How To Fix Blend Doors without Removing the HVAC Box
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- Опубликовано: 6 окт 2024
- If your VW doesn't have heat, or AC, odds are the foam on the blend doors has come off. I will show you how to fix the blend doors WITH OUT REMOVING THE BOX. You can finally get heat and AC back. I have tested several methods of doing this blend door repairs. This method is the one I find to be the best balance of time, work, and getting the repair done. This applies to most cars including my MK3 VW, and MK4 Volkswagen
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The content of this video is available for informational and educational purposes only. It is not intended to be a substitute for the professional advice of a mechanic who has personally inspected your vehicle, nor does it create a relationship of any kind between the Humble Mechanic and you. Every situation may be different, and the Humble Mechanic does not make any warranties, whether express or implied, as to the accuracy, fitness, or applicability of the information or automotive parts portrayed in this video to any project and makes no guarantee of results. The Humble Mechanic and any sponsors of this video will not be liable for any damages related to personal injury, property damage or loss of any kind that may result from the use or reliance on this video and/or any automotive parts represented in this video. You are using the information and automotive parts portrayed in this video solely at your own risk.
Who wants to guess why the doors have holes? WRONG ANSWERS ONLY! HAHA
Mix air temps I dunno, but I used high temp hvac tape and it was a PAIN , I did it while it was in
To add lightness?
Decreased drag for better MPG obviously
Because VAG.
Because VW wanted to be sure shops had something to do a few year after the cars were produced, and they know just how much shops love a dash out job!
Dearest mother of god, this repair looks overwhelming!
Yes, when the start of the video showed those plugs I expected to see some nice trick where you push your hand to some little hole after removing one plastic cover. Taking the wheel off was a final hint that this is getting ugly.
@@MikkoRantalainen it's actually not that bad I've done it probably about 30 times with leaving the dash still in and just going through where the radio is. Doing it the way I do it there's one screw that's a pretty big pain.
God has no parents nor children
What a nightmare
Years ago when I replaced the heater core on my 92 Corrado I was shocked how the blend doors had big holes. That explained why it was still partially heated on the coolest setting. Those plastic plugs are a good solution. I used aluminum with thin sticky foam backing and cut rectangles to cover the doors on both sides. It made a huge difference. This is a major VW design blunder.
I’m sure there is a very logical reason for the doors. It just didn’t hold up over time
Another great video Charles. Love the attention to detail telling us what size fasteners should be there. I always use the presence, or lack of original fasteners as a gauge of how much previous owners cared about their car.
. I removed the complete hvac unit. Replaced the heater core and fixed the blend doors. Carpet on drivers side was soaked. 3 full days of work. Thanks for the video and the link for those plastic hole inserts. Your channel has great info for R32 owners.
Wow, such clear filming and audio. I'm just finishing up a heater core replacement on my 2005 Jetta wagon TDI. I wish I'd found your video sooner. With all the VW Vortex DIYs related the removing the dash now missing photos, it's been hard to find clear instructions for getting in to a mk4 dash. Your video would have saved me a tons of time and broken plastic bits. I suggest tagging it for heater core replacement so future saps like me can find it easier. Thank you for taking the time to share your experience is such a useful, clear way.
Charles deserves WAY more than 490K Subs.
I kno I'll catch some hate but I love the mk4, definitely my favorite gen.
Oh, look at that, no one cared!
Thank you for this awesome video! My brother and I just used this kit and watched your video forward and backward for reassembly! It wasn't that bad really, just a LOT of screws. Thank you again
Hahah awesome!!!
I did this about a month ago, using the metal HVAC tape method. The heat blows hot and I was able to clean out all the buttons on the radio and Climatronix because the previous owner had spilled coffee all over it and the buttons barely worked. It was a real pain without removing the box but it only took me about 3 hours. I plan on totally redoing the HVAC box when my heater core inevitably blows on my VR6 :).
sadly no cheat on when you replace the heater core. HAHA
Ok what am I missing? Why did the automaker put a bunch of holes in the blend doors just to cover said holes with foam. Why did they not just make the doors solid?
