What else to do while replacing a front heater core?

[Paulbeard]

[djkeev]

[Paulbeard]

[teej]

Yesterday I joined the ranks of those who have taken on this project in a Vanagon. The atrocious PNW weather and a few days off from work made this the long weekend to get after it. I've been collecting all the parts and bookmarking samba threads in preparation for a while.

This heater box is 1986 original, never opened, very interesting and almost archaeological to be touching fasteners that were last handled by a tech in "West Germany" in 1986.

I will do alot of the usual "while in there" stuff.

On tidbit: my new blower motor from VC has the end bearing that can be serviced through the Mullendore port already capped/sealed.

Big thanks to those who have gone before and posted about it; all the tricky operations were easy so far armed with the correct knowledge.
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1986+ Wolfsburg Weekender Pop-Top 2.3 WBX Manual Trans

[teej]

Question: the free swinging forced air flaps originally had some foam, now dust, which is much thinner the the foam on the control flaps. What have people used on these?
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1986+ Wolfsburg Weekender Pop-Top 2.3 WBX Manual Trans

[blaumeister]

[Skidub]

Teej, IMHO the insulation tape via the link below is the best product. I did some comparisons and went with this:

http://m.homedepot.com/p/Armacell-2-in-x-30-ft-R-1...mp;cj=true

On control flap #3 you want to have the flap extend about 3/16 past the steel flap for better contact with the box. You will need to cut a small strip and apply sticky side to stick side for this overhang so that there is no stickiness exposed.

I just disassembled and rebuilt my entire heater box. PM me if you get into it and have questions.
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86 Syncro GL Tin Top
Subaru 2.5L Swap
Rblt Transaxle w/ R Locker + Decoupler

[teej]

Thanks for the replies. I used the camper tape on everything but the box is still on the bench, I will bench test today. I will have a look at the linked tape above while I'm at the Home Depot today.

I had to rebuild the hinge tabs on the free-swinging forced air flaps, they had become detached and the flaps were just laying in the box when I opened it up. That alone may explain our lame defrost air volume.

I had planned to do the resistor mod, but my original resistor still works, and there are no signs of any heat damage in the vicinity, so I will instead give the blower a good dedicated ground and reuse the resistor.

I'm hoping to finish up this weekend.
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1986+ Wolfsburg Weekender Pop-Top 2.3 WBX Manual Trans

[dhaavers]

[teej]

[dhaavers]

[teej]

Everything is back together and working great. I used the tape Skidub recommended on the free swinging flaps and camper tape on the others.

It is worth going in just to reseal the heater box flaps, the difference is dramatic and satisfying.

I partially drilled the block off plate similar to what Wildthings did in his thread. Seems great on first run but need to measure.

And after cleaning grounds and connections: Who knew the rear defroster switch had an illuminated icon???
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1986+ Wolfsburg Weekender Pop-Top 2.3 WBX Manual Trans

[dhaavers]

[Jeffrey Lee]

Anyone know if the two pre-formed heater core supply & return hoses (behind the dash, seen here in the photo from BenPlace) can be replaced with simple 5/8" ID heater hose? Or will the straight hose bind/kink?

If it'll work, know how long they are?

I'll be doing this job next spring and have some Gates Green Stripe straight hose left over from another project; would like to know how much to save for this project ...

[vanagon1991]

As long as your there messing with the heater hose, might as well drop in an off/on valve. Got his idea from Terry Kay. Eliminates hot foot in the summer. Worked great for me this last summer. Can't even see it behind the cover but can reach under and turn it on/off. Home depot part.

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1991 Tornado Red Vanagon Carat
(2003 Subaru 2.5 conversion/Smallcar kit)

[dasilva]

After tearing apart both ends of my van for a Bostig engine upgrade, I'm working to put the pieces together. My van is a 1989 Westfalia, 2WD, Automatic Transmission.

I'm working on the front heater core.

Below is a picture of the front heater core before I removed.

Obviously, I should have taken more pictures!

Jeffrey Lee, thanks for your picture from BenPlace. I believe my, 'feed,' and 'return,' line are now properly routed

I am confused about:

1) How this clip is to be used. Are both feed and return hoses supposed to be squished into the clip?

2) How this bracket is to be used. Is it for the heater hoses? Or for just the feed or return? Is the electrical supposed to be routed through the bracket? I think it's supposed to work with the clip somehow.....

3)I feel more confused when I look at the GW drawing. What are items 13 and 14 relative to item 13A?

If anyone has tips or advice I'm all ears!

Thanks in advance.

[dasilva]

Front heater core is back in. I'm reconnecting electrical. Anyone have insights to what the connection in my hand (pictured below) is for?

It's not for the side speaker. Passenger side power window???