Ok ppl everyone is wondering how to remove the heater core of a 95 passat without draining and recharging a/c and other stuff. well i ahve the solution to this problem. Do this at your own risk.
1. Make sure the battery is disconnected
2. take off the steering wheel by taking off the airbag assembly holding by two allen screws and one large 15/16 nut. make sure all wires are disconnected as well since they have to come off too.
Afterwards, take off all trims, radio, vents, headlight assembly, a/c assembly, etc that will get in the way for removing the whole dashboard. most hold by phillip screws and some just pop out. put those on the side. it should look similar like this
also if you see the pic, remove the three screwed support beams (2) that holds the dashboard up on place which will allow to remove the large bar that goes across the car holding by 4 phillip screws two on each side on the corner of the car covered by a black cover(not shown on pic)
ok now you can remove dashboard holding by 4 screws covered by the little circle covers on each side of the dashboard
now the dashboard is removed after
I wrapped all my wires so it wont get into the way. this is nightmare from vw everywhere lol
Now go to the engine bay and there will be two screws holding the heater box in place. one covered inside the insulation (flap) and one covered by a black screw cover
also remove this screw by the expansion valve so the a/c box have movibilty
Remove this as well to open up the box once dashboard is out (srry missed this one)
This is very crucial for removal. There is about 5 or 6 of these clips holding the heaterbox and a/c box together. remove them all in order to remove the box. some of the places for the clips are placed in limited space so use a small hammer and eyeglasses screwdriver and pry them off without breakage.
http://c2.ac-images.myspacecdn...d.jpg This is an example of a tightly spaced clip area
These two zip-tied things have to be broken off so buy new ones
Now after you have remove all the clips and hoses and screws for the box, it should be able to move around but still tight. This is the fun part, YANK IT OFF. now this shouldn't use much force but enough to pry it off the assembly like this
Afterward it should come out like a pop and this is the results
now your heaterbox is out and have space to exchange cores
NOTE that some new heater cores will not include the special coupler for the small vacuum hose you will find (white) so use the old one and place it on the new one
This is an excellent oppurtunity to clean out your heater box since it was leaking coolant and leave gunk and whatnots. I washed it off with water and purple power and sprayed a little bit of freshener to get a nice smell for first use
Now after the core is in, install the box back into the car. First, place the top screw with the hose side out of the car n slide it in. and then kinda pry the second bottom one into the hole. This is very tricky when placing it back into the area. After that is in, screw back the two heater screws in the engine bay area. Do Not tight them as u need play in order to line up for the clips to place back in
correct (align for clips replacement)
after that tighten all the screws after the clips are replaced. Then replace everything in reverse order as you take out the parts.
10mm deep socket
small eyeglasses screwdriver
couple of hands
5-8 hours of your life
channellock pliers for clamp removal/installaton
a full stomach because this is a time consuming stomach pumping job
further questions or comments please ask
hope this helps