HOUSING-AIR DISTRIBUTION

NOTE: The air distribution housing must be removed from the HVAC housing and disassembled for service of the blend-air and mode-air doors.

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

Fig. 99: HVAC housing assembly

1. Remove the HVAC housing assembly and place it on a workbench.

2. Remove the air distribution housing (2) from the HVAC housing (1).

3. If equipped with the 2.0L diesel engine, remove the electric positive temperature coefficient (PTC) heater unit from the air distribution housing.

4. Remove the heater core from the air distribution housing.

Fig. 100: Blend Door Actuator

5. Remove the screws (1) that secure the blend door actuator (2) to the left side of the air distribution housing (3) and remove the actuator.

6. If equipped with dual zone system, remove the screws that secure the other blend door actuator to the right side of the air distribution housing and remove the actuator.

Fig. 101: Blend Door Levers

7. Remove the blend door lever (1) from the left side of the air distribution housing (2).

NOTE: To remove the blend door pivot lever, disengage the retaining tab on the lever and pull the lever straight off the pivot shaft.

8. Remove the blend door pivot lever (3) from the end of the blend door pivot shaft (4).

Fig. 102: Mode Door Actuator & Bracket

NOTE: It is not necessary to remove the mode door actuator from the bracket when servicing the air distribution housing.

9. Remove the three screws (1) that secure the mode door actuator (2) and bracket (3) to the right side of the air distribution housing (4) and remove the actuator and bracket as an assembly.

Fig. 103: Mode Door Cam

10. Remove the mode door cam (1) from the right side of the air distribution housing (2).

Fig. 104: Parting Line & Retainers

NOTE: If any foam seal on the air distribution housing outlets is deformed or damaged, the seal must be replaced.

11. Carefully cut the two foam seals (1) along the parting line (2) of the two halves of the air distribution housing (3). If either seal is deformed or damaged, it must be replaced.

12. Remove the five screws (4) and one metal clip (5) that secure the two halves of the air distribution housing together.

13. Disengage the three plastic retaining tabs (6) that secure the two halves of the air distribution housing together and carefully separate the housing.

Fig. 105: Air Doors-Removal/Installation

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

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.

14. Disengage the air doors (1, 2, 3 and 4) from the door levers and remove the air doors from the air distribution housing (5).

Fig. 106: Mode Door Levers-Removal/Installation

NOTE: To remove the door levers, disengage the retaining tabs on the inside of the air distribution housing and pull the levers straight out of the housing.

15. If required, remove the door levers (1, 2, 3 and 4) from the right side of the air distribution housing (5).

HOUSING-AIR INLET

NOTE: The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door.

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

Fig. 107: HVAC housing assembly

1. Remove the HVAC housing assembly and place it on a workbench.

2. Remove the air inlet housing (3) from the HVAC housing (1).

Fig. 108: Recirculation Door Actuator-Removal/Installation

3. Remove the two screws (1) that secure the recirculation door actuator (2) to the right side of the air inlet housing (3) and remove the actuator.

Fig. 109: Recirculation Air-Door & Pivot Shaft

4. To remove the recirculation door pivot shaft adapter from the right end of the recirculation-air door, first carefully push down on the tab of the door lever pivot shaft adapter located inside of the air inlet housing, then pull the pivot shaft adapter straight out of the end of the recirculation-air door pivot shaft.

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

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

5. Carefully pinch the two ends of the recirculation air-door together and remove the air-door from the air inlet housing. If the seal on the recirculation air-door is deformed or damaged, the air-door must be replaced.

HOUSING-HVAC

NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator.

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

Fig. 110: HVAC housing assembly

1. Remove the HVAC housing assembly and place it on a workbench.

2. Remove the air distribution housing (2) from the HVAC housing (1).

3. Remove the air inlet housing (3) from the HVAC housing.

Fig. 111: Blower Motor & Resistor

NOTE: Manual temperature system shown. Automatic system similar.

4. Remove the three screws (1) that secure the wire lead bracket (2) and the blower motor (3) to the bottom of the HVAC housing (4) and remove the blower motor and wire lead bracket.

5. Remove the two screws (5) that secure the blower motor resistor or power module (6) to the bottom of the HVAC housing and remove the resistor or power module.

Fig. 112: Evaporator Temperature Sensor-Removal

6. Using needle nose pliers (1), disengage the two retaining tabs (2) that secure the evaporator temperature sensor (3) to the driver side of the HVAC housing (4) and remove the sensor.

Fig. 113: HVAC Housing-Separate

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

7. Remove the two bolts that secure the A/C expansion valve (6) to the A/C evaporator and remove the valve.

8. Remove and discard the O-ring seals and install plugs in, or tape over the opened expansion valve and evaporator tube ports.

9. Remove the foam seal and plastic flange (2) from the front of the two halves of the HVAC housing (4).

Carefully release the four retaining tabs located at the back of the flange and pull the flange off of the evaporator tubes. If the seal or flange is deformed or damaged, it must be replaced.

10. Remove the nine screws (3) and three metal clips (5) that secure the two halves of the HVAC housing together.

11. Disengage the nine plastic retaining tabs (1) that secure the two halves of the HVAC housing together and separate the housing.

Fig. 114: Evaporator Removal/Installation

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