Mode Door Replacement

REMOVAL PROCEDURE




1. Disconnect the battery negative cable.
2. Remove the instrument panel (IP) trim pad.
3. Remove the passenger side SIR inflator module.
4. Remove the screws from the right and left side air distribution ducts.
5. Remove the air distribution ducts.




6. Unclip the fuse block and position aside.
7. Remove the two screws below the fuse block that hold the main wire harness connector to the cross car beam.
8. Remove the brake pedal.
9. Remove the bolts from the steering column support bracket and remove the bracket.




10. Remove the retaining bolts and position the BCM bracket aside.
11. Release the wiring harness retaining clips from the cross vehicle beam and position the IP wiring harness out of the way.




12. Remove the bolts from the center support bracket of the HVAC module.
13. Remove the center support bracket of the HVAC module.




14. Remove the retaining bolts from the upper support brackets of the HVAC module.




15. Remove the bolts which secure the left cross vehicle beam to the hinge pillar.




16. Remove the bolts which secure the right cross vehicle beam to the hinge pillar.




17. Remove the bolt (1) from the cross vehicle beam.
18. Remove the cross vehicle beam from the vehicle.




19. Disconnect the vacuum lines from the mode actuator.
20. Lift the lock tab up (1) to remove the actuator.
21. Remove the mode actuator off the slides of the HVAC module assembly.
22. Disconnect the actuator pushrod from the mode door lever and remove the actuator.




23. Remove the retaining screws (1) from the air distribution case cover.
24. Remove the air distribution case cover (2).




25. Remove the mode door (2).

INSTALLATION PROCEDURE

IMPORTANT: Align the mode door assist spring to the HVAC module case.




1. Install the mode door (2).




2. Install the air distribution case cover (2).

NOTE: Refer to Fastener Notice in Service Precautions.

3. Install the retaining screws (1) to the air distributor cover.

Tighten
Tighten the screws to 1.5 N.m (13 lb in).




4. Connect the mode actuator pushrod to the mode door lever.
5. Position the mode actuator on to the mounting slides of the HVAC module assembly.
6. Ensure that the lock tab locks the defroster actuator in place.
7. Connect the vacuum lines to the mode actuator.




8. Install the cross vehicle beam to the vehicle.




9. Install the bolts which secure the right cross vehicle beam to the hinge pillar.

IMPORTANT: Do NOT tighten the bolts at this time.




10. Install the bolts which secure the left cross vehicle beam to the hinge pillar.

Tighten
Tighten the bolts to 20 N.m (15 lb ft).




11. Install the bolt (1) to the cross vehicle beam.

Tighten
Tighten the bolt to 20 N.m (15 lb ft).




12. Install the retaining bolts to the upper support brackets of the HVAC module.

Tighten
Tighten the bolts to 10 N.m (89 lb in).




13. Install the HVAC module center support bracket.
14. Install the retaining bolts to the center support bracket of the HVAC module.

Tighten
Tighten the bolts to 10 N.m (89 lb in).

15. Install the instrument panel wiring harness on to the cross vehicle beam and secure the retaining clips.




16. Install the BCM bracket and the retaining bolts.

Tighten
Tighten the bolts to 10 N.m (89 lb in).




17. Install the fuse block to the holder.
18. Install the two screws below the fuse block that hold the main wire harness connector to the cross car beam.




19. Install the support bracket and bolts for the steering column.

Tighten
Tighten the bolts to 50 N.m (37 lb ft).

20. Install the brake pedal.
21. Install the passenger side SIR inflator module.




22. Install the right and left side air distribution ducts.
23. Install the right and left side air distribution duct bolts.

Tighten
Tighten the bolts to 1.5 N.m (13 lb in).

24. Install the IP trim pad.
25. Connect the battery negative cable.