Heater Core Replacement Tips, Addendum

Bernie Benz b.m.benz at prodigy.net
Tue May 28 07:02:05 EDT 2002

To those of us that live in  less benine climates than does George, IME with
two 44 chassis cars, the fresh air blower motor is prone to failure between
150K and 200K miles.  Inasmuch as the big job is the R & R in either heater
core or fresh air blower replacement, BTDT yesterday, here is a PM tip for
the blower.

IME it is the brushes in the blower motor that wear out and they can easily
be replaced without replacing the whole blower/motor assembly.  You can
guess how much the latter would cost!?

I researched and bought these motor brushes in '96 from Helwig Carbon, in
NYC, I believe.  Phone 414-354-2411, they may have a web site now.  They
were p/n 52H, 5/16" square x 1/2" long w/ 1" lead. Cost was $1.20 each in
quanties of 1-9!  You'll need two per blower motor.


> From: George Sidman <sidman at montereynet.net>
> Date: Wed, 22 May 2002 10:58:16 -0700
> To: 200q20v at audifans.com
> Subject: Re: Heater Core Replacement Tips
> Last week I replaced the heater core in my '91 200 TQW. Tom Forhan was
> kind enough to forward a detailed description of the process. From all
> the messages and help from listers, the bugaboo is obviously getting
> the box loose from its seal. I researched Bentley and found a picture,
> with no description, of an Audi extraction tool - a jack screw on a
> beam across the shock towers - obviously not something any of us would
> have access to. Taking a clue from the picture I wrapped coat hangers
> around each end of the box, and over a four foot 2x4 positioned across
> the shock towers, and lifted up one end. The box was out 2 minutes
> later. Contrary to Bentley, you do not need to remove the center
> console; just take off the console side panels, drop the two foot well
> heat ducts, and disconnect the little plastic vacuum manifold.
> The rest was easy. You pop off all the box center clips, remove the
> three screws, and note the flap positions. The trick there is to place
> pieces of masking tape on the upper part of the box, and draw the flap
> locations on the tape, along with a picture of the lever arm setup.
> Re-assembly can be done with your fingers inserted in the box as it
> comes together. You must seal the installation end of the new heater
> core with silicon sealant, and let it cure over night.
> --
> George Sidman, President
> Monterey Network Center
> sidman at montereynet.net
> 831. 657. 1500
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