Bob, 
My 87 syncro had quite a bit of heat coming through the front heater core when it is off as well.
I thought the linkage was not adjusted correctly, but after reading your post I think I will pick up a new valve and do the same opp.
Pretty annoying with NO AC on a hot day for sure.  
I never understood how the side fresh air vents connect to blow hot air out as well, thought they were straight through to outside.
Anyway that will be an extremely nice improvement in summer for sure.

What is this??.... another "non factory procedure purging" vanagon owner???

awwww man!

bubble up!,

Doug

  ----- Original Message ----- 
  From: Bob Stevens 
  To: vanagon@GERRY.VANAGON.COM 
  Sent: Friday, May 21, 2004 4:35 PM
  Subject: Heater Valve Replacement

  I know this is an age old thread with skads of info in the archive so I'll
  be brief and direct. Replaced this today and I now have very nice, cool,
  fresh air coming through the lower dash/heater vents, and the side dash
  vents. After the valve came off I blew into it while it was "closed" and a
  very small amount of air went through. That apparently is enough for the
  persistent flow of hot air which had been coming through. Very well worth
  the effort.

  It was a great opportunity to change the coolant and that was done as well.
  But that's another age old thread as well. Suffice to say it was not
  necessary to do anything but purge the old coolant out of the system while
  things were apart and put new coolant into the radiator and plastic fill
  tank in the rear, then run the engine, burp at the rear, while adding
  coolant to the front. Took about 20 minutes.

  Messy but simple and straight-forward.

  Bob
  http://groups.msn.com/BobsPhotoShare