[xj40] no heat, upper air dor is stuck

So I have been working on trying to figure out why my 1994
XJ6 has no heat. I was able to get the lower air door to
move just fine but I had a difficult time accessing the
upper air door and it’s motor. Today I finally pulled out
the glove box and was able to access the upper air door
motor. After removing the motor, I reached in there with a
flat blade screw driver and attempted to rotate the air door
by hand. Unfortunately it seems to be stuck. It moves a very
small amount. Perhaps only 15 - 20 degrees of rotation total
and it is very hard to get it to move that much in
comparison to how easily the lower door rotates.

What can cause this and how do I fix it? I am not at all
enthusiastic about having to tear the whole dash assembly
out in order to get to the climate control system box.

Any hints or suggestions would be appreciated.–
Steven A. DuChene - XJ6VDP XJ6C XJ12C XK120SE 3.8S E-Types
Phoenix, AZ Atlanta GA, NE Oh, United States
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In reply to a message from StevenD57 sent Sun 18 Jan 2015:

It sounds like you’ll have to take the entire dash off to
gain proper access. But it’s not all that bad of a job.
And you can fix or remove the center vent damper while
you’re at it. I have the same sort of issue with my 89. I
think the PO made some modifications (he bragged about how
well the A?C worked) and disabled the heat function.–
The original message included these comments:

So I have been working on trying to figure out why my 1994
XJ6 has no heat. I was able to get the lower air door to
move just fine but I had a difficult time accessing the
upper air door and it’s motor. Today I finally pulled out
the glove box and was able to access the upper air door
motor. After removing the motor, I reached in there with a
flat blade screw driver and attempted to rotate the air door
by hand. Unfortunately it seems to be stuck. It moves a very
small amount. Perhaps only 15 - 20 degrees of rotation total
and it is very hard to get it to move that much in
comparison to how easily the lower door rotates.


Pete Peterson 70E(193K) XJ40s(88-270K,89-97K, 94-122K)
Severna Park, Maryland, United States
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In reply to a message from StevenD57 sent Sun 18 Jan 2015:

Steven,

The last time I heard of a similar problem, the reason for
the restricted movement of the upper blend flap was that a
piece of the demist/defrost vent had broken off and fallen
in to the blend flap aperture effectively jamming it.

No solution other than to remove the dash and then the CCU
to repair / replace (although they are NLA from Jaguar) the
demist/defrost vent flap. I have the details of that
incident with IIRC some photographs on my home computer but
I am currently abroad until next week so I cannot forward
them to you yet.–
The original message included these comments:

So I have been working on trying to figure out why my 1994
XJ6 has no heat. I was able to get the lower air door to
move just fine but I had a difficult time accessing the
upper air door and it’s motor. Today I finally pulled out
the glove box and was able to access the upper air door
motor. After removing the motor, I reached in there with a
flat blade screw driver and attempted to rotate the air door
by hand. Unfortunately it seems to be stuck. It moves a very
small amount. Perhaps only 15 - 20 degrees of rotation total
and it is very hard to get it to move that much in


Bryan N, now Jag-less, but fun while it lasted.
Cambridgeshire, United Kingdom
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In reply to a message from Bryan N sent Sun 18 Jan 2015:

Bryan and Pete:
Thanks for the replies. Are there any available directions
on how to remove the dash and climate control unit?–
Steve

Steven A. DuChene - XJ6VDP XJ6C XJ12C XK120SE 3.8S E-Types
Phoenix, AZ Atlanta GA, NE Oh, United States
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In reply to a message from StevenD57 sent Wed 21 Jan 2015:

Steve,

I have such directions for dash and CCU removal on my home
computer. I will be back home in the UK on Sunday so I will
PM them to you (if jet-lag doesn’t dull the memory!)–
The original message included these comments:

Thanks for the replies. Are there any available directions
on how to remove the dash and climate control unit?


Bryan N, now Jag-less, but fun while it lasted.
Cambridgeshire, United Kingdom
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In reply to a message from Bryan N sent Wed 21 Jan 2015:

Steve,
When I took out the heat/ac unit in my car I noticed how one of the
center housing panels had warped.And if that panel warps enough it
could bind up the movement of the blend door.There are pictures of
the unit dissasembled in the photo album to give you an idea of the
panel that is bent.That may be part of your problem.Taking out the
dash sounds like an ugly project but actually it was not that
bad.All the wire plugs are unique to each harness so they only fit
one specific harness.Just take lots of reference pics so you have a
visual of each section as you disconnect wires and vacuum hoses.I
think there are pics in the photo album of the dash dissassembled
also. Cary–
The original message included these comments:

Thanks for the replies. Are there any available directions
on how to remove the dash and climate control unit?


94 XJ6
kingsville/ohio, United States
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In reply to a message from Bryan N sent Wed 21 Jan 2015:

Steve,

Details sent via PM today.

Let me know if well received.–
The original message included these comments:

In reply to a message from StevenD57 sent Wed 21 Jan 2015:
Steve,
I have such directions for dash and CCU removal on my home
computer. I will be back home in the UK on Sunday so I will
PM them to you (if jet-lag doesn’t dull the memory!)

The original message included these comments:

Thanks for the replies. Are there any available directions
on how to remove the dash and climate control unit?


Bryan N, now Jag-less, but fun while it lasted.
Cambridgeshire, United Kingdom
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Bryan:
After almost five years I have finally taken your advice and pulled the dash out of my car.
I guess I could say that it took me this long to read all the way through your directions. :slight_smile:
I just hope now that I have the dash out that I can figure out how to repair the broken defrost door flaps and can remember where all of the bolts and screws go when I go to put the dash back int the car permanently.
Thanks for all your help and suggestions so far.

Steve