Heater Matrix replacement hell!

[slowerlawnmower]

Been trying to replace heater matrix on 1.6d

Got dash out ok

But screws rusted tight on heater box

Already sheared one off

Can’t get them out even with WD40/heat etc

It’s done my head in. So going to join up hoses and bypass heater.

Anyone done this?
And recommendations on what pipe to use to link the two??

Thanks

G

[slowcoach]

Think used an impact driver with a long extension on those (the type you snack with a hammer, so you get a good dead hit and torque at same time). If you have one of those it'd be worth a shot. A Pain though isn't it

[Splurt]

I sheared the same screw as you and screw above came half way out before I runged the head. Luckily i was able to get in behind with a multi to cut it off. The others came ok but I ended up then spending most of a day drilling the two remaining bits out breaking many drill bits in the process.

The impact driver is definitely worth a go, and a reverse thread drill bit also would be best for removing the sheared piece. Or just leave it, three out of four should hold it.

It was all worth the hassle, the heater box refurbished with new foam and a new motor is great, it wasnt really fit for purpose before

[Stesaw]

You can get to the top two screws from the outside if you take off the grill (if i recall right). I wire brushed the threads that were showing and put some plug gas on them. To get mine shifted I just used a socket wrench with a posi bit on and worked them back and forth a bit at a time.

[davidoft1]

If the snap off, once the heater is out of the way they are easy enough to drill out and worse way put a nut on the outside s

[slowerlawnmower]

Thanks all!!

I’ll give it another bash tomorrow !!

Cheers
G

[Robsey]

I have to agree with Davidoft1...
Once the heater is fully out, I had to drill two of my six broken pieces out.
(Six M6 bolts, or Two M6 nuts on the bottom two mounting brackets).

Correct size is 5.2mm high speed steel bits.
I piloted the holes first with 3mm diameter drills used for stainless steel.
Then drill out to 5.2 mm dia.
I then cleaned all six bolt holes with an M6 tap set.

Whilst I had the dash panel off and the heater assembly out, I also went round cleaning all the other threads whilst I was at it.

[slowerlawnmower]

Ended up drilling out and rebolting 3 screws.

On the home stretch now but I’ve got a problem. Connecting everything back up - I’ve got an extra connection block!!! Can’t figure out what it connects to - all dash switches connected.

Can anyone help me?

Image below.

[slowcoach]

Good result well done

Hand brake?

[Splurt]

Correct! Hand brake warning light.  I forgot to connect it too but had to go digging for it after I realised it wasn't working.  You'll be glad to see the end of that job

[slowerlawnmower]

Aha!!
Thanks!

[slowerlawnmower]

All back together!!
And working fine!!

Thanks for your advice folks!!

[slowcoach]