Air Distribution Housing

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.

NOTE: LHD model shown. RHD model similar.





1. Remove the air distribution housing (2) from the HVAC housing and place it on a workbench HVAC Housing - Removal.
2. On models equipped with the 3.0L diesel engine, remove the electric Positive Temperature Coefficient (PTC) heater from the air distribution housing Cabin Heater - Removal.
3. Remove the screws (1) that secure the blend door actuator (7) and the blend door actuator bracket (6) to the left side of the air distribution housing and remove the actuator and bracket.
4. Remove the screws (3) that secure the mode door actuator (4) and the mode door actuator bracket (5) to the air distribution housing and remove the actuator and bracket.





5. Remove the instrument panel door linkage (3) from the pivot shaft located on the left side of the air distribution housing (8) and carefully disconnect the linkage rod (2) from the instrument panel door lever (1).
6. Remove the defrost/demister door linkage (7) from the pivot shaft on the air distribution housing and carefully disconnect the linkage rod (12) from the defrost/demister door lever (11).
7. Remove the mode door cam (6) from the air distribution housing.
8. Remove the floor door linkage (5) from the floor door lever (4) and the air distribution housing.
9. Remove the blend door cam (9) from the blend door lever (10) and the air distribution housing.





10. Remove the screws (2) that secure the blend door actuator (1) to the right side of the air distribution housing (3) and remove the actuator.
11. Remove the screws (4) that secure the blend door actuator mounting bracket (5) to the passenger side of the air distribution housing and remove the mounting bracket.





12. Remove the blend door cam (1) from blend door lever (2) and the pivot shaft located on the right side of the air distribution housing (3).





13. Remove the six screws (1) that secure the floor distribution duct (3) to the air distribution housing (2) and remove the duct.





14. 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.
15. Remove the screws (4) 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 housing (2).
17. Remove the center partition (3).





18. To remove the air doors (1) from the air distribution housing (2), first carefully push down on the tab (3) of the air door lever (4) located in the pivot shaft of the air door being removed.

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

19. Gently pull the air door lever out of the pivot shaft and remove the air door(s) from the air distribution housing as required.