Service Procedure

NOTE:
Use suitable covers to protect upholstery, carpeting, etc. when performing this Service Procedure.

1. Write down all radio station presets.

2. Disconnect the negative battery cable.

3. Remove the AC/heater control assembly and the instrument panel assembly (refer to the "IP" section of the applicable Electronic Service Manual - ESM - for removal instructions).





4. Inspect the Temperature Control (Air Mix) Cable connection to the Temperature Control (Air Mix) Lever (see Figure 2).

^ If the Temperature Control (Air Mix) Lever is broken or damaged, replace the AC/Heater Control Assembly. Then proceed to step 6.

^ If only the cable is bent or damaged, replace only the cable and the cable clamp. Then proceed to step 5.

NOTE:
Do not re-install the AC/Heater Control Assembly at this time.

5. Inspect the Mode Control Cable/Rod connection to the Mode Control Lever (see Figure 2).

^ If the Mode Control Lever is broken or damaged, replace the AC/Heater Control Assembly. Then proceed to step 6.

^ If only the cable is bent or damaged, replace only the cable and the cable clamp.

Then proceed to step 6.

NOTE:
Do not re-install the AC/Heater Control Assembly at this time.

6. Inspect the foam seals (top and bottom) on both Mode doors and the Air Mix door:





a. Look down into the Heater Unit Assembly to visually see if any foam seals are missing or loose on top of each door (see Figure 3).





b. Use your hands to feel around the bottom of each door for any missing or loose foam seals (see Figures 3 and 4)

^ If only top foam seals are missing or loose, replace only the top seals (see step 8 and Figure 3) Do not remove the Heater Unit Assembly.

^ If any bottom foam seals are loose or missing, remove the heater unit assembly and replace the top and bottom seals (see steps 7 and 8, and Figures 3 and 4)

IMPORTANT:
Remove any seal material you find.

NOTE:
Perform step 7 only if required - as determined in step 6.

7. Replace bottom seals on the Heater Unit doors:

^ Remove the Heater Unit and disassemble it. Refer to section MTC in the applicable ESM as needed.

^ Replace all of the bottom seals on both Mode Doors (see Figure 4).

^ Replace only three of the bottom seals on the Air Mix door. Replacement of the seal next to the hinge is not needed, that seal does not come in the kit (see Figure 4).

NOTE:
Remove all adhesive residue with Isopropyl Alcohol before installing the new foam seals.

8. Replace the top seals on the heater unit doors (see Figure 3).

^ Replace the four foam seals on both of the Mode Doors.

^ Replace only three of the foam seals on the Air Mix Door. Replacement of the seal next to the hinge is not needed, that seal does not come in the kit.

NOTE:
Remove all adhesive residue with Isopropyl Alcohol before installing the new foam seals.

9. Re-install / reassemble all parts removed in the reverse order.

10. Re-connect the negative battery cable and re-program all radio station presets.