HVAC question and dash removal etc

[Reddirt204]

It's me again.....

I have noticed that my D2a has very poor fan/blower output and the aircon/heater seems to really struggle, after a bit of investigation it looks like the dash has been removed, or a fair chunk of it as I think the heater core has been replaced. It looks like (from the glovebox access) that the air direction unit (or what ever it's called) seems to have not been put back properly, there seems to be a 5-20mm gap between the upper and lower sections. Sooooo this might explain where all the air is going[bighmmm]

My questions are,
Do I need to pull the whole dash to fix?
Do I need to disconnect the aircon to do this work?
I have a D2 parts doner with good dash etc, they look the same (pre and post facelift) will they interchange? as mine has some damage
Will the HVAC unit swap over if I find mine has been damaged (might just be poor installation)

I know this isn't an afternoon job, but planning for Christmas as I have a few weeks off, just wanting to get things sorted before I jump right in

cheers

Redd

[AK83]

I had a similar issue to my D2 some years back(so can't recall perfectly).

very little air output, despite a very energetic fan.
I pulled the dash fascia off and found that some gorilla had smashed the heater box area "to tiny bits"!
The damage was mainly on the pass/glovebox side, but couldn't reach any of the damaged area via glovebox(removed).

I superglued as much as I could reach back together but for sure I missed some bits that I couldn't see, and the 'bits' I couldnt' get too I just used silicon to seal up some of the smaller holes I could see.

I really should have removed dash and just replaced heater box, but didn't have time back then.

There are foam sealing rings between many duct joints, and if not put back will leak. Something else to look for.
They also deteriorate and can dissolve away and or crumble away if touched.
I've had both situations(D1 and D2).
Some packing foam is usually good as a replacement, which I cut a little bit thicker to help which rattles and squeaks too.

Can't say for sure for 'ya ... but between the glovebox removed and fascia removed you may have enough access to get to what you need. But if the backside has the same gap, then for sure it'll be a dash out job.

[Reddirt204]

Thanks AK83

Yeah, when I was hunting for the SRS light fix (behind the glove box, it was unplugged..) I could see the gap between the upper and lower sections, I did try to stuff a bit of foam and wrap some gaffer tape around the 2 sections but didn't really make much difference, my sons D2 aircon/heating works very well so I know mine is leaking somewhere.

cheers

Redd