04-30-2008, 05:46 PM
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Location: VB, VA
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80-01 Replacing 164 a/c air distribution drum
Trying to rescue Non-Quik Silver and have to fix busted a/c air distribution drum 82419831. Since piece that keys to front stepper motor missing in action, I decided to pull dash back and split heater box to get drum out. What a pain as this process above and beyond the right side only dash pull to get stepper motors.
I have more parts removed than I thought possible but I got it out. Now can I repair or replace drum and put Humpty Dumpty together again?
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Ciao, Alfisto Steve
Virginia Beach, VA
AROC 164 Tech Advisor
sdpatchin@aroc-usa.org
http://www.aroc-usa.org/tech/index.asp
http://www.aroc-usa.org/
Daily drivers: USA models 91 Bianco 164B 5-speed ALFA 4ME, 91 Argento aka "Quik Silver" 164B ALFA 4US w/AT, 93 Rosso 164L 5-speed - semi-daily driver with issues.
164L Rescue projects: 91 Argento aka Non-QS, and organ donor 91 Nero 164L
"A day without an Alfa whine is like a day without sunshine"
Last edited by Alfisto Steve; 04-30-2008 at 05:53 PM.
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04-30-2008, 05:58 PM
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With engine and a/c blower, evaporator and heater core out I still had to remove wiper motor to get at nuts holding dash in.
__________________
Ciao, Alfisto Steve
Virginia Beach, VA
AROC 164 Tech Advisor
sdpatchin@aroc-usa.org
http://www.aroc-usa.org/tech/index.asp
http://www.aroc-usa.org/
Daily drivers: USA models 91 Bianco 164B 5-speed ALFA 4ME, 91 Argento aka "Quik Silver" 164B ALFA 4US w/AT, 93 Rosso 164L 5-speed - semi-daily driver with issues.
164L Rescue projects: 91 Argento aka Non-QS, and organ donor 91 Nero 164L
"A day without an Alfa whine is like a day without sunshine"
Last edited by Alfisto Steve; 04-30-2008 at 07:05 PM.
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04-30-2008, 06:21 PM
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Join Date: Jan 2004
Location: Martinez California
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Wow! You are very dedicated Steve! I can only imagine the amount of hours it would take a shop to do this job, and the bill that would go along with it. Thanks for the pics,
Jon
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Proud owner of the White Dragon (a.k.a. 1991 164L)
1989 Peugeout 405 MI16, 1980 Moto Morini 3 1/2 Sport
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04-30-2008, 11:29 PM
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Join Date: Sep 2005
Location: Hamilton, NZ
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Congratulations Steve on getting another huge task ticked off the list!
 Quote:
Originally Posted by Alfisto Steve
With engine and a/c blower, evaporator and heater core out I still had to remove wiper motor to get at nuts holding dash in.
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Therefore I believe it's easier to take the whole lot out, though it is a terrifying scene when you reach the point of your picture (or my picture below). And, in my picture, I obviously took off more parts than needed first 
Taking out the four - or is it eight - nuts on the bulkhead is almost all you have to do to get the whole dashboard assembly loose - also the centre console and the steering column, and all the massive electrical plugs in the footwell - of course you know all this know, I'm just posting here to agree with the magnitude of the operation but at the same time to reassure anyone else that it really is possible. I managed to remove mine without disconnecting or removing air conditioning but, like you, I did have to take the wiper motor out.
And, below, I have the pics to prove it just like Steve's... 
My heater matrix had already been replaced, but there was certainly the evidence of the past failure...
My distribution drum wasn't actually broken, but the seals were non-existent so it was having little effect. The hot air at face-level was fatiguing.
I experimented with a couple of different materials for the seal (soft foam, neoprene foam) and ended up using thin grey felt-like carpet, of the type usually used for speaker boxes.
-Alex
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'91 164 3L V6 Manual, green, '01 Punto Sporting CVT, yellow, '88 Uno Turbo, white
Last edited by AlexGS; 04-30-2008 at 11:45 PM.
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05-01-2008, 04:30 AM
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Well, you really did pull dash. I actually did it the way TSB said, but once I found drum broken and end broken off for stepper motor shaft I had to seperate dash from firewall and split heater box but all is still in car as shown in pictures.
I had to remove defroster ducts because of THAT HIDDEN SCREW inside heater box that holds two halves together.
I am far from having this checked off the list what you see in the pictures is where I am at. I ordered a new drum yesterday hope it comes in today as Difatta said they had one in stock.
__________________
Ciao, Alfisto Steve
Virginia Beach, VA
AROC 164 Tech Advisor
sdpatchin@aroc-usa.org
http://www.aroc-usa.org/tech/index.asp
http://www.aroc-usa.org/
Daily drivers: USA models 91 Bianco 164B 5-speed ALFA 4ME, 91 Argento aka "Quik Silver" 164B ALFA 4US w/AT, 93 Rosso 164L 5-speed - semi-daily driver with issues.
