Core replacement Completion!!! But beware, these pix are for the strong stomached (major bww)
11-30-2003, 07:01 AM
#1
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Core replacement Completion!!! But beware, these pix are for the strong stomached (major bww)
After a complete week of work I finally finished up my project. I had to replace my evaporator core because it had cracked, and replaced the heater core just because I had it all apart already. While it only took me a few hours (5 or so) to get the dash out, I found more things that needed to get fixed along the way. I pulled my battery and found a huge amount of rust on the tray itself and corrosion on the paint and what not from the acid. Needless to say, I wanted to stop the rusting of my second firewall and prevent it from spreading. I bought rust stopper/preventer from the local napa and sprayed it down with a little plastic dip, which is suppposed to at least slow the acid corrosion. In addition I noticed that my dash was starting to peel from the hard plastic base so I had to contact cement that in place. But here are some pix of the progress... hope you all enjoy!
Pic of the operating table and the patient:
<img src="http://pictureposter.audiworld.com/21175/dscf0126.jpg">
center console and glovebox removed:
<img src="http://pictureposter.audiworld.com/21175/dscf0133.jpg">
Steering wheel removed and lower knee bolster:
<img src="http://pictureposter.audiworld.com/21175/dscf0136.jpg">
The parts that have gathered so far:
<img src="http://pictureposter.audiworld.com/21175/dscf0140.jpg">
Battery removed... notice all the rust:
<img src="http://pictureposter.audiworld.com/21175/dscf0142.jpg">
Dash removed... brace yourself this is nasty:
<img src="http://pictureposter.audiworld.com/21175/dscf0148.jpg">
And with every project there is always at least one casualty... this was that bunch of plugs I couldn't get to and pulled a little too hard on the dash... Once it was unplugged and removed everything pulled right out:
<img src="http://pictureposter.audiworld.com/21175/dscf0147.jpg">
Here's the dash on the ground and the a/c box out:
<img src="http://pictureposter.audiworld.com/21175/dscf0156.jpg">
The raging F'ing p.o.s. that broke!!!
<img src="http://pictureposter.audiworld.com/21175/dscf0152.jpg">
Battery tray removed (before, during and after repair):
<img src="http://pictureposter.audiworld.com/21175/dscf0162.jpg">
<img src="http://pictureposter.audiworld.com/21175/dscf0169.jpg">
<img src="http://pictureposter.audiworld.com/21175/dscf0177.jpg">
And the final repair (I patched up the rust on the frame too with the same stuff... then painted it with the plastic dip) Hopefully this will slow the problem.
<img src="http://pictureposter.audiworld.com/21175/dscf0183.jpg">
And that pretty much completes the process... minus this one... dash repair
<img src="http://pictureposter.audiworld.com/21175/dscf0172.jpg">
I have probably 50+ pix of this process, but my pic poster only allows so many =P
I did use a baking soda mix to neutralize the battery acid and what not... and damn that stuff fizzed when I put it on...
Hope you all enjoyed the show... It was a good project to undertake but I def have a lot of bloody knuckles from it. I do have a good feeling of accomplishment once this was done though (esp when the airbag did not blow up in my face and there were no CEL lights), but a bummed feeling because I did not do anything "cool" =P Just plain old maintenance... oh well... with time I will have some more fun
Pic of the operating table and the patient:
<img src="http://pictureposter.audiworld.com/21175/dscf0126.jpg">
center console and glovebox removed:
<img src="http://pictureposter.audiworld.com/21175/dscf0133.jpg">
Steering wheel removed and lower knee bolster:
<img src="http://pictureposter.audiworld.com/21175/dscf0136.jpg">
The parts that have gathered so far:
<img src="http://pictureposter.audiworld.com/21175/dscf0140.jpg">
Battery removed... notice all the rust:
<img src="http://pictureposter.audiworld.com/21175/dscf0142.jpg">
Dash removed... brace yourself this is nasty:
<img src="http://pictureposter.audiworld.com/21175/dscf0148.jpg">
And with every project there is always at least one casualty... this was that bunch of plugs I couldn't get to and pulled a little too hard on the dash... Once it was unplugged and removed everything pulled right out:
<img src="http://pictureposter.audiworld.com/21175/dscf0147.jpg">
Here's the dash on the ground and the a/c box out:
<img src="http://pictureposter.audiworld.com/21175/dscf0156.jpg">
The raging F'ing p.o.s. that broke!!!
<img src="http://pictureposter.audiworld.com/21175/dscf0152.jpg">
Battery tray removed (before, during and after repair):
<img src="http://pictureposter.audiworld.com/21175/dscf0162.jpg">
<img src="http://pictureposter.audiworld.com/21175/dscf0169.jpg">
<img src="http://pictureposter.audiworld.com/21175/dscf0177.jpg">
And the final repair (I patched up the rust on the frame too with the same stuff... then painted it with the plastic dip) Hopefully this will slow the problem.
<img src="http://pictureposter.audiworld.com/21175/dscf0183.jpg">
And that pretty much completes the process... minus this one... dash repair
<img src="http://pictureposter.audiworld.com/21175/dscf0172.jpg">
I have probably 50+ pix of this process, but my pic poster only allows so many =P
I did use a baking soda mix to neutralize the battery acid and what not... and damn that stuff fizzed when I put it on...
Hope you all enjoyed the show... It was a good project to undertake but I def have a lot of bloody knuckles from it. I do have a good feeling of accomplishment once this was done though (esp when the airbag did not blow up in my face and there were no CEL lights), but a bummed feeling because I did not do anything "cool" =P Just plain old maintenance... oh well... with time I will have some more fun
11-30-2003, 02:56 PM
#4
AudiWorld Super User
Any chance of you e-mailing me the rest of the pics?
I have to replace my core too. I purchased all the parts but wimped out this year. In the spring I am gonna need to get at it.
11-30-2003, 04:06 PM
#5
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Actually... I never noticed it peeling up.
When I pulled the dash off I noticed it peeling up. I had read here about people having this issue, so I counted myself lucky that it never peeled up and pulled out the jug of contact cement and had at it.
It's really easy to fix, just a pain in the a$$ to get to.
It's really easy to fix, just a pain in the a$$ to get to.
11-30-2003, 04:09 PM
#6
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They're pretty high res, so I might run into issues sending them via email.
What I actually did was print out all the info on the bentley manual and then talked to my mechanic for hints. If you have a fax machine, I can fax you the info that I have...
Email me if this sounds like something of interest to you. I can also help you out with some hints as well.
Email me if this sounds like something of interest to you. I can also help you out with some hints as well.
