12.10.2009: Saab 9-5 Blend Door Repair

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12.10.2009: Saab 9-5 Blend Door Repair

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ACC blend door repair on a 1999 Saab 9-5.

If your air vents blow cold in the winter, or hot in the summer, if the A/C calibration shows error code 08 on the climate control display, then you probably have this problem. It's very common, especially on early 9-5s.

The climate control system has an air mixing flap on each side. They mix cold and hot air, so the temperature can be controlled separately on the driver and passenger side. Each flap is operated by a small stepping motor. The range of movement is limited by a short plastic stop arm. Its function is critical, because the mixing flap can cross its path with other moving parts if misaligned, and cause irreparable damage.

The ACC can detect when the stop arm is broken and stop the motor. Timely repair is important to prevent further damage. Don't put it off after the problem presented itself. A cracked stop arm or a broken shaft tip can be easily repaired. In more severe cases, the may snap inside the unit, which can only be fixed by removing the ACC module from the car and taking it apart, which is extremely labour intensive. There are various repair kits available from many online Saab parts retailers.

The only tools you need for the job is a pair of Torx and Phillips screwdrivers.

	12.10.2009 Driver footwell Undo the Torx screws holding the trim in the driver's footwell.		12.10.2009 OBD connector Unscrew the OBD-II connector from the trim panel.
	12.10.2009 Left motor Locate the left stepping motor (it has a large "L" on it). Unplug the connector and any other wires in your way. Undo two screws holding the motor and pull it out.		12.10.2009 Shaft position Make sure the notch on the shaft is pointed upwards. If it's not, plug the motor connector back in and run the ACC calibration until the shaft is positioned correctly.
	12.10.2009 Broken arm Old style green plastic stop arms often crack at the base, allowing the shaft to spin freely. Newer style white arms have this end reinforced, however they sometimes crack at the upper notch instead.		12.10.2009 Arm removed Remove the stop arm. Inspect the yellow shaft, make sure it turns and is not broken. You can peek through the lower vent, or remove the vent completely for easier access to the inner part of the shaft.
	12.10.2009 New vs old This replacement arm was fabricated by my relative who works at the machine shop. It's made out of military grade aluminium, very light and strong. There are similar aftermarket replacement arms sold online.		12.10.2009 Alumimium arm Install the new arm. It will be seated tight, so push it in carefully - all the way until the catch clicks. Before re-installing the motor, make sure the shaft profile is aligned with the notch on the motor shaft.
	12.10.2009 Carpet clips The passenger side is less prone to failure, but I decided to replace both as I had extra parts. Start by pulling the clips out of the carpet trim.		12.10.2009 Lower trim Next, undo the four screws holding the lower plastic panel.
	12.10.2009 Glovebox screws Unscrew the lower edge of the glove box.		12.10.2009 Upper screws Open the glovebox and undo the remaining screws along the top.
	12.10.2009 Glovebox removed Pull the glovebox, disconnect the vent hose and the electrical connector.		12.10.2009 Right motor Locate the stepping motor with a large "R" on it, unhook the wires and unscrew the motor.
	12.10.2009 Original arm The passenger side arm is connected to a metal rod that operates additional vents on the floor.		12.10.2009 Arm removed Unhook the rod and pull the stop arm off the shaft. Inspect for damage. My arm was starting to develop a crack at the upper notch.
	12.10.2009 Rod fitting Remove the soft plastic rod bushing from the old arm and insert it into the new arm.		12.10.2009 Installed Installation is the reverse of removal. Once everything is done, start the car and run the ACC calibration by pressing AUTO+OFF.

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