Club 80-90 Forums

Okay I have read the wicki, the Haynes and the bentley manual, the only one thats any good is the wicki as the rest say nowt much....

Problem i am having is in the wicki it says, "Take front grille off and undo 2 Phillips head screws just above radiator, identified by large washers for size of screw! "

However i have removed the front grill and cannot see any such thing as 2 phillips head screws just above radiator,

My T25 is a c reg 1986 1.6d na.

Dash is out, I really dont want to put it back together until i have at least checked to see if the motor is u/s or just needing freeing off....

Thanks for your time.

Any ideas hoping to get it finished tomorrow, got a 600 mile trip to do this weekend !!

I thought taking out the dash, removing/pulling/cutting off the heater box, knocking off the fan from the shaft, and then lubing up the motor's bearings was it...

what do these screws do?

I dont know what these screws do Kev, I am just trying to follow the wicki, I have never removed a heater box before, I have the dash out i have removed the four large screws holding the box in place and 2 screws at the front either side of the box, it will move a few mm but will not come away from the bulkhead, would you expect to have to exert a lot of force to move it away from the bulkhead ?


Should i be trying to take the top cover of the box to get to the motor ? I thought the box could be removed and then you could get to the motor through the air intake.

When i try to move the top of the box towards me it is very tight against the top of the bulkhead, maybe im just not applying enough force, dont want to break anything !!

Cheers Kev.

Of the 6 mounting bolts only 2 are on the outside accessible from behind the grill and I have to say that the 4 on the bulkhead were all sods to get out so the wd40 soaking is a good call!.

took this from a previous post

The main culprits were the 4 bolts holding the casing to the bulkhead,what a sod!,3 of them chewed up and broke altho' 2 of them nearly came out bar a couple of mm,the third was about 10mm in and took a load of time to get out,being near the brake cylinder didn't help with the removal!.

Cheers Kev, I have had a look on the samba and i think i have all the mounting bolts out I'm gonna put some weight on it in the morning i think i am being over cautious. Thanks for your help. Will post tomorrow night and let you know how i go.

So tried again with more force, and it came away from the bulkhead the heater box is so out of shape from where the motor had melted and the box had melted too, replaced the entire unit today with a second hand one. will post some pictures tomorrow night, they are worth a giggle, must have been a small fire in there the previous owner must've cacked it big time,

Strangely enough the one i replaced it with slipped in to place with no fuss at all, just got a few odds and ends to tidy up tomorrow and i will be all set for me trip up t North to civilisation on Friday afternoon/evening.

I have a fan again !! well actually first time there has been a fan in this bus since i have bought it. Only works on speed 1 and 2 new switch required me thinks.

Thanks for your help and encouragement. photos tomorrow!!

Congratulations friend

I know it has been typed about before, but I reckon many would be happy if you could share your experiences of doing this job

Waiting now for the pics

When it looks like this you are ready to pull the heater box out, mine took considerable force to remove due to the box being out of shape (melted)



It shouldnt look like this.

So the job is disconnect battery earth.
Remove steering wheel
Undo two sheer bolts on steering coloumn
undo 2 x 13 mm bolts further down steering coloumn and lay coloumn on drivers seat.
remove instrument cluster cover then disconnect the plugs at the back of the cluster, then remove the cluster.
Carefully pry the control levers off the heater controls, then carefully pry the facia off, mines a diesel so remove the enrichening device/choke thingy
remove the blower switch.
drop the glovebox
remove the six small screws at the top of the dash (dont remove the big ones they hold the wipers in) remove the 4 large screws holding the dash in, you have to open the drivers and passengers doors to see these screws.
Undo the 3 screws holding the heater controls to the dash board these are behind the facia and one is inside the hole where the instrument binacle was removed from.
if you have a radio or any extra bits n bobs these will need to be removed also.
Now the dash will come away.
6 screws hold the heater box in place, 2 either side at the top and bottom of the until, 1 either side on the front of the bulkhead, on the right they are hidden by the water hoses.
I did not drain the system, I removed the heater box at this stage and split the box in the van then removed the matrix without disconnecting the pipes.
As you can see from the photo my heate motor was slightly goosed, so i had to replace the box and the motor but i used the original matrix.

Putting it back together is easy, taking it apart is easy as well.

Be careful routing the cables when you reassemble i had to remove the dash again and reroute wires more directly.

I have heat again horay.........

jeez.. that's extreem
well done fella.. It's a brave man that removes a dash