No airflow into heater -- stuck door?

[sshanky]

Hi,

I didn't know where else to place this thread, since there's no "heating and ventilation" forum.

I don't get any airflow into the car. I removed the two center consoles and found that lowering the bottom part of the heater box (the part with the fan) allows air to flow freely through and come out the lower ducts...this led me to the control cable on the left side which controls the air intake vent on the top. I found that the cable was simply sliding when I moved the lever because something either in the cable or at the other end seems to be stuck. I tried manually moving the wire inside the cable but it moves only about 1/4 or 1/2 inch in total. I started lubricating it with oil, but then came to the conclusion that the door itself at the top of the cable is probably stuck.

I am not sure how to verify this, though -- does anyone know how to reach that door and find out if it's stuck? Or, is there any other way to fix this problem? I have not had any air blowing into the car since I got it, and now it's starting to get a bit chilly here at night and I'd love to have the heat.

Thanks a lot for the help!

[RRoller123]

I think the air flap you are looking for is under the front cowling, just ahead of the windshield. There are some threads here that can be found with the search engine about removing the cowling, it comes off pretty easily with just a few screws. Just be careful because it is really easy to badly scratch the fenders when taking it off. We usually tape up some protective material before removing it. While under there, you can refurb the windshield wiper mechanism and check for rust and treat that too etc.

[vandor]

You can get to the flap either by removing the cowl, or by removing the heater box.
It is not uncommon for the door to be rusted shut. A good lubrication should free it, and then make sure to use it every now and then to be sure it does not freeze up again.

[sshanky]

Thanks! That's awesome that you had the exact photo needed to show what the door looks like! I can't wait to try fixing it. I'll report back.

[baltobernie]

Peer down in there once you've opened the flap; there's usually old (and sometimes new!) nests and other debris in the plenum or on the core.

[RRoller123]

get the shop vac ready.....

[4uall]

just be careful not to pull any of the electrical wires or hoses

[sshanky]

Jay, I hope you're not driving yours now, eh? -- Ottawa's cold! I have family there and have been there many times. O Canada!

[4uall]

I think "cold" is a relative term It all has to do with geographical placement and someones tolerance to temp. We had our first light snowfall this week and it will probably be gone this weekend with the +8*C temp Fiona was put in the garage 06Nov12 and will be out on my birthday 06Apr13. There is a really good link of someone who did a complete cowl/vent maintenace project. I will try to find however, work links are different then home links arrggh Either way, good luck and come visit your family, they miss you LOL

[RRoller123]

December 1st to April 1st is my storage time here in Foxboro (Boston). We are a little milder than our frozen friends have it up north.

[sshanky]

Update...

I fixed it successfully. It was pretty stuck. A bit of penetrating oil and after a few minutes of playing and jiggling it came free. Works like a charm now. In fact, it's the smoothest lever of the three. Not too much debris on the heater core, as the vent was stuck closed. The suggestion about putting some tape on the edges of the fenders was GREAT. I can see that I would have had a bunch of scratched paint otherwise. Thanks!

I lubed all the wiper mechanism joints (took them apart, put lithium grease on the posts, oiled the shafts), but the wiper motor is still too weak to move the wipers initially on the dry windshield. I might need a new motor. But then again, living in AZ, probably don't really care.

There was a tube connected to the washer nozzles, but I could find no evidence of a washer fluid reservoir, nor a pump, and no noise could be heard when pulling on the wiper stalk lever.

It was a good cleanout, though. While I had the center console off (initially trying to debug the flap freezeup) I cleaned everything out, repaired wiring issues (the courtesy light works with the doors and the switch now, and I put a fresh bulb in the green lighter illumination ring but it still doesn't work).

And best of all, the heater works!

Thanks again for your input everyone.

[4uall]

Glad to hear/see it all worked out