Heater Box and Fans

I had to remove the heater box and ventilation fans in order to work on the wiring as the wire bundle ran behind the heater box.

As I was putting everything back together, I tried the interior fan.  It was a little noisy, so I took apart the heater box and oiled it.

The other thing I noticed was the cowl vent flap rubber was toast.  You can see some of the rubber that broke off sticking up vertically.  It originally was sandwiched between two metal plates as shown by the arrow.

I tried to pry apart the two layers, but they are spot welded together (evidently after the rubber was inserted, must have stunk).  I ended up just gluing some thin rubber to each side where they will seal against the opening.  You can just see the new rubber lying against the metal housing.

After that was done, I could install the heater box.  It goes on the inside under the dash with the heater pipes and a large air pipe going through the firewall.  First I insulated the firewall behind where it was to go.  Then I put some foam tape between the heater box and cowl opening.  Once that was done, the heater box slid into place and I put the fan switches back on.

Then the defrost fan inserts from the engine side, fitting into the large air pipe.  The wiring for that fan also goes through the air pipe and out the left side.  Right where the wiring would go through the heater box, it was damaged, presumably from rubbing on the metal edge.  First I put a bit of shrink wrap where the damage was to prevent a short.  I also put a grommet in the hole so no damage will happen in the future.  Of course, I bench tested the fan.  Here's the defroster part that's in the engine compartment.  The defroster hoses will run from the pipes on each side of the unit through the holes in the firewall that are above them.