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I’ve got the later, manual air distribution controls, which now seem to be stuck on dash only. Ever since I had the car all positions have worked except full demist, which just clicked so I guess a rod is jammed or broken. But now I get no noise from the dash at all when I turn it.

As I had to take the pod off yesterday to replace a warning lamp bulb in the dash (Major PITA!) I suspect I’ve disturbed something in the switch or wiring (although to be honest I have no idea when I last moved the switch off demist/foot wells so it could have been toast for a while.

Does anybody have a pin out diagram for the HVAC connector on the back of the pod so I can test it before taking anything else apart? The only diagrams I can find are for the auto aircon pods. Also is there a specific fuse or relay for the mode control flaps? I can’t see one in any of the fuse boxes. The blower works fine so I know the connector is going home fully and both A/C fuses are good.

Thanks,

Chris

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Thanks both. I’ve stripped down the pod and cleaned everything up, no difference. I can hear the flap moving for recirculation and for the heater control, but the vents stay on dash only. I’ll dig into that wiring diagram now and see if I can find the culprit. If I can get at least some air into the demist vents I’ll be happy!

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Posted (edited)

Well from what I can tell the switch seems to be behaving as expected from the circuit diagram (although it’s had to be sure given none of the resistors are labelled with values!). But two things strike me as a little odd:

1) If I unplug the pod when the ignition is on a motor whirs somewhere, and when I short out pins 3 and 9 sometimes it whirs again, not sure if this is a sign of life from the air mix motor or not;

2) When I turn the switch to full demist, the recirculation flap opens regardless of the position of the switch, and the fact that the recirc light stays on. But it does prove that signals from the switch are making it through in at least one position.

I suspect number 2 might be normal operation of demist, but I’m damned if I can tell from the diagram. Anybody out there with manual controls know if theirs behaves like this?

Beginning to suspect the air mix motor might be kaput, but I can barely see it so I’ve not worked out how to get it out yet!

This is where I’m really missing the “self diagnosis” function of the auto aircon pod!

Edited by Scarecrow
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Posted (edited)

AndrewG you, sir, are a gentleman and a scholar. Those values match what I’m getting.

As it happens I have just found this online (should be a photo attached!)

It passes step A with flying colours, so the switch unit appears to be ok. Which means the problem is probably with the wiring between the switch connector and the amp connector. Deep joy. Looks like I have some ferreting around behind the dash in my immediate future…

9A37767A-C2F1-4196-A56C-03FE5AF060E6.jpeg

Edited by Scarecrow
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Possible progress. Following the loom around the instruments (ie where I was messing around replacing a bulb yesterday) I found this hanging. Looks like it could be “Intermediate Connector M49” in the HVAC loom, which seems to be vent related. Now I just need to find where it’s supposed to go. Access is a nightmare!

if anybody recognises this and it’s not related please shout! Abandoning till tomorrow morning now.

473F4A4A-3D23-4517-86DF-270C51CEBCD8.jpeg

A708E995-0132-42D3-989D-203F30561116.jpeg

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I did actually mean the instrument cluster but looking again I think it’s for the light pod, not ac.

Inked15434f78-b3e2-4a12-8834-e89c8c1de6cc_zps2ed1072c.jpg.5413f7edc187237185ab13a7bed730d8_LI.jpg.6f4d1a06031d157606fdd805988d8de2.jpg

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Posted (edited)

That connector was down behind the cluster while the cluster and all the pod connectors were still plugged in. There’s nowhere for it to go in either pod, and it’s mot long enough to reach the lighting pod. I suppose it could be an alternative connector for the auto version of the aircon pod? It just seems suspicious that after disturbing the wiring around the cluster I have mode doors not working and a cable disconnected!

Edited by Scarecrow
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I think your hope of it being a plug and play for the digital pod is very optimistic 😆.

I’d check my car for you but it’s not here with me, sorry.

I am swapping out the manual system for the S2 digital, one of many jobs for the Bristol one.

