Well it looks like some drastic remedial action is required if I ever want heat again in the car!!. Something has been fouling the operation of the heater control which Ive traced to some sort of a problem in internal operation of the heating duct itself. Something’s up either with the paddle or the cogs that operate it, thats closes off the hot air from the matrix, controling the temperature thru the vents. It seems stuck on the closed setting, not allowing any hot air to pass into the system. 
I cant see how its connected to the removal of the old and not working dealer fit aircon from the engine bay, although it did happen shortly afterwards . Unless some muck has got in from the pipes that were cut and somehow blocked the internal paddle thing, or that something just broken in there. Whatevetr it is it's worse case senario and something’s up inside the unit.
My first thought is to attempt to remove the complete blower assembly from the left hand side of the central matrix housing to gain some access that way. Heck of a lot of wiring and relays and stuff around it that I think is all aircon related and not now needed. Looks like it could be fun!!
Some pics with the glove box removed
Fortunately I do have a spare non-aircon blower unit that I can use as a replacement as the one that’s in is now redundant and massive too! As its dealer fit they seem to have run out of room for the ECU so Ive also got an odd tray assembly you can see in the pics (very well made actually) that sits under the glove box – this can go also and the ECU put back where it should go.
Anyone done anything like this before? There are a lot of differences between the air/non aircon assemblies but im guessing that the heater matrix assembly it bolts to is the same. Same controls anyway. All the aircon stuff is at the blower end I hope. Will this make it a straight swap? One key difference is that the attachments to the centre housing have a different clip arrangement. Also worried about how I’ll attached the clips at the back/engine bay side on the central matrix housing
All this said I might still not be able to fix the problem this way - its in the heater matrix section and the very worst to get to - in which case the only other option is to pull the dash…. I have done this before on the old 80 – whole dash out, but there’s a heck of a lot more under the dash on an S2 than a B3 80!!, so I really, really, really would rather not have to!!
All tips & suggestions welcome!!
cheers
Paul
I cant see how its connected to the removal of the old and not working dealer fit aircon from the engine bay, although it did happen shortly afterwards . Unless some muck has got in from the pipes that were cut and somehow blocked the internal paddle thing, or that something just broken in there. Whatevetr it is it's worse case senario and something’s up inside the unit.
My first thought is to attempt to remove the complete blower assembly from the left hand side of the central matrix housing to gain some access that way. Heck of a lot of wiring and relays and stuff around it that I think is all aircon related and not now needed. Looks like it could be fun!!
Some pics with the glove box removed
Fortunately I do have a spare non-aircon blower unit that I can use as a replacement as the one that’s in is now redundant and massive too! As its dealer fit they seem to have run out of room for the ECU so Ive also got an odd tray assembly you can see in the pics (very well made actually) that sits under the glove box – this can go also and the ECU put back where it should go.
Anyone done anything like this before? There are a lot of differences between the air/non aircon assemblies but im guessing that the heater matrix assembly it bolts to is the same. Same controls anyway. All the aircon stuff is at the blower end I hope. Will this make it a straight swap? One key difference is that the attachments to the centre housing have a different clip arrangement. Also worried about how I’ll attached the clips at the back/engine bay side on the central matrix housing
All this said I might still not be able to fix the problem this way - its in the heater matrix section and the very worst to get to - in which case the only other option is to pull the dash…. I have done this before on the old 80 – whole dash out, but there’s a heck of a lot more under the dash on an S2 than a B3 80!!, so I really, really, really would rather not have to!!
All tips & suggestions welcome!!
cheers
Paul
The flaps are controlled by a temp sensor which in turn controls the motor that drives the main flap to the outside air intake. You either have a vacuum leak in the lines or 
Try using a "mighty Vac " tool too see if the flaps are operational. 
You could try to dis-engage the lever by taking the screw out of the lever but then .......
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