Because it’s a VW
German engineeering
I'd guess the reason is either trying to avoid warping the door due temperature changes or to reduce weight of the flap to make it easier to rotate with the servo. Though I really don't believe a steel flap could warp with the temperatures that those flaps see. And the weight reduction is not big enough to really matter.
Maybe some kind of relief valve setup in case pressure gets really high the foam will rip?
to save weight
perhaps when closed it's for some moisture ventilation or air pressure to pass through, but really annoying repair.
I find your videos very calming. When I'm trying to figure out some software issue, I watch your video and get back to it feeling a lot calmer. There is just something about watching someone doing work on a car with confidence that also inspires confidence in you.
Great video and editing btw. Very clear and informative. Really like how you stop to point out all gotcha's.
Just picked up a silver one right at 160k miles with this same issue . My ac seems ok but heat is luke warm. I would think it was the heater core if it wasn't for the foam coming through the vents when fan is on high. No wet floor boards, no "sweet" smell when heat is on, and coolant level/ engine temps all seems fine. Hoping this is my issue and to have it done before temps start to drop. You're then man dude! PS I've been watching your stuff for a while and have been getting super jealous of the cars. The MK4 R32 has been my attainable dream car and your vids pushed me to pull the trigger on getting one. Keep up the great work bud.
I really miss this about VWs. I could get amazing videos/help like this for my MKIV VR6, but now I have a Hyundai that's new and easy. I love the VW community and really miss it. Thank you Charles! I'll keep watching even if my VW isn't here anymore
On my Audi TT MK1 i used Roof insulation tape with butyl and it works flawlessly, i only had to remove the glove box and partially the center console + dash
I followed Hesty32’s procedure but referred to your video several times while doing the job. Would never do this if I had to remove the instrument cluster. Really appreciate your video. Nice to have a functioning defroster again, as well as strong air flow where desired once again. Been getting by without it for at least 8 years.
Doing mine now…also went without for eight years. Tired of no heat in the winter and ready for max AC in the summer as my car is black. I’m trying plugs with RTV and 3/16” camper shell foam folded over the edges of the doors like in Charles’s other video, but with the box still in the car 😬
@@zachwyant8665 I think it can be done. I wanted to tape up both sides of each hole but there was no way to reach both sides of the doors without removing the box. You don't want a plug to fall thru the hole while trying to get it installed as might be hard to retrieve. The tape has worked so far for me, but the plugs would be more permanent. Curse VW for putting those holes in the doors!
The center vent louvers all but came apart. I managed to get them reinstalled but have never touched them since for fear they'll break. And the on-off button and a couple others on either side of the stock radio disintegrated when removing it. Was able to keep it in use for a few months but ended up replacing it. That old plastic is so brittle! Have to expect with a 23-year-old car in Louisiana.
My Mkiv Tdi Wagon has been blowing foam for a while now. Last summer on really hot days the AC wouldn’t get cold. Just sort of cool-ish. The car is 18 years old so I’m not sure if the AC system needs to be service or the blend doors need to be covered. It’s just my commuter to work and local trail heads so I’m not even sure I want to put the time and effort into it yet lol. This was a great video if I decide to service the doors and I’ll definitely be going with those plastic inserts. Thanks for putting the time into this amazing resource!
More than likely it’s leaked out. When you get a chance get the ac system leak tested. They put a dye in and it’ll show you if it’s got a leak and then recharge it
@@sammurray1395 that works most times but sometimes it’s a nightmare still
@@mercury0214 that’s true mate, most jobs on our cars are nightmares haha
@@sammurray1395 oh yea sorry I didn’t mean to say dye is a bad idea in my first comment either I just meant even with it sometimes it’s still terrible lmao
Just what i needed, im gonna have to do this on my alh soon lol
Very nice tut video there Charles, you do it well.
I was behind a Golf on Wednesday here in Johannesburg and as he pulled away at the traffic light I noticed it's a manual transmission.
