Air Door: Service and Repair

MODE DOOR REPLACEMENT

REMOVAL PROCEDURE
1. Remove the HVAC module assembly.




2. Remove the mode actuator screws.
3. Remove the mode actuator.




4. Remove the mode cam.




5. Remove the primary lever screws.
6. Remove the primary levers.




7. Remove the sub-levers with a flat-bladed screwdriver.




8. Remove the recirculation actuator screws.
9. Remove the recirculation actuator.




10. Remove the temperature door actuator.




11. Open the heater core pipe connector collars and remove. Clamps may need to be rotated to gain access to the retaining tab.
12. Pull the heater core pipes out of the heater core and through the HVAC module case to remove.




13. Remove the heater core retainer.
14. Remove the heater core from the module.




15. Turn the module upside down.
16. Remove the lower case screws and remove the lower case.
17. Separate the case halves.
18. Remove the evaporator and TXV seal assembly by lifting straight up.




19. Turn the module right side up, and use a razor blade to cut the defroster/vent seal, and blower motor opening seal at the center line.




20. Release the recirculation door connecting rod from the retainer.
21. Remove the rod from the small door lever and remove.
22. Remove the large and small recirculation doors.




23. Remove the case half retainer clips and screws.

IMPORTANT:
- There are 2 clips and 9 screws. Two of the screws are located in deep cavities.
- One screw is located at the center of the case.




24. With case laying on the left side, lift the right side straight up to separate the HVAC module.




25. Remove the doors from the HVAC case:
- Temperature
- Defrost
- Vent
- Heater
- Mode

INSTALLATION PROCEDURE




1. Install the doors into the HVAC case:
- Mode
- Heater
- Vent
- Defrost
- Temperature
2. Install the right side of case, carefully lining up door shafts with case openings.
3. Verify that each door can be easily rotated through out the doors entire motion.




4. Install the HVAC module screws and clips.

NOTE: Refer to Fastener Notice in Service Precautions.

Tighten the screws to 1.0 N.m (9 lb in).




5. Install the evaporator into the bottom of the HVAC module.
6. Install the lower case to the upper case.
7. Install the lower module screws.

Tighten the screws to 1.0 N.m (9 lb in).




8. Install the heater core into the case.




9. Install the heater pipes through the case and into the heater core.The shorter pipe is the upper pipe.

IMPORTANT: Verify that both pipes have a bushing and O-ring installed before installing into the heater core.

10. Install the heater pipe retaining clamps.
11. Install the heater core retaining strap.

IMPORTANT: The lower heater pipe clamp hinge fits into the tab on the heater core retainer strap.




12. Install the evaporator and TXV seal assembly.




13. Install the recirculation doors.
14. Install recirculation door rod to small door. With both doors held firmly closed, snap rod into retainer clip and close the clip.




15. Install the recirculation actuator assembly onto door shaft.The shaft has two flats that must be aligned to actuator.
16. Install the recirculation actuator bracket to module screws.

Tighten the screws to 1.0 N.m (9 lb in).




17. Install the vent and heater sub-levers.These sub-levers are identical and should have the slotted end facing inward.
18. Install the defrost door to sub-lever.




19. Install the vent primary lever.
20. Install the vent primary lever fastener.

Tighten the fastener to 1.0 N.m (9 lb in).

21. Install the heater primary lever.
22. Install the heater primary lever fastener.

Tighten the fastener to 1.0 N.m (9 lb in).




23. Install the cam. Rotate the cam to verify proper installation.




24. Install the mode actuator.
25. Install the mode actuator fastener.

Tighten the fastener to 1.0 N.m (9 lb in).

26. Install the HVAC module assembly.