convenient
to remove the handle from the gear selector so that I could take the
center console out totally to make a little more room to maneuver. This
is an automatic, so as far as I can tell the handle doesn't just screw
off.

- Am I going to be able to do this without interfering with the air
conditioning?

thanks,
Tobin
Ads
  #2  
Old December 27th 07, 05:53 AM posted to rec.autos.makers.vw.watercooled
dave AKA vwdoc1
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Posts: 951
Default 92 GTI heater core replacement

http://en.allexperts.com/q/Volkswage...eater-core.htm


"Tobin Fricke" > wrote in message
news:Pine.GSO.4.64.0712261920350.14917@apocalypse. OCF.Berkeley.EDU...
>I am working on replacing the heater core of my '92 GTI (automatic, 8v).
>Some questions:
>
> - Where are the top instrument panel nuts? They're labeled "A" on the
> diagram 70-A039 in the Bentley book (page 13-8), which explains that they
> are located in the air plenum in the engine compartment. I've removed the
> "drip tray" in the engine compartment but don't see any promising bolts,
> unless perhaps something is hiding behind the windshield-wiper motor.
>
> - How can I remove the drive selector/gear shift? It would be convenient
> to remove the handle from the gear selector so that I could take the
> center console out totally to make a little more room to maneuver. This
> is an automatic, so as far as I can tell the handle doesn't just screw
> off.
>
> - Am I going to be able to do this without interfering with the air
> conditioning?
>
> thanks,
> Tobin



  #3  
Old December 28th 07, 02:11 AM posted to rec.autos.makers.vw.watercooled
PatAL7L
external usenet poster
 
Posts: 7
Default 92 GTI heater core replacement

On Dec 26, 6:28*pm, Tobin Fricke > wrote:
> I am working on replacing the heater core of my '92 GTI (automatic, 8v).
> Some questions:
>
> - Where are the top instrument panel nuts? *They're labeled "A" on the
> diagram 70-A039 in the Bentley book (page 13-8), which explains that they
> are located in the air plenum in the engine compartment. *I've removed the
> "drip tray" in the engine compartment but don't see any promising bolts,
> unless perhaps something is hiding behind the windshield-wiper motor.


They are behind the windshield wiper moter - or at least one of them
is. Once you get the plastic drip tray guard out, you kind of feel
around up nd behind for a pair of 10mm nuts. They're almost
impossible to see, but they're there.

>
> - How can I remove the drive selector/gear shift? *It would be convenient
> to remove the handle from the gear selector so that I could take the
> center console out totally to make a little more room to maneuver. *This
> is an automatic, so as far as I can tell the handle doesn't just screw
> off.


It's attached with an allen screw in the bottom of the T handle, and
there are two side screws and one screw under the pop-out cover for
the drive selector. Once you get that screw out, be very careful when
pulling the console. It helps to get the seats all the way back, and
take off both accessory trays under the dash. If you aren't careful,
you'll break off the little tab the inside screw goes through - it
tends to hook on the gear housing as it comes out.


>
> - Am I going to be able to do this without interfering with the air
> conditioning?


Nope. You need to take the car to a garage that services air
conditioning and have them empty your system. They'll deduct the
volume they take out from the recharge you put back. If they're
willing to do it, have them loosen the two union nuts that attach the
air conditioning unit to the compressor - they're up against the
firewall on the passenger's side. They're made out of aluminum, and
are really easy to bugger up. You want the little square block out of
there without buggered threads, or you're into the junkyard for a
replacement.

If you can, go to a junkyard and take another 85-92 with air
conditioning apart for practice. There are a lot of little clips and
stuff you'll have trouble finding when you put it all back together,
and a full set of spares is really nice to have. The little flapper
door that shuts off airflow to the floor in the defrost mode will
probably have one end broken off, which is why you haven't been able
to get it to shut off for the last 80,000 miles.

If you can afford it, buy a new heater fan and install it when you put
everything back together. There is no other fix for the early morning
wailing when you first start up cold.

I've done this repair twice on 85's (identical underneath). It's
difficult, time-consuming, and involves a lot of fiddling to get
everything back in place. I'd advise taking a lot of pictures with a
digital camera as you take it apart so you have them to refer to when
you're trying to figure out how the Hell Wolfsburg managed to route
all those hoses.

Pat Moore
85 Jetta in Juneau, AK
>
> thanks,
> Tobin


  #4  
Old December 28th 07, 02:49 AM posted to rec.autos.makers.vw.watercooled
[email protected]
external usenet poster
 
Posts: 25
Default 92 GTI heater core replacement

PatAL7L > wrote:

>> - Am I going to be able to do this without interfering with the air
>> conditioning?

>
>Nope. You need to take the car to a garage that services air
>conditioning and have them empty your system.


Wrong. The heater core sits in one box. The A/C evaporator
sits in another box. The two boxes are held together with 8 or 10
metal clips. Undo all the clips and the heater core box can be taken
out, leaving the A/C evaporator box in place. A couple of the clips
are on the back side (towards the firewall) and are a bitch to get out
and put back on.

Todd
Seattle,WA
'86 GTI, Red of course. (exciting racey car) 268,000 miles
'87 Golf, Polar Silver. (boring work car) 639,000 miles <- Yeah,
baby!
  #5  
Old December 28th 07, 01:51 PM posted to rec.autos.makers.vw.watercooled
Lost In Space/Woodchuck[_2_]
external usenet poster
 
Posts: 86
Default 92 GTI heater core replacement

VW time was just over 2 hours to replace the core when the recall was done.
Most of us VW techs were doing the core in 1 hour or less. That said here is
my don't list

1- don't need to remove the dash.
2- don't need to remove the AC box
3- don't need to discharge the AC

"Tobin Fricke" > wrote in message
news:Pine.GSO.4.64.0712261920350.14917@apocalypse. OCF.Berkeley.EDU...
>I am working on replacing the heater core of my '92 GTI (automatic, 8v).
>Some questions:
>
> - Where are the top instrument panel nuts? They're labeled "A" on the
> diagram 70-A039 in the Bentley book (page 13-8), which explains that they
> are located in the air plenum in the engine compartment. I've removed the
> "drip tray" in the engine compartment but don't see any promising bolts,
> unless perhaps something is hiding behind the windshield-wiper motor.
>
> - How can I remove the drive selector/gear shift? It would be convenient
> to remove the handle from the gear selector so that I could take the
> center console out totally to make a little more room to maneuver. This
> is an automatic, so as far as I can tell the handle doesn't just screw
> off.
>
> - Am I going to be able to do this without interfering with the air
> conditioning?
>
> thanks,
> Tobin



 




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