EVC Blender Doors Fix by Jorrit Dijkstra

Moderately difficult Eurovan blender door fix.
As many people know, the Eurovans as well as other VW’s from that time period have a design
flaw in the blender box, where the air from the heater and air conditioner gets directed to the
various vents in the dashboard. Over time the foam on the two blend doors comes off, exposing
the 20 holes in these metal doors. This makes the distribution of hot and cold air problematic and
makes the heater and air conditioner not function properly. To do the repair, these holes need to
be covered with either aluminum HVAC tape, or with special plugs that can be sealed into the
holes. This 3D-printed plug set is made for MK4 VW Jetta’s, but works with Eurovans as well.
The plug set can be purchased from a small company called Digi Sport Performance on eBay
HERE for $20 plus tax and shipping. Their recommended sealant is Reinzosil (part #176404A2)
made by Victor Reinz.
So far there seem to be 2 ways that people access the blender doors:
1: Take off the entire dashboard, and get easy access the blender box. This is the best method,
since the blender box could be entirely taken out and cleaned, and the blender doors can be
easily covered. This method also has the advantage that the heater core can be replaced, if it’s
malfunctioning, and other areas of foam and weather stripping can be replaced. A big project,
that involves getting off the steering wheel and airbag, which might be a challenge that not
everyone is up to.
2: Take off the bottom parts of the center console, and access the blender box from the bottom
vent. You can go into the blender box with one hand, and try to tape over the holes without being
able to see what you’re doing. The rear door will be the big challenge. It’s worked for some
people with very small hands.
And then there’s the “in between” method, where the dash stays in place, but the radio and
heater controls are removed, and the Center Air Duct behind it is disconnected from the blender
box, and moved to the side. This way you can access the blender doors from the front, plugging
(or taping) the holes from the front, with one hand (yes, your hand will be scratched up).
This is how I did it:
- Purchase a set of 3D printed DSP blender door plugs (you don’t need the 4 oval shaped
ones, they are for VW Jettas and Passats), Reinzosil sealant and self-stick automotive
weather seal stripping, about 9/16” wide.
Reinzosil, weatherstripping and plug set. No need for the 4 oval ones on the right.
- Take a look at this picture in the Bentley manual. #17 is the Center Air Duct that will come
off the opening to the blender box (#20), to gain access to the blender doors.
- Remove the bottom console (cupholders, tray) and #16, the Footwell air outlet console
behind/above it.
- Remove the radio, heater controls and upper vent in the center console. The fronts of
these units and the top vents just pop off with a screwdriver. There are 3 cables that
operate the blender doors. Mark them and remove them, detach the electrical connectors
and remove heater control switches.
- Remove the knee padding under the passenger airbag. To do so, you need to pop off the
grey plastic cover to the right side of it, by the passenger door. There are three nuts to
remove. Also remove the bracket on the left side that attaches the knee padding
compartment to the metal frame above it.
- Locate the 2 plastic nuts on the left and right side of the Center Air duct. Take off these
nuts.
Remove this bracket Nut on Left (driver) side Nut on Right (pass.) side
- The Center Air Duct can now come off the blender box. Detach it from the 2 ducts that
feed air to the left and right air vents of the dash. Move the Center Air Duct to the left side,
it won’t come out of the dash, unfortunately. Now you can access the blender box from
the front, with one hand.
The Center Air Duct moved to the left side.
- Take a look at the picture below (thanks internet), which gives an idea of the location of
the holes in the blender doors. The door in the back has 7 small holes on the left side, and
4 small holes and 6 medium holes on the right side. The door on the front (left from the
opening) has 3 big holes. You need to go in and feel how it’s all located, and practice first.
You might need to remove all foam that’s still attached, and clean it all out with a vacuum
cleaner.
- Practice how you’re going to move your hand into the blender box opening and maneuver
the plugs into the holes. When you’re ready, apply Reinzosil sealant to the edge of each
plug, one at a time. Also apply a bit of sealant (or silicone caulk) to your right index finger,
and temporarily glue the plug to your finger, so you can get your hand plus plug in there.
The back door is the big challenge. You can move the doors by pulling the cables that
open the doors.
Your hand goes in here. Plug temporarily glued to finger.
- Watch out! Don’t drop the plugs! They will fall into the blender box and it’s unlikely you
can just pick them up. If one does fall, try sucking it up with a vacuum cleaner.
- Proceed till you have plugged all 20 holes. Your hand will be damaged. It’s not an easy
job, and you’ll have to prepare and practice to get your hand in there with a plug and not
lose it. With your left hand you can push the Center Air Duct out of the way.
- Clean the rim of the blender box opening, removing all remaining foam. Apply new
weather stripping to the edge of the opening (4 sides).
The plugs in place, minus one. Weather stripping applied to the opening.
- Push the Center Air Duct back onto the blender box opening, and re-attach the plastic
nuts.
- Put all the consoles and controls back, and finish off with the passenger knee padding.
Good Luck!
Jorrit Dijkstra
[email protected]

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Moderately difficult Eurovan blender door fix.

This is how I did it:

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