Remove the blend door actuator and see if the blend door can be moved by hand. If not, repair the door or heater case as needed. At the blend door actuator, test the wires. The Dark Blue wire should have battery voltage with the key "on". The Black/Light Green wire should be a ground. The Yellow/Orange wire should have varying voltage somewhere between 0 and 12 volts as the control head is turned from hot to cold and back again. If the voltage does not change, the control head is likely at fault. If the voltage varies, then the actuator is likely at fault.
THe AC coming on may be a separate issue. We will know once we have fully diagnosed one of these problems.
YES... you should be able to gain access to this actuator without removing the dash.
You should be able to move the actuator pretty easy by hand.
Let me do some research and see if I can get you any pictures that might be able to help you.
Ok.. here is the procedure from alldata to remove and replace the blend air door actuator.
Turn the ignition switch to the run position. Locate the temperature control knob in the mid (12 o'clock) position. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Remove the instrument panel from the vehicle. Refer to Instrument Panel System for the procedures. Remove the HVAC housing from the vehicle..Fig.24 Blend Door Actuator Remove/Install
Unplug the wire harness connector from the blend door actuator. Remove the two mounting screws which secure the actuator to the housing. Slide the blend door actuator off the blend door shaft. NOTE: A black plastic coupler may be attached to the blend door shaft. Remove the coupler and inspect for damage. Reinstall if there is no damage found.INSTALLATION
NOTE: Before installing the blend door actuator, be certain that the blend door is not binding and is capable of full travel in both directions.
Align the actuator with the blend door shaft and rotate the actuator to align it to the mounting bosses on the HVAC housing. Align and install the actuator screws. Tighten the mounting screws to 2.2 Nm (20 in. lbs.) . Plug in the wire harness connector to the blend door actuator. Install the HVAC housing in the vehicle. Install the instrument panel in the vehicle. Refer to Instrument Panel System for the procedures. Make sure the Temperature Control Knob is in the mid (12 o'clock) position to allow the actuator to automatically position itself in the mid position and come to a complete stop when powered up. Connect the battery negative cable.
I was able to get the actuator out without removing the dash. I can't turn it by hand, but if I open it up and take the motor out, all the gears turn individually. The motor shaft turns as well. I'm going to try hooking it back up to the connector with the gears removed just to see if the motor turns, but I may just buy a new actuator if I can find one (hopefully I can find it somewhere other than a dealer). The blend door can be moved by hand as well.
Hopefully the actuator problems resolves the A/C coming on at the wrong switch position as well.
Sounds like you are right on track!
Let me know if you have any further questions!
I opened the actuator up and found a couple of the electronic components were charred. Any idea if that's normal for these things? I ordered a new one ($135.00) and would hate to hook it up and have it fry too. Anything else I should check before I install the new one?
Do you think whatever is causing the A/C to come on in the dash/floor switch postion could be related? Seems unlikely to me but thought it would be worth asking.
You've been right on so far! Thanks.
Sorry for the delay! I am having computer problems...
Have I have not come across anything that would cause it to go bad electronically. Just be sure to check the inputs...powers and grounds to be sure that they are ok.
Glad to hear that the actuator fixed the problem!
Let me do some research for you and get back to you in a bit.
Ok.. I looked in my references and cannot find anything specific on this matter. You could call your local dealership and ask them or get a subscription from alldat or Mitchell on demand and they should have all the information in there.
But if the AC is working just fine.. honestly... I would not worry about it.