Repair Procedure

THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.

1. Turn the ignition switch to the "on" position and place A/C control in floor mode. Turn the ignition switch off.

2. Disconnect battery.

3. Remove center console.

4. Remove cluster bezel.

5. Remove knee blocker and lower center instrument panel trim panel.

6. Remove kick panels and lower door trim strip in order to free-up carpet.





7. Remove short instrument panel support brace (Fig. 1) located near the accelerator pedal.

8. Peel front carpet back for access.

9. Remove center instrument panel bolts (2), left and right instrument panel attaching bolts (4) and instrument panel roll-back bolts (2).

10. Grasp metal at center of the lower instrument panel and pry the instrument panel away from dash panel (2 in.). Place spacer in that gap to keep instrument panel in place.

11. Disassemble tunnel slider duct from floor duct (DN ONLY).

12. The floor duct that is attached to the HVAC unit is assembled in two pieces. Remove two screws that hold the passenger side of the floor duct to the HVAC unit. Remove the duct.

13. Remove two screws that hold the driver side of the floor duct to the HVAC unit. Remove the duct.

14. On the driver's side half of the floor duct, use an alcohol-based solvent to clean the seal surface before seal application.

15. Take the driver's side floor duct and install the foam seal provided and apply it to the seal surface. Be sure to press the seal to the duct firmly along the entire length of the seal. Set duct aside.

16. Remove foam seal on floor outlet of HVAC unit. Be careful to leave no adhesive residue on the housing.

17. Insert right larger deflector onto the passenger side forward (Closest to the engine compartment) flange of the heat outlet with the extension flap outboard as shown. Snap into place until positive lock is heard

18. Insert left air deflector onto the driver side forward flange of the heat outlet as shown. Snap into place until positive lock is heard

19. Make sure that both deflectors have tension on them and do not rattle. If they do, remove, bend appropriately and re-install.





20. Insert smaller deflectors (Fig. 2)- one on the passenger side forward flange of the heater outlet and one on the driver side rearward (Closest to the passenger compartment) flange of the heater outlet. Snap into place until positive lock is heard.

21. Make sure that both deflectors have tension on them and do not rattle. If they do, remove, bend appropriately and re-install.

22. Carefully slide driver's side floor duct half (now with foam seal attached) into place. Be sure to carefully slide the duct into opening without rolling over the foam seal. After seal is properly sandwiched between the duct half and housing, Install the two attachment screws.

23. Slide passenger side floor duct half into place. Make sure this half properly mates with the driver's side half. Install the two attachment screws.

24. Remove the mode actuator from the driver's side of the HVAC unit. (If vehicle is a DN, remove both mode actuators on this side.

25. Remove cam and discard.

26. Close the floor door and note the position of the floor door lever. Remove floor door lever and discard.

27. Position floor door in closed position. While holding the floor door in the closed position, install new floor door lever supplied in the repair kit in the position noted earlier. Make sure the lever snaps and locks into place.





28. Set the template over panel door and floor door levers as shown (Fig. 3).

29. Lay defrost lever on the outboard face of the cam. Install new cam aligning the hole in the cam with the mark on the template as shown (Fig. 3). Make sure that the proper pins fit into the proper traces on the cam back of the cam per the template. Remove template.

30. Install actuator.

31. Install the remainder of the of the parts removed earlier by reversing the removal procedure.