Air Door: Service and Repair

Doors

A/C Air Temperature Control

Removal

1. Remove A/C evaporator housing as outlined.

2. Remove foam seals from evaporator core tubes.

3. Remove four retaining screws and A/C electronic door actuator motor (19E616) from A/C evaporator housing.






4. Disengage spring from heater core cover (18B300) and remove spring from lever.






5. NOTE:Do not attempt to bend any part of the lever; it is brittle and will break.

Gently depress locking ramp and remove lever from secondary A/C air temperature control door end.






6. Rotate primary A/C air temperature control door shaft down; then swing metal link and remove from pin.

7. Remove retaining screws from around flange joint of A/C evaporator housing.

8. With side cutters (or equivalent), cut all snap loops around flange joint of A/C evaporator housing.

9. Remove upper evaporator housing case from lower evaporator case housing.

10. Disengage A/C damper door shaft link (19A600) from primary A/C air temperature control door and remove primary A/C air temperature control door from A/C evaporator housing.






11. To remove supplemental or secondary A/C air temperature control doors, flex A/C evaporator housing to disengage door pivot ends and remove door from housing.






Installation

1. Flex A/C evaporator core housing to permit installation of supplemental and/or secondary A/C air temperature control doors.

2. Engage A/C damper door shaft link to primary A/C air temperature control door and position door into upper half of A/C evaporator housing.

3. Install upper evaporator case housing to lower evaporator case housing making sure heater air damper door lower post is positioned in pivot hole in lower evaporator case housing.

4. Install retaining screws around flange joint of A/C evaporator housing.

5. Install metal link over pin on primary A/C air temperature control door shaft.

6. Install secondary A/C air temperature control door lever on metal link.

7. Install secondary A/C air temperature control door lever to secondary A/C air temperature control door end.

8. Engage spring to heater core cover and secondary A/C air temperature control door lever.

9. Install A/C electronic door actuator motor to A/C evaporator housing with four retaining screws.

10. Install foam seals over evaporator tubes.

11. Install A/C evaporator housing assembly as outlined.

Windshield Defroster

The heater air plenum chamber (18471) on vehicles with rear passenger A/C registers will have an additional vacuum control motor (18A318) connected to a supplemental A/C damper door.

Procedures for servicing the supplemental A/C damper door are the same as for the windshield defroster door.






Removal

1. Remove heater air plenum chamber as outlined.

2. Remove two retaining screws and A/C plenum demister adapter (19E662) from heater air plenum chamber.

3. Remove two screws retaining windshield defroster door vacuum control motor and/or supplemental A/C damper door vacuum control motor to heater air plenum chamber.

4. NOTE:Do not attempt to bend any part of the pivot shaft; it is brittle and will break.

Rotate vacuum control motor and disengage arm from pivot shaft.

5. Gently depress locking ramp and remove pivot shaft from windshield defroster door (18A478) and/or supplemental A/C damper door end.

6. Remove any retaining screws if present from around flange joint of heater air plenum chamber.

7. With side cutters (or equivalent), cut all snap loops around flange joint of heater air plenum chamber and separate halves of heater air plenum chamber.






Installation

1. Position windshield defroster door and/or supplemental A/C damper door between halves of heater air plenum chamber and install retaining screws around flange joint of heater air plenum chamber.

2. Install pivot shaft to windshield defroster door and/or supplemental A/C damper door end.

3. NOTE:Do not attempt to bend any part of the pivot shaft; it is brittle and will break.

Engage arm of vacuum control motor onto pivot shaft and rotate vacuum control motor to its mounting location.

4. Install vacuum control motor to heater air plenum chamber with two retaining screws.

5. Install A/C plenum demister adapter to heater air plenum chamber with two retaining screws.

6. Install heater air plenum chamber as outlined

Heater Air Damper

Removal

1. Remove A/C evaporator housing as outlined.

2. Remove foam seals from evaporator core tubes.






3. Remove four retaining screws and A/C electronic door actuator motor from A/C evaporator housing

4. Disengage spring from heater core cover and remove spring from lever.






5. NOTE:Do not attempt to bend any part of the lever; it is brittle and will break.

Gently depress locking ramp and remove lever from secondary A/C air temperature control door end.






6. Rotate primary NC air temperature control door shaft down; then swing metal link and remove from pin.

7. Disconnect vacuum hose from heater air damper door vacuum control motor.

8. Remove two retaining screws and metal cover from A/C evaporator housing.

9. Remove screw retaining heater damper door vacuum control motor to A/C evaporator housing.






10. NOTE:Do not attempt to bend any part of the pivot shaft; it is brittle and will break.

Rotate vacuum control motor and disengage arm from pivot shaft.






11. Remove retaining screws from around flange joint of A/C evaporator housing.

12. With side cutters (or equivalent), cut all snap loops around flange joint of A/C evaporator housing.

13. Remove upper evaporator housing case from lower evaporator case housing.

14. Gently depress locking ramp and remove pivot shaft from heater air damper door.






Installation

1. Position heater air damper door between halves of A/C evaporator housing and install retaining screws around flange joint of A/C evaporator housing.

2. Install pivot shaft on heater air damper door end.

3. NOTE:Do not attempt to bend any part of the pivot shaft; it is brittle and will break.

Engage arm of vacuum control motor onto pivot shaft and rotate vacuum control motor to its mounting location.

4. Install vacuum control motor and metal cover to A/C evaporator housing with three retaining screws.

5. Reconnect vacuum hose to vacuum control motor.

6. Install metal link over pin on primary A/C air temperature control door shaft.

7. Install secondary A/C air temperature control door lever on metal link.

8. Install secondary A/C air temperature control door lever to secondary A/C air temperature control door end.

9. Engage spring to heater core cover and secondary A/C air temperature control door lever

10. Install A/C electronic door actuator motor to A/C evaporator housing with four retaining screws.

11. Install foam seals over evaporator tubes.

12. Install A/C evaporator housing assembly as outlined.

Heater and A/C Air Inlet Duct

Removal

1. Remove A/C recirculating air duct as outlined.

2. Remove two screws retaining A/C air inlet duct door vacuum control motor.

3. NOTE:Do not attempt to bend any part of the pivot shaft; it is brittle and will break.

Rotate vacuum control motor and disengage arm from pivot shaft.

4. Remove retaining screw from pivot arm and lift pivot arm off primary A/C air inlet duct door pivot shaft.

5. Swing metal link and remove from supplemental A/C air inlet duct door pivot shaft.






6. Remove retaining screws from around flange joint of A/C recirculating air duct and separate halves of A/C recirculating air duct.

7. Gently depress locking ramp and remove pivot shaft from heater and A/C air inlet duct door (18731) and/or supplemental A/C air inlet duct door end.










Installation

1. Position heater and NC air inlet duct door and/or supplemental A/C air inlet duct door between halves of NC recirculating air duct and install retaining screws around flange joint of A/C recirculating air duct.

2. Install pivot shaft on heater and A/C air inlet duct door and/or supplemental NC air inlet duct door.

3. Install metal link over pin on supplemental A/C air inlet duct door pivot shaft.

4. Install pivot arm on metal link and A/C air inlet duct door pivot shaft and secure to post on A/C recirculating air duct with retaining screw.

5. Engage arm of vacuum control motor onto pivot shaft and rotate vacuum control motor to its mounting location.

6. Secure vacuum control motor to A/C recirculating air duct with two retaining screws.

7. Install A/C recirculating air duct as outlined.