Front Air Distribution Housing Removal

HOUSING-AIR DISTRIBUTION

WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation Warning and Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury.

WARNING: 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 follow these instructions may result in accidental airbag deployment and possible serious or fatal injury.

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. 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 Disassembly.