Look under the dash on the driver side toward the center of the dash. You will see a couple of vacuum actuators mounted to the side of the HVAC case. Down at the bottom of the case, there is a linkage that connects to a white lever. Operate the heater mode control while observing the linkages. You will notice the white lever will wobble around. The lever is broken where it attaches to a door.When this happens, the floor vents will not open. You will have to remove the HVAC case to repair this. The parts cost about 30.00.
Yes, the whole thing needs to come out. It is about a 7 to 8 hour job.
Heater/Vent Module Replacement Removal Procedure
Important: Mark and use the same mounting bolt for the heater/vent module during the installation process. Other mounting bolts are longer and will obstruct the operation of the temperature door.
Important: The heat/vent mounting stud has a flange on the inside and cannot be removed from under the hood. Stop turning the stud after the threads are off the heat/vent module.
Important: Before installing the HVAC module to the vehicle, ensure that the HVAC module mounting studs are located in the proper positions.
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
Tighten Tighten the HVAC module mounting stud to 4.5 N·m (40 lb in).
Tighten Tighten the heat/vent module mounting studs to 4.5 N·m (40 lb in).
Tighten Tighten the HVAC module mounting nuts to 4.5 N·m (40 lb in).
Tighten Tighten the A/C evaporator and blower module heat shield screws 2.2 N·m (19 lb in).
Tighten Tighten the HVAC module mounting bolt to 4.5 N·m (40 lb in).
Tighten Tighten the HVAC module mounting nut to 4.5 N·m (40 lb in).
Important: Use the same mounting bolt marked during removal for the HVAC module during the installation process. Other mounting bolts are longer and will obstruct the operation of the temperature door.
Tighten Tighten the screws to 1.9 N·m (17 lb in).
Important: Do not use RTV. Apply the adhesive bead as straight as possible. Allow the adhesive to set for 15 minutes or until the adhesive becomes tacky.
Instrument Panel Carrier Replacement Removal Procedure
Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.
Caution: This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System. Failure to follow the correct procedure could cause the following conditions:
Important: Label all of the connections in order to avoid improper installation.
If replacing the instrument panel carrier, retain the parts for assembly of the new instrument panel carrier.
Tighten Tighten the fastener to 1.9 N·m (17 lb in).
Tighten Tighten the screws/bolts to 6.3 N·m (56 lb in).
Tighten Tighten the bolt to 11.5 N·m (102 lb in).