Front Air Distribution Housing

AIR DISTRIBUTION HOUSING

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

NOTE: LHD model shown. RHD model similar.

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

2. 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 (Figure 1).












Figure 1 Actuators


3. 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 (Figure 2).











Figure 2 Air Door Linkage

4. Remove the six screws that secure the floor distribution ducts to the air distribution housing and remove the ducts (Figure 3).











Figure 3 Front Floor Distribution Duct

5. Remove the screw from the center of the driver side of the air distribution housing (Figure 4).

6. 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.

7. Remove the seven screws that secure the two halves of the air distribution housing together and carefully separate the housing.











Figure 4 Air Distribution Housing Screws

8. 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 (Figure 5).

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

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











Figure 5 Dual Zone Driver Side Blend-Air Door

10. Remove the screw that secures the driver side air vane to the passenger side of the air distribution housing and remove the vane (Figure 6).

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

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











Figure 6 Air Doors and Partition - Driver Side

12. Remove the screw that secures the passenger side air vane to the passenger side of the air distribution housing and remove the vane (Figure 7).

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

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











Figure 7 Air Doors and Vane - Passenger Side