how to remove the airbag connector-heater core job!

It basically just unplugs - hard to explain how except it has two small pins - you should pull it straight out - sort of like a snap. Just did my heater core on my GTI VR6 and didn't have any problems with the heater core - just electrical - just a tip - if you unplug anything label BOTH the plugs so you know they go together! Don't know about the internal structure of the Passat but there are some hidden nuts on the firewall of the engine compartment that need to be removed if you want the heater core to come out. They are hidden beneath the silver foil aspestos covering and look like ushaped flaps - the 10mm nuts are under the flaps. To take the dash out the nuts are under the plastic cowl covers - by the windshield wipers - also

Don't know if you evac'd the AC - you don't really have to - just separate the heater box from the AC box - its held together by 5 or 6 clips that are not difficult to remove and put back on - just feel for the raised edge with your finger then pop them off with a flat screwdriver - the ones on the back are more difficult but can be done the same way. Once the clips are out - remove the front vent extension - white plastic piece then start to jockey the heater core out - I removed the crossbeam across the dash - I wouldn't do it again - its a pain and you have to drill out the steering wheel bolts that holt the column to the crossbeam - I'm pretty sure you can remove the core without doing this as long as the white translucent vent extension is removed first and you should have encough clearance - then find the right angle to remove it once the box is separated from the AC section. It may take awhile - but removing the crossbeam is a pain and you may mess up some electrical connections in the process.

Once everything is out - hopefully you won't have a problem - look at the heater box internals - notice the foam covering on the blend doors - replace it if its starting to decompose - you don't want to remove this again! Cover with foil backed tape or foam backed tape from a hardware store - you can get it in the plumbing/duct section. If the foam is shot you won't get proper heating cooling.

Put everything back together and check the operation before you put the dash back on. Assume you will flush the system and bleed out any air.

If you run into problems just email me and I normally don't give my number but - I'm still dealing with some electrical problems so my dash is still out of the car as we speak and I'm working to get it back together. Made the mistake of tidying my fusebox area - and removed a key piece on top of the fusebox - contains two single fuses a 15 and 30 amp in single fuse connectors - put it in a parts box and threw it out - having difficulties with the wiring. Once you get your dash out - if you could check yours - see if you have two single fuse connectors on the fusebox top - by the accessory relays - let me know PLEASE - trying to trace some of the wiring and it would be very helpful if you have the same setup.

Scott Timinski snipped-for-privacy@charter.net

Thanks for the quick reply Scott,

Now I can go back to work and try the airbag. I have my digital camera so I will take some pictures and look for the items you mentioned.

btw, did you remove the shear bolts that hold the steering column as the manual states or were you able to remove the instrument panel without doing this?

I may try to remove the instrument panel without doing the shear bolts. I will post the results of this job when I am finished.

Mark

Stephen Tim> It basically just unplugs - hard to explain how except it has two small

oops. Please disregard my quesion about the shear bolts. I saw that you referred to them in your post. My baby was crying while I replied so my attention was split.

Mark

Stephen Tim> It basically just unplugs - hard to explain how except it has two small

Here are some pictures of a '93 passat heater core job.

Lucky for me the a/c was not functioning due to leaks so I did not have to capture any refrigerant.

later, dave (One out of many daves)

Would appreciate the info, hopefully have the same wiring setup. Tried salvage yards, etc. and no luck. Good luck with your project - its really not that bad once the dash is out and you have some patience with the clips surrounding the airbox. You'll save about 600 and up by doing it yourself. Thought it would be a problem with the clip removal - but if you concentrate and have a good sense of touch - they pop off and go back on in a few minutes.

If you do have to remove the cross beam and disconnect the steering column from the crossbeam - its a MAJOR pain - hopefully you won't have to. The shear bolts that are attached to the beam require a very hard drillbit to get them drilled out - had to run out and get a Cobalt bit - and the bit actually wore out - had to buy two. The second thing about the crossbeam is that is contains a central ground strap and ground plug for about 6 grounds - be careful and remove it before dropping the crossbeam if you are doing it.

Just completed putting my fusebox together tonight and everything works except for the cig lighter, radio and trunk release. Hopefully you'll be able to come up with something that could help me out.

Stephen,

email me at

snipped-for-privacy@yahoo.com

if you would like me to mail some pictures of my car. This is a temporary email address that I will disable if I get spam from posting this.

The dash is out now. I cannot believe how messy the wiring of this car is! I wonder if all cars are made this way. absolutely terrible! There are so many, many connectors on each harness. I think they should have created another junction box by the fusebox to make a lot of these connections. I hope I can get it back together without the trouble you have experienced.

Mark

Stephen Tim> Would appreciate the info, hopefully have the same wiring setup. Tried

Thanks dave!

I had come across at least one of your pictures before; not sure if it was on this forum or perhaps it was on Bentley or vwvortex.

Sorry to hear your AC is not working. it is one of my favorite features. Fortunately for me the AC on my car has been flawless since I bought it at 2years old and I assume it was ok before that.

so I noticed that in your picture, the Heating and cooling unit (HVAC unit) is partially turned or pulled back from the firewall. How did you do that?

in the Bentley at this step immediately after removing the dash it says "Partially remove heating and ventilation unit". The very next step is;

"- Press retainer clips and remove heater core"

Unbelievable!

No mention of which screws or nuts or clips to remove or anything. Normally I say that I love the Bentley manual but on this procedure it is [insert bad word here].

Can you be of any help? Do I need to remove the nuts that are on the engine-side firewall? how many? Did you use the Bentley manual to do your job? If so, do you remember what you did that was not written in the manual?

I am getting desperate now since it is Sunday night. I may have to put this whole thing back together without the heater so I can drive it .... to... the... dealer!

Sincerely,

Mark

dave AKA vwdoc1 wrote: