Heater box installation sequence

Sven

Sven

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Just trying to reinstall the heater box and AC blower assembly and getting frustrated. I thought the sequence was:
1. Install heater box unit (this part was easy).
2. Attach the AC base plate to the top of the transmission tunnel (4 screws).
3. Slide in AC box, while guiding the two pipes through the firewall, and getting the plastic plenum to engage the heater box.

The problem is getting the plastic air plenum (which I have first mounted on the top of the AC box) to slide into the receiving end of the heater opening. The alignment is off by about 5-10mm. I am fairly sure that preassembling the whole thing and sliding into place will not work (no way to attach the base plate to the tunnel in that scenario + no room to tilt the heater unit fore/aft).

Any suggestions?
Thanks,
 
some photos

Thanks Jerry. The assembly instructions make it look easy. Maybe the Bavaria has more room for shifting/tilting the AC into place. It does appear that the heater box should be fully installed before putting in the AC box. I will think about the geometry a bit more...
 

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  • PlenumCloseUp.jpg
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The 1/2" dynaliner in under the mounting bracket. The tabs for the bracket drop down through the foam to the metal tunnel, so the liner should not matter.

I may try removing the bracket, then slidd the AC unit into place, and then slide the bracket underneath the AC unit, and install the front three accessible screws only.
 
did one of these this weekend-
heater box all the way installed
plate with 4 screws
ac box with plenum
bracket for ac box in but not tightened !!!
remove 3 left side glove box hinge bolts and let box hang down.
use your hand in the ac box for leverage if needed
 
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