For 1990-2009 cars

Step | Action | Yes | No
--- | --- | --- | ---
1 | Verify the customer's complaint. Are the customer's concerns verified? | Go to Step 2 | System OK
2 | Move all controls except for the temperature adjustment. Is an excessive effort required to move the controls? | Go to Step 15 | Go to Step 3
3 | Move the temperature control. Is an excessive effort required to move the controls? | Go to Step 6 | Go to Step 4
4 | Move the temperature control. Does the temperature door move too easily? | Go to Step 5 | System OK
5 | Remove the cable from the controller. Does the control knob turn freely. | Go to Step 15 | Go to Step 14
6 | Inspect the cables for:

• | Improper routing

• | Kinks

• | Wiring interference

• | Other instrument panel interference

Is there a problem with the cable?

Go to Step 7

Go to Step 8

7 | Repair as needed. Is the repair complete? | System OK | --
8 |

1. Remove the cable from the temperature door.
2. Cycle the door manually.
3. Inspect for door binding.

Is there any door binding?

Go to Step 9

Go to Step 12

9 | Inspect a binding door seal for proper installation. Is the door seal installed properly? | Go to Step 10 | Go to Step 11
10 |

1. Inspect a binding door for the following conditions:

• | Shaft alignment

• | A bent shaft

• | A bent door

• | A warped case

2. Repair as needed.

Did you complete the repair?

System OK

--

11 | Repair the door seal, as needed. Did you complete the repair? | System OK | --
12 | Inspect for control binding. Does the control bind? | Go to Step 14 | Go to Step 13
13 |

1. Reinstall the cable to the door.
2. Inspect the clearance for the cable-to-dash components.
3. Repair any interference.

Did you complete the repair?

System OK

--

14 |

1. Remove the cable from the control.
2. Inspect the control for binding.

Does the control bind?

Go to Step 15

Go to Step 16

15 | Replace the control. Did you complete the replacement? | System OK | --
16 | Replace the cable. Did you complete the replacement? | System OK | --