A WITCH! A witch I say. He speaks in tongues and communes with dark and eeeevil forces. BURN THE WITCH!!!

Ok, I have to ask..how? Brand new parts? Fixing the existing system? Ive managed to find 3 aluminum bodied servos in the junkyards and all but this one had rusted the internals solid(and now that I think about it, I bet thats why this one stopped working....a leak)

Gavin

In my service records, I found a P.O in the 1990's paid 20 hours of labor to replace every connector and vacuum piece in the system. :eek: Poor guy.

To have the elusive working ACC1, I replaced the broken servo which had a crack in the housing with a used one, and used my mityvac to test all the vacuum flaps, and the one directly behind the glovebox was leaking. I replaced the rubber inside that for $6, and now the system works as it should. Blower speeds work, temp wheel, etc etc. If there is one vacuum leak in the system nothing will work, since the switch to turn on the blower isn't getting enough vacuum to turn the blower on. I just studied the schematics for the system and read up on it from the forum.

Next time it breaks though, i'll use a different solution if I can't find another servo around $100. Changing the servo is a messy piece of cake, it took under and hour to replace and and under and hour to find the vacuum leak.

One of the things that kills these servos is using coolant that's not using distilled water, flushing the system with the servo attached, heat, etc.

You know, it looked like english, but I swear it seemed like you said you had a working ACCII system.... still does not compute :confused:.

Anyway, I dont have much use for that pile of parts any more. The last time I cracked the servo apart, the gears were in good shape and the internal motor was functional(may need to check it again though). Send me a message If there is something you need.

Gavin

Indeed it is the doorlocks that are preventing the vacuum pods from working all the time. If the doors are open the vacuum pods do not work, if closed...everything works fine.

With the way things are its not much of a "problem" since you'd want the doors closed anyway, but its good to have a pointer to what the issue is. This should be a simple fix as well.

now about that A/C......

Gavin

Great job!
 

This DIY is now in the Wiki HERE.

wiring...
 

Gavin,
First of all great write up!! I have been contemplating this swap for over a year and actually just recently changed over the whole under dash unit, heater core, condenser, etc. aka the 'right way'... Anyway, i didn't get as much of the harness as I should've so I was wondering if you have any closeups of what wires on the fan switch go to the 4 pin connecter, etc. I haven't even looked at it yet(just too happy to get the auto crap out, and I had the 'good' auto system), but I assume that if there is a same color wire, itll prolly go to the same wire on the other end.
Have you attempted the A/C wiring yet? Pics of that would also be much appreciated, otherwise, I forsee another trip to the part yard for even more donor parts(I actually have all the extra bits to accomplish what you did to modify your old system...just looked at it one day and said f that and got the whole shebang. I def. know how much extra work you did the route you went. Anyway, any and all info is greatly appreciated!
josh

I am doing this on my 77 I pulled everything from an 82 240D. I plan on not having functional ac since I never use ac on any of my cars. Ive got it all wired in and works good, 100% functional too.