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Thread: Cold air on passenger side

  1. #41
    Join Date
    Jan 2007
    Location
    Dayton Ohio
    Posts
    1,463

    Default Success

    Well I finally got it all back together today. Here is a pic of the actuator arm I created. I built it out of three pieces of aluminum and welded them together with alumiweld. Amazing stuff... Anyway arm worked and you can do this repair without removing the IHKA. I could make this arm for other members but it takes about 3 hours of machining and welding, so it won't be cheap . Also found out why the flap broke. The stepper motor was pulling to far so installed a shim between the stepper motor arm and the stop. I also reinforced the mounting bracket with JB Weld, filled in all the holes and then wrapped it with parafilm until it set up.


  2. #42
    Join Date
    May 2004
    Location
    Japan
    Posts
    9,201

    Default

    very nice!
    Post that also on Bimmerboard E32 forum with the pics and a short writeup. Maybe you also mention the price for these parts if someone is interested to buy.
    Use the test forum there first to see if the pics work.
    Thanks a lkot, good stuff!

  3. #43

    Default

    Quote Originally Posted by Jehu View Post
    I have a somewhat related question. I am finding some green residue on the ground under where the Air Conditioning Condensation drains out thru the two hoses.. I initially feared it was Green Anti freeze leaking into the air box from faulty heater core o-rings then I realized my Windshield Washer Fluid is also Green but the dripping is not really where the washer Reservoir is located. I then realized it is perhaps just washer fluid from the excessive use due to many insect suicides on my windshield which has been sucked into the air intake at the base of the windshield and is mixing in the air box with condensation and draining out . The residue is not smelling like antifreeze and is not really oily like that.. am I correct that this is probably washer fluid that has splashed up and been sucked into the Air box?

    Heck,while I'm asking... With all settings on the manual climate control set to full cold, center wheel all the way down, two dials all the way to the left(blue) and the AC button the Manual says to keep the bottom(foot well) slider slightly open for the temp sensor but I then get Hot Air to my feet which is very uncomfortable in the summer when I want the AC. is this a stepper motor /Mixing Flap issue or it the Heater valves faulty? When I turn the center vent wheel the temp will change but I thought when the wheel was all the way to cold the water valves were shutting completely and should't allow any heated coolant into the Heater Core at all which must be happening if I feel heat to my feet even with all setting to cold....
    jehu- nice attempt to threadjack- I actually have same problem. any luck on fixes? am looking at controller/ temp sensor and heater valve

  4. #44
    Join Date
    May 2006
    Location
    NH
    Posts
    2,059

    Default

    Quote Originally Posted by NoBummers View Post
    jehu- nice attempt to threadjack- I actually have same problem. any luck on fixes? am looking at controller/ temp sensor and heater valve

    I'm satisfied my explaination for the green residue under the car is that it is windshield washer fluid entering the air box and draining out with the A/C Condensation.

    As far as the other...not yet.. I have to take the dash apart soon to replace a CD changer cable and change some bulbs in the cluster. At that Time I'll inspect the stepper motors and see if I notice any arms broken.

    The plastic mount for the bottom belden cable has broken off the air box.I'll JB Weld that on then too... This isn't a huge problem for me yet becasue despite daily blather about global warming the temps up here are unseasonably low and the present functioning is adequate but when Hot Summer temps arrive I'm sure I'll have motivation to try changing the Climate Controls, The IHKR Unit and the heater/Water Valves..
    1995 540i Manual build 1/95

  5. #45
    Join Date
    May 2004
    Location
    Japan
    Posts
    9,201

    Default

    @Kibokojoe
    do you still produce these mounting brackets?

  6. #46
    Join Date
    Jan 2007
    Location
    Dayton Ohio
    Posts
    1,463

    Default

    I have two left and I am going to keep one for a pattern

  7. #47
    Join Date
    May 2004
    Location
    Japan
    Posts
    9,201

    Default

    as I had a similar problem with no air from vents, I investigated further on my car and we found no broken stepper motor mount, but the stepper motor did not hold in place with the clips, so we fixed it with zip tie, works like a charm now.
    Have made a youtube on my spare IHKA unit to show how the flaps work

    How it works aircon top flap control - YouTube

    Stepper motor IHKA picture by shogun_bucket - Photobucket
    Applies to defroster flap and temperature regulator flap, 2 actuators per car

    stepper motor IHKA picture by shogun_bucket - Photobucket
    Only applies to leg room flap, rear flap, air re-cycling flap and fresh air flap. Six actuators per car

    http://www.bimmerboard.com/members/h...m%20holder.jpg

  8. #48
    Join Date
    Jan 2007
    Location
    Dayton Ohio
    Posts
    1,463

    Default Wish there was a way

    Wish there was a way of installing the replacement arm without having to tear the dash apart

    Quote Originally Posted by shogun View Post
    as I had a similar problem with no air from vents, I investigated further on my car and we found no broken stepper motor mount, but the stepper motor did not hold in place with the clips, so we fixed it with zip tie, works like a charm now.
    Have made a youtube on my spare IHKA unit to show how the flaps work

    How it works aircon top flap control - YouTube

    Stepper motor IHKA picture by shogun_bucket - Photobucket
    Applies to defroster flap and temperature regulator flap, 2 actuators per car

    stepper motor IHKA picture by shogun_bucket - Photobucket
    Only applies to leg room flap, rear flap, air re-cycling flap and fresh air flap. Six actuators per car

    http://www.bimmerboard.com/members/h...m%20holder.jpg

  9. #49
    Join Date
    May 2004
    Location
    Japan
    Posts
    9,201

    Default

    After 4 months of operation I can confirm that the zip tie solution on my car works like a charm, no modification required so far. So I leave it as it is now.

  10. #50
    Join Date
    Jan 2007
    Location
    Dayton Ohio
    Posts
    1,463

    Default

    Ok so how did you do the zip tie repair? Hey my son just landed a 91 325i convertible, know anyone who knows how to modify the electric top to manual?

    Quote Originally Posted by shogun View Post
    After 4 months of operation I can confirm that the zip tie solution on my car works like a charm, no modification required so far. So I leave it as it is now.

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