Join Date: Jun 2006
Location: Eastern ON Canada
Car: 07 OBW 2.5i D-4AT
Feedback Score: 5 reviews
Different approach (than in my post #22), but still a conclusion. Great!
Been a good run -- from isolating the strange cold air blast, to finding the recirc actuator and door, and finally isolating the actuator problem to the control module.
Looking at the last set of photos, I believe the six rectangular green and red "bulbs" are actually LEDs. (The three, round, green-capped lights are probably mini-incandescents.) The LEDs operate with not more than about 20 milliamps of current. Placing a battery directly across an LED's terminals, without any current limiting, will very likely cause it to burn out quickly.
I can see diodes, resistors, and two transistors on the printed circuit board, some, or all, of which might be there to limit/control the current going to the individual LEDs and bulbs. I can't think of any other purpose.
Were you able to identify what was burning?
Even if a bulb or LED is burned out, the associated switch should still work. So it would seem that there's a problem at the recirc. switch itself, either bad connections or the internal mechanism is faulty.
It is a learning experience that, as a result of your efforts (posting, providing photos, and persisting), might well help others in future.