Air Inlet Housing Removal and Installation
AIR INLET HOUSING
WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation Service Precautions Failure to follow these instructions may result in possible serious or fatal injury.
WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (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 airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury.
NOTE: The air inlet housing does not need to be removed from the HVAC housing for service of the recirculation-air door only Air Door
NOTE: The air inlet housing does not need to be removed from the HVAC housing for service of the recirculation-air door only Air Door
1. Disconnect and isolate the negative battery cable.
2. Drain the engine cooling system.
3. Disconnect the heater hoses from the heater core tubes.
4. Remove the Powertrain Control Module (PCM) to gain access to the two nuts (3) that secure the HVAC housing (1) to the engine compartment side of the dash panel (2) and remove the nuts Engine Control Module
5. Remove the instrument panel from the passenger compartment Interior Moulding / Trim
6. Remove the bolt (5) that secures the HVAC housing (4) to the floor bracket (6).
7. Remove the two nuts (3 and 7) that secure the HVAC housing to the passenger compartment side of the dash panel (1).
8. Carefully pull the right side of the HVAC housing rearward to gain access to the front of the air inlet housing.
9. Remove the recirculation door actuator (1) from the air inlet housing (2) and disconnect the HVAC wire harness (4) from the actuator.
10. Remove the two screws (3) that secure the rear of the air inlet housing to the top of the HVAC housing (5).
11. Release the two retaining clips (1) that secure the front of the air inlet housing (2) to the top of the HVAC housing (3) and remove the air inlet housing.
NOTE:If the foam seal on the air inlet housing is deformed or damaged, it must be replaced.
12. If required, disassemble the air inlet housing Overhaul
Installation
NOTE: If the foam seal on the air Inlet housing is deformed or
damaged, it must be replaced.
1. Position the air inlet housing (2) onto the top of the HVAC housing (3).
2. Engage the two retaining clips (1) that secure the front of the air inlet housing to the HVAC housing.
3. Install the two screws (3) that secure the rear of the air inlet housing (2) to the top of the HVAC housing (5). Tighten the screws to 1.1 N.m (10 in. lbs.).
4. Install the recirculation door actuator (1) onto the air inlet housing Air Door
5. Connect the HVAC wire harness (4) to the recirculation door actuator.
6. If removed, install the fresh air inlet (2) onto the dash panel (1).
7. Reposition the HVAC housing (4) to the passenger compartment with the mounting studs and the condensate drain tube in their proper locations in the dash panel.
8. Install the two nuts (3 and 7) that secure the HVAC housing to the passenger compartment side of the dash panel. Tighten the nuts to 6.8 N.m (60 in. lbs.).
9. Install the bolt (5) that secures the HVAC housing to the floor bracket (6). Tighten the bolt to 6.8 N.m (60 in.lbs.).
10. Install the instrument panel assembly Interior Moulding / Trim
11. Install the two nuts (3) that secure the HVAC housing (1) to the engine compartment side of the dash panel (2). Tighten the nuts to 6.8 N.m (60 in. lbs.).
12. Install the Powertrain Control Module Engine Control Module
13. Connect the heater hoses to the heater core tubes.
14. Reconnect the negative battery cable.
15. Refill the engine cooling system Cooling System
16. Initiate the Actuator Calibration function using a scan tool Testing and Inspection