Air Distribution Housing

DISASSEMBLY

NOTE:
- The air distribution housing must be removed from the HVAC housing and disassembled for service of the mode-air and blend-air doors.
- LHD model shown in illustrations. RHD model similar.

1. Remove the air distribution housing from the HVAC housing and place it on a workbench.

Actuators And Heater Core:

2. Remove the two screws that secure the heater core to the driver side of the air distribution housing and carefully remove the heater core.
3. Remove the screws that secure the mode door actuator and the blend door actuator(s) to the driver side of the air distribution housing and remove the actuators.

Air Door Linkage:

4. Remove the defrost door linkage arm, instrument panel door linkage arm, mode door cam, floor door gear, driver side blend door gear (if equipped) and the passenger side blend door stop from the driver side of the air distribution housing.

Front Floor Distribution Duct:

5. Remove the six screws that secure the floor distribution ducts to the air distribution housing and remove the ducts.

Air Distribution Housing Screws:

6. Remove the screw from the center of the driver side of the air distribution housing.
7. Carefully cut the foam seal along the parting line of the two halves of the air distribution housing. If the seal is deformed or damaged, it must be replaced.
8. Remove the seven screws that secure the two halves of the air distribution housing together and carefully separate the housing.

Dual Zone Driver Side Blend Air Door:

9. If equipped with dual zone heating -A/C system, push down on the retaining tab of the driver side blend door gear and carefully pull the gear out of the blend door pivot shaft.

NOTE: If the seal on the air door is deformed or damaged, the air door must be replaced.

10. Remove the blend-air door from the driver side of the air distribution housing.

Air Doors And Partition Driver Side:

11. Remove the screw that secures the driver side air vane to the passenger side of the air distribution housing and remove the vane.

NOTE: If the seal on any air door is deformed or damaged, the air door must be replaced.

12. Remove the air doors and the partition from the air distribution housing.

Air Doors And Vane Passenger Side:

13. Remove the screw that secures the passenger side air vane to the passenger side of the air distribution housing and remove the vane.

NOTE: If the seal on any air door is deformed or damaged, the air door must be replaced.

14. Remove the air doors from the passenger side of the air distribution housing.

ASSEMBLY

NOTE: The air distribution housing must be removed from the HVAC housing and disassembled for service of the mode-air and blend-air doors.

1. Install the air doors into the passenger side of the air distribution housing as required. Align the air doors with the pivot shaft holes in the housing.
2. Install the air vane and retaining screw to the passenger side of the air distribution housing. Tighten the screw to 2 N.m (17 in. lbs.).
3. Align the air door pivot shafts with the pivot holes in the center partition and install the partition onto the passenger side of the air distribution housing.
4. Install the driver side air vane and retaining screw to the center partition. Tighten the screw to 2 N.m (17 in. lbs.).
5. Install the blend-air door to the driver side of the air distribution housing. Align the air door with the pivot shaft hole in the housing.
6. If equipped with dual zone heating-A/C system, align and install the blend door gear into the pivot shaft of the driver side blend-air door. Make sure that the retaining tab on the door gear is securely engaged to the pivot shaft.
7. Align the air door pivot shafts to each other and carefully install the driver side half of the air distribution housing to the passenger side half of the housing.
8. Install the seven screws that secure the two halves of the air distribution housing together. Tighten the screws to 2 N.m (17 in. lbs.).
9. Inspect the foam seal, especially at the parting line. If the seal is deformed or damaged, it must be replaced.
10. Install the screw to the center of the driver side air distribution housing. Tighten the screw to 2 N.m (17 in. lbs.).
11. Position the floor distribution ducts onto the air distribution housing.
12. Install the six screws that secure the floor distribution ducts to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.).

NOTE: Align the guide pin on the linkage arms with the guides on the mode door cam during installation of the floor door gear and linkage arms.

13. Install the passenger side blend door stop, driver side blend door gear (if equipped), floor door gear, mode door cam, instrument panel door linkage arm and the defrost door linkage arm onto the driver side of the air distribution housing.
14. Position the mode door and blend door actuators onto the driver side of the air distribution housing. If necessary, rotate the actuators slightly to align the splines on the actuator output shaft with those in the air door linkage.
15. Install the two screws that secure each actuator to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.).
16. Carefully install the heater core into the driver side of the air distribution housing.
17. Install the two screws that secure the heater core to the air distribution housing. Tighten the screw to 2 N.m (17 in. lbs.).
18. Install the air distribution housing onto the HVAC housing.