Air Distribution Housing

HOUSING-AIR DISTRIBUTION

NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar.





1. Install the four mode door levers (1, 2, 3 and 4) onto the right side of the air distribution housing (5) Make sure the lever retaining tabs are fully engaged to the housing.




NOTE: Properly position the air doors within the air distribution housing by first aligning the four mode door levers to the scribe lines located on the right outer side of the air distribution housing. Then, install the air doors onto the mode door levers with the UP mark on each air door facing toward the top of the housing.

NOTE: If a seal on an air door is deformed or damaged, the air door must be replaced.

2. Align the four mode door levers to the scribe lines on the right outer side of the air distribution housing (5) and install the air door(s) (1, 2, 3 and 4) onto the mode door levers with the UP mark on each air door facing toward the top of the housing.




3. Align the air door(s) with the pivot shaft hole(s) in the air distribution housing (3) and install the two halves of the housing together. Make sure the three plastic retaining tabs (6) are fully engaged.
4. Install the five screws (4) and one metal clip (5) that secure the two halves of the air distribution housing together. Tighten the screws to 2.2 Nm (20 in lbs.). Make sure the metal clip is fully engaged to the housing halves.

NOTE: If any foam seal on the air distribution housing outlets is deformed or damaged, the seal must be replaced.

5. Inspect the foam seals (1), especially at the parting line (2). If a foam seal is deformed or damaged, it must be replaced.




NOTE: Align the pins on the mode door levers with the grooves in the back of the mode door cam prior to installation of the cam.

6. Align the mode door levers on the right side of the air distribution housing (2) to the mode door cam (1) and install the cam onto the housing. Make sure the levers are correctly engaged to the cam.




7. Position the mode door actuator (2) and bracket (3) onto the right side of the HVAC air distribution housing (4). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the mode door cam.
8. Install the screws (1) that secure the mode door actuator bracket to the air distribution housing. Tighten the screws to 2 Nm (17 in. lbs.).




9. Install the blend door pivot lever (3) onto the end of the blend door pivot shaft (4) located on the left side of the air distribution housing (2). Make sure the lever retaining tab is fully engaged to the pivot shaft.

NOTE: Align the pin on the blend door lever with the groove in the pivot lever prior to installation of the blend door lever.

10. Install the blend door lever (1) onto the air distribution housing. Make sure the levers are correctly aligned to each other.




11. Position the blend door actuator (2) onto the left side of the air distribution housing (3). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the blend door lever.
12. Install the screws (1) that secure the blend door actuator to the air distribution housing. Tighten the screws to 2 Nm (17 in. lbs.).




13. If equipped with the 2.0L diesel engine, install the electric positive temperature coefficient (PTC) heater unit into the air distribution housing (2) .
14. Install the heater core into the air distribution housing Installation.
15. Install the air distribution housing onto the HVAC housing (1) HVAC Housing - Installation.
16. Install the HVAC housing assembly HVAC Housing - Installation.