For those addressing the "Magic Blower Syndrome" here is a little detail that was not immediately obvious to me when I tackled this on my white 86.5 5-speed: When you are looking at the resistor pack from the outside of the tunnel, you are actually looking at the back of a 7-pin plug that connects to it. I know the instructions allude to this, and tell you to disconnect the wiring. In fact the linked instructions tell you to unplug it BEFORE undoing the two screws that hold the resistor pack to the tunnel. However, my 7-pin plug was on there pretty good, and I had to be sure of what I was dealing with, before I started prying on it hard to take it off. Below is a picture after I got it off. Note that I had already taken off the bottom right screw. That screw is a bear to get to anyway, but it is much easier AFTER unplugging the 7-pin plug.
Also, when plugging the 7-pin connector back, I heard a distinct "click", so there may be some sort of tab-slot fit that holds it securely, which is what may have caused resistance to my pulling it off. I did not look closely at it before putting it back on however (and was DONE with it by the time I got it plugged back in, so I didn't unplug it again).
Finally, I recommend NOT messing with the Blower Motor assembly, unless you have very clear access to it (i.e., the hood is off). I started going this route with my hood on, and dropped an 8mm socket in there, which took me a while to fish out! That is why I recommend against it! After that, I abandoned that route, and simply got a long needle-nosed plier and used it to grab the resistor pack after the last screw was off the front, and "hand it" to myself through the rubber boot gap (having pushed aside the rubber boot). Small hands (like mine) are helpful here, however. When putting it back, do the reverse, and push the resistor pack carefully through the rubber boot gap, until you can grab it from outside the tunnel through the small rectangular opening it sits in. Another pair of hands would be very helpful here - I did it myself, but I was able to stick my hand into the tunnel to hold the resistor pack from inside while I pushed the plug on halfway, allowing me to leave it there while I got the screws and screw driver and was able to start the top left screw, then unplugged the plug to do the bottom right screw (again, quite difficult to get to), then plugged the 7-pin connector back on. Whew!
Anyway, I hope the picture, below, helps others!
Attached files
[img]media/attachments/7444=811-IMAG0249 w notes.JPG[/img]
