91 jetta gl ac problems

[1967ss]

Hi guys, I have a 91 jetta gl wolfsburg edition that started blowing foam out the vents awhile back. Now I can't get any cold air or hot air from the vents. What could be the problem and what is a detailed fix for it? I'm not new to cars but new to volkswagons. Thanks

[Doug Tatham]

The A/C evaporator box and heater core box have panels that direct flow of air. They are made of metal and covered with foam rubber. I used window self adhesive insulation and protable A/C unit filters to fix mine.
You have to remove the instrument panel, instrument cluster, and dashboard to get to the cores. You have to drain the coolant to get before removing the heater core as well as have the A/C system discharged. The heater core and evaporator boxes have bolts on the engine side of the firewall that will have to be removed. You should replace the drier on the A/C after opening the system up. Expect to put in a very full day.

[1967ss]

Thanks for the information. Just exactly how does the dash come out? I removed the lower part and console and removed the side screws and lower screws but it still doesn't move. As far as where the panels that direct air are, do they slide apart or do they have screws somewhere? I've looked hard at this (maybe I'm looking too hard) but I can only see it sliding upward for access to the door panels inside the box. Am I missing something?
Thanks

[Doug Tatham]

If I recall correctly there are 6 screws that hold the dash on. One on each side, which you found. Two on the bottom of the dash that attach to the metal frame work. And finally there are two nuts inside the engine compartment. One is hard to get to because the windshield wiper motor and mechanism is in the way, the other is beside the outside air intake vent. You have to remove the plastic cowl to access the nuts. You have to remove the instrument cluster first, it sounds like you've done this. The plastic part that surrounds the cluster has screws behind the light switch and a couple other blanks or switches. When you remove the dash you'll be able to access the boxes. The boxes are held together by clips that pop on and off. They have holes in the top and bottom that act as hinges for the air flow directing panels.

[1967ss]

Thanks a bunch! Just what I needed to know.