Air Distribution Housing
HOUSING-AIR DISTRIBUTIONNOTE: The air distribution housing must be removed from the HVAC housing and disassembled for service of the mode-air and blend-air doors.
DISASSEMBLY
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 blend door actuator (4) and the mode door actuator (7) to the left side of the air distribution housing and remove the actuators.
3. Remove the screws (3 and 6) that secure the blend door actuator mounting bracket (5) and the mode door actuator mounting bracket (8) to the left side of the air distribution housing and remove the mounting brackets.
4. Using a flat bladed tool, remove the upper defrost/ panel door pivot gear (1), front floor door pivot gear (4) and the blend door stop (5) from the left side of the air distribution housing (3).
5. Remove the upper defrost/panel door linkage rod (8) and the mode door cam (7) from the air distribution housing.
6. Remove the lower defrost/panel door pivot gear (2) and the front floor door linkage rod (6) from the air distribution housing.
7. On RHD models carefully pull the heater core out of the left side of the air distribution housing.
8. Remove the screws (1) that secure the rear floor/ console door actuator (2) to the right side of the air distribution housing (3) and remove the actuator.
9. If equipped with dual zone heating-A/C, remove the screws (6) that secure the blend door actuator (7) to the right side of the air distribution housing and remove the actuator.
10. If equipped with dual zone heating-A/C, remove the screws (4) that secure the blend door actuator mounting bracket (5) to the right side of the air distribution housing and remove the mounting bracket.
11. On LHD models equipped with dual zone heating-A/C, remove the blend door stop (1) from the right side of the air distribution housing (2).
12. On LHD models carefully pull the heater core (3) out of the right side of the air distribution housing.
13. 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.
14. Remove the 4 metal clips (4) that secure the two halves of the air distribution housing together.
15. Remove the eight screws (5) that secure the two halves of the air distribution housing together.
16. Carefully separate the left half of the air distribution housing (1) from the right half of the air distribution housing (2).
17. Remove the center partition (3) from the distribution housing.
NOTE: If the seal on any air door is deformed or damaged, the air door must be replaced.
18. If required, remove the front floor air doors (1 and 3) from the center partition (2) by disengaging the retaining tabs (4) and pulling the air doors apart from each other.
NOTE: If the seal on any air door is deformed or damaged, the air door must be replaced.
19. Remove the upper defrost/panel-air door (1), lower defrost/panel-air door (2), directional vane (3), rear outlet-air door (4) and the blend-air door (5) from the right side air distribution housing (6) as required.
NOTE: If the seal on any air door is deformed or damaged, the air door must be replaced.
20. Remove the upper defrost/panel-air door (1), lower defrost/panel-air door (2), directional vane (3) and the blend-air door (4) from the left side air distribution housing (5) as required.
ASSEMBLY
1. Install the upper defrost/panel-air door (1), lower defrost/panel-air door (2), directional vane (3) and the blend-air door (4) into the left side air distribution housing (5) as required. Align the air doors with the pivot shaft holes in the housing.
2. Install the upper defrost/panel-air door (1), lower defrost/panel-air door (2), directional vane (3), rear outlet-air door (4) and the blend-air door (5) into the right side air distribution housing (6) as required. Align the air doors with the pivot shaft holes in the housing.
3. If removed, align the front floor-air doors (1 and 3) with each other and install then into the center partition (2). Make sure that the air door retaining tabs (4) are fully engaged.
4. Install the center partition (3) into the right half of the air distribution housing (2).
5. Install the left half of the air distribution housing (1) onto the right half of the air distribution housing. Align the air door pivot shafts with each other and with the pivot shaft holes in the housing.
6. Install the eight screws (5) that secure the two halves of the air distribution housing (3) together. Tighten the screws to 2.2 N.m (20 in. lbs.).
7. Install the four metal clips (4) that secure the two halves of the air distribution housing together.
8. Inspect the foam seal (1), especially at the parting line (2). If the seal is deformed or damaged, it must be replaced.
9. On LHD models, carefully install the heater core (3) into the right side of the air distribution housing (2).
10. If equipped with dual zone heating-A/C, install the blend door stop (1) onto the right side of the air distribution housing.
11. Position the rear floor/console door actuator (2) onto the right side of the air distribution housing (3). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those on the floor/console door pivot shaft.
12. Install the screws (1) that secure the rear floor/ console door actuator onto the right side of the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.).
13. If equipped with dual zone heating-A/C, position the blend door actuator mounting bracket (5) onto the right side of the air distribution housing and install the retaining screws (4). Tighten the screws to 2 N.m (17 in. lbs.).
14. If equipped with dual zone heating-A/C, position the blend door actuator (7) onto the blend door actuator mounting bracket and install the retaining screws (6). Tighten the screws to 2 N.m (17 in. lbs.). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those on the blend door stop.
15. On RHD models, carefully install the heater core into the left side of the air distribution housing (3).
16. Install the front floor door linkage rod (6) and the lower defrost/panel door pivot gear (2) onto the left side of the air distribution housing.
NOTE: Align the arrow on the lower defrost/panel door pivot gear with the locator in the window of the mode door cam during installation of the mode door cam.
17. Align and install the mode door cam (7) onto the left side of the air distribution housing.
NOTE: Align the guide pin on the upper defrost/ panel door linkage rod with the guides in the mode door cam during installation of the upper defrost/panel door linkage rod.
18. Align and install the upper defrost/panel door linkage rod (8) onto the left side of the air distribution housing.
NOTE: Align the detent in the upper defrost/panel door pivot gear with the locator in the upper defrost/panel door linkage rod during installation of the upper defrost/panel door pivot gear.
19. Align and install the blend door stop (5), front floor door pivot gear (4) and the upper defrost/panel door pivot gear (1) onto the left side of the air distribution housing.
20. Position the blend door actuator mounting bracket (5) and the mode door actuator mounting bracket (8) onto the left side of the air distribution housing (1) and install the retaining screws (3 and 6). Tighten the screws to 2 N.m (17 in. lbs.).
21. Position the blend door actuator (4) and the mode door actuator (7) onto the mounting brackets and install the retaining screws (2). Tighten the screws to 2 N.m (17 in. lbs.). If necessary, rotate the actuators slightly to align the splines on the actuator output shaft with those on the mode door cam and the blend door stop.
22. Install the air distribution housing onto the HVAC housing.