So I'm tired of freezing (yes. Freezing is relative. When it's 50 degrees outside I'm freezing and want my heater! Yes. I'm a So. Calif. temperature wuss!).
So I have to remove it. I looked at Mjolnir's FAQ and went out to the car to discover that mine is different. Not too suprising. His seems to have a neat hole with a cover held by 4 screws. Not so with mine.
After removing the rain tray I discovered a huge monster plastic box. Thus:
I noticed that on the driver's end there's a nut. In the middle there's a screw. At the pass end I noticed a tell-tale screw end sticking up, laughing at me and telling me that I have to crawl under the dash. *SIGH!*. Fresh air inlet. Notice the dashpot. Otto only pushes air through the defroster so I sucked on the dashpot tube and the big flap came up (recirc mode) so that much of it, at least, works.
To get the screw out you crawl under the dash and locate it. It's above the lambda controller. It could probably be removed without pulling the computer. I opted to pull the computer. While you're there, look up and you'll see the two vacuum lines that connect to the inlet part of the big-rain-tray-housing-thing. The screw you pulled is on one end of the opening. There's another one. Pull that as long as you're there. You might as well mark the two vacuum hoses and pop those off while you're under there, view from under dash:
Next pic is the hole in the middle of the housing where the screw was:
The screw has a washer and then a grommet. Under the dash, a nut (DOH! Who designed this?). Once you loosen the screw the grommet will hold the screw tight enough so you can get the nut off without a friend.
At the driver's end there's a nut. How convenient...heh...NOT! The nut attaches to a screw driving from under the dash (again? Yes!). However, it has a washer and a grommet and the grommet holds the screw tight so you can easily remove the nut. Pull off the washers and leave the grommet for now, as it will hold the screw and save you time.
Once you've pulled the 2 screws holding the end piece, it will separate. I'm pointing to the dashpot.
Now the end piece slides to the pass side and lifts out of the rain tray. You can see the hole leading to the dash and the two vacuum hoses.
Now you should be able to freely move the main piece of the housing (except that you still have the screw on the driver's side held by the grommet). So get a screwdriver and work the grommet off of the screw. If you're careful you'll be able to lift the whole plastic piece off the screw without the screw dropping down into the pass compartment. If you succeed at this, put the grommet back onto the end of the screw and the screw will stay put until you are ready to put it all back in. Move the middle piece to the pass side of the rain tray and twist the bottom up to slide it out:
And what to my wondering eyes should appear? The fan housing and speed resistor! Almost home!
The cover just snaps into place. It lifts right out:
Here's a close-up view. That screw has to be removed.
Next you have to remove the strap holding the motor on. It's sort of wedged in and has to be snapped out. In this pic you can see that I've removed it and you can also see the driver's side screw held in place by the grommet. I'm pointing at the metal motor strap:
Back into the car. Remove the fan switch, and the slider knobs (they all pull straight out). Then use a flat blade to pry the face off where the slider knobs were. Careful! There's a light bulb at the bottom right. If it's dead you now know how to get at it! Once the face is off, you can see the switch itself. Push from the back of the switch and it will come out the front. It's held in place by a small piece of plastic sticking out on the bottom left and on the right side by a spring clip. You'll need to push the spring clip in, then the right side of the switch will pop forward and you can work the whole thing out. Might be easier if you remove the cable first. Once the switch is out, pull the cable through the hole and get under the dash (again!) but this time on the driver's side. Shine your light under the dash while pulling on the switch cable until you locate the connector that it goes to. Disconnect the connector (ironically this was the hardest part of the whole ordeal!). Leave the wires from the connector to the switch connecter where they are, but follow the others. You will see that they go up to the motor. There's a rubber grommet thingy that is rectangular. I was able to feed the small end through the hole and then go under the hood and pull it all the way through. Now lift the motor assy up and away, pulling on the wires. The connector will hang at the hole. Set the motor down, back under the dash and push the connector through the hole. Then, under the hood, pull the connector free. Slide the motor all the way to the pass side and it will come out of the rain tray! Success!
Now you are free to test the motor at will.
Good news: my motor works GREAT and it doesn't bind anywhere.
Bad news: Problem in wiring. Waste of time pulling the motor (except that I was able to create this FAQ!).