About a month ago, I rebuild my 860 2.5GLV AT gearbox. Yesterday, I drove down to Melaka for my business trip. While reaching Melaka, there's some strange burnt smells come out from my air cond vent. After a while the smells goes away. About half and hour later, the same smells come out again from the air con vent. I suspect something must be burnt inside the air con vent. Thus I stop my car and check if there's anything burnt. I didn't found anything, the air cond still working as usual.

I spent a night in Melaka. This morning, as usual I start my car and drove to my customer site for meeting around 11am. The air cond still working as usual.

I finish my meeting around 11.45pm. I came out from my customer site and start my car. When I wanted to turn on my air cond, there's totally no respond. No air blow out from the air cond vent. The AC light and Ventilation light is off.

My initial suspect was the 2 relays in the glove box. I opened my glove box and check out the relay. There's no burnt smells. I got no choice, but to drive without air cond from Melaka back to KL.

Back to KL, I went to a spare parts shop to get new BOSCH relay to replace the two relay in the glove box. This is to try if the problem lies on the relay. Unfortunately, the air cond is not working even after I changed the relay.

Then I realize there's a possibility of fuse burnt. I popped my bonnet and run a visual inspection check on the fuse. The fuse is not burnt.

Since it is quite late today, most shop only open for half day. I got no choice, but to drive without air cond.

The next best thing I found out is white smoke coming out from my exhaust when I start my car. I really hope that I don't need to overhaul entire engine.

What a bad day.

Anyhow, what I can do now is to concentrate to solve the air cond problem. I suspect the wiring is short somewhere and cause the entire air cond system to breakdown.

Anyone encounter such case before? All sort of help is much appreciated.

Thanks

 

I have seen it a ton of times. I will bet the climate module burnt.

 

What's the recommended solution to this? Change the climate module? Mine using a Manual System...

 

You do not have the AUT setting on yours?

 

I don't think the climate control is automatic.

Anyway here's the photo of my AC control panel

 

Yes that is the manual setup. Not as common to mess up as the electronic setup.
Does any of the lights work at all?

 

The light is on when I on my head light.
But the AC compressor and Air Recirculation light does not turn on even the switch is in ON position.

Here's how it looks like when I removed the front panel.

 

I wonder if the Manual one burned up. Do you see any burn marks?

 

Manage to solve the problem. I manage to locate the burnt supply cable (Black and Yellow) at the glove box. The burn was on cable connector.

To solve this, I cut both end of the cable and soldered it together. Then use heatshrink on the exposed soldered part.

Problem solved.

 

Good job! Glad you got your AC working.

 

sounds like a good plan on the repair there. nice job!

 

I would check the motor as well because they tend to get little tigt and draw more current then normal and that might create a overheated wire like this. Did you ever niticed a squeak from your blower ever?

I removed cleaned and lubricated mine last year after I noticed the sqeaking intermittently from it and its working fine since then.

 

Now there's sound from the air recirculation motor. I doubt the blade might disintegrate and draw more current. Well at least now I got my air con running except for the sound from the air recirculation motor.

 

that noise means the bearings may be going out and is causing the fan to not spin freely. The added friction can cause it to draw more amperage to move the motor, causing the wire to overheat and burn...!