Attachment III - Technical Information

Villager Secondary Inlet Screen Inspection and Installation





1. Remove both front wiper arms by first placing the blades in the upright position, then pulling the lock tab out and removing the arms from the pivot shafts. See Figure 1.

2. Open both front doors.





3. Pull down on the front door weather-stripping to expose the side windshield moulding screws, then remove the five (5) screws per side and remove mouldings. See Figure 2.





4. Remove the one (1) screw located in the center of the lower windshield moulding. See Figure 3.





5. Unlock the five (5) plastic twist-lock fasteners located across the top of the lower windshield moulding. See Figure 4.

6. Open the hood and cover the fenders.





7. Remove the four (4) plastic screws securing the lower windshield moulding. See Figure 5.





8. Lift up on the lower windshield moulding and disconnect the washer hose at the Y-connector, then remove the moulding from the vehicle. See Figure 6.

9. Inspect the air inlet duct to see if the secondary inlet screen has already been installed. If not, continue with this installation procedure. If the screen is in place, go to Step 19 for installation of the removed components.

10. From under the right side of the instrument panel, locate the blower motor.





11. Disconnect the blower motor electrical connector. See Figure 7.





12. Remove the blower motor air vent tube. See Figure 8.





13. Remove the three (3) screws securing the blower motor to the evaporator case then remove the blower motor from the vehicle. Also, remove the two (2) blower motor resistor screws and remove the resistor from the evaporator case. See Figure 9.





14. Clean all the debris from around the air inlet duct and surrounding area, blower housing, blower motor and wheel, and air vent tube. Clean any remaining debris from the evaporator case using either a shop vacuum or compressed air. Reach inside case and verify all debris has been removed from around resistor area. See Figure 10.





15. Position the secondary air inlet screen over the air inlet flange as shown. See Figure 11.





16. Twist the dual attachment wires together to secure the screen to the flange. Verify screen is tightly fastened to flange before continuing. See Figure 12.





17. Apply duct tape all the way around the flange and screen joint as shown to prevent any NVH concerns. See Figure 13.

18. Reposition the blower motor and install the three (3) retaining screws. Position the blower resistor and install the two (2) retaining screws.

19. Install the blower motor air vent tube, then connect the blower motor electrical connector.

20. Position the lower windshield moulding making sure to first connect the washer hose to the Y-connector.

21. Lock the five (5) plastic twist-lock fasteners into position securing the lower windshield moulding.

22. Install the four (4) plastic screws along the lower edge of the lower windshield moulding.

23. Remove the fender covers then close the hood.

24. Install the one (1) screw located in the center of the lower windshield moulding.

25. Position the windshield side mouldings and install retaining screws then close front doors.

NOTE:
The LH and RH wiper arms are not interchangeable. The arms are clearly marked with a "D" on the drivers side and a "V" on the passenger side.

26. Install both front wiper arms, making sure to close the lock tab once arm is properly positioned.

27. Check blower motor, wiper and washer operation.