Air Door Position Sensor / Switch: Testing and Inspection

Control Linkage Adjustment Manual
MODE DOOR
1. Move side link by hand and hold mode door in DEF mode.
2. Install mode door motor on heater unit and connect it to main harness.
3. Turn ignition switch to ON.
4. Select VENT mode.
5. Attach mode door motor rod to side link rod holder.
6. Select DEF mode. Check that side link operates at the fully-open position.






AIR MIX DOOR (Water cock)
1. Move air mix link by hand and hold air mix door in full cold position.
2. lnstall air mix door motor on heater unit and connect sub- harness.
3. Turn ignition switch to ON.
4. Slide temperature control lever to full cold.
5. Attach air mix door motor rod to air mix door link rod holder.
6. Check that air mix door operates properly when temperature control lever is slid to full hot and full cold.
7. Slide temperature control lever to full cold.






8. Attach water cock cable to air mix door linkage and secure with clip.
9. Rotate and hold water cock lever and plate in the full cold position (CLOCKWISE completely).
10. Attach water cock cable to plate and secure with clip (white mark on cable housing should be centered under the retaining clip).
11. Check that water cock operates properly when temperature lever is slid to full hot and full cold. (After several cycles, water cock lever should be midpoint of plate opening when temperature slider is full cold).






INTAKE DOOR
1. Connect intake door motor harness connector before installing intake door motor.
2. Turn ignition switch to ON.
3. Turn REC switch ON.
4. Install intake door motor on intake unit.
5. Install intake door lever.
6. Set intake door rod in REC position and fasten door rod to holder on intake door lever.
7. Check that intake door operates properly when REC switch is turned ON and OFF.






FRESH VENT DOOR
1. Connect fresh vent door motor harness connector before installing fresh vent door motor.
2. Turn ignition switch to ON.
3. Install fresh vent door motor on heater unit.
4. Attach fresh vent door rod to fresh vent door link rod holder.
5. Check that fresh vent door operates properly when bi-level switch is turned ON and OFF with the temperature control lever in the middle position.






MODE DOOR
1. Install mode door motor on heater unit and connect it to main harness.
2. Set up code No. 46 in Self-diagnosis STEP 4.
3. Move side link by hand and hold mode door in DEF mode.
4. Attach mode door motor rod to side link rod holder.






5. Make sure mode door operates properly when changing from code No. 41 to 46 by pushing DEF switch.






AIR MIX DOOR (Water cock)
1. Install air mix door motor on heater unit and connect it to main harness.
2. Set up code No. 41 in Self-diagnosis STEP 4.
3. Move air mix door lever by hand and hold it in full cold position.
4. Attach air mix door lever to rod holder.






5. Make sure air mix door operates properly when changing from code No. 41 to 46 by pushing DEF switch.






6. Set up code No. 41 in Self-diagnosis STEP 4.
7. Attach water cock cable to air mix door linkage and secure with clip.
8. Rotate and hold water cock lever AND plate in the full cold position (CLOCKWISE completely).
9. Attach water cock cable to plate and secure with clip (white mark on cable housing should be centered under the retaining clip).
10. Check that water cock operates properly when changing from code No. 41 to 46 by pushing DEF switch. (After several cycles, water cock lever should be midpoint of plate opening when code No. 41 is set.)






INTAKE DOOR
1. Install intake door motor on intake unit and connect it to main harness.
2. Set up code No. 41 in Self-diagnosis STEP 4.
3. Move intake door link by hand and hold it in REC position.
4. Attach intake door lever to rod holder.






5. Make sure intake door operates properly when changing from code No. 41 to 46 by pushing DEF switch.






FRESH VENT DOOR
1. Install fresh vent door motor on cooling unit and connect it to main harness.
2. Set up code No. 46 in self-diagnosis STEP 4.
3. Move fresh vent door link by hand and hold it in CLOSE position.
4. Attach fresh vent door lever to rod holder.






5. Make sure fresh vent door operates properly when changing from code No. 41 to 46 by pushing DEF switch.