Housing-Air Inlet

NOTE: The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door.

NOTE: LHD model with A/C shown in the following illustrations. RHD and heater-only models are similar.

Fig 1: HVAC Housing Assembly

Courtesy of DAIMLERCHRYSLER CORP.

Remove the HVAC housing assembly and place it on a workbench (Refer to HEATING & AIR CONDITIONING/DISTRIBUTION /HOUSING-HVAC - HOUSING-HVAC ASSEMBLY - REMOVAL) .
Remove the air inlet housing (3) from the HVAC housing (1) (Refer to HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - HOUSING-AIR INLET - REMOVAL) .

Fig 2: Actuator - Recirculation Door
Courtesy of DAIMLERCHRYSLER CORP.
Remove the three screws (1) that secure the recirculation door actuator (2) to the left side of the air inlet housing (3) and remove the actuator.

Fig 3: Recirculation Door Pivot Lever - Removal
Courtesy of DAIMLERCHRYSLER CORP.

NOTE: Remove the recirculation door pivot lever by carefully pulling it straight out from the end of the recirculation door pivot shaft.
Remove the recirculation door pivot lever (1) from the end of the recirculation door pivot shaft on the driver side of the air inlet housing (2).

Fig 4: Air Inlet Housing - Fasteners
Courtesy of DAIMLERCHRYSLER CORP.

NOTE: If the foam seal on the air inlet housing is deformed or damaged, the seal must be replaced.
Carefully cut the foam seal (1) along the parting line (2) of the two halves of the air inlet housing (5). If the seal is deformed or damaged, it must be replaced.
Remove the screws (4) that secure the two halves of the air inlet housing together.
Carefully separate the two halves of the air inlet housing and remove the recirculation-air door (3).