That's when I decided to pay attention, and it turned out to be a MK4 Wookie.
Wookie's and Gti's from those years have become rare here in SA.
Was very pleased to see one alive and well.
Best regards.
I've never seen a dash removal video look so clean and smooth. Great job!
Also how many incorrect fasteners were there? 😂
I personally like to paint those pieces of metal when I get that deep into a car. A lot of cars from the 80s and 90s are pretty rusty behind the dash from my experience so I like to try and prevent that
Awesome video Charles! I look forward to your video on pulling the whole "suitcase" and re-foaming.
Me too!
I literally bought an old VW just so I could make better use of these awesome videos. My fav on RUclips
Saved me a ton of time! I had to do the same thing to my mark3 a few years back, and it was pain in the a.. Great video!
Charles, i have to say, wow! I love your detailed words and disassembly! You were very clear and awesome! I'm not even a vw guy. But i like your videos on disassembly jobs and your car builds. It's something about ya that gets excited doing it making me to watch and enjoy the video! You knocked it out of the park, bud! 100% excellence! Many thumbs up 👍👌
Thanks so much Josh!! This is one of those videos that takes forever to make. Hahah glad you enjoyed
@@HumbleMechanicwow that is long time! Getting awesome answers from commentors makes it worth while doing the edits and making the video!
Love your Videos! Always saving the Day with your Awesome Content. Just bought my own MK4 today!
thank you! Congrats on the ride!
Just did this. It’s completely worthwhile to take it apart because there is just so much stuff left that you can’t get. 85% is fair for the time savings but it’s only a matter of time until a piece of chunky foam lodges itself in the pivot or sweep area. Then something breaks.
Side note: my doors look exactly like yours and I’m super happy you showed us how
Awesome job Charles! Looking forward to your complete blend door and heater core video.
Can't wait to see the full progress 🙌 with the evaporator
I'm still looking for the "tally fastener" you mentioned at 3:02. Haha...nice video as always Charles!
I did this job in my Jetta a couple years ago. I think it took an hour to pop those clips on the airbag. They really did not want to cooperate! Lots of PG-13 language was used.
Never heard of a mechanic that liked a VW before. ...oh well learn something new every day!
We are a rare breed 🤣. Or just have severe mental problems.
great video, I have the same problem with my 06 TDI beetle. If I did this all of the plastic pieces would break including the wiring connector retaining clips. then I would have to glue the whole thing back together. I think I'll just live with it.
Yep, happened to my Beetle turbo S. It would spit foam at me for years, then one cold day I realized, no real heat! I was able to go under the dash where the box can be split in two. there are a few videos here on RUclips on how to fix. It does take patience!
What a video ! Thank you for the effort of Making this video .
Thank you for explaining everything.
I did not know from where the foam was coming from
VW logic was thought out at a bar on Friday night after few beers. I guess it doe snot take to much to be VW engineer!
At first I'm like cool a short cut.... but then by the time you pulled almost everything out I started having flash backs to my beetle full box out last year and I started wondering
I think at this point one might be farther ahead to go the full monty and replace the heater core before it pops and you have to tear all this apart again later
I liked this and the full box of repair that you did...I referenced it a few times when I did the 03 beetle TDI .... man that was a pain in the butt
Yeah there is a lot of value on that!!!
Just realized just how broken my center console is by looking at how nice yours is 😂. Just got a tropical orange vr. Love the vids
And the glove box!! So nice and not broken hahahaha
Do you have a video on replacing the heater core? This video was the best one I found for getting the dash out. I seen the part in the beginning where you had the AC lines removed and thought that might be part of a different video I am not finding through the search option. Thank you
That’s actually helped out so much! I’ll be removing my dash at some point as I’ll be doing a dials-climatronic conversion. Be going to the breakers to get all the bits tomorrow 👍
NICE!!
I was considering this too. Seems like a huge project though.
Did that with my ranger to replace the heater core a few months ago. It was about the same process as this car, just more philips screws.
