[V8] Heater Box Removal....AAGH!!!

[Klein, Nathan P]

It looks like I've finally got a weekend to do this heater box thing.  

Any last-minute BTDTs? 

-----Original Message-----
From: v8-bounces at audifans.com [mailto:v8-bounces at audifans.com] On Behalf
Of dsaad at icehouse.net
Sent: Monday, September 19, 2005 10:40 AM
To: V8 at audifans.com
Subject: Re: [V8] Heater Box Removal....AAGH!!!

... And there is a multi port vacuum connector on the passenger side.
Quick recap from memory (so I might miss something)

-> from inside the car, remove both foot well and defroster ducts. (both

-> sides) aforementioned vacuum connector

under the hood:

-> I choose to remove the hood. It is easy and makes access so much 
-> easier, but
you need three people.

-> remove rain diverter
-> remove wipers and motor assembly - and remove the plastic nut from 
-> the body
that the wiper assy bolts too. I broke mine when pulling out the heater
box.
-> remove the heater box hold down band
-> slide back the accordian boot
-> disconnect all wires and hoses to heater box get the A/C line out of 
-> the way - I removed the clamp at the driver fender to
give more wiggle room
-> I removed the boot/clamp thingy that the engine wireing harness and 
-> heater
hoses go through. It gives you a little more wiggle room. You also want
to have a good look at the heater hoses. They are really expensive, but
if they are old you may as well get this over and done with now. Ditto
for the blower motor. You can see the brushes so either figure out how
to replace them or get a new blower.

-> with every thing disconnected and out of the way, you are ready to 
-> pry up the
box. It is basically glued in so use slow even pressure and don't break
anything. I found that as I got it to budge up, I would stuff a small
block of wood under the gap to hold it up. That helped.

-> remove the heater flap motor and e-clip remove any screws for the 
-> case or flaps remove the case clips

On re-assembly - pay close atttention to the screws and e-clips holding
the box together. It wouldn't hurt to mark the box.

I had to cut the box a little to get the new (made in china) heater core
to fit.

The core is set in silicone. I used that spray foam stuff instead. Don't
know if that was genius or stupid yet. Time will tell.

Replace the weather seal either with the real OEM part or I just used
weather strip foam from the parts store. You will have a bad water leak
if you don't do this right.


I have never seen the infamous "steak knife method", but there is no
need to break or cut anything in this process. It is a PITA, but
definately a DIY job that will save you some money.

Dave


Quoting Dave Head <v8q at bellsouth.net>:

> Remove both cardboard under-dash covers (both footwells). You will 
> need to disconnect the footwell light on the driver's side. On the 
> outside of each side of the trans tunnel you will see 2 1/2" (or so) 
> plastic piping in a 'J' type configuration. Both of these need to be 
> removed. There are screws on each that attach them to the heater box 
> assembly body. Once the screws are removed you can 'manuever' them
out.
> Down low in the center of the tunnel right at the carpet there is a 
> rubber connector that is essentially a long oval. There are rubber 
> tabs on each side. Pull outward and back on them to disconnect the 
> rubber connector. Not a whole lot of clearance. Fun part is getting it

> back on when yer done...
>
> Klein, Nathan P wrote:
>
> >I didn't disconnect anything in the cabin.  I just followed what the 
> >big 4-volume manual instructed for heater box removal (section 87.70,

> >I
> >believe) - basically, simply remove the obstructions and remove the 
> >heater box.  They make it seem so easy!
> >
> >How would I get to the plastic connector pipes?
> >
> >-----Original Message-----
> >From: Dave Head [mailto:v8q at bellsouth.net]
> >Sent: Monday, September 19, 2005 8:25 AM
> >To: Klein, Nathan P
> >Subject: Re: [V8] Heater Box Removal....AAGH!!!
> >
> >Did you disconnect the dash piping connections in the car? There a 
> >rubber connection and two hard plastic connector pipes that have to 
> >be removed...
> >
> >Klein, Nathan P wrote:
> >
> >
> >
> >>Anyway, I've removed all of the obstructions to the box (hoses, 
> >>windshield wiper assembly, etc.) and can only lift it up a few
inches.
> >>
> >>Either I'm missing a step or I need Herculean strength to get the 
> >>box out.  I don't think it's the latter.
> >>What to do?  Any ideas?  I've got to get her going again...
> >>
> >>Thanks in advance!
> >>Nathan
> >>
> >>_______________________________________________
> >>Audifans V8 mailing list
> >>Send posts to: mailto:V8 at audifans.com Manage your list connection:
> >>http://www.audifans.com/mailman/listinfo/v8
> >>Have an Audi V8 question?  Check the Audifans Knowledgebase!
> >>http://www.audifans.com/twiki/bin/view/Audi/V8
> >>Have a V8 answer? ... Please help others by adding to the KB ... all
> >>
> >>
> >contributions welcome!
> >
> >
> >>
> >>
> >>
> >>
> >
> >
> >
> >
> _______________________________________________
> Audifans V8 mailing list
> Send posts to: mailto:V8 at audifans.com
> Manage your list connection: 
> http://www.audifans.com/mailman/listinfo/v8
> Have an Audi V8 question?  Check the Audifans Knowledgebase!
> http://www.audifans.com/twiki/bin/view/Audi/V8
> Have a V8 answer? ... Please help others by adding to the KB ... all 
> contributions welcome!
>



_______________________________________________
Audifans V8 mailing list
Send posts to: mailto:V8 at audifans.com
Manage your list connection: http://www.audifans.com/mailman/listinfo/v8
Have an Audi V8 question?  Check the Audifans Knowledgebase!
http://www.audifans.com/twiki/bin/view/Audi/V8
Have a V8 answer? ... Please help others by adding to the KB ... all
contributions welcome!