Front Air Distribution Housing 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.

NOTE: LHD model shown in illustrations. RHD model similar.





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 Nm (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 Nm (20 in. lbs.).
8. Tighten the bolt that secures the heater core tubes to the heater core to 3 Nm (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 Nm (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 .