Air Distribution Housing
HOUSING-AIR DISTRIBUTIONDISASSEMBLY
1. Remove the air distribution housing (1) from the HVAC housing and place it on a workbench.
2. Remove the screws (2) that secure the mode door actuator (4) and the blend door actuator (7) to the driver side of the air distribution housing and remove the actuators.
3. Remove the screws (5) that secure the blend door actuator mounting bracket (6) and the mode door actuator mounting bracket (3) to the driver side of the air distribution housing and remove the mounting brackets.
4. Remove the instrument panel door linkage (3) from the pivot shaft located on the driver side of the air distribution housing (8) and carefully disconnect the linkage rod (2) from the instrument panel door lever (1).
5. Remove the defrost/demister door linkage (7) from the pivot shaft on the air distribution housing and carefully disconnect the linkage rod (12) from the defrost/demister door lever (11).
6. Remove the mode door cam (6) from the air distribution housing.
7. Remove the floor door linkage (5) from the floor door lever (4) and the air distribution housing.
8. Remove the blend door cam (9) from the blend door lever (10) and the air distribution housing.
9. Remove the screw (1) that secures the heater core retaining bracket (2) to the driver side of the air distribution housing (3) and remove the bracket.
10. Carefully pull the heater core (4) out of the air distribution housing.
11. If equipped with dual zone heating-A/C, remove the screws (1) that secure the blend door actuator (2) to the passenger side of the air distribution housing (3) and remove the actuator.
12. Remove the screws (4) that secure the blend door actuator mounting bracket (5) to the passenger side of the air distribution housing and remove the mounting bracket.
13. If equipped with dual zone heating-A/C, remove the blend door cam (1) from blend door lever (2) and the pivot shaft located on the passenger side of the air distribution housing (3).
14. Remove the six screws (1) that secure the front floor distribution duct (2) to the bottom of the air distribution housing (3) and remove the duct.
15. Carefully cut the foam seal (1) along the parting line (2) of the two halves of the air distribution housing (3). If the seal is deformed or damaged, it must be replaced.
16. Remove the screws (4) that secure the two halves of the air distribution housing together.
17. Carefully separate the left half of the air distribution housing (1) from the right half of the housing (2).
18. Remove the center partition (3).
19. To remove the air doors (1) from the air distribution housing (2), first carefully push down on the tab (3) of the air door lever (4) located in the pivot shaft of the air door being removed.
NOTE: If the seal on the air door is deformed or damaged, the air door must be replaced.
20. Gently pull the air door lever out of the pivot shaft and remove the air door(s) from the air distribution housing as required.
ASSEMBLY
1. Install the air door(s) (1) into the air distribution housing (2) as required. Align the air door with the pivot shaft hole in the housing.
2. Align and install the air door lever (4) into the pivot shaft of the air door. Make sure that the tab (3) on the door lever is securely engaged to the pivot shaft.
3. Align the air door pivot shafts with the pivot holes in the center partition (3) and install the partition onto the left half of the air distribution housing (1).
4. Align the air door pivot shafts to each other and carefully install the left half of the air distribution housing to the right half of the housing (2).
5. Install the screws (4) that secure the two halves of the air distribution housing (3) together. Tighten the screws to 2.2 N.m (20 in. lbs.).
6. Inspect the foam seal (1), especially at the parting line (2). If the seal is deformed or damaged, it must be replaced.
7. Position the front floor distribution duct (2) onto the air distribution housing (3).
8. Install the six screws (1) that secure the front floor distribution duct to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.).
9. If equipped with dual zone heating-A/C, install the blend door cam (1) onto the blend door lever (2) and the pivot shaft located on the passenger side of the air distribution housing (3).
10. If equipped with dual zone heating-A/C, position the blend door actuator mounting bracket (5) onto the passenger side of the air distribution housing (3).
11. Install the screws (4) that secure the blend door actuator mounting bracket to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.).
12. Position the blend door actuator (2) onto the air distribution housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those on the blend door cam.
13. Install the screws (1) that secure the blend door actuator to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.).
14. Carefully install the heater core (4) into the driver side of the HVAC air distribution housing (3).
15. Install heater core retaining bracket (2) onto the air distribution housing.
16. Install the screw (1) that secures the heater core retaining bracket onto the air distribution housing. Tighten the screw to 2.2 N.m (20 in. lbs.).
17. Install the blend door cam (9) onto the blend door lever (10) and the pivot shaft located on the driver side of the air distribution housing (8).
18. Install the floor door linkage (5) onto the floor door lever (4) and the pivot shaft on air distribution housing.
NOTE: Align the guide pin on the floor door linkage with the guides on the mode door cam during installation of the floor door linkage.
19. Install the mode door cam (6) onto the pivot shaft on air distribution housing.
20. Connect the defrost/demister door linkage rod (12) onto the defrost/demister door lever (11).
NOTE: Align the guide pin on the defrost/demister linkage with the guides on the mode door cam during installation of the defrost/demister linkage.
21. Install the defrost/demister linkage (7) onto the pivot shaft on air distribution housing.
22. Connect the instrument panel door linkage rod (2) onto the instrument panel door lever (1).
NOTE: Align the guide pin on the instrument panel linkage with the guides on the mode door cam during installation of the instrument panel linkage.
23. Install the instrument panel linkage (3) onto the pivot shaft on air distribution housing.
24. Position the blend door actuator mounting bracket (6) and the mode door actuator mounting bracket (3) onto the driver side of the air distribution housing (1).
25. Install the screws (5) that secure the mounting brackets to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.).
26. Position the blend door actuator (7) onto the air distribution housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those on the blend door cam.
27. Position the mode door actuator (4) onto the air distribution housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those on the mode door cam.
28. Install the screws (2) that secure the blend door actuator to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.).
29. Position the mode door actuator mounting bracket (6) onto the driver side of the air distribution housing (1).
30. Install the screws that secure the blend door actuator mounting bracket to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.).
31. Position the blend door actuator (7) onto the air distribution housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those on the blend-air door linkage.
32. Install the screws (2) that secure the blend door and mode door actuators to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.).
33. Install the air distribution housing onto the HVAC housing.