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I'm in the final stages of getting my A/C working again and am checking everything to make sure it's operating properly. Just had the HVAC control assembly out to replace the fan switches (both of which went bad) and hooked up the vacuum lines again. With the water drained from the system I took a MityVac to the hot water control valve to figure what vacuum would cause it to fully close. I also bought a replacement heater control valve and both the new one and the original close at the same setting. With the left control levers in the up position (OFF) vacuum is normally applied to the kick panel door and it is open. Vacuum is simultaneously applied to the hot water heater control valve and it is fully closed - blocking off any hot water to the core. When I move the left control lever down to VENT, the kick panel vent door closes immediately. At Max A/C the heater control valve is still closed,as is the kick panel door, but moving the lever down to NORM (normal A/C?) the hot water heater control valve opens and the kick panel door is still closed. Seems to me that Normal A/C should keep the hot water control valve fully closed. I would also think that Max A/C would recirculate the interior air by pulling it back in through that kick panel door. Obviously it can't do that if the door is closed. I understand the hot water valve opening when the left lever is set at HEAT but it seems to me it's opening too soon. Maybe my vacuum switch isn't working properly either. Is my kick panel door working properly and if it is then how does the air get recirculated?
 

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There is a vacuum diagram in the AIM in the C60 section (its a big section!). Max air closes the cowl vent and opens the kick vent. Normal closes the kick and opens the cowl. The heater valve should open and close with heat only. sound like something is not hooked up right or not adjusted properly.
 

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Thanks Kevin. I found the control system and wiring diagram in the AIM for the A/C and now I see the vacuum switch table. It shows vacuum applied - kick panel door is open when the left switch is OFF, closes when the lever is at VENT, opens again at the MAX A/C position and then closes again at NORMAL. I discovered my problem was applying the vacuum statically - without the engine running. When I moved the lever from OFF to VENT it seemed to work properly but the vacuum was lost. When moving the lever along to MAX A/C I needed to apply vacuum again (statically). The hot water control valve also closes again. All seems to be working properly. Thanks again.
 
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