Air Distribution Housing Removal and Installation
HOUSING-AIR DISTRIBUTIONNOTE: LHD model with A/C shown in the following illustrations. RHD and heater-only models are similar.
REMOVAL
WARNING:
- ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE NEGATIVE BATTERY (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH.
- REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION AND FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH.
NOTE: The air distribution housing must be removed from the HVAC housing and disassembled for service of the blend-air and mode-air doors.
1. Remove the HVAC housing assembly and place it on a workbench.
2. Remove the left and right floor distribution ducts.
3. Remove the three screws (1) that secure the heater core cover (2) to the driver side of the air distribution housing (3) and the HVAC housing (4) and remove the cover.
NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced.
4. Remove the foam seal (1) from the flange (2) located on the driver side of the HVAC housing (6).
5. Remove the two screws (4) that secure the heater core (5) to the driver side of the air distribution housing (3).
6. Carefully pull the heater core out of the driver side of the air distribution housing.
7. Remove the screws (1) that secure the air distribution housing (2) to the rear of the HVAC housing (3).
8. Remove air distribution housing from the HVAC housing by tilting the top of the air distribution housing rearward and disconnecting the distribution housing from the tab-and-slot type retainers located at the bottom of the housing.
9. If required, disassemble the air distribution housing.
INSTALLATION
1. Install the air distribution housing (2) onto the rear of the HVAC housing (3) by inserting the tabs on the bottom of the distribution housing into the slots located on the bottom of the HVAC housing and tipping the distribution housing forward until it is properly aligned with the HVAC housing.
2. Install the screws (1) that secure the air distribution housing to the HVAC housing. Tighten the screws to 2.2 N.m (20 in. lbs.).
3. Carefully install the heater core (5) into the driver side of the air distribution housing (3).
4. Install the two screws (4) that secure the heater core to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.).
NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced.
5. Install the foam seal (1) onto the flange (2) located on the driver side of the HVAC housing (6).
6. Position the heater core cover (2) onto the driver side of the air distribution housing (3) and HVAC housing (4).
7. Install the three screws (1) that secure the heater core cover to the air distribution housing and HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
8. Install the left and right floor distribution ducts.
9. Install the HVAC housing assembly.