Heater Blower replacement

[bitler1@gmail.com]

Hi All,

Trying to get the dash out of my van to change the blower motor using Covkid's detailed instructions (thanks!).... Come up with a couple of snags along the way:

It says "take front grille off and undo 2 Phillips head screws just above the radiator, identified by large washers for size of screw" - where are these exactly? I can just see two screws with square nuts on them behind the radiator near the top.

Also, what is the plastic heater cover panel? I have removed a plastic cover (4 phillips screws) which i think it may be.

ANy advice advice or expansion would be great cheers (it's breaking my heart pulling the dash apart!!)

Phil

[noggintom]

Hi,

Having done this myself I know how much time it takes! Especially when not exactly sure what everything is. It did seem a bit like open heart surgery....although I learnt so much doing it I think I would not be anywhere near as frightened next time!!

Anyway, to your questions:

I assume you have got the dash off (removing/undoing steering column etc.).

The screws hold in the very big black plastic box that has coolant tubes going into it in the middle of the van behind the dash. They were phillips and had a round head approx. 10mm if I recall correctly with small washer behind in my case. If you have a buddy you can begin to unscrew them and see if they are moving inside the van (you should be able to see the other end of them).

Not sure what you have unscrewed but the heat blower is inside an approx. 60cm x 60cm x 30cm deep large plastic box. If no one has been to this before the top is glued to the bottom and needs to be cut free with a craft knife. If someone has been there before it will be held together at tabs around the edges with special VW clips (or self tapping screws in my case).

When I did mine we unscrewed the big plastic box from the front of the van (taking out the screws above the radiator) and sat it on our knees and cut off the top. Once you are 'in' it does not take very long to swap the heat blower units. Well worth testing the electrics in there for fan operation as you will not want to go back in in any hurry!

Good luck and keep posting if you need help.

Tom.

[bitler1@gmail.com]

Tom,

Thanks for the reply! I haven't actually removed the dash - I have undone all of the screws and unclipped everything, but in the instructions it didn't actually say at what stage to remove it! I gave it a tug and I think 25 years of being stuck there means it's a bit reluctant to come out.

I guess that I'll give it a bigger tug tomorrow and get it out. Then maybe everything will become a bit clearer!

Your description of open heart surgery is very accurate - especially when everything else works so it's like operating on a patient that's not very sick and hoping they survive!

Thanks for the help... will let you know how I get on (weather depending!)

Phil

[grumfuttock]

i took my heater out last month, and yes. it does become a bit alarming.
however, once done you will never fear doing it again, because it isn`t half so difficult as it first appears.
good luck!

[CovKid]

Other than getting to blower to free it if its seized (and in my experience rather short-lived) you have to remove dash to get to anything including blower box bolts/screws. Removing outside front grill enables you to get some WD40 on rear of blower box screws (and via a newly drilled hole to reach blower bearings) but thats all to be honest.

Dash is held in various places including sides and along front window edge. Dash clocks have to come off too. Steering wheel just needs unbolting from brackets and with driver seat out, column will lay down without having to be removed (as Haynes seems to claim).

[bitler1@gmail.com]

Thanks for the replies.... let you know how I get on....

[VERAT25]

i have done this job...............not easy but with a bit of common s it all falls into place(hardest part was releasing the 2 special bolts(machined flats on them to make re attachment easier)................took about 8 hrs on weekend/// as previous test all switches etc before re assembly.

good luck

verat25(cardiff)

[CovKid]

Also a great opportunity to do any of the following:

1)Sort out windscreen leaks whilst dash is out - much easier (and safer) with all that lot out of the way.https://club8090.co.uk/wiki/Bo ... well_leaks

2)Make good all earth crowns

3)Replace/upgrade washer pipes and jets

4)Lube/replace/check windscreen wiper motor and associated assembly

5)Generally tidy up existing cables/wiring and reroute where prudent

6) Deal with any rot/rust

7)Drink a lot of tea and get disturbed by the usual "I always wanted one of those" or "you look busy" etc

[bitler1@gmail.com]

Guys,

Thanks again for all the advice and help.

Progress report... I have finally (after much grunting and cursing) managed to get the dash out this evening... I am now sighted on the big black box in the middle - it seems to be screwed to the front of the van by 4 philips head screws - 2 on each side. None of them look like they're keen to budge in the near future (soaking them with WD40 overnight to try to get some lube in).

I plan to get the black box off tomorrow evening. In the meantime, just one question... I think I may have damaged the lid of the clutch/brake fluid reservoir under the dash - it looks like it should have a small black lid on it, but seems to have a little blue plastic piston which sticks out of the top? It's about the size of a lollipop stick? I am wondering if I knocked the lid with the dash whilst getting it out?

Thanks again guys...

Phil

[noggintom]

Well done in getting the dash out! Progress is good

The screws to the big black heating box were quite easy to get out in my van but I guess depends on age etc. My van is 1990 so quite a late one.

Spooky with the brake fluid lid, I did exactly the same and had the blue periscope thing standing up. Now, I cannot remember exactly how I fixed it.....let me think. I'm thinking......

Ah yes, amazing what comes out when you give the brain a wee bit of time.... I think the metal bit on top of the blue periscope is held down as part of an electric circuit to show if you have brake fluid, now i just cannot remember if there was another black cap that went on the top...?? Maybe someone else can post if they recall. If not I'll investigate mine next time I take her out (later in the week). I have a strange feeling there is a cap. If so you should find it eventually, either 'living in the wiring' or when it finds its way to the van floor.

Keep on posting progress and best of luck.

Tom.

[bitler1@gmail.com]

Thanks Tom.

Even my wife is now impressed at how helpful everyone is!

Phil

[edoh]

hiya
plus gas might be a better bet than wd40 for stubborn nuts and screws -

hope it works out for you -
edoh

[CovKid]

I can confirm those heater box screws can be damned tight. Difficult to get at with an impact driver (ideal tool) so you have to contend with either a VERY big screwdriver or do as I did and put a suitable screwdriver or impact bit in a socket using adaptors or junk from your toolbox on the end of an extension bar and throw all your weight on the screw head while you turn it. If you round it, you'll have even more work. This is why WD40 from the rear helps. When I did it I sheared one but put heater box back with it missing.

[1664]

Ok so it's been an awful long time since I had to muck about with my heater blower on my old camper but I didn't have to remove the entire heater box, I just removed the top cover section to reveal the motor, resistors etc. Was still a pig of a job though.....................

[CovKid]

Some just won't come apart at all though. Mine was like that - completely sealed. I ended up changing it for a s/h box that had the clips.

There does seem to be some differences depending on year.