Vent Door Replacement

VENT DOOR REPLACEMENT

Removal Procedure
1. Remove the HVAC module.





2. Remove the vent door lever (1) from the vent door by performing the following:
2.1. Using a flat-blade screw driver, disengage the locking tang securing the vent door lever to the vent door.
2.2. Remove the vent door lever from the vent door.





3. Remove the thermal expansion valve (TXV) joint bracket screws (3) and remove the bracket (2) from the HVAC unit.
4. Remove the heater core.





5. Disconnect the vacuum line (3) from the intake actuator.
6. Remove the vacuum lines (5) and retainers (2) from the front HVAC module case (4).
7. Remove the defroster actuator vacuum line from the defroster actuator (1).
8. Remove the defroster actuator rod from the lever.
9. Remove the defroster actuator retaining screws.





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





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





15. Remove the vent door (2) from the HVAC module case.

Installation Procedure





1. Install the vent door (2) to the HVAC module case.





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

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 lever.
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 vent door lever (1) to the vent door.
17. Secure the vent door lever with the clip.
18. Install the HVAC module.