HOUSING-AIR DISTRIBUTION

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

Fig. 115: Mode Door Levers-Removal/Installation

1. If removed, install the four 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.

Fig. 116: Air Doors-Removal/Installation

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

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

NOTE: If equipped with dual zone heating/A/C system, there are two blend-air doors that mate together at the centerline of the housing.

2. Align the four 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 door levers with the UP mark on each air door facing toward the top of the housing.

Fig. 117: Parting Line & Retainers

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 N.m (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.

Fig. 118: Mode Door Cam

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.

Fig. 119: Mode Door Actuator & Bracket

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 N.m (17 in. lbs.).

Fig. 120: Blend Door Levers

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.

Fig. 121: Blend Door Actuator

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 N.m (17 in. lbs.).

13. If equipped with dual zone system, position the blend door actuator onto the right side of the air distribution housing and install the retaining screws. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the blend door. Tighten the screws to 2 N.m (17 in. lbs.).

Fig. 122: HVAC housing assembly

14. If equipped with the 2.0L diesel engine, install the electric positive temperature coefficient (PTC) heater unit into the air distribution housing (2).

15. Install the heater core into the air distribution housing. 16. Install the air distribution housing onto the HVAC housing (1). 17. Install the HVAC housing assembly.

HOUSING-AIR INLET

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

Fig. 123: Recirculation Air-Door & Pivot Shaft

1. Carefully install the recirculation-air door (1) into the air inlet housing (2) by pinching the two ends of the air-door together and aligning the pivot shafts of the air-door to the pivot shaft holes in the air inlet housing.

NOTE: Install the recirculation door pivot shaft adapter by carefully pushing it straight into the end of the recirculation door pivot shaft.

2. Install the recirculation door pivot shaft adapter (3) into the right side pivot shaft of the recirculation airdoor.

Make sure the adapter is fully engaged to the pivot shaft.

Fig. 124: Recirculation Door Actuator-Align

3. Install the recirculation door actuator (1) onto the right side of the air inlet housing (2). If necessary, rotate the actuator slightly to align the splines of the actuator output shaft (3) with those on the recirculation door pivot shaft adapter (4).

Fig. 125: HVAC housing assembly

4. Install the air inlet housing (3) onto the HVAC housing (1). 5. Install the HVAC housing assembly.

HOUSING-HVAC

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

Fig. 126: Evaporator Removal/Installation

NOTE: Make sure that the foam insulator is properly positioned around the A/C evaporator and in the HVAC housing.

1. Carefully install the A/C evaporator (1) and foam insulator (2) into the lower half of the HVAC housing (3).

Fig. 127: HVAC Housing-Separate

2. Install the two halves of the HVAC housing (4) together and engage the nine plastic retaining tabs (1).

Make sure the retaining tabs are fully engaged.

3. Install the nine screws (3) and three metal clips (5) that secure the two halves of the HVAC housing together. Tighten the screws to 1.2 N.m (10 in lbs.). Make sure the metal clips are fully engaged to the housing halves.

NOTE: If the foam seal or plastic flange is deformed or damaged, it must be replaced.

4. Install the plastic flange and foam seal (2) over the evaporator tubes and onto the front of the HVAC housing. Make sure the four flange retaining tabs are fully engaged to the housing.

5. Remove the tape or plugs from the expansion valve and evaporator ports.

6. Lubricate new O-ring seals with clean refrigerant oil and install them onto the evaporator tube fittings.

Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

7. Install the A/C expansion valve (6) and the two retaining bolts. Tighten the bolts to 11 N.m (97 in. lbs.).

Fig. 128: Evaporator Temperature Sensor-Install

8. Install the evaporator temperature sensor (1) into the driver side of the HVAC housing (2). Make sure the retaining tabs (3) are fully engaged to the housing.

Fig. 129: Blower Motor & Resistor

NOTE: Manual temperature system shown. Automatic system similar.

9. Position the blower motor (3) into the bottom of the HVAC housing (4).

10. Install the wire lead bracket (2) and the three screws (1) that secure the blower motor to the HVAC housing. Tighten the screws to 1.2 N.m (10 in. lbs.).

11. Position the blower motor resistor or power module (6) into the HVAC housing.

12. Install the two screws (5) that secure the resistor or power module to the HVAC housing. Tighten the screws to 1.2 N.m (10 in. lbs.).

Fig. 130: HVAC housing assembly

13. Install the air inlet housing (3) onto the HVAC housing (1).

14. Install the air distribution housing (2) onto the HVAC housing.

NOTE: If the heater core is being replaced, flush the cooling system.

15. Install the HVAC housing assembly.