Nice video as always Charles. Wish you were local in the UK. Any chance on a video to show how to repair/replace the vent grills on the R32. Mine has a broken slats like yours has there.
Like the one in this car? I will be fixing it for sure. Those drive me crazy
Bless you Charles! I'm starting to collect bookmarks of all the repairs you've documented that apply to my R32. Since I have a glove box to replace, an antenna connector to repair, I'll get this all at once. Now I need to make the decision to replace the MFA (as usual mine fades in the heat) and polish the instrument cover.
BTW - with this method, can you get behind the blend doors to remove that foam also?
I have a 2004 Golf that would not spin pass 3100 rpm. It had p0343, 351, 352, 353 and 354. The dealer wanted $2048 to replace timing belt, tensioner and water pump. I replace a $17 temp sensor and the car run like before.
Charles is there a link for the plugs that you used?
I have to believe that removing just the front 2 vents with a screwdriver and using an endoscope with the magnet attached to the end you can buy the plug kit and glue a tiny piece of metal on center of plug. Put gasket maker around plug. With endoscope, carefully maneuver plug down and into 1 hole at a time. Hold in place till sealer dries then pull magnetic tipped endoscope off ply. Repeat for each one. Sure this will take time but u can do 1 plug at a time at your convenience. It seems there’s plenty of room inside that Airbox to maneuver the plug once other vent is removed. I have to think this must work instead of removing anything. Kinda like endoscopic surgery?
Or, use endoscope for your eyes then use a flexible grabber tool which might be more sturdy n give u more pushing power to install each plug.
Thoughts?
Mk3s are built around the heater core LOL. I did it on mine, well it was a tough task, but for the second time it was much easier.. Still, i have two leftover bolts :D
I literally have my 01 TDI torn down with the motor and trans out as it blew the diff pin and i was literally on my way to pick up timing belt tools to do the TB.. Now im considering tearing into the dash after i get the motor and replacement trans back in as the car has never had decent heat even in the summer.. but hopefully the new thermostat and "freshen up" (EGR Delete) on it will fix that
Great video! I have an ‘02 Jetta GLS TDI. It’s been blowing pieces of foam through the vents for quite awhile. Heat comes out lukewarm at best on really cold days. There are no coolant odors and nothing appears to be leaking. Thinking this might be what my Jetta needs to get back to hot and cold airflow.
Could you do a video on how to diagnose and fix a broken cruise control, or maybe take about how it work on the mk4?
Try pulling the dash out of an '05 Ford dump truck. Took three days. Had to do it to remove the a/c condenser.
All three of my VW have had this problem. 84, 97, 01. I remember taping my MK4 without removing the dash. Watching this I'm not sure how I did it. Haha. Maybe I have an earlier Mk4.
Do we know the diameter of the holes of the hot/cold blend door? I can't find the plugs and i think i could make some
Just now got around to doing mine today, and found that the gear for the temperature adjustment was ripped off by the previous owner. Now time to figure out how I'm gonna fix it before I put it back together
so much good info for VAG owners, cheers
I have to do this to my 01 Beetle.. I'm undecided on if I want to do the quick and dirty way or just suck it up and pull the whole dash and do it the right way.
Hey Charles,
Enjoy your thorough coverage on your videos. I just did the temporary fix by removing the foam and replacing it with hvac metal tape. Anyways, do you have a decent diagram or picture of where all the electric actuators are for the mk4 golf with climatronic system? I must have a broken actuator since I continuously get hot air even after the blend door fix. Any options that don't require ripping the whole dash out to get to these actuators? Thanks in advance.
