Air Duct: Service and Repair

REMOVAL

Instrument Panel Ducts And Outlets Remove/Install:

Ducts And Outlets
Only the demister hoses and the panel outlet barrels can be removed without instrument panel assembly removal. Removal of the fresh air duct and collar requires that the heater-A/C housing also be partially removed. The panel outlet housings and demister outlets are serviced only as a part of the instrument panel or instrument panel center bezel.

WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAG AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

Heater-A/C Housing Ducts Remove/Install:

Defrost/demist Duct

1. Remove the instrument panel assembly from the vehicle.
2. Remove the two push-nuts that secure the defrost/demist duct to the studs on the dash panel.
3. Remove the defrost/demist duct from the studs on the dash panel.
4. Reverse the removal procedures to install.

Demister
1. Disconnect and isolate the battery negative cable.
2. Remove the glove box from the instrument panel to service the passenger side demister hose. Refer to Glove Box in the Body and Frame/Interior Trim/Glove Compartment/Service and Repair for the procedures. Remove the knee blocker from the instrument panel to service the driver side demister hose. Refer to Knee Blocker in the Airbags and Seat Belts/Airbags/Knee Diverter/Service and Repair for the procedures.
3. Reach through the glove box opening or the steering column opening of the instrument panel to disconnect the ends of the demister hose from the demister outlet and the defrost/demist duct.
4. Reverse the removal procedures to install.

Floor Duct
1. Remove the instrument panel from the vehicle. Refer to Instrument Panel Assembly in Instrument Panel Systems/Service and Repair for the procedures.
2. Remove the two screws that secure the floor duct to the bottom of the heater-A/C housing.
3. Release the snap clip that secures the floor duct to the dash panel side of the heater-A/C housing by pushing the snap clip towards the dash panel
4. Slide the floor duct out from under the heater- A/C housing.
5. Reverse the removal procedures to install. Tighten the screws to 2.2 Nm (20 in. lbs.).

Fresh Air Duct And Collar
1. Remove the instrument panel from the vehicle. Refer to Instrument Panel Assembly in Instrument Panel Systems/Service and Repair for the procedures.
2. Remove the five nuts from the heater-A/C housing mounting studs on the engine compartment side of the dash panel. If necessary, loosen the battery hold-downs and reposition the battery for additional access. Refer to Battery for the procedures.
3. Remove the floor duct from the bottom of the heater-A/C housing. See Floor Duct for the procedures.
4. Remove the one screw that secures the heater- A/C housing to the plenum bracket on the passenger compartment side of the dash panel.
5. Push gently down on the top of the heater-A/C housing until sufficient clearance is obtained to unsnap the fresh air duct from the top of the heater-A/C housing.
6. Remove the fresh air duct collar from the cowl plenum panel by reaching up above the heater-A/C housing fresh air duct opening and pulling the collar downward. The collar is retained in the cowl plenum panel by a light snap fit.
7. Reverse the removal procedures to install, Tighten the plenum bracket screw to 3.4 Nm (30 in. lbs.). Tighten the dash panel mounting nuts to 6.2 Nm (55 in. lbs.).

Panel Ducts
1. Remove the instrument panel from the vehicle. Refer to Instrument Panel Assembly in Instrument Panel Systems/Service and Repair for the procedures.
2. Remove the demister hoses from the demister outlets.
3. Remove the two screws from the center of the rearward facing side of the instrument panel that secure the main panel duct to the instrument panel base.
4. Remove the one screw that secures each end panel duct and/or the center panel duct to the instrument panel base.
5. Remove the panel ducts from the instrument panel.
6. Reverse the removal procedures to install. Tighten the screws to 2.2 Nm (20 in. lbs.).

Panel Outlet Barrels
1. Using a trim stick or another suitable wide fiat-bladed tool, gently pry the panel outlet barrel out of the panel outlet housing. The barrel is retained by a light snap fit.
2. To install, position the barrel in the panel outlet housing and press in firmly and equally at both ends of the barrel until it snaps into place.