TSB: 07-001/01

1999-00 Protege - COLD AIR LEAKS AT BLOWER AND COOLING UNIT FOAM SEALS

APPLICABLE MODEL(S)/VINS

All 1999-2000 Proteges with VINs lower than JM1 BJ 399999.

DESCRIPTION

Some customers may experience a cold air draft on the passenger side of vehicle in extremely cold regions. This condition may be caused by cold air leaking from the foam seals at the cooling and/or blower units.

Customers having this concern should have their vehicle repaired using the following procedure.

INSPECTION PROCEDURE

1. Verify customer concern.

2. Adjust air intake door cable at blower unit.

• For models equipped with manual REC/FRESH select lever, proceed to STEP 3.

• For models equipped with electronic REC/FRESH switch, proceed to STEP 10.

3. Remove glove box according to the Workshop Manual GLOVE COMPARTMENT REMOVAL/INSTALLATION (section 09-17 INTERIOR TRIM).

4. Set REC/FRESH select lever to FRESH position.

5. Pull cable clip tang enough to release the cable.

6. Pull cable down to align the set hole of the air intake link with the boss hole of the blower unit case.

7. Secure cable back in clip.

8. Move REC/FRESH select lever to REC then back to FRESH to confirm that the air intake door fully closes when in the FRESH position.

9. Verify adjustment.

• If the cold air draft is still present after the adjustment, proceed to STEP 10.

10. Check for cold air draft with air intake door in the re-circulate and fresh positions.

• If draft is felt in the re-circulate position, proceed to STEP 1 (Blower Unit Seal Replacement).

• If draft is felt in the fresh position, proceed to STEP 1 (Cooling Unit Seal Replacement).

REPAIR PROCEDURE (Blower Unit Seal Replacement)

1. Remove blower unit according to the Workshop Manual BLOWER UNIT REMOVAL/INSTALLATION (section 07-11).

NOTE: Dashboard removal is not required when removing the blower unit.

2. Cut the tab off if the tab is present.

3. Replace blower unit seal.

4. Inspect cooling unit inlet and outlet side seals for tears or deterioration and replace them as necessary.

5. Replace cooling unit pipe seal and drain seal.

6. Install additional seals on the blower and heater units at locations specified in the illustration below.

NOTE: Be sure to clean contact surfaces with Isopropyl Alcohol for proper adhesion.

7. Install blower unit according to Workshop Manual BLOWER UNIT REMOVAL/INSTALLATION (section 07-11).

8. Install cooling unit according to Workshop Manual COOLING UNIT REMOVAL/INSTALLATION (section 07-11).

NOTE: Prior to recharging A/C system, road test vehicle to confirm all air leaks have been corrected.

9. Adjust air intake door according to STEPS 4 through 9 of the INSPECTION PROCEDURE.

10. Recharge A/C system.

11. Verify repair.

REPAIR PROCEDURE (Cooling Unit Seal Replacement)

1. Remove cooling unit according to Workshop Manual COOLING UNIT REMOVAL/INSTALLATION (section 07-11).

2. Inspect cooling unit inlet and outlet side seals for tears or deterioration and replace them as necessary.

3. Replace cooling unit pipe and drain seal.

4. Install additional seals on the blower and heater units at locations specified in the illustration below.

NOTE: Be sure to clean contact surfaces with Isopropyl Alcohol for proper adhesion.

5. Install cooling unit according to Workshop Manual (section 07-11 COOLING UNIT REMOVAL/INSTALLATION).

NOTE: Prior to recharging A/C system, road test vehicle to confirm all air leaks have been corrected.

6. Adjust air intake door according to STEPS 4 through 9.

7. Recharge A/C system.

8. Verify repair.

PARTS INFORMATION

WARRANTY INFORMATION

Note: This information applies to verified customer complaints on vehicles covered under normal warranty. Refer to the SRT microfiche for warranty term information.

With Blower Unit Seal Replacement

(Includes Cooling Unit Seal Replacement)

With Cooling Unit Seal Replacement Only