Purchased the Jetta 1yr ago for $2k with 130k(160k currently). Did the valve cover gasket, water pump, coolant flange gasket, heater core, Plus all the little MK4 issues like the headliner. Just gotta fix the vacuum leaks from the old brittle lines and the Jetta will be healthy enough for a ECU tune and GTI front end swap🍿
Don’t forget the battery top fuse box. More specifically the the harness from the alternator a larger gauge and copper lugs. Did you check your sunroof drains when you did the headliner? The rusted harness for the hvac resistor could also be water ingress from the cabin filter housing gasket. If you plan on modifying the car and driving it like a VW should be get a beefier dogbone mount or atleast stiffer inserts. The m10 center bolt into the trans case likes to snap. If you lower it get the H&R front sway bar to avoid hitting the axle/cv half shaft , adjustable end links don’t work. The Mk4 can be a real fun car to drive.
@@joshcb7how’s that car coming? Now that you’ve done all that (as long as you don’t sleep on the timing chain and guide service) do a couple more time out part replacements (like motor and trans mounts)!that car will last you for many more years. Cheers bro and thanks for the video… I have 3 Mk4s and 1 needs a heater core replacement. My anniversary GLI. It’s bypassed for now but I’m going to wait for better weather. Just doing research for now. 🤙🏽
@JoelCaseyJonesMusic I gotta get the suspension right, Fix the A/C, 185k on the timing chain. It's $1,000 away from perfect, But if I put $1,000 in it today it would still be $1,000 away from perfect if that makes sense. I'll probably get a skid plate, Lifting the engine has to have other effects on the center of gravity and stuff? Thanks for watching
I had to disconnect my AC to do this job, 2005 Mk4 BEW engine, so plan on getting set up to discharge your AC first. Might as well have a shop do it but you have to go there before ever beginning the project. A TDI (diesel) is way more compact and I had to remove all the intake hoses and took the EGR and antishudder off as well. (They need to be cleaned anyways. Seems like I had to pull wiring loose on the HVAC box, not off just loose and cut the plastic ties or pull out the tie brackets, then pull box and crash bar towards me sitting in passenger seat, and finally got to the heater core! After 4 working days of research and trying to avoid AC discharge, etc... All you have to disconnect is a AC bracket that connects hi-lo lines, and the 2 firewall bolts, (nuts with washers) one nut stayed on this mtg bracket deal, other one came off. I took the expansion brass deal off as well but not necessary. Absolute nightmare on Elm street!!! Yet happy now, it's not back up and running yet, but also bought a resistor while it's all apart anyways. Drain plug was easy for coolant. Have to jack car up on drive up ramps to get enough room under there and I also took off the front bumper and skid plate of course. Will go back together way faster as you know where everything goes as long as you don't wait too long and forget everything... Have fun and I'm not done yet, next weekend I should be all completed.
Thank you for this video. I didn't think about just pulling the AC box forward a little without disconnecting the AC lines. Been struggling to remove the left half of the box and those little brass tabs.
When the rusted ass wiper studs won't let the wipers loose and you crack the windshield on ur boss's car 🥴🥴 Thanks for the video though! It helped a lot
I used this video and the other video for my TDI BEW, other guy is named Josh as well and his video is better for a TDI, Humble Mechanic has a good video about the heater box flaps. My car has manual flaps so it's easier. Watch lots of youtube videos, not just this video, it will fill in all the gaps!
I am getting ready to do this same job on a early 2005 BEW mk4 GLS TDI Wagon. Any issues I need to be concerned about? Probably going with the mid range Behr heater core as car has 268,000 miles appx. Had the timing belt changed very recently mileage wise and probably water pump, but not heater core. So need to reflush system is my guess, and just replace the core and resistor. Good or bad, resistor might be able to wait on that if it tests out okay. AC works good at 268k as the TDI wagons were made in Wolfsburg GY, and seem to be very high quality builds. This has been a great vehicle... I have had it since 2009 and am 2nd owner. Bought it from a VW dealer in 2009. Not sure if it's original clutch or not, I have another BEW Jetta Wagon, (Manual also), with 198K on it. timing belt was done by dealer at 107K but clutch went out. So after watching this video, I can drive without a heater core, but not without a clutch!!! Ordering me up a heater core, and aluminum tape... Great video, there is another video for a Mk 4, so between the 2 video's should be covered. The AC discharge thing won't matter in the middle of winter in WA State... Yet trying to avoid that step. (I forgot to put the year in, both vehicles are 2005 BEW Jetta GLS Wagons, Manual Tranny, so thats why it's edited)
Hello, I must replace the a/c evaporator in my 2002 Volkswagen Jetta. The exact model is yours. Can I get the procedure/checklist that you used from you?
