HVAC job

[speedydtp247]

Since I have no heat with my avant, I ordered a new heater core which should be delivered tomorrow. I dove in removing the dash to get to the HVAC box out. I used this video as a guide. Then I came across this video. where you don't have to unplug any of the electrical connectors at either the driver/passenger side ends (down by your feet).

Dash pad removed.



As you can see here, the door flap isn't metal with holes. The center stack bracket for the radio/HVAC control was a HUGE PAIN in the butt to remove!

The HVAC box out.




Heater core tubes damaged and cracked. This is all the coolant that came out of the core. By the way, this drain pan wasn't clean before I poured out the coolant.


Now some pics of the HVAC box since there isn't that many out there.

Door flap near the heater core.


Door flap at the other end of the HVAC box with a sensor. What is this sensor for?


Door flap motor

Another door flap motor


Door flap motors at the bottom of the box.


The center dash vents has a sensor. What is this sensor for?

The new heater core arrived today.


Test fitted. It doesn't fit 100% but what do you expect for buying a cheap aftermarket unit.


Test fitted the firewall grommet.

[LJS]

WOW-
That's a bunch of work---GOOD JOB
FWIW-
when replacing your heater core be sure to use the Passat Heater core---the piping and tank caps are metal--a bit pricey but worth it.
https://www.ecstuning.com/b-genuine-...re/8d1819031c/

[2006b7a4]

seems like the oem passat heater core is NLA from VW unless ECS has them in stock.
https://parts.vw.com/p/48609518/8D1819031C.html

[speedydtp247]

WOW-
That's a bunch of work---GOOD JOB
FWIW-
when replacing your heater core be sure to use the Passat Heater core---the piping and tank caps are metal--a bit pricey but worth it.
https://www.ecstuning.com/b-genuine-...re/8d1819031c/

Thanks. It's not that bad of a job. The only thing that was a huge pain was getting the center stack bracket removed. I did end up buying the all aluminum core.

seems like the oem passat heater core is NLA from VW unless ECS has them in stock.
https://parts.vw.com/p/48609518/8D1819031C.html

The all aluminum core that I bought is an aftermarket unit from amazon.

[RMode]

That core is meant to be insulated. Otherwise heat is going to be quite mediocre with all that space around it

The sensor is for auto climate control

The original VW one is discontinued officially - ECS won't be able to supply it, but I still get my hands on them from Europe from time to time. Did one in my car last fall.

[speedydtp247]

Interesting.....what's the best way to insulate the heater core?

Thanks for the info on the sensor.

That's good to know that you can get them from time to time.

[RMode]

There is a piece of foam with double sided tape that the catalog calls for


Sent from my iPhone using Tapatalk

[okkim]

It is SO much easier to remove the whole complete dash than remove the parts like that. It comes off maybe in two hours, and you don't have to open "hundreds" of bolts and try to remember how the parts were installed. And the connectors are easy to disconnect and connect, no problems at all. They go only in one place.

Just remove the glovebox, center console and the drivers side bottom part. Disconnect steering wheel shaft, radio, clutch and brake switch connectors and all the connectors from the both sides of the dash. I Just pulled it off like that.

[speedydtp247]

That maybe easier but I really didn't want to unplug all the electrical connectors and disconnect the steering wheel shaft.

- - - Updated - - -

I now have heat! New heater core did the trick.

[belms4]

Lots of work! Fwiw, this is the video that helped me figure out how to just push the dash back far enough to replace the heater core. I ended up pulling the entire dash out for a different project but this video would be plenty for just heater core swap.

https://youtu.be/CygjYaCXsSc?si=aoj2cxCd7o7jhsvR

I don't think he even needed to detach most or any of those grounds to move the dash that little bit in the video.

I used foam with an adhesive edge all around the passat core to match the factory heater core setup and block off those empty spaces.

My best wishes to you in reassembly.

Sent from my SM-F741U1 using Audizine Forum mobile app

[speedydtp247]

I did see that video. Part of the reason why I took out my hvac box is because there wasn't decent pictures of it.