Hey there, I'm not sure if you watched the video until the very end but he says with the climatronic system, you have to go back in with VCDS and set the blend doors to their original settings. Unless you have access to a VCDS unit, would probably need to take to a VW mechanic or dealer 👎 I personally don't fully understand why it would need VCDS considering we didn't take apart the HVAC box and move the blend doors but my guess is the system has the blend doors "out of whack" while it was trying to compensate for the holes in the blend doors and now that it is repaired, it doesn't know it's in the wrong position, whether fully open or closed. That's the best way I could word it and I'm def paraphrasing lol but you get the jist of it. I'm getting ready to tackle this job myself, debating on this procedure or to suck it up and pull the box and do the full job. Good luck to you! Would like to know if you do or were able to figure it out.
Adam banda, I did get a new bushing. The old one dropped out the bottom to the floor. It was a real pita cuz I had to disassemble the whole dash again, all the way to the blend doors. From there I had to fight with the shaft at the bottom of the blend door while trying to line up the bushing. After many attempts, I finally got it lined up and reattached to the new electric actuator. It's not easy cuz it's all at the floor level under the dash. The next job is changing out both radiator cooling fans. The vr6 doesn't give much room for removal, it looks like.
Having a beast of a time getting the HVAC separated top from bottom (2002 Golf); what am I missing? Periphery seems to be freed up, but something in the middle is holding it together (?).
(Did that "full start to finish, including replacing heater core and evaporator" video ever happen? Would love to see that.)
In Audi 80 same problem. Last time I disassembly dashboard and HVAC in 1.5 hour.
For the middle console you forgot to show the rear cup holder remove, pop the base off with flat head then the screws underneath
I knew there were a few differences between eu and us models... But this looks like a different car. The metal braising - the White insulation matt - the radio - the center console - and the airbag clock unit is all different and probably a lot more.... And what the hell is the red ashtray for??
Great video! Where did you get that custom flight tag? Would love to have my own made!
12:10 If the car has ESP, make sure you don't accidentally rotate the wheel rotation sensor 360 degrees in either direction (that black thing with two plastic poles). Doing that will cause spring coil like wiring to fail sooner or later.
Edit: I see you taped it at 14:10
Great point!!! I try to always do little things like the tape to prevent future sadness. Haha
the #1 repair we've all been putting off lol. only thing im wondering about is, i've heard you can do it without removing the steering wheel and dash?
You can. 100% not worth it. It’s a handful more bolts and you can do a better repair. With no fighting
@@HumbleMechanic thanks for responding! Super cool to have someone helping us all out. Ok we'll see how this one goes, the dash it is!
Subscribed ofc :)
it is also good opportunity to replace V72 servo motor, all VW from that era have issues with it
Is this possible without the steering wheel removal? I have an 01 and and 04 GOLF TDI basic interior. This car seems to have allot more options.
yes, you still need to loosen the dash to make it happen, but it absolutely can be done with the steering wheel on.
If you have quick disconnect steering wheel,clearance is easier too
Brother, nice job.
I'm having a headache with my mk4. It's running water into the car through the rear door and I don't know where it comes. I already bought new rubber but I think it will need to correct the doors alignment. Could you help me with a solution? It will be a great video for you channel.
TY
Hi! I have an Audi A3 8L from 1997, and it's like a brother from another mother to the Golf 4. What do you think, can I repair the blend doors like this, or should I take out the entire heater box? Big thanks from Hungary :)
So my old boss was a pulmonologist. He had a Mercedes S class and he kept getting this black dust blowing at him. He claimed it was mold. Mercedes vacuumed the vents out, but they refused to tear the dash apart. A couple days later, more of the material. He again, claimed it was mold. Mercedes said it wasn't, and vacuumed again. This went on for 4 months. Finally they Lemon Lawed the car and he got a Lexus instead. 2 years later he claimed he got pulmonary mycosis or something and sued Mercedes. Well because Mercedes didn't keep any of the Material and refused to tear apart the dash to document it, they couldn't prove it wasn't mold and he had mold he claimed came from the car. So he was awarded 650k out of court after attorney fees. First thing he bought, Mercedes SLS. Bet they wish they tore the dash apart like you did.
Mucho respect on your patience and vocal walk through on the experience and talent to you HumbleMechanic,on a serious note:I think I would prefer to purchase another vehicle,liked the use of the actual "Duct Tape"..
