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A/C - Floor/Defroster Shutter (Air Door) THE FIX !!!

Help, Advice and DIY Tutorials on Volvo's extremely popular car line -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, including 850 R, 850 T-5R, 850 T-5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

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marginal
Posts: 320
Joined: Wed Sep 23, 2009 9:24 pm
Year and Model: V70 D5 2003
Location: Ladarevo
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Volvo Repair Database A/C - Floor/Defroster Shutter (Air Door) THE FIX !!!

Post by marginal »

Well, I should probably have just added a post to that topic, but I decided to open a new one.
Let the moderators and administrator decide whether they should leave it as it is or merge it to the other topic.
So, there's no much to add to the already available info for disassembling the glove compartment, the lower dash panel and the bolster.
Only, I would like to introduce you to this tool:
Image
It is made by Gearwrench and I like it a lot for jobs where it's too tight as this one.
Also, you better use some paper and a 1/4" adapter to hold the screwdriver bit and the screw in place and start screwing it in by hand:
Image
So, my plastic which goes on the square steel shaft from the damper motor was so badly damaged, it fell off almost by itself.
I decided then, to use another system to fix this problem.
As you can see, there's an opening in the base of that plastic part, and it is much stronger than the rest:
Image
I decided to use it for controlling the air door opening.
Here's what you'll need:
1. A 1/4" plastic refrigeration flexible tubing like this one:
Image that I bought @ 18 cents for a foot from my local RONA store.
A CR-V1/4 screwdriver bit as this one:
Image
And a couple of small and black tie raps (as long as I remember, these ones are the most resistant to high temperatures amongst others).
First, you file the screwdriver bit from both sides about a mm. in order to bring it a little narrower and cut it about 2 mm. below the lock mark (I cut it exactly on the mark, but it is a little short) to shorten it up like that:
Image
Then, you add both the lenghts of the metal shaft of the electric motor which is this:
Image
And about 3/4 of the lenght of the screwdriver bit which is that:
Image
And you cut a piece of the refrigeration tubing of the same lenght.
After that, you stick the metal shaft of the motor in the plastic tubing all the way.
Then, you take the modified screwdriver bit with a pair of pliers and stick it in the other end of the plastic tubing until it seats firmly on the motor's metal shaft like that:
Image
Be careful to orient the screwdriver bit with its edges corresponding to the edges of the square electric motor shaft.
After that, you tighten the plastic tubing with the tie raps taking care to put the tie raps exactly in the middle of the shaft and the middle of the screw driver bit part of it like that:
Image
That's all about it.
After that, you reassemble the motor using the same modified tool for the difficult screw on the bottom rear side.

Enjoy :) !!!
PS, Please note, all the pix in this posting are thumbnails, if you click on them, you'll see much bigger pix.
In order to see even bigger, please email me and I'll send you the original pix.

marginal
Posts: 320
Joined: Wed Sep 23, 2009 9:24 pm
Year and Model: V70 D5 2003
Location: Ladarevo
Has thanked: 1 time

Post by marginal »

Here's the second version of the fix using a modified philips CR-VPH.2 screwdriver bit.
It is better than the slotted one as the edges of the modified phillips bit go in the four corners of the plastic opening of the vent door, and the slotted edges go only in two of them.
So, same procedure, you take a phillips CR-VPH.2 screwdriver bit like this one: Image
Then, you cut it on both ends like that: Image
Following is the insertion of the square shaft and the modified screwdriver bit in the plastic refrigeration tubing like this: Image taking care to match the edges of the modified phillips bit and the square el. motor shaft.
Then, you finalize it by tightening it with tie raps like this: Image taking care to align the locks of the tie raps so they don't disturb the motion of the el. motor shaft.

Enjoy :-).

Free2drive!
Posts: 226
Joined: Tue Oct 24, 2006 3:31 am
Year and Model: 2004 V70
Location: York
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Post by Free2drive! »

Hello, I really appreciated your fix and have spent this afternoon reconnecting my floor/defrost flap to the motor.

I am still getting code 2-3-2 and 2-3-3, I can't clear them and I am still not getting heat to the floor.

Do you have any advice?
Thanks
Matt

marginal
Posts: 320
Joined: Wed Sep 23, 2009 9:24 pm
Year and Model: V70 D5 2003
Location: Ladarevo
Has thanked: 1 time

Post by marginal »

Hi Matt and thanks for the compliment :) .
The mechanical and the electronic parts of this system are completely apart (unless, I guess, there's a force stopping the el. motor from turning).
So, have you tried to test the floor heater with the el. motor disassembled from its stand?
Meaning, while repairing the plastic shaft of the floor heater door and having taken off the el. motor if you turn the control knob on the climate control panel you can see whether it turns or not.
You might also put some load on the metal shaft in order to see whether it has the necessary strenght (something that it should).
If all this functions OK, the problem is in the electronic part of the system.
In this case, can't you borrow a climate control panel (they're very easy to take off and put on) and try again.
Hope this helps.

