[V8] another heater core veteran

[Korn, Bob]

The parts, new core and mixer valve,  are sitting in my garage, have the
same issue from what it sounds like, I can smell coolant sometimes, no
major loss of fluid yet so I haven't done this yet.  I've read several
procedures on how to do this, how much of a PIA was it to get the heater
box loose from the firewall?  I've read where they suggest a 2x4 as a
lever arm to pry it loose.  What was your experience?
Thanks,

Bob

-----Original Message-----
From: v8-bounces at audifans.com [mailto:v8-bounces at audifans.com] 
Sent: Monday, January 10, 2005 10:22 AM
To: v8 at audifans.com
Subject: [V8] another heater core veteran



I have joined the club!
I thought I had a heater core leak and so finally decided to R&R it. I
am not
really sure if it was bad - maybe only the hose connection was loose but
a new
part was only $75 so I changed it out anyway. I also found that the
blower was
near death as well. The brushes were worn to the end of their travel.
The motor
bearings looked OK and I probably could have just replaced the brushes
but a new
Bosch blower was also $75 so I just got a new one. Overall not a hard
job, but
it took me most of a weekend. I had to pull the hood, and the
replacement core
was slightly defective in that the hose connections would not pass
through the
opening in the housing. I had to heat them up and turn them a bit. The
new core
is all brass btw. The old part - true to Audi form, was a piece of art.
The new
part is downright ugly but it will probably outlast the car.
The manual was suprisingly un-helpful for this job but it was pretty
obvious
what had to happen.
I used spray foam to seal the new core to the right air box half (the
manual
recomended silicone), and foam tape for the left.
I also used new foam tape for the air box to firewall seal.
The only problem I had was a left over "E" clip with a felt and metal
washer. I
remember taking it off - but could not find a place to put it back on.
Everything seems to work OK however.

After doing this job, I am a little puzzled about reading previous posts
where
people recomend breaking and cutting parts. I never came across a need
for that.

Dave


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