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Air Distribution Housing







HOUSING-AIR DISTRIBUTION

WARNING: The heater core tubes are not serviced separately from the heater core. The heater core tubes should not be repositioned, loosened or removed from the heater core. Failure to follow this warning could result in a coolant leak and possible personal injury or death.

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

NOTE: LHD model shown in illustrations. RHD model similar.





1. Remove the HVAC housing assembly and place it on a workbench HVAC Housing - Removal.
2. Remove the air distribution housing (4) from the HVAC housing HVAC Housing - Removal.
3. Remove the screws (3) that secure the mode door actuator (2) and the blend door actuator (6) to the actuator mounting bracket (5) located on the driver side of the air distribution housing and remove the actuators.
4. Remove the three screws (1) that secure the actuator mounting bracket to the air distribution housing and remove the bracket.
5. Remove the two screws (8) that secure the driver side front floor duct (7) to the air distribution housing and remove the duct




6. Remove the defrost door lever and gear assembly (1), mode door cam (2), panel door gear (3), blend door gear (4), blend door lever (6) and the blend door cam (5) from the driver side of the air distribution housing (7).
7. If equipped with the 2.8L diesel engine, remove the electric positive temperature coefficient (PTC) heater unit from the air distribution housing .




8. Remove the two screws (1) that secure the upper front passenger side floor duct (7) to the passenger side of the air distribution housing (8) and remove the duct.

NOTE: If the foam seal for the heater core tube flange is deformed or damaged, it must be replaced.

9. Carefully remove the foam seal (3) from the heater core tube flange (4). If the seal is deformed or damaged, it must be replaced.
10. Remove the screw (2) that secures the heater core tube flange to the air distribution housing.
11. Disengage the plastic retainer (5) from around the heater core tubes (6) and remove the flange.




NOTE: If the foam insulator around the heater core is deformed or damaged, the insulator must be replaced.

12. Disengage the four plastic retaining tabs (1) that secure the heater core (2) to the passenger side of the air distribution housing (3) and carefully remove the heater core from the housing.




13. Carefully cut the foam seal (1) along the parting line (2) of the two halves of the air distribution housing (3 and 6). If the seal is deformed or damaged, it must be replaced.
14. Remove the screw (5) that secures the two halves of the air distribution housing together located on the bottom of the housing, near the center.
15. Disengage the four plastic retaining tabs (4) and carefully separate the two halves of the air distribution housing.




16. Remove the air deflector vane assembly (1) from the passenger side of the air distribution housing (2). Disengage the two plastic retaining tabs (1) and slide the vane straight out of the housing.




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

17. Remove the floor-air door (1), blend-air door (2), panel-air door (3) and the defrost-air door (4) from the driver side of the air distribution housing (5) as required.
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