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Constant Fresh Air

I've searched this topic with no success. It seems I have a constant supply of fresh air. If I have the fresh air set to the floor there is air to the floor even thoght the fresh air is off. Same when it's set to go to defrost.

The thing is when I set the fresh air lever to be wide open the amount of fresh air is increased. But It just can't be shut completly off. Do you think this may be a simple cable adjustment or is it something worse?
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Old 02-03-2007, 08:06 AM
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1. lube cables

2. adjust cables

3. something worse

do in that order...

I usually have some fresh air going no matter how cold - I just add hot air to it
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Old 02-03-2007, 10:28 AM
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Front hood not latching properly or the hood seals are bad and leaking. In both cases you will get air leaking thru the defrost vents. If not what Randy said.
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Old 02-03-2007, 06:37 PM
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The foam seals on the butterfly valves inside the fresh air box are most likely shot. I've rebuilt them using weatherstripping from the hardware store. Not difficult, just time consuming as you have to remove the fresh air blower assembly.
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Old 02-03-2007, 08:08 PM
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I think David got it. If the seals are shot, you can never completely shut off the flow of outside air. You can't buy new seals for the butterflies, but you can make them. Here's a pic showing the original butterfly seal on the right and the restored one on the left:


Closeup of thebutterfly showing how the old seal disintegrated around the perimeter:


Closeup of the butterfly with the new seal I made:
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Old 02-03-2007, 08:54 PM
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Thanks - one for the Long Term Maintenance List...

- what are the hose clamps for?
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Old 02-03-2007, 11:26 PM
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One other thing. If the car in question is a Euro specification car, it may only have one butterfly valve in place. The had a different center vent that was able to be closed completely. I've had to install the second butterfly valve in a Euro car to allow me to completely kill the flow of fresh air.

JR
Old 02-04-2007, 04:50 AM
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Awesome information! Thanks! I don't believe it's the trunk everything there look good. It must be a cable issue or more than likely the butterfly valves.

A couple questions:
1. Where did you did up that gasket material? If the material itself is hard to come by, it seems like foam from a fabric store could be used. That way you are just cutting 2 circles out of a foam sheet.
2. I guess another question is how thick is the material?
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Old 02-04-2007, 05:22 AM
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Also, Where are these things? I would like to get an idea about where they are before I start trying to get them out.

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Old 02-04-2007, 05:43 AM
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khamul02,
What items (their numbers) are you asking about in the picture?
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Old 02-04-2007, 05:52 AM
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I'm assuming the butterfly vavles should be in the section of the PET. But from just looking at the image I can't id them. And the text that refers to this section doesn't mention butterfly vavles or anything like that.
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Old 02-04-2007, 06:03 AM
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They are part of item 6. There are also valves of a different sort in 18 and 19.

JR
Old 02-04-2007, 06:07 AM
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How much of a pain is it to pull that blower assembly?
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Old 02-04-2007, 06:14 AM
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It's a little work. Maybe half an hour if you've never done it.

JR
Old 02-04-2007, 06:36 AM
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Let's see if this helps with some of the questions:


khamul02, Javadog is right, the blower assembly is easy to remove. You may need the seal around the air intake , #2 in the diagram. to prevent any water leaks. The interior lip of this seal is glued to the blower assembly to prevent leaks. The butterfly valves and seals are not available, as you see when you look at the PET diagram...you have to make your own seals.

Randy, I beveled one side of the hose clamps to form a cutting-edge, and after getting the diameter right I used the clamps as a die to stamp out the new seals for the butterfly valves. I first tried cutting a few seals with an xacto knife, and with scissors too, but could never achieve the semi-precise shape I needed.

I got some neoprene-like foam material at a hose/rubber supply company to make the seals...needs to be about 6mm thick. The butterfly valves are two-piece, bolted together, and the seal is doughnut-shaped, sandwiched between the two pieces of the butterfly valve. You have to get the OD of the seals you make just right so the seal will actually seal inside the blower housing, but without binding.

Here's a few more pics that may help:










Old seal on the left and new seal, installed on the right:


Be sure to note the orientation of the pivot rods and how they're sandwiched between the butterfly valve halves. Hope this helps.
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Old 02-04-2007, 09:55 AM
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I guess you never learn everything about these cars... I've always told people they have to replace EVERY piece of rubber on an old 911, but even I never thought about these.

Thanks for the great pics Bob.
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Old 02-04-2007, 09:57 AM
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Everything you need to know about the freash air blower. Thanks a ton Bob.
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Old 02-04-2007, 10:08 AM
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Randy and Tom, glad to help. I never thought, or even knew, about these butterfly seals, but after I saw mine I took the pics since I figured most all of our 911s are in this condition by now. What got me looking in there was realizing I needed to clean up the fan motor and oil the bushings.

Motor before and after:







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Old 02-04-2007, 10:09 AM
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I was going to dismantle mine this summer - but only 'cuz the painter didn't block it off and it no doubt full of body dust, metal sanding dust and small chips of paint. At least, that's what I was greeted with from the blower vents when I first drove the car after I got it back from him.... great fun to have a face full of that crap.

Anyway, now, I'll rebuild the foam/rubber seals. Worth it even tho I guess I'm a Euro style wind in the face guy since I never close mine all the way no matter how cold it gets here (not very).
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Old 02-04-2007, 11:01 AM
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Welp,
I got mine all apart It looks like the fan only needs some oil. It's pretty clean.
Since I have it all apart I would like to go ahead and change out the foam for the butterfly valves. Mine's in decent shape. Turns out my problem was the fresh air cable clips is missing (new one on the way from pelican) so me sliding the fresh air controler in the cabin was doing nothing.

Anyhew, I think I going to dig up a mouse pad to cut out the new foam gaskets. I can't help mysellf I'm a computer nerd
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Old 02-17-2007, 05:12 PM
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