Just skip :37- :55. For anyone wondering about the AC system,(or if I pulled on the HVAC box too much) Nope, The AC system has been diagnosed as still good pressure, and functional but weak AC compressor. Will do AC compressor in the future. Appreciate all the likes on this 1, Hope it helps you guys save some money and DIY👍
It's the same size as the top nut. There's a plastic part (2 piece clips together) around the ac lines at the firewall, taking that off might help. Or are you asking how to find where it is?
so im new to these cars, im having my motor swapped, wile the motor is out is it eazy to swap heater core? or does the dash still have to be removed..?
There *is* a firewall panel, the whole of the firewall, almost, on a mk4 car, that would allow you to pull out the HVAC box into the engine bay. You would have to remove the dash to access all the bolt heads, though, so it's a moot point. :D
No, I did not disconnect the AC lines. On my car there was a plastic cover over the AC fittings against the firewall, I removed that plastic and that let's the AC lines move into the cabin a little bit. Pull on the driver's side of the HVAC box and it will move just enough to get the heater core out. According to online experts my car was supposed to have a split HVAC box because it's manual temp controls but that was not the situation.
@@joshcb7 00-01 are the MK4s that have the split box. I'm doing a heater core replacement right now(and head gasket/timing belt change) and of course I have an 02; one big box.
great job dude. I have to do it in my Seat Leon but I will send it to the garage. 200 bucks for the job. Do you think is expensive? By the way, I took picture of those blend doors before and after the repair you did so I will show it to the mechanic to save money buying new blend doors. Cheers.
@@SnackyPaper 👍. What I was saying is most people don't have the VR6 so sometimes I feel like it's pointless to make these videos. There's a lot more 1.8ts out there. I had a MK5 R32 but there's only so many people looking for R32 videos 🤷♂️I like everything MK5 and earlier 👍
Yup, I didn't remove the crash bar, Didn't disconnect the AC lines, And didn't remove the HVAC box. You could do it without draining the coolant if you clamp the hoses🤷♂️
Terrible video doesn't show much of anything...typical Utube wanna be mechanic. How did you get 59 likes?? How many dislikes?? I see utube took that away to save Utube Masters!
Seriously though I just finished my heater core today and it would’ve been faster if he had actually pointed out what needs to be taken off and how at some points
I about just sold my car watching this
@@dubstepremade8901 i bought a new car because the endless coolant leaks these things constantly go through.
Same, at this point, ours might be scrapped. :-)
I thought there was some trick to not having to remove the dash, easy my ass.
Taking all these parts off is the easy part. Remembering how to put it all back together is a pita.
Recent content, from someone taking care of their mk 4. Beautiful. One day I’ll need to do it on my 01 gti
Purchased the Jetta 1yr ago for $2k with 130k(160k currently). Did the valve cover gasket, water pump, coolant flange gasket, heater core, Plus all the little MK4 issues like the headliner. Just gotta fix the vacuum leaks from the old brittle lines and the Jetta will be healthy enough for a ECU tune and GTI front end swap🍿
Don’t forget the battery top fuse box. More specifically the the harness from the alternator a larger gauge and copper lugs. Did you check your sunroof drains when you did the headliner? The rusted harness for the hvac resistor could also be water ingress from the cabin filter housing gasket.
If you plan on modifying the car and driving it like a VW should be get a beefier dogbone mount or atleast stiffer inserts. The m10 center bolt into the trans case likes to snap. If you lower it get the H&R front sway bar to avoid hitting the axle/cv half shaft , adjustable end links don’t work. The Mk4 can be a real fun car to drive.
@@joshcb7how’s that car coming? Now that you’ve done all that (as long as you don’t sleep on the timing chain and guide service) do a couple more time out part replacements (like motor and trans mounts)!that car will last you for many more years.
