The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door.LHD model with A/C shown in illustrations. RHD and heater-only models similar.

Remove the HVAC housing assembly and place it on a workbench (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION /HOUSING-HVAC - HOUSING-HVAC ASSEMBLY - REMOVAL).Remove the air inlet housing (2) from the HVAC housing (1)(refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - HOUSING-AIR INLET - REMOVAL).

Remove the two screws (1) that secure the recirculation door actuator (3) to the right side of the air inlet housing (2) and remove the actuator.

To remove the recirculation door pivot shaft adapter (1) from the right end of the recirculation-air door, first carefully push down on the tab of the door lever pivot shaft adapter located inside of the air inlet housing (2), then pull the pivot shaft adapter straight out of the end of the recirculation-air door pivot shaft.If the foam seal on the air inlet housing is deformed or damaged, the seal must be replaced.If a rubber seal on the recirculation air-door is deformed or damaged, the air-door must be replaced.Carefully pinch the two ends of the recirculation air-door together and remove the air-door from the air inlet housing. If the seal on the recirculation air-door is deformed or damaged, the air-door must be replaced.