No heat to the footwell made me test its pod. It is ok. However, there's no vac to it and center flap from the controller.

Re 124 Repair Manual [2CD] 83-620 Checking Flap Control
A4 Testing the check valve: Vac slowly decreases
A6 Testing vac reservoir: Won't hold any vac = either bad reservoir or line to it.
B3 Testing line from firewall to Y7 Switchover controller: Won't hold any vac = either bad controller or line to it.

How can I access the Switchover valve [Y7] to test its vac? From CD Repair Manual [83-600] I know its location, but there's isn't a glove box to access it because there's a passenger airbag. Will removing the bottom panel in the passenger footwell allow access without fear of the airbag deploying?

What's the chance that the Switchover controller is bad?
Does the vac tube to it go accross the top of the dash or lower near the climate control push button controller?
Am I correct in assuming the push button controller won't affect these vac tests?

Bob
PS Happy New Year

Don't remember exactly but I think you can get to the valve by removing the passenger side airbag. There is a red connector in the footwell on the passenger side. Pull the carpet back from firewall and then remove the black false panel. Disconnecting this red plug disables airbag. There is a single bolt that holds the airbag assembly in place. Use a socket extension up through the bottom of dash knee bolster to remove this bolt. The pull airbag assembly out.

This is described on the CD under SRS. (suggest you read this because inadvertant airbag deployment is not pleasant)

You may also have to remove the knee bolster.

J. M. van Swaay

Removing the passenger airbag is easy and safe if done correctly. The previous instructions are correct, but you also need to disconnect the battery before unplugging the red connector in the footwell.

The airbag can be a bit fidgety to remove; it's in there quite tightly. But only the single 10mm bolt holds it in place. The two electrical connectors to the back of the airbag can be pulled off by hand. Be sure to set the airbag face up.

The vacuum valve is easily accessed once the airbag is removed. I doubt you could access it from below.

- JimY

J.M. & JimY

Thanks for the reply. I feel a lot more confident regarding the airbag R&R. Hopefully IDing & fixing the vac problem will be as easy.

Bob
PS Hope you're feeling well this morning after.

I decided to pull the passenger fender liner and check the Vac reservoir. The red w gray tube is very tight.

1] Am I correct in presuming it pulls out like any tube?
2] It appears the tube is routed below the battery shelf. What is its route past the heater box [under, in front of] to its check valve?
3] What does the lower reservoir [see pik] with black w gray tube feed?

Bob

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Hi Bob - Quick answers.

1. Yes, it pulls out. After all these years the tube and grommet may be rather firmly attached. It may not be possible to separate them without damage. You can test the vacuum reservoirs from the switchover valve over by the brake master cylinder. My '93 had a leak in the vacuum line near the battery.

2. The tubing runs in front of the heater box, underneath the wiper mechanism. Access isn't too difficult.

3. Shoot, I used to know this, but I'm drawing a blank. I believe it's for the remainder of the vacuum operated stuff on the car, which in this case means the rear headrest retraction. For some reason there are separate vacuum reservoirs for the climate system and everything else.

Cheers,

- JimY

Thanks JimY

Being reluctant to pull the Air Bag, I went after the Reservoir because I couldn't get a vac from where it connects to the Check Valve. I pulled the fender inner panel, released the reservoir and CUT the line. Reservoir tested OK. [At least that's one item I don't have to buy.] But no vac to check valve. Removed the battery, its tray and the tube to the check valve and found the cause. A worn area [see pik] about 4" from the battery in front of heater box. The puzzle is what caused the hole, considering the slack in the tube.

Fortunately, I had some spare tubing. I did the repair and now have vac from check valve to reservoir. Unfortunately, the footwell pod still isn't opening. I think I'll pay my ide to test the Climate Control unit before I pull the air bag to check the vac controller. I'd be really embarrassed to find the climate control unit bad after I pulled the air bag.

Bob
PS I'm guessing the other reservoir is for the seats.

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Bob -

That's interesting. Mine failed in exactly the same manner, exactly the same location. To me it almost looked like acid damage from the battery, but there were no other signs of spilled acid. Like you, I've no idea what caused the rupture.

After repairing on my '93, in addition to not having the air conditioning blow out the defost vents during acceleration, I also noticed the transmission shifted more smoothly (more vacuum), and the idle was a bit smoother/more stable (less unmetered air). It's a good little fix.

- JimY

I answered one of my own questions.

The vac reservoir attached below the Climate Control reservior is fed by a yellow check valve that also feeds the Switchover aka Changeover Valve located behind the brake booster. The Changeover Valve also feeds the vac element for shift retard on the trans - the infamous upshift delay Code 26.

Bob

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