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Air Outlet Duct Replacement - Defroster

TOOLS REQUIRED
J 38778 Door Trim Pad Clip Remover

REMOVAL PROCEDURE

IMPORTANT: The defroster door must be closed to allow clearance during defroster duct removal.




1. Set the HVAC controls in the VENT mode to close the defroster door.

IMPORTANT: Remove the cross vehicle beam with the defroster duct attached.

2. Remove the cross vehicle beam.
3. Remove the side window ducts from the defroster outlet duct.




4. Remove the defroster outlet duct to cross vehicle beam retaining screws.
5. Using the J 38778 remove the lower defroster outlet duct retaining clips..
6. Remove the defroster outlet duct from the cross vehicle beam.

INSTALLATION PROCEDURE




1. Position the defroster outlet duct to the cross vehicle beam.
2. Connect the lower defroster outlet duct retaining clips.

NOTE: Refer to Fastener Notice in Service Precautions.

3. Install the defroster outlet duct to cross vehicle beam retaining screws.

Tighten
Tighten the screws to 10 N.m (89 lb in).




4. Install the side window ducts to the defroster outlet, duct.
5. Install the cross vehicle beam.