Front Air Distribution Housing

HOUSING-AIR DISTRIBUTION





1. If removed, install the linkage (6) onto the floor console air door (7).
2. Install the floor console air door and linkage into the right side of the air distribution housing (3).
3. Install the right side partition (1), blend air door (2) and mode air doors (4 and 5).





4. Align the air door pivot shafts and the right side partition with the holes in the center partition (4) and carefully install the center partition onto the right half of the air distribution housing (5).
5. Install the left side partition (1), blend air door (2) and mode air doors (3).





6. Align the air door pivot shafts and the left side partition with the holes in the left half of the air distribution housing (5) and carefully install the left half of the air distribution housing onto the right half of the air distribution housing (4).
7. Install the thirteen screws (3) that secure the two halves of the air distribution housing together. Tighten the screws to 2.2 Nm (20 in. lbs.).
8. Inspect the foam seal (1), especially at the parting lines (2). If the foam seal is ok, adhere the cuts made at the parting lines back together with a small amount of RTV sealer. If the foam seal is deformed or damaged, it must be replaced.





9. Install the floor air door (1) into the left side of the air distribution housing (2).





10. Install the floor air door linkage rod (2) and the left side floor air door gear (4). First, align together the largest tooth opening on the gear with largest tooth on the linkage rod (1). Then install the gear into the left side floor air door (3), with the door in the open position as shown. Make sure the gear is fully engaged to the air door.





11. Align the blend door gear (1) with the blend air door on the left side the air distribution housing (2) and install the gear. Make sure the gear is fully engaged to the air door.





12. Align the blend door drive gear (1) with the blend door gear on the left side of the air distribution housing (2) and install the drive gear. Make sure the gears are aligned as shown.
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13. Position the blend door actuator (1) into the vehicle.
14. Install the blend door actuator onto the driver side of the HVAC air distribution housing (2). If necessary, rotate the actuator slightly to align the flat area of the splines on the actuator output shaft (4) with the flat area in the blend door cam (3).





15. Install the two screws (1) that secure the blend door actuator (3) to the left side of the air distribution housing (4). Tighten the screws to 2 Nm (17 in. lbs.).





16. Install the evaporator temperature sensor (1) onto the right side of the air distribution housing (2).





17. Install the floor air door (1) onto the right side of the air distribution housing (2).





18. Position the mode door gear bracket (2) onto the right side of the air distribution housing (1) and install the retaining screw (3). Tighten the screw to 2 Nm (17 in. lbs.).





19. Align the blend door gear (1) with the blend air door on the right side the air distribution housing (2) and install the gear. Make sure the gear is fully engaged to the air door.




Align the two mode air door levers (1 and 2) with the mode air doors on the right side the air distribution housing (3) and install the levers. Make sure the levers are fully engaged to the air doors.





20. Align the previously installed mode air door lever to the slot in the back of mode door driven gear (2) and install the driven gear.
21. Align the console air door lever (1) to console air door linkage rod and the slot in the front of the mode door driven gear and install the lever. Make sure the lever is fully engaged to the linkage rod and the driven gear.





22. Install the floor air door linkage rod (1) and the right side floor air door gear and lever assembly (2). First, align together the largest tooth opening on the gear and lever assembly with largest tooth on the linkage rod (3). Then install the gear and lever assembly into the right side floor air door (4), with the door in the open position as shown. Make sure the gear and lever assembly is fully engaged to the air door and that both floor air doors open and close together simultaneously.





23. Align the mode door driven gear (1) to the mode door drive gear (2) in the position shown (3).
24. Align the previously installed mode air door lever to the slot in the back of mode door drive gear and install the drive gear.





25. Align the tab on the back side of the mode door drive gear lever (2) with the slot on the front of the mode door drive gear (1) and install the lever.
26. Connect the mode door drive gear lever arm (4) to the right side floor air door lever (3).
27. Rotate the mode door drive gear back and forth by hand. Make sure that the mode air doors at the top of the housing, and the floor air doors on each side of the housing, open and close fully, with no binding or excessive effort required.





28. Position the mode door actuator bracket (2) to the right side of the air distribution housing (3) and install the three retaining screws (1). Tighten the screws to 2 Nm (17 in. lbs.).
29. Align the blend door drive gear (4) with the blend door gear and install the drive gear. Make sure the gears are aligned as shown.
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30. Install the blend door actuator (1) onto the right side of the air distribution housing (4). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (2) with those on the blend door drive gear (3).





31. Install the mode door actuator (3) onto the mode door actuator bracket (1). If necessary, rotate the actuator slightly to align the flat area of the splines on the actuator output shaft (4) with the flat area in the mode door drive gear (2).





32. install the five screws (3) that secure the mode door actuator (2) and the blend door actuator (4) to the right side of the air distribution housing. Tighten the screws to 2 Nm (17 in. lbs.).
33. Install the air distribution housing onto the HVAC housing HVAC Housing - Installation.