Free2drive!
Posts: 226
Joined: Tue Oct 24, 2006 3:31 am
Year and Model: 2004 V70
Location: York
Been thanked: 1 time

Post by Free2drive! »

marginal wrote:Hi Matt and thanks for the compliment :) .
The mechanical and the electronic parts of this system are completely apart (unless, I guess, there's a force stopping the el. motor from turning).
So, have you tried to test the floor heater with the el. motor disassembled from its stand?
Meaning, while repairing the plastic shaft of the floor heater door and having taken off the el. motor if you turn the control knob on the climate control panel you can see whether it turns or not.
You might also put some load on the metal shaft in order to see whether it has the necessary strenght (something that it should).
If all this functions OK, the problem is in the electronic part of the system.
In this case, can't you borrow a climate control panel (they're very easy to take off and put on) and try again.
Hope this helps.
Thanks, neither of the motors move heat/defrost or ventilation when away from the heater unit so it could be a problem with the control panel. Or both motors have burned out, I need to test them away from the car.

The flap moves freely without the motor connected so very little resistance.

I guess if the motors are seized or burned they would leave a code.
Matt

marginal
Posts: 320
Joined: Wed Sep 23, 2009 9:24 pm
Year and Model: V70 D5 2003
Location: Ladarevo
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Post by marginal »

Hi Matt.

Why don't you just test the current coming to the el. motor?

milesursogood
Posts: 101
Joined: Sat Sep 26, 2009 7:55 am
Year and Model: 850 T-5, 1997
Location: Portland
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Post by milesursogood »

Marginal - how is this fix working for you. It should be a few months now since your post. Is it still working well? It appears in this fix that you completely broke-off the broken end of the damper shaft so there's clearance around the tie-wrap. How did you get the damper off as shown in one of the images? Did you have to disconnect the battery when you completely disconnected the electric motor?

marginal
Posts: 320
Joined: Wed Sep 23, 2009 9:24 pm
Year and Model: V70 D5 2003
Location: Ladarevo
Has thanked: 1 time

Post by marginal »

Hi milesursogood.

Everything is working OK ...
The parts that were still on (2 out of 4 walls of the square plastic opening) were soooooooo very much loose, that I decided to just brake them and take them off.
The remaining opening is on the contrary very strong.
I even forced the modified screw driver bit into it with no damage (so it stays firm on the plastic) ...
BTW, I didn't brake the loose plastics in order to make room for the tie-wrap, but because they were just hanging on a small, thin fragile plastic ...
You don't need to disconnect the battery, there's no big deal about disconnecting this el. motor.

Good luck, and don't hesitate to ask in case you have any further questions.

Free2drive!
Posts: 226
Joined: Tue Oct 24, 2006 3:31 am
Year and Model: 2004 V70
Location: York
Been thanked: 1 time

Post by Free2drive! »

Free2drive! wrote:
marginal wrote:Hi Matt and thanks for the compliment :) .
The mechanical and the electronic parts of this system are completely apart (unless, I guess, there's a force stopping the el. motor from turning).
So, have you tried to test the floor heater with the el. motor disassembled from its stand?
Meaning, while repairing the plastic shaft of the floor heater door and having taken off the el. motor if you turn the control knob on the climate control panel you can see whether it turns or not.
You might also put some load on the metal shaft in order to see whether it has the necessary strenght (something that it should).
If all this functions OK, the problem is in the electronic part of the system.
In this case, can't you borrow a climate control panel (they're very easy to take off and put on) and try again.
Hope this helps.
Thanks, neither of the motors move heat/defrost or ventilation when away from the heater unit so it could be a problem with the control panel. Or both motors have burned out, I need to test them away from the car.

The flap moves freely without the motor connected so very little resistance.

I guess if the motors are seized or burned they would leave a code.
Matt
OK this is totally fixed now!!! I have heat on the floor or on the windscreen for defrost/demist. I am very happy, thanks for the help. I removed the motor and reattached the parts that drive the flaps. Then reattached the motor and bingo it works.

I was able to read codes from a homemade code reader from the Volvo club uk: http://www.volvoforums.org.uk/showthread.php?t=83897

I had codes (10 altogether) and as I persisted cleaning out the fans above the upper door handles and eventually the whole thing came together.

It works, its cold, and I'm warm in my car. Thanks!
Matt

marginal
Posts: 320
Joined: Wed Sep 23, 2009 9:24 pm
Year and Model: V70 D5 2003
Location: Ladarevo
Has thanked: 1 time

Post by marginal »

Glad to know you succeeded.
No more cold feet :D ...

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