Last weekend started working on my vacumn issues in the 87S4. Used Pirtles writeup and other threads as guides.

Here is the list of what I found.
Blue = good = recir flap
White = good = heater valve
Orange = bad = center comb flap
Green = bad = defrost
Yellow = bad =footwell flap

Removed the center console to access the center comb and footwell actuators. Disassembled easy enough. Hope I remember how it all goes back together. Disappointed to find some broken plastic parts in the center console. Few screws missing as well.

Now to get new diaphrams from Roger.

Even though the recir flap tested good I need to investigate further as a first look up there appears to be some type of modification. Tie wrap and blue tape?

 

Ahh, the tiewrappenblutapen option. Yes. That's a good one. Mine also has the bigwasherductapen option in a few places. I actually found vandalism (I guess?) inside the door panel, someone signed it in pencil with a date. Don't know what's up with that.

Good luck with that. I've tackled most of the mechanicals in mine, but haven't attempted any work on the HVAC system yet. That looks like a real can of worms.

 

Talked to Roger last night during the rain/hail/tornado storms and I think we are going to try to get a tech session together for the local folks on A/C issues. All of mine need it.

 

Having just completed this, I can lend a hand.

 

My whole HVAC system is dead (plus I have no AC belt - was like that from the PO) so I would love to try and join a tech session up north.

Cheers

 

I'll come and help out. Where, when?

Note; I'll have some RS relays for those who need the relay fix in the head. Takes about an hour or so. It's a retroactive fix, or can be proactive if you've got the head out of the car.

 

I just had the same failures the hardest piece to fix was the center comb flap, there is not to much room to work with and it's difficult to see through the side vent. If you dont allready have one I would recomend picking up a small led flashlight it made a world of difference than my small aaa maglite. I bought my from Home Depot about 30.00

 

Next step was the defrost diaphram. Pod came out pretty easy. Obviously has been out before. One of the allen head bolts was stripped out but luckily it was the one easily accessible. One thumbwheel switch base was broken, superglued. Missing a couple of dash lights. The defrost diaphram was the hardest one to get at so far. The plastic part where the rod attaches to the flap partially broke off. I see Sean R. had the same issue and was able to fix. Sean, how did you get to that??

Parts on the way from Roger.

Here's some pics on the mess I have so far.

 

I used a small nut and bolt combo. Red Loc tighted the nut at the end of the bolt so it gave wiggle room for the actuator arm.

Having smaller hands helped a lot.

Oh, on edit.

Be sure to test the actuators after you replace them, using the connectors on the vacuum rail. Some of mine took a couple of tries when assembling them. Don't assume that just because the parts are installed, that they are seal correctly.

 

I was in over my head so figured I might as well pull the dash out at this point. I have another dash that's in much better shape than the original. Dash actually came out pretty easy. Didn't have to pull the A pillar covers. One more hand would have been nice. That gave me more room to work on the defrost diaphram arm. Was able to get in there and remove the arm. Now I need to find a pin like they have on one of the other actuator arms.

The blue thing holding the flap on the passenger side turned out to be a blue safety belt? Funny thing is that this diaphram worked fine. Replaced it anyway since it was all apart.

Ran into an issue with the defrost diaphram. The one I got from Roger isn't the same size???? Obviously a different size than original Doesn't hold vacumn. Sean, thanks for reminding me to check before putting everything back together.

Hope I'm not creating more issues messing around with the fuse panel. There's already several modifications/fixes in there.

 

It's all going back together now. I had this washer in my pod bag. Don't know if it actually came from there. Anyone know where it goes?

 

Fixed the defrost arm much the same as SeanR. Drilled a hole in the arm and used a bolt and nylock nut to put it back together.

 

Plenty of extra wire that seems to go nowhere branching off in all directions. Removed a bunch to try and clean things up.

Now my horn doesn't work. Wonder which wire that was???

Tomorrow I'll check and see how fixing all the new vacumn diaphrams work.

 

before you go to much troubleshooting to fix the horn make sure the horn ring is touching the back of the steering wheel, also check fuses

 

First thing I looked at was the fuses. I'll check the horn ring since the steering wheel was removed maybe something happened there.