I remembered the RAVE CD I have includes the gen III range rover. I confirmed there is an HEVAC Control Module, component D243. It is behind the center console, and you must remove fascia to access it. "Remove Fascia" is LR-speak for bend over, apparently. According to the manual you will have to drain the AC refrigerant, remove A pillar upper and lower trim, footwell trim, shifter, handbrake, center console, tons of switches, honestly its a very long list. Before you even get to removing the dash itself.
There is a hot/cold blend motor that only requires removing the Navigation system, and there is a fresh and recirculated air motor that only requires removing 1 center console panel and one under dash panel on the passenger side. So I'd try testing this problem with hot air and cold air and try testing it with fresh air vs recirculated air. Since you have dual zone, you shuold try to see if you can get face air on passenger side or not, on driver side or not, in the rear seating area or not. These things may help narrow down exactly which motor/flap is acting up. Theres a chance its one of these easy to get to motors. Any analysis or more sophisticated description of the problem you can explain to the shop could save you money, but if they do have to yank your dash out, the labor is going to be obscene.
To give you a hint of how bad, my wife has an 97 S420 mercedes which is known to be a model that will someday have a problem with the AC evap unit in the dash. the labor estimate is six thousand bucks at an Indie shop. The new evaporator is less than $500. I pulled the interior out of my 1991 Classic so I guess I could do this repair, but it will be a bit more complex, and anything I break along the way will be expensive to replace. I may have to cut my losses on the car at that point. Hopefully I can avoid this another couple years...
So - its just my opinion - but sounds like you may have an expensive problem to fix. I'd like to see what others say.
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Pat Herman
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