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Difficult To Operate Temperature And Air Distribution Control Knobs (870-2270)

Publication date: 2003-05-01
Reference number: 870-2270
Supersedes refnos: 854-2205, 854-2383 UTG. 2

DIFFICULT TO OPERATE TEMPERATURE AND AIR DISTRIBUTION CONTROL KNOBS

DIFFICULT TO OPERATE TEMPERATURE AND AIR DISTRIBUTION CONTROL KNOBS

TECHNICAL SERVICE BULLETIN

Reference Number(s): 854-2383 UTG. 2, Date of Issue:  May 2003
SAAB: 1998-2000 9-3
MARKET: All
Superceded Bulletin(s): 854-2205, 870-2270

SUBJECT

Difficult to operate temperature and air distribution control knobs

This SI replaces SI 854-2205 and SI 870-2270

CARS AFFECTED

For cars with MCC only

For cars with MCC only 9-3 M98-M00 up to and incl. VIN Y2016481 and Y7005479.

BACKGROUND

The heat and air distribution control knobs can be difficult to move. The reason for this is twofold: grease missing from certain locations in the heating and ventilation unit and the drum which is pressed against the unit.

Perform the following procedures after customer complaint.

SYMPTOM DESCRIPTION

Difficult to operate temperature and air distribution control knobs. Difficult to control air flow and adjust temperature.

PARTS REQUIRED

  1. 87 81 718 (CA: 30576981) Silicone grease (enough for approx. 2 cars)
  2. 79 76 897 (CA: 30509261) Screw, 2 per car

If necessary :

  1. 51 74 669 (CA: 30585921) Cable
  2. 53 35 906 (CA: 30591714) Shaft kit, air distribution
  3. 53 30 923 (CA: 30587279) Shaft kit, temperature control knob
  4. 53 31 665 (CA: 30586362) Control knob
  5. 43 64 279 (CA: 30550626) Telescoping control shaft between control panel and heating and ventilation unit
  6. 92 88 127 (CA: 30522088) Butyl tape (enough for approx. 20 cars)

PROCEDURE

  1. Remove the glove box.
    2. Fig 1: Glove Box And Center Console Side Panel
    G00416046
  2. Remove the center console side panel.
  3. If necessary, remove the knee shield stay.
  4. Remove the air ducts.
    5. Fig 2: Removing Air Ducts
    G00416047
  5. Remove the data link connector and the lower dashboard section on the driver's side.
    6. Fig 3: Removing Data Link Connector And Lower Dashboard Section
    G00416048
  6. Remove the knee shield on the driver's side.
  7. Loosen the screws and move the fuse board aside.
    8. Fig 4: Fuse Board And Air Duct
    G00416049
  8. Remove the air ducts.
  9. Check the following:
    1. 9.a.  that the temperature control knob is not damaged or difficult to move and that the temperature control cable is not difficult to move. Replace the temperature control knob if necessary, see the following method description for "Replacing temperature control knob and shaft". Check the temperature control cable by disconnecting the cable from the lever and turning the temperature controls. If the knob is difficult to maneuver, replace if necessary, see WIS - 9-3 - Body - MCC - Adjustment/Replacement - Control cable. Fit the cable to the lever.
    2. 9.b.  that the air distribution control knob functions satisfactorily. Replace if necessary, see the following method description "Replacing the air distribution control knob shaft".
    3. 9.c.  that there is no play with regards to the telescoping air distribution control shaft in relation to the knob and that it is properly pressed into the heating and ventilation unit. Replace if necessary, see WIS - 9-3 - Body - MCC - Adjustment/Replacement - Control shaft.
      4. Fig 5: Telescoping Air Distribution Control Shaft
      G00416051
  10. Remove the screw on the right-hand side.
    11. Fig 6: Removing Screw On Right-Hand Side
    G00416050
  11. Remove the screw on the left-hand side.
    12. Fig 7: Removing Screw On Left-Hand Side
    G00416052
  12. In those cases where the car has been previously modified with screws as shown in Fig 8 , remove the screws and seal the holes with sealing compound 92 88 127 on both sides.
    Fig 8: Screw Location From Previous Modification
    G00416053
  13. Fit the new screw 79 76 897 on the car's left-hand side.
    14. Fig 9: New Screw On Left-Hand Side
    G00416054
  14. Fit the new screw 79 76 897 on the car's right-hand side.
    15. Fig 10: New Screw On Right-Hand Side
    G00416055
  15. Use a brush approx. 300 mm long and 10 mm wide when applying lubricant. Apply silicone grease 87 81 718.
  16. Grease the angle gear from the right-hand side as shown in Fig 11 .
    17. Fig 11: Greasing Angle Gear From Right-Hand Side
    G00416056
  17. Grease all moveable surfaces from the right-hand side as shown in Fig 12 .
    18. Fig 12: Greasing Moveable Surfaces From Right-Hand Side
    G00416057
  18. Grease all moveable surfaces from the left-hand side as shown in Fig 13 .
    19. Fig 13: Greasing Moveable Surfaces From Left-Hand Side
    G00416058
  19. Turn the temperature control knob to the max. heat setting. Grease the contact surface for the heating damper seal from the car's right-hand side.
    20. Fig 14: Greasing Contact Surface For Heating Damper Seal From Right-Hand Side
    G00416059
  20. Turn the heating control knob to the max. cooling setting. Grease the contact surface for the heating damper seal.
    21. Fig 15: Greasing Contact Surface For Heating Damper Seal
    G00416060
  21. Grease the contact surface for the heating damper seal from the car's left-hand side.
    22. Fig 16: Greasing Contact Surface For Heating Damper Seal From Left-Hand Side
    G00416061
  22. Turn the heating control knob to the max. heat setting. Grease the contact surface for the heating damper seal as shown in Fig 17 .
    23. Fig 17: Greasing Contact Surface For Heating Damper Seal
    G00416062
  23. Turn the air distribution control knob anti-clockwise until the arrow points down. Grease the housing near the drum from the car's right-hand side as shown in Fig 18 .
    24. Fig 18: Greasing Housing Near Drum From Right-Hand Side
    G00416063
  24. Grease the housing near the drum from the car's left-hand side as shown in Fig 19 .
    25. Fig 19: Greasing Housing Near Drum From Left-Hand Side
    G00416064
  25. Fit the air ducts on the passenger side.
    26. Fig 20: Fitting Air Ducts On Passenger Side
    G00416065
  26. If necessary, fit the stay to the knee shield.
  27. Fit the center console side panel.
    28. Fig 21: Center Console Side Panel And Glove Box
    G00416066
  28. Refit the glove box.
  29. Fit the air duct to the dashboard vent on the driver's side.
    30. Fig 22: Air Duct And Fuse Board
    G00416067
  30. Fit the fuse board.
  31. Fit the air duct to the floor vent.
  32. Fit the knee shield.
    33. Fig 23: Fitting Knee Shield, Lower Dashboard Section And Data Link Connector
    G00416068
  33. Fit the lower dashboard section.
  34. Fit the data link connector.
  35. Clean the control panel.
    NOTE: After the procedure is completed, the air distribution control knob may be difficult to maneuver in a horizontal position. This is not abnormal and is due to the heater's basic construction.

