With the bad weather we've been having recently, I noticed that my Golf has two heat settings; cold, and bloody freezing!
Now in the early nineties VW recalled all mk2 Golfs due to an exploding heater matrix problem, due to a design flaw they couldn't handle the pressure the cooling system runs at. However, rather than replace the matrices they fitted a bypass valve. These valves are now showing their age and tend to seize up, blocking the flow of hot coolant to the heater. Problem is you can't buy them any more, so if the bypass valve goes a bollock you need to replace it with the standard hose, and unless you fancy risking scalded legs, replace the heater matrix with one from the mk3 Golf.
So, having traced the problem to my bypass valve, I went to GSF last week and bought a new matrix and the hoses. By the way you can't buy mk2 matrices any more, so no worries about getting the wrong part!
GSF do two, a cheap arsed one for £21+vat, or the OEM spec one for £37.80+vat. I went with their reccommendation for the OEM one as apparently its more heat-efficient than the aftermarket jobbie.
So on with the job:
While the engine's cooling down, unscrew the gear knob and pull off the gaiter:
Unscrew and remove the driver and passenger side undertrays (lots more screws than shown in these pics, but you'll find them):
Undo the screw by the gearstick, and slide centre colsole back to remove, and remove the connection for the cigarette lighter:
Undo the screws and remove the side panel:
Unscrew the centre heater vents at the top as shown, and lift up the tabs at the bottom to remove:
Unscrew the dash mounting bolts at the side and underneath. This allows the dash panel to be pulled forward at the bottom to improve access for the air distributor box.
Unscrew the two nuts arrowed and pull out the air distributor box. It needs a bloody good tug and some serious wiggling to get it free:
At last, the heater!
Unscrew the three bottom box mounting screws. Two on the right:
One on the left:
Pulling it down and forwards to remove:
Now we have three cables exposed, held in by clips which need prying off with a small pair of pliers.
Blue does hot/cold, black ones do face/screen/feet:
Fuck up number 1. It wasn't until I tried to get the heater box out that I realised there were three cables, not two.
Next is the plastic duct from the blower. Take off the insulation cover, held in with four screws to access the duct. This duct joins to the heater box with a square housing, with 6 clips (fuck up number 2: I was told there were 5 clips holding it on. I discovered the 6th when it broke off pulling the heater box out!
), 2 each side, 1 on top and 1 on the bottom:
Look at the vent coming out the top of the heater box to feed the windscreen. Its held in place by two screws (one either side, though I couldn't get the camera in to get the other one) which, if undone will allow the duct to flex and ease removal of the heater box (this is best viewed through the dash air vent hole):