D.Air Blowing Constantly From Defroster Outlets Model 107

If air continues to exit from the defroster outlets, with buttons "Normal" or "EC" engaged and the system is in the cooling mode, the linkage attachment eyelet on the left defroster flap may be broken off.

NOTE: It is not necessary to replace the left flap. Both right and left flaps are identical and need only to be exchanged from side to side. Short-cut methods involving replacement of only the left flap by defroster duct removal are not allowed since complete re-attachment of the duct is not possible. Also, the chances for dropping a shaft bushing are greatly increased. Both conditions will lead to future noise complaints. Warranty will be rejected if the following repair method is not used.

FIGURE 11:

Exchanging Air Flaps

1. Remove instrument panel, (Job 68 - 100)

2. Remove clip (9) on left and right side of airduct (Figure 11).

3. Pull flap shaft (common shaft for right and left flap) out to the right, but only far enough to allow the flaps to be removed.

CAUTION: Do not drop the shaft end bushings into the housing when removing flaps. If a busing is dropped into the housing it must be removed to prevent future noise complaints.

4. Examine the eyelet on the nap removed from the right side for any signs of cracks or damage. If none, exchange left with right air flap and reinstall shaft and clips.

5. Check to be sure that the flaps open and close without binding. If a new attachment rivet is needed, use part no. 000 990 34 92.

6. The remaining re-installation is performed in reverse order.

FIGURE 12:

NOTE: To prevent flap damage during reassembly before installing the instrument cluster, apply vacuum to the element to close the flap as shown in Figure 12. Keep the flap in this position by locking the linkage of the vacuum element with a wedge (arrow). After the instrument panel is installed remove the wedge.
Time Allowance

83-S36-01 Major Operation 8.9 hours
83-S36-02 Related Operation 8.7 hours