Blower motor - condensation on outside of windshield
 

1993 300e 2.8 - Just replaced blower motor and now with AC running condensation builds up on the outside of the windshield where the defrost vents would blow on the inside. Maybe this issue was present before and I didn't notice it as I rarely ran the AC.

Is the defrost flapper not closing allowing a small amount of cold air in the defrost vents? Perhaps its a vacumme pod issue?

Comments appreciated.

Sounds like it. The defrost pods are open by design, and are supposed to close when A/C is selected. If these are still the original pods from the factory, you got your money's worth. My original pods lasted 15 years.

I think you're both on the right track.

Remove the glove box liner and you will see a vertical manifold by looking to your left and down from the glovebox opening.

Remove the vacuum lines from the manifold (switchover valve) and test them with an aux vac source. I don't have the list at hand telling which is which, but one of them should actuate the defrost pod which can be felt to the left of the glovebox and rearward toward the rearward face of the dash, just to the right of the center of the dash.

If you get no movement of the arm on this pod by applying vacuum to all of the lines one at a time, then that pod is bad. Fortunately, it's the only pod that you have a chance of replacing without complete dash removal, a 15 hour job.

Hope this helps

Don't have a glove box in my 1993 300e 2.8, passenger air bag is there. Need to lay on my back this afternoon and see if there are any panels that can be removed to access the defrost flapper.

When I replaced the blower motor the flapper behind it seemed to have plenty of "spring" and pulled tightly closed.

If you are using the double solid arrow your condition is normal, switch to the single solid down arrow or E/C to turn off the winshield action.

A/C in the double solid mode is supposed to cool the winshield. High humidity is making the condensation of course.

Not a chance.