Air Distribution Housing, Removing And Installing

The following information refers to LHD vehicles. Information for RHD vehicles is the same.

Removing

-- Remove the heater and A/C unit. Refer to HEATER AND A/C UNIT, REMOVING AND INSTALLING .

-- Remove the coolant pipes from the heater core. Refer to HEATER CORE COOLANT PIPES, REMOVING AND INSTALLING .

-- Disconnect the connector from the fresh/recirculated air door motor and free up the wiring harness.

-- Remove the bolts -2-.

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-- Release the mounting tabs -1 and 3-.

-- Tilt the air distribution housing -4- toward the rear in direction of -arrow- and disengage.

If the air distribution housing is replaced, the following parts must be installed on the new housing:

These parts are included in the adjusting unit repair kit. Refer to the Parts Information.

Transfer the installation position and door position from the >>old<< air distribution housing.

• Adjuster for air distribution doors. Refer to AIR DISTRIBUTION DOOR ADJUSTER, REMOVING AND INSTALLING .
• Operating lever for climatronic defroster door -item  2-.

-- Install the operating lever -1- in the position shown on the door -2-.

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-- The assembly begins on the upper door in direction of -arrow A-.

-- To do so hold the upper air door -2- and push the operating lever -1- straight in the mount in the direction of -arrow-.

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-- Adjust the lower air door -2- so that the mount is positioned opposite the operating lever -1-.

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-- Push the operating lever -1- in the lower mount in the direction of -arrow-.

-- Check the operating lever -1- for secure fit by pulling on it.

-- Repeat the procedure on the other side.

-- Convert the heat exchanger. Refer to Removing - Remove the bolt -2- and then remove the bracket -3- for the heater core. .

-- Convert the wiring harness for the air distribution housing.

If the air distribution housing is replaced, the following components of the >>old<< air distribution housing must be converted:

• To remove the actuators, the operating lever must first be partially removed.
• Replace the removed operating lever with a new one from the adjusting unit repair kit. Refer to the Parts Information.

Vehicles with Electric-Manual Climate Control System:

• Temperature Control Door Motor -V68-. Refer to Temperature Control Door Motor -V68- WITH Temperature Control Door Motor Position Sensor -G92-, REMOVING AND INSTALLING .
• Air Distribution Door Motor -V428-. Refer to Air Distribution Door Motor -V428- WITH POSITION SENSOR Air Distribution Door Motor Position Sensor -G645-, REMOVING AND INSTALLING .

Vehicles with Climatronic:

• Right Temperature Control Door Motor -V159-. Refer to Right Temperature Control Door Motor -V159- WITH Right Temperature Control Door Position Sensor -G221-, REMOVING AND INSTALLING .
• Defroster Door Motor -V107-. Refer to Defroster Door Motor .
• Left Temperature Control Door Motor -V158-. Refer to Left Temperature Control Door Motor -V158- WITH Left Temperature Control Door Motor Position Sensor -G220-, REMOVING AND INSTALLING .
• Front Air Distribution Door Motor -V426-. Refer to Front Air Distribution Door Motor -V426- WITH Air Distribution Door Motor Position Sensor -G642-, REMOVING AND INSTALLING .

Continuation for All Vehicles

Install in reverse order of removal. Note the following:

-- Check the DTC memory and erase any displayed entries, then perform the "basic setting". Use the Vehicle Diagnostic Tester in the "Guided Fault Finding"  function.

-- Check the heating and A/C system function.

Tightening Specifications

• Refer to HEATER AND A/C UNIT, DISASSEMBLING AND ASSEMBLING