So this is why my winter beater TT Quattro doesn't have heat. Most of the interior is stripped anyway so dash out shouldn't be too big of a job. Don't want to mess with evacuating A/C though so I'm going to give this a shot.
Nice video man, so detailed! Keep it up!! Thanks a lot....
I'm lookin forward for the while I'm in there vid!!!!!!
Charles: Be very careful
*Proceeds to HUCK panel across garage*
the other method is to cut the dash, if you can do that i'd think popping the plugs in would be easier than tape. kind of don't wanna evac and drain coolant but, maybe new cores would be good at this age. double check wires and grounds maybe. i would like best performance and cleanliness big time though.
This was such a painful job on mine. Fun fact: 24:50 On mine there was a plastic piece that clipped to the upper und lower part, holding them together mostly airtight.
But I broke it. Knowing you don't even have it I can stop feeling bad about breaking it ^^
vw please this was an issue on the mk2 why not fix it on the newer platforms
Thanks a lot brother for this informative video
life hack: if the steering wheel is seized on the steering shaft, before you reef on the wheel to get it off, put the bolt back in a couple of turns. saves you from hitting yourself in the head with the wheel
I know I'm late to the game, but is this basically the same as a dash removal on a TTS mk2??? I'm about to do this job on mine, and this is slightly intimidating. I did just change out the thermostat boost pump housing a few months back... so that works now, however... this looks just as challenging.
Wow what a job....
Great detailed video, how much difference would a MK1 Audi tt be?
I’m not sure really. I’ve never had one apart. My guess if it’s very similar. The TT is an “A” platform car like golf, beetle, Jetta
Some users have started using plastic plugs to block the holes in the blend doors.
Charles. Have you ever seen this issue with the B7 Passats. I have a 2014 that is blowing hot out of the drivers side and cold out of the passengers side. Checked the actuators and both are opening and closing properly. This is my only other guess. Any advice is greatly appreciated.
I WAS WONDERING WHERE ALL THAT FOAM WAS COMING FROM IN MY CAR!!!! Mk4 Jetta TDI. Might have heat again once I fix that!!
Thank you for the video I have a vw passat 2004 TDI and AC blowing half cold half warm passenger side cold driver side warm I had replaced AC compressor 2 years ago and I refilled the gas everything was working fine until last week I don’t know what is the problem any help I appreciate
Have you tried this
Awesome
Thanks Charles!!!!
Awesome....thanks Charles !!!!
Do you have a video for doing vcds for the electronic climate control to run bs setting to reset blend doors?
My AC is fine but the heat is super weak plus im getting foam coming out the vents is it the heater core or the box? Where did you get those plastic inserts.
Very interesting... I have to do something like this to my vehicle, a 20 year old truck... oy!
Would this cause the recirculation button not to work right. Plus it blows hot air on the passenger side floorboard
Dude . Your awesome 👌
Great job Charles:):)
My Boxster has this exact problem. The various ways all really disturb me. A lot of collateral damage. They VW/Porsche/Audi really should have had a better plan.
Is disconnecting only the negative terminal on the battery safe enough, so that the airbag doesn't explode in our face, or we should disconnect both + and - sides?
Just negative is fine. Be sure isolate it so the cable can’t pop on.
Another great video
So I assume I should stay organized and be patient when pulling the dash?
Nah, I’ll just throw shit anywhere I can and hate myself when I can’t find it later.
Do they still use this same method on the newer cars? I had this issue on an mk3 jetta tdi and on an mkiv jetta tdi wagon.
Ah yes. It's a feature in my car. You can't put the fan on 3 or 4 or it will blow foam out into your face. Wait, no, that's not a feature...
Unrelated question: what do I do with subframe, ball joint, control arm, sway bar and strut top mount bolts/nuts. Tighten a bit, and torque on the floor? My Haynes manual doesn't say anything about it.
I've got no heat just cold air all the time, is it likely to be blend door issue??