Hi,
I think the point is to get the Center Air Duct off the blender box, and I believe that¡¯s the same in the pre 1997 EVC¡¯s, if I understand the Bentley manual correctly. You¡¯re right some gloves would have been good¡ But only very thin ones will work.
Good luck!
JD
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This is very helpful. I have a 1996 van, so there are probably some differences. No airbags and cup holders, for instance. I¡¯ve seen some foam from the vents but heating and cooling still work, although I avoid the higher fan levels. I wonder if?disposable gloves for mechanics might help avoid some scrapes during a repair process.
Take care,
Barry?
On Apr 6, 2021, at 9:03 PM, post@... wrote:
?I just finished repairing my ¡®99EVC blender doors. As many people know, the foam that covers these doors inside the heater blender box comes off after a while, exposing the holes in these doors, and making the heater/AC not function properly. Some people open the entire dash to get access to the blender box, a huge project, which does have the advantage that you can change the heater core as well, if needed. Others manage to tape up the holes with one hand (without being able to see what you do) from the vent on the bottom, by removing the bottom center console.?
I found a 3rd way, involving removing the radio, heating/AC controls, and knee padding under the passenger airbag. This gives you access to the Center Air Duct, which is attached to the front opening of the blender box and the vents in the middle and sides of the dash. By detaching and moving this Center Air Duct to the left, you can gain access to the blender doors from the front, with one hand. And you can sort of see what you¡¯re doing.?
I also found a set of 3D printed plugs on eBay, designed by a small auto parts company in TX for VW Jetta¡¯s and Passats of that time period. The plugs, plus a special recommended sealant work very well to cover the 20 holes. Total cost of the repair is about $40. The hard part of the job is reaching into the blender box with one hand, plugging one hole at the time. Your hand will be scratched up and you will have to do some precision work in there. I find this a more elegant solution than taping the holes with Aluminum HVAC tape.?
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I created a PDF document outlining the procedure for people who are interested. Download it here:??
Good luck!?
