I spent some time with mine today, just tinkering around and rerouting wires, vents, and vacuum lines under the dash. One thing I figured out is that what I though was an auxiliary/additional blower, I'm now thinking might be an
additional blower that gets used when the A/C is turned on (a blower that blows across the A/C coils but never the heater core). If I unhook the "auxiliary" fan and just turn on the dash fan, very little air comes through the vents. If I hook up the "auxiliary" fan while the dash fan is on, air comes pumping through the vents like it should. Typing that "out loud" has me thinking... I suppose the other possibility is that one blower is for
intake/return and the one I'm calling "auxiliary" is the blower that actually pushes air through the vents. In other words, maybe the factory HVAC utilizes two blowers, one in and one out? That would make sense considering what I'm experiencing.
Additional info.: there were three wires from the "auxiliary" blower hooked up to a three way switch that was obviously installed by the previous owner (weird location and obviously an aftermarket switch). One wire is for low, one is for med., and one is for high. If my new theory is correct, I'm betting at some point those were hooked up to the factory controls to automatically follow the low, med., high on the dash controls, as it changes the speed of what I'm now calling the "intake" blower.
I also found a light blue wire from the dash HVAC controller that is not hooked up to anything. It is only hot when the dash fan controls are on. Thus, I could use that wire to supply
12v to the vent blower and it would only come on when I turn on the dash fan, however, I would still have to use a three way switch to control the output level of the vent blower (low, med, high).
I suppose I could also "do the right thing" at this point, and dig into the dash controls to see what's really going on with the dash fan control and what
should happen with the two different blowers.
I just thought of something else... I think I saw a distribution block under the dash somewhere that both blowers are hooked up to. Somebody probably messed with that to add that weird manual vent blower switch, and I'm thinking if I return all the wiring for that block to how it
should be, the dash fan control will probably switch both blowers to the same speed at the same time.
It's a mystery as to why anyone changed it in the first place!