Inked15434f78-b3e2-4a12-8834-e89c8c1de6cc_zps2ed1072c.jpg.5413f7edc187237185ab13a7bed730d8_LI.jpg.6f4d1a06031d157606fdd805988d8de2.jpg

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1 minute ago, phutumsch said:

I think your hope of it being a plug and play for the digital pod is very optimistic 😆.

I’d check my car for you but it’s not here with me, sorry.

I am swapping out the manual system for the S2 digital, one of many jobs for the Bristol one.

No idea what it is, but one thing I do know is it’s not anything I disconnected when I took the cluster out, so it’s either fallen out during the process or it’s always been hanging there. It’s got one of the press-in clips on the side so I can’t see how it could fall out.

I think I can see the wiring connectors to the mode door motor, just trying to get fingers to them to check for security. Really hoping there isn’t a wire broken somewhere inside the loom 😞

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There’s no way one of those plugs is falling out, they’re a struggle to remove at the best of times 😡.

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Inked15434f78-b3e2-4a12-8834-e89c8c1de6cc_zps2ed1072c.jpg.5413f7edc187237185ab13a7bed730d8_LI.jpg.6f4d1a06031d157606fdd805988d8de2.jpg

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It’s a red herring. I’ve confirmed I have located the mode control motor and it’s connector, and the connector is firmly in place. But the motor equally firmly refuses to do anything. I think either the motor is dead, the control amp is faulty, or there is a break in the loom. I can’t see how to get access to the motor or amp without taking the entire dash out though.

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Expert advice from Jimmer is that the gears in the mode door motor have almost certainly fragged themselves through old age. It always did make a horrible noise trying to get into defrost, I guess that was the death rattle. The motor seems to be unavailable anywhere, so it looks like I’ll be moving the rods round by hand and fixing them in defrost/footwell position. Once the current monsoon finishes, that is…

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17 minutes ago, Scarecrow said:

Expert advice from Jimmer is that the gears in the mode door motor have almost certainly fragged themselves through old age.

Must have missed that post ☺️.

Inked15434f78-b3e2-4a12-8834-e89c8c1de6cc_zps2ed1072c.jpg.5413f7edc187237185ab13a7bed730d8_LI.jpg.6f4d1a06031d157606fdd805988d8de2.jpg

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3 hours ago, AndrewG said:

With my curiosity piqued it looks like someone has had a go at fixing the gears, amazing the detail you can get to with 3D printing.

https://imgur.com/gallery/Bk5aer5

 

Wow. I had no idea there were so many wiper arms in there! Pity you can’t get stainless replacement ones like the ones I found to replace the crumbling door lock actuator cams.

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Posted (edited)

Job done! After disconnecting the control rod from the motor there was still no life so the gears are either totally jammed or it’s burnt out, so I didn’t bother trying to manoeuvre it out. Just left it disconnected and locked the side link in the demist/footwell position.

For reference if you ever have to do the job, all you actually need to remove is the panel under the steering wheel and the two pieces of duct behind it, plus the instrument console glare shield if you want to get to the screw that holds the motor in. By far the hardest part is getting the ducts back into place, but well worth it to have demist back.

Edited by Scarecrow
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  • 2 weeks later...

Holy thread resurrection Batman… But the motor is working again. It took me 3 hours on my back in the footwell, a USB endoscope and some moves that would impress a Pilates instructor, but I managed to undo the screws and get the little blighter out from below. Turns out there was one broken tooth on the output gear wheel in the position it goes to for full demist.

Probably been broken for years, but what seems to be new is the broken bits had shifted and jammed the gearbox. Cleaned them out, put it back together, more yoga and all is working. Except I haven’t tried full demist and never will!

It might go again and if it does, it does, but confirmation the motor can be swapped without removing the dash, should you ever have to. And may the Lord have mercy on your soul if you do, I don’t ever want to contort like that again. Should have followed advice and taken the seat out!

Anyone know a good physio…? 🙂

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