2.0 8V bottom end rebuild (by idiots)

[eyesoreracing]

Sometimes if you turn the fan to Auto, it would turn off and was hard to turn back on again. Partially this was the damaged knob, but partially it was this missing stopper that allowed the knob to go past Auto to no-mans land where the contacts didn't tell the system anything.



But what''s that blurry little white thing in the lower right corner? Its the missing stopper!



Superglue to the rescue!

That was what, failure mode #4? NO! 5! I can't even count this high...

[eyesoreracing]

6th and most idiotic failure mode:

I expected all the fialure to be under the dash, so I raised the suspension and drove the car up onto some ramps to make it easier to work down there. First thing you have to do is remove the kick panel, which holds the parking brake cable. If you've heard this story before, its because another of our co-idiots worked here in his sloped driveway and inadvertently released the parking brake, letting the car roll backwards across the street and into a brick wall, which it knocked over. He almost ran over himself in the process.

I forgot all about this, worked in the same spot, walked into my garage to get a socket and heard movement outside. Looked back just in time to see the XM run into the front of my Hayabusa-powered Miata.

Never work under the dash without wheel chocks.



Deepened a existing dent in the Miata, removed a bit of paint from both cars. Ripped a hole in my car cover. Reinforced the accuracy of this thread's title...

[Dieselman]

The servo moved when the newly fixed temperature knob is turned. But it was out of position when I tried re-installing it with everything set to the full cold position. I forced it into position, skipping some teeth as I did so. Seems it was overactuating in the past (I heard strange noises from exacly this location) and perhaps stripped some gear teeth.

Now, when I turn the knob to full cold, I can hear it clicking, as it tries to go colder than possible. If I back off the knob just one click, it stops making noise.


This is the servo if you happen to know of any crossover applications we might be able to find in California.

That's two failure modes...

Take the servo unit back out and split in two by undoing the screws.
The output gear and rheostat drive gear have synchronising dots which need aligning.

P/no is 6447 64

The temperature selection control wiper should be held in place by the centre pip being pushed in and causing the grips to splay outwards. It looks like one grip is broken off.

Good to hear the temperature and A/c is now functioning and no-one was harmed in the making of these pictures...

[eyesoreracing]

Too late for this servo. Lots of missing teeth. I'm guessing some of the teeth stripped when we heard gerbil noises under the dash, as the servo kept trying to go somewhere impossible. I may have stripped some more forcing it into position.

Thank you for the part number. Looks like there was one on eBay here back in april, but nothing available now, so far.

Seems the same as a Saab 9-5 servo, which doesn't help much. and similar to a Range Rover, but maybe not identical.



For now, AC is blowing cold, and we can adjust fan speed and vent position for the first time!