164L Rescue projects: 91 Argento aka Non-QS, and organ donor 91 Nero 164L
"A day without an Alfa whine is like a day without sunshine"
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05-01-2008, 04:35 AM
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Location: Grosse Pointe, MI
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All I can say is that I hope I never have to do this! But thanks both of you for posting your projects.
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- Rich D.
I like Alfas
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05-01-2008, 04:46 AM
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Join Date: Sep 2005
Location: Hamilton, NZ
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Quote:
Originally Posted by Alfisto Steve
Well, you really did pull dash. I actually did it the way TSB said, but once I found drum broken and end broken off for stepper motor shaft I had to seperate dash from firewall and split heater box but all is still in car as shown in pictures.
I had to remove defroster ducts because of THAT HIDDEN SCREW inside heater box that holds two halves together.
I am far from having this checked off the list what you see in the pictures is where I am at. I ordered a new drum yesterday hope it comes in today as Difatta said they had one in stock.
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If I had to do dash steppers, I'd still remove dash completely I think - quicker overall because you're not battling for access that way. The whole lot comes to bits much easier out of the car. But anyway, it goes back together pretty easily. These cars were made for easy assembly!
Ah yes, the hidden screw - deep in the webbing. I remember also the plated steel strip that was stuck on by what looked like duck tape minus the 'tape' layer - in other words, a sticky white woven adhesive... has to come off to get the two halves apart.
I wonder how much of the glorious foam you have had to dig out from around the dash. My biggest mistake in the whole operation was in leaving the white carpet mats in the footwells. I had to liberally wash them in mineral turpentine afterwards, but they never came completely clean. One's still hanging in the garage where I hung it up to try, three years ago.
-Alex
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'91 164 3L V6 Manual, green, '01 Punto Sporting CVT, yellow, '88 Uno Turbo, white
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05-01-2008, 06:00 AM
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Yes I had to get a bright light to see and peel loose that item 16 metal adhesive strip inside heater core box. The air drum is item 4 and flat side shown in picture has flexible air seals along edges held together by those 10 rectangles.
Item 18 is hidden screw hidden deep down inside that lower defrost duct opening on driver's side on LHD model.
At least shop manual mentions screw as step 3 pg 80-30 and shows it in pictures as a fairings connection screw.
__________________
Ciao, Alfisto Steve
Virginia Beach, VA
AROC 164 Tech Advisor
sdpatchin@aroc-usa.org
http://www.aroc-usa.org/tech/index.asp
http://www.aroc-usa.org/
Daily drivers: USA models 91 Bianco 164B 5-speed ALFA 4ME, 91 Argento aka "Quik Silver" 164B ALFA 4US w/AT, 93 Rosso 164L 5-speed - semi-daily driver with issues.
164L Rescue projects: 91 Argento aka Non-QS, and organ donor 91 Nero 164L
"A day without an Alfa whine is like a day without sunshine"
Last edited by Alfisto Steve; 05-01-2008 at 06:07 AM.
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05-01-2008, 06:20 AM
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I am always amazed by the information you have at your fingertips, Steve!
I blundered into the job with only one of those 'dash partial removal' guides, and about halfway through, thought "bugger this, I'm going to go the whole way"... It was just guesswork from then on for me, helped by the way the wiring plugs only fit one way. It really didn't take long to put back together - once you know how it came apart, it's easy.
I installed extra sound deadening on the firewall and made a few other improvements. It was also a good time to glue together the cracked top vent cover, because it can actually go on the dash prior to bolting back into place.
One thing I did while the dash was out was I installed a cabin temp sensor in the 'old' location near the steering column (punched a hole in the vinyl, mounting was behind), with a hose across the heater box and a fan attached to the stepper bracket. I got the necessary parts from a Lancia Thema which I was familiar with. I did this because my 164 had no sensor in the roof console and no wiring for one - very strange. I'm 99% sure it left the factory without a cabin temp sensor - and a permanent fault code! It was a worthwhile 'upgrade' as the temp control was pretty vague without it.
Now, my older 164 has the roof console sensor, so no problems.
-Alex
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'91 164 3L V6 Manual, green, '01 Punto Sporting CVT, yellow, '88 Uno Turbo, white
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05-01-2008, 06:32 AM
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My wife is amazed or maybe more annoyed, too cause she says I spend to much time on computer doing this stuff but she is at work now.
I am off to flooring store to pick up samples for master bath project so car project waits for parts delivery.
__________________
Ciao, Alfisto Steve
Virginia Beach, VA
AROC 164 Tech Advisor
sdpatchin@aroc-usa.org
http://www.aroc-usa.org/tech/index.asp
http://www.aroc-usa.org/
Daily drivers: USA models 91 Bianco 164B 5-speed ALFA 4ME, 91 Argento aka "Quik Silver" 164B ALFA 4US w/AT, 93 Rosso 164L 5-speed - semi-daily driver with issues.
164L Rescue projects: 91 Argento aka Non-QS, and organ donor 91 Nero 164L
"A day without an Alfa whine is like a day without sunshine"
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