Quote:
Originally Posted by callisto9
.....I don't smell it when the recirc is on, only when the air is coming from outside.....
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Well that narrows it down. If you aren't smelling it with recirc on, then the source of the stink is NOT the evaporator. So stop focusing on it as the source. The source of the stink has to be somewhere in the plenum before the door that shuts the outside air off. The good new is that you don't have to replace the evaporator. The bad news is that you may have to just tear things apart to find exactly where the souce is. What I would do is start from the outside and work inward. The HVAC system draws air in from the outside under the cowling in and around the wiper arm mecahnism. I'll bet there is some rotting organic material (leaves and such) thats gotten down in there.
You should be able to get to this from the engine compartment. You'll have to remove the plastic shroud at the base of the windshield. I've never done this on a Beetle so don't know whats involved. Worst case - you may have to tear out part of your dash to get to all the air chambers to clean the junk out.