REPLACING TEMPERATURE CONTROL KNOB AND SHAFT

  1. Remove the control panel from the rear. Push down the catches using a screwdriver.
    2. Fig 24: Removing Control Panel
    G00416069
  2. Unplug the connectors from the control panel.
  3. Remove the clips securing the cable to the control panel by pushing in the catches.
  4. Unhook the cable eye and lift out the control panel.
  5. Turn the temperature control knob to the max. heat setting and push out the knob through the small hole on the back side of the panel with a narrow screwdriver.
    6. Fig 25: Removing Temperature Control Knob
    G00416070
  6. Push the cable attachment lever towards the front of the panel so that the meshed gears holding the spindle shaft are released.
  7. Pull the lever downwards and out through the hole. Pull out the shaft through the side of the panel.
  8. Recycle grease from the removed parts to lubricate the shaft and lever. Grease the gear rings and apply a small amount of grease to where the ball will be placed.
  9. First fit the spring to the shaft followed by the ball.
  10. Insert the shaft into the panel until the ball stops against the panel. Use a narrow screwdriver to depress the ball. At the same time, press in the shaft to snap it into the correct position.
    11. Fig 26: Inserting Shaft Into Panel
    G00416071
  11. Fit the lever to the panel.
  12. Turn the lever clockwise (from an overhead perspective) until it snaps into the correct position.
    13. Fig 27: Fitting Temperature Control Knob And Cable
    G00416072
  13. Fit the temperature control knob.
  14. Attach the cable to the panel.
  15. Check that the gears are in the correct position by turning the knob to the max. heat setting. The cable should run in a straight line from its attachment point, through the center of the lever hole towards the clip plate.
    16. Fig 28: Checking Gear Position
    G00416073
  16. Plug in the connectors.
  17. Fit the control panel and control shaft.
    18. Fig 29: Fitting Control Shaft
    G00416074
  18. Return to step 9b under "Procedure".

REPLACING THE AIR DISTRIBUTION CONTROL KNOB SHAFT

  1. Remove the control panel from the rear. Push down the catches using a screwdriver.
    2. Fig 30: Removing Control Panel
    G00416075
  2. Unplug the connectors from the control panel.
  3. Remove the clips securing the cable to the control panel by pushing in the catches.
  4. Unhook the cable eye and lift out the control panel from the car.
  5. Remove the air distribution control knob.
  6. Remove the control shaft by
    1. 6.a.  turning it anti-clockwise (seen from the front side of the panel) until the guide pin is in the same position as shown in Fig 31 .
      2. Fig 31: Removing Control Shaft
      G00416076
    2. 6.b.  carefully insert the locking tab using a screwdriver and turn the shaft anti-clockwise until the guide pin is located in the center of the groove.
    3. 6.c.  carefully pull the control shaft out; retrieve the ball and spring.
  7. Recycle the grease from the removed shaft and apply it to the new shaft.
  8. Fit the spring and ball to the new shaft.
    9. Fig 32: Fitting Spring And Ball To New Shaft
    G00416077
  9. Insert the shaft to the control panel. Use a screwdriver to hold the ball in place. Turn clockwise from the front side of the panel and make sure the locking tab locks.
    10. Fig 33: Inserting Shaft To Control Panel
    G00416078
  10. Position the control cable on the back side of the panel. The cable should be positioned above the control shaft.
  11. Fit the control knob.
  12. Plug in the connectors.
  13. Position the control panel and fit the telescoping control shaft.
    14. Fig 34: Fitting Telescoping Control Shaft
    G00416079
  14. Test knob function.
  15. Return to step 9c under "Procedure".

TIME/WARRANTY INFORMATION

Upon customer complaint for a vehicle under warranty, use the following information for claims:

  1. Failed Object: 85453
  2. Fault/Reason code: 27
  3. Location code: 09 (US=9)
  4. Warranty Type (US): 1
  5. Repair/Action code: 07
  6. Labor Operation (US):85453-02 (CA: D2507)
  7. Time: 1.1 hrs.

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