OK. I've finally installed it. It is a PITA, I can tell you that much. You will need 4 parts taken from a B5 Passat (and a lot of patience...):
Hose 3B1-816-311 $12.10
Valve 3B0-816-355-01C $2.04
Outlet 3B1-820-701 $10.44
Some long tie-wraps
[image]http://pics.tdiclub.com/showphoto.php?photo=14906&password=&sort=1&size=medium&cat=500&page=[/image]
First start by removing the armrest cover
[image]http://pics.tdiclub.com/showphoto.php?photo=14905&password=&sort=1&size=medium&cat=500&page=[/image]
Remove the 13mm bolt for the armrest and pull up on the armrest to remove it.
[image]http://pics.tdiclub.com/showphoto.php?photo=14907&password=&sort=1&size=medium&cat=500&page=[/image]
Open and remove the rear ashtray and remove the 2 bolts under it.
[image]http://pics.tdiclub.com/showphoto.php?photo=14908&password=&sort=1&size=medium&cat=500&page=[/image]
Pull out the tabs for the center console bolts and remove the bolt on each side
[image]http://pics.tdiclub.com/showphoto.php?photo=14909&password=&sort=1&size=medium&cat=500&page=[/image]
Remove the fron console bolts in each footwell.
[image]http://pics.tdiclub.com/showphoto.php?photo=14910&password=&sort=1&size=medium&cat=500&page=[/image]
Pull up on the shifter boot ring to seperate it from the console
[image]http://pics.tdiclub.com/showphoto.php?photo=14911&password=&sort=1&size=medium&cat=500&page=[/image]
Pull the e-brake up all the way. Lift the fron console up to seperate it from the center console and lift the center console up from the rear in a swiveling motion to slide it over the e-brake.
[image]http://pics.tdiclub.com/showphoto.php?photo=14912&password=&sort=1&size=medium&cat=500&page=[/image]
NO PIC... revome the red fron ashtray and revove the bolt underneath. Slide the front console towards the rear while pushing the ashtray assembly towards the front. It will slide out as you remove the console. Rund the shift boot through the console as you lift.
Remove the driver side under dash panels. There are 3 bolts under the panels. DO NOT remove the 2 bolts for the diagnostics adaptor.
[image]http://pics.tdiclub.com/showphoto.php?photo=14913&password=&sort=1&size=medium&cat=500&page=[/image]
Open the fuse box cover and pull out the dash side panel
[image]http://pics.tdiclub.com/showphoto.php?photo=14914&password=&sort=1&size=medium&cat=500&page=[/image]
Pull the left under-dash panel out
[image]http://pics.tdiclub.com/showphoto.php?photo=14915&password=&sort=1&size=medium&cat=500&page=[/image]
Remove the last bolt for the right under-dash panel and pull the panel out.
[image]http://pics.tdiclub.com/showphoto.php?photo=14916&password=&sort=1&size=medium&cat=500&page=[/image]
Picture of the car without the consoles showing the boot and ashtray left behind
[image]http://pics.tdiclub.com/showphoto.php?photo=14917&password=&sort=1&size=medium&cat=500&page=[/image]
Remove glove box bolt under radio
[image]http://pics.tdiclub.com/showphoto.php?photo=14918&password=&sort=1&size=medium&cat=500&page=[/image]
Open glove box and pull out the right dash side panel
[image]http://pics.tdiclub.com/showphoto.php?photo=14919&password=&sort=1&size=medium&cat=500&page=[/image]
Remove all 6 remaining glove box bolts: 3 inside on top and 3 under the glove box
[image]http://pics.tdiclub.com/showphoto.php?photo=14920&password=&sort=1&size=medium&cat=500&page=[/image]
As you pull the glove box out, don't forget to disconnect the glove box light!
[image]http://pics.tdiclub.com/showphoto.php?photo=14921&password=&sort=1&size=medium&cat=500&page=[/image]
Remove the 4 radio/climate control module bolts
[image]http://pics.tdiclub.com/showphoto.php?photo=14922&password=&sort=1&size=medium&cat=500&page=[/image]
Pull out the panel under the AC switch and remove the bolt behind it, then pull the radio/ A/C module out and let it hang
[image]http://pics.tdiclub.com/showphoto.php?photo=14923&password=&sort=1&size=medium&cat=500&page=[/image]
Drill a 7/8" hole in the bottom right corner of the A/C duct. There is a flat surface there. This location will work only when the front vents are selected (no windshield vent). I didn't want to risk hitting the A/C coil in the ducts...
[image]http://pics.tdiclub.com/showphoto.php?photo=14924&password=&sort=1&size=medium&cat=500&page=[/image]
Pull the white insutation up from the bottom and insert it in the upper dash to hold it temporarily while you work in there. Run the glove box A/C hose from the hole to behind the glove box behind the metal support in the dash
[image]http://pics.tdiclub.com/showphoto.php?photo=14925&password=&sort=1&size=medium&cat=500&page=[/image]
Make sure the wire harness is placed as in this picture
[image]http://pics.tdiclub.com/showphoto.php?photo=14926&password=&sort=1&size=medium&cat=500&page=[/image]
Install the outlet tabs behind the wire harness and connect the hose to it. The tabs will hold the wires tightly so wear is not an issue
[image]http://pics.tdiclub.com/showphoto.php?photo=14927&password=&sort=1&size=medium&cat=500&page=[/image]
Install a tie-wrap around the 2 bolts shown by the arrows. The tie should wrap at the front of the outlet to push it in making sure it stays straight
[image]http://pics.tdiclub.com/showphoto.php?photo=14928&password=&sort=1&size=medium&cat=500&page=[/image]
Put the insulation back in place and cust a hole in it for the outlet to seal against the glove box
[image]http://pics.tdiclub.com/showphoto.php?photo=14929&password=&sort=1&size=medium&cat=500&page=[/image]
I had to snip pieces of the outlet foam away to better aling the hole in the glove box valve
[image]http://pics.tdiclub.com/showphoto.php?photo=14930&password=&sort=1&size=medium&cat=500&page=[/image]
Punch the hole piece out of the glove box. Push on it from the inside. It will pop out
[image]http://pics.tdiclub.com/showphoto.php?photo=14931&password=&sort=1&size=medium&cat=500&page=[/image]
Push the valve in the hole
[image]http://pics.tdiclub.com/showphoto.php?photo=14932&password=&sort=1&size=medium&cat=500&page=[/image]
Re-install in the reverse. Here is the ETKA diagram for the Passat B5 air ducts. Number 27A on the diagram is a rubber seal that retails for $50. It is not needed. I tested my new glove box A/C on a few trips and I was quite successful at keeping drinks and baby formula cold!