Heater matrix replacement

[Airmech953]

I have recently finished replacing the heater core on my 05 D3 and I have a couple of observations. First up, the heater worked well on the driver side but not the passenger. When I removed the core water appeared to flow through it but a comparison of the new core weight to the original gave a good indication of blockage.
Having removed a lot of the centre console to get at the core, a look at the panels showed me that if I made a cutout of approximately 4"x 2" it would be possible to access and remove the heater without disturbing the centre console. There is enough room behind the trim panel to cut it in situ and refit the removed portion using anchor nuts.




IMG_20221211_162730403.jpgIMG_20230101_112749976.jpgIMG_20230101_112820816.jpg
This will save a lot of time for anyone contemplating a heater replacement and when the panel modification is painted it will be hardly visible.

[haydent]

You need to post a template here of that pattern, that we can trace with. Im guessing the AC evap tx valve wont be accessible anyway, but have a look for us while in there

edit, actually a template may not be necessary, as you gave dimensions and the dots are not critical ? just for cutting out ? what are the dots on the outside of the box for ?

[BradC]

A bit of upholstery paint on those rivets and screws and it'd just disappear. Neatly done.

[Airmech953]

You need to post a template here of that pattern, that we can trace with. Im guessing the AC evap tx valve wont be accessible anyway, but have a look for us while in there

edit, actually a template may not be necessary, as you gave dimensions and the dots are not critical ? just for cutting out ? what are the dots on the outside of the box for ?

Hope this picture, that shows where I cut the panel, clears up any queries. once the panel is cut, a backer needs to be made. I use 1mm sheet steel, riveted to the cut portion and then secured to the larger panel with 10-32 csk screws which picked up anchor nuts on the backer plate

IMG_20230103_134258932.jpg

[haydent]

looks great