Front Air Distribution Housing Removal and Installation

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 BATTERY NEGATIVE (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 AIR-BAG 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. 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 mode-air and blend-air doors.
- LHD model shown in illustrations. RHD model similar.

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

Blend Door Actuator:

2. Disconnect the HVAC wire harness connectors from the mode door actuator and the blend door actuator(s) located on the driver side of the air distribution housing and position the HVAC wire harness out of the way.

Heater Core Tubes:

3. Remove the foam seal from the heater core tubes and the flange located at the front of the HVAC housing. If the seal is deformed or damaged, it must be replaced.
4. Remove the plastic retaining strap that secures the heater core tubes to the front of the HVAC housing.

NOTE: Take the proper precautions to protect against spilled engine coolant. Have absorbent toweling readily available to clean up any spills.

5. Remove the bolt that secures the heater core tube sealing plate to the heater core.
6. Disconnect the heater core tubes from the heater core and remove and discard the O-ring seals.
7. Install plugs in, or tape over the opened heater core ports.

Retainers Air Distribution Housing:

8. Remove the four screws that secure the air distribution housing to the rear of the HVAC housing.
9. Tilt the top of the air distribution housing rear ward to disconnect the distribution housing from the two tab-and-slot type retainers located at the bottom of the housing and remove the distribution housing.
10. If required, disassemble the air distribution housing.

INSTALLATION

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 distribution housing onto the rear of the HVAC housing by inserting the two 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 four screws that secure the air distribution housing to the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
3. Remove the tape or plugs from the heater core ports.
4. Lubricate new rubber O-ring seals with clean engine coolant and install them onto the heater core tube fittings. Use only the specified O-ring as they are made of a special material for the engine cooling system.
5. Position both heater core tubes and the sealing plate simultaneously onto the heater core.

NOTE: The heater core tubes each have a slot that must be indexed to a location tab within each of the heater core ports. Adjust the position of the tubes as required so that the sealing plate fits flush against the heater core supply and return ports, which indicates that the tubes are properly indexed.

6. Index both heater core tubes to the heater core ports.
7. Install the bolt that secures the heater core tube sealing plate to the heater core. Tighten the bolt to 3 N.m (27 in. lbs.).
8. Install the plastic retaining clamp that secures the heater core tubes to the front of the HVAC housing.
9. Install the foam seal onto the heater core tubes and the flange located at the front of the HVAC housing.
10. Position the HVAC wire harness onto the air distribution housing.
11. Connect the HVAC wire harness connectors to the mode door actuator and the blend door actuator(s) located on the driver side of the air distribution housing.
12. Install the HVAC housing assembly.