Air Temperature Door Replacement

AIR TEMPERATURE DOOR REPLACEMENT

Removal Procedure
1. Remove the HVAC module.





2. Using a small screw driver disengage the locking tangs (3) securing the temperature door levers (2) to the temperature doors.
3. Remove the temperature door levers and the return spring (4) from the HVAC unit (1).





4. Remove the thermal expansion valve (TXV) joint bracket screws (3) and remove the bracket (2) from the HVAC unit (1).
5. Remove the heater core.
6. Disconnect the vacuum line (3) from the intake actuator.





7. Remove the vacuum lines (5) and retainers (2) from the front HVAC module case (4).
8. Remove the defroster actuator vacuum line from the defroster actuator (1).
9. Remove the defroster actuator rod from the lever.
10. Remove the defroster actuator retaining screws.





11. Remove the screws attaching the front HVAC module case to the upper HVAC module case and lower HVAC module case assembly.
12. Separate the front HVAC module case from the upper HVAC module case and lower HVAC module case assembly.





13. Remove the screws (3, 5) attaching the HVAC module case - upper (1) to the HVAC module case - lower (6).
14. Remove the clips (4) attaching the HVAC module case - upper to the HVAC module case - lower.
15. Separate the HVAC module case - upper from the HVAC module case lower.





16. Remove the temperature doors (2) from the HVAC module case.

Installation Procedure





1. Install the temperature doors (2) to the HVAC module case (3).





2. Align and install the HVAC module case - upper (1) to the HVAC module case - lower (6).
3. Install the clips (4) attaching the HVAC module case - upper to the HVAC module case - lower.

NOTICE: Refer to Fastener Notice in Service Precautions.

4. Install the upper HVAC module case to the lower HVAC module case retaining screws (3, 5).

Tighten
Tighten the screws to 1.6 N.m (14 Ib in).





5. Align and install the front HVAC module case to the upper HVAC module case and lower HVAC module case assembly.
6. Install the front HVAC module case to the upper HVAC module case and lower HVAC module case assembly retaining screws.

Tighten
Tighten the screws to 1.6 N.m (14 Ib in).





7. Install the defroster actuator (1) to the HVAC module assembly.
8. Secure the defroster actuator with the retaining screws.

Tighten
Tighten the screws to 1.6 N.m (14 Ib in).

9. Install the defroster actuator rod to the ever.
10. Install the defroster actuator vacuum line.
11. Secure the retainers (2) and vacuum lines (5) to the HVAC module case - front (4).
12. Connect the vacuum line (3) to the intake actuator.





13. Install the heater core.
14. Install the TXV joint bracket (2) to the HVAC unit (1).
15. Secure the bracket with the retaining screws (3).

Tighten
Tighten the screws to 1.6 Nm (14 Ib in).





16. Install the temperature door levers (2) and the return spring (4) to the HVAC unit (1).
17. Install the temperature door levers to the temperature doors.
18. Install the HVAC module.