| Changing the HVAC blower motor and resistor pack on your
Z3- by W.B.|
This is not an insurmountable job but bring your patience with you. This
job is basically the same if you have to change the fan motor itself.
First the symptoms... If your blower motor does not work except on high
then your resistor pack has probably gone bad and needs changing. It is
located beneath the motor itself and getting to it requires removal of
the windshield wipers, the wiper arms with associated motor drive unit
and the plastic liner beneath your wiper blades. For that you also have
to remove the weather strip that runs along the front of that piece (very
First remove the negative lead from your battery, close the trunk and
open the hood. You can then pull the plastic caps and retaining nuts
off of your wiper arms. Now pull the arms off and if stuck too tight
try a gear puller or a small amount of wiggle and upward pull to the
arm. At this time you may also remove the weather-strip, it just pulls
straight up (previous photo).
Now with a small flat bladed screw driver or similar tool start pulling
the center pieces of the expandable plugs that retain the plastic trim.
Pull slowly and maybe use another screwdriver as a fulcrum to help disengage
the part. After the center is out the expandable piece itself can be
removed but again a little help from a flat blade will get it started
and then wiggle it as you pull outward(upward).
The plastic tray can now be removed. It will be lightly adhered to the
bottom of your windshield by a sticky tar-like bead that should stay
attached to the tray. Be patient, pull slowly a little at a time starting
at one edge and working your way across. Here again a flat bade (putty
knife) may help in a clean release. After removal you will see the wiper
arm assembly which requires a torx bit to remove the two mounting fasteners.
Removal of the torx screws allows you to position the assembly out of
your way to gain access to the fan motor cover. Bentley says to remove
the assembly, I actually just pushed it out of the way as it is really
wedged into the area.
The wiper arm assembly now loose you can attack the blower motor cover.
The bower motor cover is held on with two nylon straps that just need
to be popped apart and pushed outboard. The fan cover then comes loose
and you will see your motor. Mine had two wires taped together and tie-wrapped
to the blower motor retaining clip. Snip the tie wrap and disconnect
I then took a larger flat screwdriver and popped the bottom of the motor
retaining clip which loosened the motor itself and enables removal the
motor. The two squirrel cage fans are firmly (permanently) attached
to this motor so a little jiggling will be needed to pull the assembly
Also at this time if you want you can clean the fan blades and vacuum
out the area beneath the motor on the car (bugs, leaves, other residue)
being careful not to bend the fins of the heat exchanger. This is also
when you can inspect the condition of the motor, clean if needed and
lightly lubricate it. The resistor pack is located beneath where the
motor was and is now readily accessible.
To remove it, pull forward and upward towards the front of the car.
It should pop right out and goes back in just about as easy but in reverse.
Once installed look around againto make sure you have not dropped anything
and the area is clean..
Installation of everything is just a reverse of this process but after
getting the motor lined up in its cradle, reinstalling the retaining
clip and securing the resistor wires, I hooked up the battery and made
sure the fan worked as advertised. It was then that I reinstalled the
fan cover and continued with putting the rest back in place.