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Front Air Distribution Housing Removal and Installation

HOUSING-AIR DISTRIBUTION

NOTE:
- The air distribution housing must be removed from the HVAC housing and disassembled for service of the mode-air and blend-air doors.
- LHD model shown in illustrations. RHD model similar.

REMOVAL

WARNING:
- REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH.
- ON VEHICLES EQUIPPED WITH AIRBAGS, 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 TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH.




1. Remove the HVAC housing assembly and place it on a workbench.
2. Disengage the HVAC wire harness retainer (1) from the rear of the air distribution housing (2).
3. Disconnect the HVAC wire harness (3) from the blend door actuator (4) and the mode door actuator (5) located on the driver side of the air distribution housing.




4. Disconnect the HVAC wire harness (1) from the mode door actuator (2) located near the bottom of the air distribution housing (3).
5. If equipped with dual zone heating-A/C, disconnect the HVAC wire harness from the blend door actuator (4) located on the passenger side of the air distribution housing.




6. Remove the five screws (1) that secure the heater core and tube cover (2) to the HVAC housing (3).
7. Remove the heater core and tube cover from the HVAC housing.

NOTE: Take proper precautions to protect the carpeting from spilled engine coolant. Have absorbent toweling readily available to clean up any spills.




8. Remove the screw (1) that secures the heater core tube retaining bracket (2) to the HVAC housing (3).
9. Remove the bolt (5) that secures the heater core tubes (4) to the heater core (6).
10. Disconnect the heater core tubes from the heater core and remove and discard the O-ring seals.
11. Install plugs in, or tape over the opened heater core tubes and heater core ports.




12. Remove the seven screws (1) that secure the air distribution housing (2) to the HVAC housing (3).
13. Release the locking tabs located at the top of the distribution housing and tilt the distribution housing downward to disengage the tab-and-slot type retainers located at the bottom of the housing.
14. Remove the air distribution housing from the HVAC housing.
15. If required, disassemble the air distribution housing.

INSTALLATION




1. Position the air distribution housing (2) onto the rear of the HVAC housing (3) by inserting the tabs on the bottom of the distribution housing into the slots located on the bottom of the HVAC housing.
2. Tip the air distribution housing upward until it is properly aligned with the HVAC housing and the locking tabs at the top of the distribution housing are fully engaged.
3. Install the seven screws (1) that secure the air distribution housing to the HVAC housing. Tighten the screws to 2.2 N.m (20 in. lbs.).




4. Remove the tape or plugs from the heater core tubes (4) and the heater core (6).
5. Lubricate new rubber O-ring seals with clean engine coolant and install them onto the heater core tube fittings. Use only the specified O-rings as they are made of a special material for the engine cooling system.
6. Install the heater core tubes onto the heater core and loosely install the bolt (5) that secures the tubes to the heater core.
7. Install the screw (1) that secures the heater core tube retaining bracket (2) to the HVAC housing (3). Tighten the screw to 2.2 N.m (20 in. lbs.).
8. Tighten the bolt that secures the heater core tubes to the heater core to 3 N.m (27 in. lbs.).




9. Install the heater core and tube cover (2) onto the HVAC housing (3).
10. Install the five screws (1) that secure the heater core and tube cover to the HVAC housing. Tighten the screws to 2.2 N.m (20 in. lbs.).




11. Connect the HVAC wire harness (1) to the mode door actuator (2) located near the bottom of the air distribution housing (3).
12. If equipped with dual zone heating-A/C, connect the HVAC wire harness to the blend door actuator (4) located on the passenger side of the air distribution housing.




13. Connect the HVAC wire harness (3) to the blend door actuator (4) and the mode door actuator (5) located on the driver side of the air distribution housing (2).
14. Engage the HVAC wire harness retainer (1) to the rear of the air distribution housing.
15. Install the HVAC housing assembly.
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