Air Duct: Service and Repair

Air Distributor Duct Replacement

Removal Procedure

1. Remove the instrument panel trim pad.




2. Remove the screws and the center air duct.




3. Remove the screws and the RH side air duct.




4. Remove the screws and the LH side air duct.
5. Remove the bolt from the accessory wiring junction block.
6. Disengage the junction block tabs from the passenger knee bolster. Remove the junction block from the knee bolster.
7. Disconnect the booster push rod from the brake pedal.
8. Remove the brake pedal.
9. Remove the brake pedal brace bolts from the I/P carrier cross car beam.
10. Lower the body control module (BCM) away from the I/P carrier.
11. Disconnect any ground wires, as necessary.
12. Reposition the I/P wiring harness out of the way.
13. Remove the bracket bolts from the HVAC module center support.
14. Remove the bracket bolts from the HVAC module upper support.
15. Remove the right and the left I/P carrier bolts.
16. Remove the I/P carrier.
17. Remove the cross car air duct bolts from the I/P carrier.
18. Remove the cross car air ducts from the I/P carrier.

Installation Procedure

1. Install the cross car air ducts to the I/P carrier.

Notice: Refer to Fastener Notice.

2. Install the cross car air duct bolts to the I/P carrier.

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

3. Install the I/P carrier to the vehicle. Align the I/P carrier to the HVAC module and the hinge pillars.
4. Install the bolts to the right and the left I/P carrier.

Tighten the bolts to 25 N.m (18 lb ft).

5. Install the bolts to the HVAC module upper support bracket.

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

6. Install the bolts to the HVAC module center support bracket.

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

7. Position the I/P wiring harness to the original position.
8. Connect any disconnected ground wires.
9. Install the BCM.
10. Install the brake pedal brace bolts to the I/P carrier.
11. Install the brake pedal.
12. Install the booster push rod to the brake pedal.
13. Seat the bottom junction block tabs and snap the top of the junction block to the passenger knee bolster.
14. Install the junction block bolt.

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




15. Install the RH side air duct.
16. Install the RH side air duct screws.

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




17. Install the LH side air duct.
18. Install the LH side air duct screws.

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




19. Install the center air duct.
20. Install the center air duct screws

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

21. Install the instrument panel trim pad.