HVAC (1 OF 6)
I got into this system because the heater was fubab’ed and I wanted to get it working before I really needed the warmth. I found a lot of missing, broken, disconnected, worn out, dirty, and deteriorated parts during this quest for heat. My goal was to get the whole system functioning properly with the exception of the AC compressor loop. I don’t really need or want AC and the compressor is missing anyway. So here is a list of what I had to do to the heating, ventilating, and air conditioning (HVAC) system to get it functional and me warm.
This schematic in the Service Manual gives
a good overall picture of the HVAC system.
PROBLEM 1: The passenger side AC diverter ball housing has two broken retaining tabs so the ball flops around in the hole.
SOLUTION: I wanted to reuse the existing housing because it has factory paint. I installed a screw near one tab and epoxied near the other (no easy way to drill in this location). The ball now sits firmly between the felt pads.
PROBLEM 2: The uppermost lever in the Control Unit (CU) is broken.
SOLUTION: I got a new lever, removed and disassembled the CU, installed the new lever, cleaned and lubed as necessary, and reinstalled the CU. The CU is a busy little mechanism what with two lamps, the fan speed connector, three Bowden cables, three vacuum lines, and a bracket connected to it, all in a very confined space. It’s a good idea to mark everything and take a lot of pics so you know where stuff goes when you hook it back up.