Cheers bro and thanks for the video… I have 3 Mk4s and 1 needs a heater core replacement. My anniversary GLI. It’s bypassed for now but I’m going to wait for better weather. Just doing research for now. 🤙🏽
@JoelCaseyJonesMusic I gotta get the suspension right, Fix the A/C, 185k on the timing chain. It's $1,000 away from perfect, But if I put $1,000 in it today it would still be $1,000 away from perfect if that makes sense. I'll probably get a skid plate, Lifting the engine has to have other effects on the center of gravity and stuff? Thanks for watching
I had to disconnect my AC to do this job, 2005 Mk4 BEW engine, so plan on getting set up to discharge your AC first. Might as well have a shop do it but you have to go there before ever beginning the project. A TDI (diesel) is way more compact and I had to remove all the intake hoses and took the EGR and antishudder off as well. (They need to be cleaned anyways. Seems like I had to pull wiring loose on the HVAC box, not off just loose and cut the plastic ties or pull out the tie brackets, then pull box and crash bar towards me sitting in passenger seat, and finally got to the heater core! After 4 working days of research and trying to avoid AC discharge, etc... All you have to disconnect is a AC bracket that connects hi-lo lines, and the 2 firewall bolts, (nuts with washers) one nut stayed on this mtg bracket deal, other one came off. I took the expansion brass deal off as well but not necessary. Absolute nightmare on Elm street!!! Yet happy now, it's not back up and running yet, but also bought a resistor while it's all apart anyways. Drain plug was easy for coolant. Have to jack car up on drive up ramps to get enough room under there and I also took off the front bumper and skid plate of course. Will go back together way faster as you know where everything goes as long as you don't wait too long and forget everything... Have fun and I'm not done yet, next weekend I should be all completed.
Think I'll just sale my car when the time comes for mine needing replaced. I wouldn't mind doing it but no way I'd have time doing it.
I’m in the process of it and it’s not all that bad
I take back everything I said, this one hose clamp is such a pain but over all easy
@@jacobandrews3470 there's always that one thing that makes it such a bugger!
About to give my 2003 Passat away
Thank you for this video. I didn't think about just pulling the AC box forward a little without disconnecting the AC lines. Been struggling to remove the left half of the box and those little brass tabs.
Thank God that was the easy way
Have you done the water pump yet? Or the coolant pipe? Outta all the MK4 coolant leaks the heater cores not that bad.
@@joshcb7thank god i already had all yhat done LOL
When the rusted ass wiper studs won't let the wipers loose and you crack the windshield on ur boss's car 🥴🥴
Thanks for the video though! It helped a lot
But there are two or three blend doors? Is it possible to tape them also on the back side without dismounting everything?
Good video. Its neccesary to recharge refrigerant gas?
I am standing in from of my car, wondering if I should do this or just freeze till spring. My gut says to freeze.
Now I forget to turn the heat on because I got used to it not working(Riding around with the heated seats on 5 but cold fingers).
I'd get a heated motorcycle suit instead.
I used this video and the other video for my TDI BEW, other guy is named Josh as well and his video is better for a TDI, Humble Mechanic has a good video about the heater box flaps. My car has manual flaps so it's easier. Watch lots of youtube videos, not just this video, it will fill in all the gaps!
I am getting ready to do this same job on a early 2005 BEW mk4 GLS TDI Wagon. Any issues I need to be concerned about? Probably going with the mid range Behr heater core as car has 268,000 miles appx. Had the timing belt changed very recently mileage wise and probably water pump, but not heater core. So need to reflush system is my guess, and just replace the core and resistor. Good or bad, resistor might be able to wait on that if it tests out okay.
AC works good at 268k as the TDI wagons were made in Wolfsburg GY, and seem to be very high quality builds. This has been a great vehicle... I have had it since 2009 and am 2nd owner. Bought it from a VW dealer in 2009.
Not sure if it's original clutch or not, I have another BEW Jetta Wagon, (Manual also), with 198K on it. timing belt was done by dealer at 107K but clutch went out. So after watching this video, I can drive without a heater core, but not without a clutch!!! Ordering me up a heater core, and aluminum tape... Great video, there is another video for a Mk 4, so between the 2 video's should be covered. The AC discharge thing won't matter in the middle of winter in WA State... Yet trying to avoid that step. (I forgot to put the year in, both vehicles are 2005 BEW Jetta GLS Wagons, Manual Tranny, so thats why it's edited)
Hello, I must replace the a/c evaporator in my 2002 Volkswagen Jetta. The exact model is yours. Can I get the procedure/checklist that you used from you?
