Air Door: Service and Repair

REMOVAL

WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible serious or fatal injury.






1. Disconnect and isolate the negative battery cable.

2. Remove the glove box from the instrument panel.

3. Remove the passenger side cowl trim panel.

4. If equipped with dash mounted audio amplifier, remove the instrument panel assembly.

5. Remove the two screws (1) that secure the recirculation door actuator (2) to the inboard side of the HVAC air inlet housing (3).

6. Remove the recirculation door actuator from the air inlet housing and disconnect the HVAC wire harness connector (4) from the actuator.






7. Disconnect the HVAC wire harness lead (1) from the blower motor (2).

8. Remove the HVAC wire harness lead from the two wire harness retainers (3).

9. Remove the three screws (4) that secure the blower motor to the bottom of the HVAC housing (5) and remove the blower motor.






NOTE: Illustration shown with air inlet housing removed from the HVAC housing for clarity.

NOTE: The actuator coupler is retained to the recirculation-air door by three integral retaining tabs located inside of the air inlet housing.

10. Using pliers carefully pull the actuator coupler (3) located on the inboard side of the air inlet housing (2) straight out of the pivot shaft of the recirculation-air door (1).

11. Reach up through the blower motor opening in the bottom of the HVAC housing and remove the recirculation-air door from the air inlet housing. Rotate and tilt the air door as required for removal.

INSTALLATION






NOTE: If the seals on the air door are deformed or damaged, the air door must be replaced.

NOTE: Illustration shown with air inlet housing removed from the HVAC housing for clarity.

CAUTION: Make sure that the recirculation-air door pivot shaft is properly seated in the pivot seat located in the air inlet housing.

1. Reach up through the blower motor opening in the bottom of the HVAC housing and position the recirculation-air door (1) into the air inlet housing (2). Rotate and tilt the air door as required. Make sure the end of the recirculation-air door pivot shaft that accepts the actuator coupler (3) is located at the inboard side of the air inlet housing.

CAUTION: Make sure the actuator coupler is correctly aligned with the notch in the recirculation-air door pivot shaft and is properly engaged to the air inlet housing.

2. Align the actuator coupler (3) with the notch in the recirculation-air door pivot shaft and install the coupler. Make sure coupler retaining tabs are fully engaged to the inside of the air inlet housing and that the coupler arm is located between the two stop tabs on side of the housing.






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






4. Install the two screws (1) that secure the recirculation door actuator (2) to the air inlet housing (3). Tighten the screws to 1.1 Nm (10 in. lbs.).

5. Connect the HVAC wire harness connector (4) to the recirculation door actuator.






6. Position the blower motor (2) into the bottom of the HVAC housing (5).

7. Install the three screws (4) that secure the blower motor to the HVAC housing. Tighten the screws to 1.7 Nm (15 in. lbs.).

8. Connect the HVAC wire harness lead (1) to the blower motor and install the wire harness lead into the two wire harness retainers (3).

9. If equipped with dash mounted audio amplifier install the instrument panel assembly.

10. Install the passenger side cowl trim panel.

11. Install the glove box.

12. Reconnect the negative battery cable.

13. Initiate the Actuator Calibration function using a scan tool.