AC Aspirator

PeterBergin at PeterBergin at
Wed Jan 31 11:29:36 EST 2007

Matt, replacing the aspirator is a real PITA!  It runs when ever the  heater 
controls are on. Mine started going bad by an occasional squeal on cold  
mornings which dulled to a rattling noise after the car warmed up.  Finally  it 
turned into a full time squeal that was louder than the radio turned  up.  I 
bought the part at SJM for around $50, (you will need to remove the  connector 
from the old motor, remove the one from the new motor and solder the  wires so 
the stock harness plug will work.  Follow the instructions in the  Bentley (not 
real clear) and some help from the SJM site, I think the SJM  pictures are off 
a 5000 and the 200 is different.
The fan sucks air through the small vent on top the dash over a sensor that  
controls the climate control interior settings.  You can test that air is  
moving through the opening by placing a very thin tissue on the vent to see if  
it sticks (fan running).  
The quick version on replacing is as follows:
Remove instrument cluster, glove box and wood dash trim.  Remove  right side 
dash speaker (I have an Avant).
Remove the hose from the right side dash vent hose, the screw is deep  under 
the speaker (good to used magnetic screw driver).  
There is a metal plate that holds the aspirator, the cruise control  brain 
box etc, mounted vertically behind the metal recessed area above the glove  box 
(behind where the wood trim was). You will see the 4 small hex screws in  that 
recessed opening, remove them to free the plate.
I laid inverted on the passenger seat (if I did it again I would remove the  
seat for easier access), push the air hose from the vent out of the way,  
blindly remove the connectors to everything on the metal plate, slide the hose  (4 
of 5 inches long) off the nipple on the aspirator motor that goes to the  
sensor/dash vent off.
Remove the plat from behind the dash and the old aspirator motor, do the  
plug/solder connection and put everything back together.
If you IC need work, may as well do it at the same time.  You do not  need to 
remove the dash cover.
If you need more explicit directions drop me another E-mail.  I think  I 
remembered everything. 
Plan on spending the better part of a day on this job.
While I was in there I fixed my AC recirclelation flap and cleaned a thick  
layer of crud off the AC condensor (it had a thick mat of crud and leaves on  
it), got much better air flow after words.
Good Luck
Pete, 91 Avant

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