The VW service manual might help but I don't own it.
Just skip :37- :55.
For anyone wondering about the AC system,(or if I pulled on the HVAC box too much) Nope, The AC system has been diagnosed as still good pressure, and functional but weak AC compressor. Will do AC compressor in the future.
Appreciate all the likes on this 1, Hope it helps you guys save some money and DIY👍
Nivel vídeo, its neccesary yo disconnect the ac lines from evaporator?. If i want to replace then too, how i can ti do It? Thanks in advance
8:14 Hey ! How were you able to move the screw underneath the ac line ??
It's the same size as the top nut. There's a plastic part (2 piece clips together) around the ac lines at the firewall, taking that off might help. Or are you asking how to find where it is?
so im new to these cars, im having my motor swapped, wile the motor is out is it eazy to swap heater core? or does the dash still have to be removed..?
Still has to come out
There *is* a firewall panel, the whole of the firewall, almost, on a mk4 car, that would allow you to pull out the HVAC box into the engine bay. You would have to remove the dash to access all the bolt heads, though, so it's a moot point. :D
Amazing job! Thanks!
how long does it take to replace the heater core? One of the plastic nozzels broke on mine. How much you do you think a mechanic might charge?
Vw said “2500”
@@brysonholton790 damn
Dude, I cannot get the AC Lines to budge 03 GLS Manual AWP Engine
The passenger side of the HVAC box only comes in a little, Pull more on the driver's side of the HVAC box
@@joshcb7 finally after removing two hidden screws I got it, new ones in and I'm putting the steering wheel on now
@@joshcb7 hmm, it'll start for a second, the dashboard won't illuminate
@@joshcb7 any ideas?
@@oZixn Plug on the back of the gauge cluster not plugged in?Check fuses
That is ridiculous 🤣, to have to take the whole day car apart then to find out it's not the heat core. Is their any way to know for sure?
If you smell or see coolant inside your car
Thanks!!! just about to tackle it...
This appears to be my problem. Oh goody. No heat. But no coolant leak yet.
Did you actually have to disconnect those AC lines to pull the heater core out? Sounded like you might have but wasn't sure. Thanks!
No, I did not disconnect the AC lines. On my car there was a plastic cover over the AC fittings against the firewall, I removed that plastic and that let's the AC lines move into the cabin a little bit. Pull on the driver's side of the HVAC box and it will move just enough to get the heater core out. According to online experts my car was supposed to have a split HVAC box because it's manual temp controls but that was not the situation.
@@joshcb7 thanks so much bro I'm literally in the same situation
@@joshcb7 00-01 are the MK4s that have the split box. I'm doing a heater core replacement right now(and head gasket/timing belt change) and of course I have an 02; one big box.
QUE AÑO ES ?
yeah im gonna go with the 20 dollar bypass kit instead lol
The easy way? Can I buy weed from you bro that must be good shit 😂
great job dude. I have to do it in my Seat Leon but I will send it to the garage. 200 bucks for the job. Do you think is expensive? By the way, I took picture of those blend doors before and after the repair you did so I will show it to the mechanic to save money buying new blend doors. Cheers.
200$ is a fucking steal for this. Make sure the guy knows what he’s doing that’s mega cheap
“You probably don’t have the vr6” wishes he got a tdi
Which one is the top of the line flagship model???jk
@@joshcb7technically yes, but a vr6 costs more money to make the same power as say a basic modded tdi or 1.8t
@@SnackyPaper 👍. What I was saying is most people don't have the VR6 so sometimes I feel like it's pointless to make these videos. There's a lot more 1.8ts out there. I had a MK5 R32 but there's only so many people looking for R32 videos 🤷♂️I like everything MK5 and earlier 👍
Wanna do mine ?
Sure, If you live in my area I would.
The EASY way? 😂
That's the easy way.. 😂😂😂
Yup, I didn't remove the crash bar, Didn't disconnect the AC lines, And didn't remove the HVAC box. You could do it without draining the coolant if you clamp the hoses🤷♂️
@@joshcb7 hell yeah! Super!
p̶r̶o̶m̶o̶s̶m̶ 😁
Terrible video doesn't show much of anything...typical Utube wanna be mechanic. How did you get 59 likes?? How many dislikes?? I see utube took that away to save Utube Masters!
Seriously though I just finished my heater core today and it would’ve been faster if he had actually pointed out what needs to be taken off and how at some points