Question about 2003 Ford Focus

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Air ventilation 2002 Ford Focus: The air circulation does not come out through the front window vents when I select the appropriate position on the knob. All the other positions work fine. It is almost like something is jamming the window vent. How do I take apart the dash to inspect??

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  • shill136 Jul 17, 2008

    Thanks for that. I confirmed with a Ford service center and they said it was the heater unit itself and would involve pulling the dash off. Not happy but at least I know what I am in for.

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Taking the dash out is not for the faint of heart. I just disassembled one on a wrecked car. It is pretty difficult. It involves disabling the air bags, lowering the steering wheel, and removing the whole top section of the dash in one piece. If you are up for it I could give a little more specific guidance, but I don't know about the air bag problem. You don't want the thing exploding in your face.
The heater assembly has a control assembly on the drivers side of the heater box (the box is right in the center of the car). You might be able to inspect that for free movement of the flaps that dirsect the air.

Posted on Jul 14, 2008

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SECTION 412-01: Air Distribution and Filtering 2001 Focus Workshop Manual DESCRIPTION AND OPERATION Air Distribution and Filtering The new heating and ventilation system ensures even air distribution.
The temperature control and air distribution flaps are controlled by two operating cables. All vehicles have a recirculated air function, with the flap controlled by a servo motor.
Air is supplied to the windscreen and side windows regardless of the air distribution setting.
The clean air filter is fitted as standard in most countries. This cleans the incoming fresh air of pollen and dirt particles. It must be renewed after every 40,000 km under normal operation conditions, or after 20,000 km under difficult conditions. If no clean air filter is installed, a plastic grille is fitted over the air intake. This can easily be replaced with a clean air filter.
Air distribution operating switch
Face level The main flow of air enters the passenger compartment at face level.
Face level/floor level The main flow of air enters the passenger compartment in equal parts at face level and floor level, and a small amount flows to the demister nozzles of the side windows.
Floor level The main flow of air enters the passenger compartment at floor level, and a smaller amount flows to the demister nozzles of the side windows.
Demist/floor level The main flow of air enters the passenger compartment in equal parts at the windscreen and at floor level, and a smaller amount flows to the demister nozzles of the side windows.
Demist The main flow of air enters the passenger compartment at the windscreen and a smaller amount flows to the demister nozzles of the side windows.
Air distribution operating switch Air distribution operating cables
NOTE: The Bowden cables for LHD and RHD vehicles are identical. However, they are fastened to the air flap operating mechanism with the respective reverse side of their connectors.
The air distribution switch operates with two Bowden cables. The cables operate the air distribution valves in the heater housing.
To remove and install the cables, the rotary switch must be turned as far as it will go to the left. The air flap mechanism engages easily in this position, making the installation of the cables easier.
--------------------------------
Air Distribution Cable Control Assembly Removal
s1y~us~en~file=ani_caut.gif~gen~ref.gif CAUTION: Disconnect the battery ground cable. For additional information, refer to Section 414-01 .
  1. Remove the radio/cassette unit and the CD player (if equipped). For additional information, refer to Section 415-01 .
  1. Remove the bezel with heater/air conditioning controls.
  1. Remove the bezel with heater/air conditioning controls (continued).
    • Pull off seven electrical connectors (six shown).
  1. NOTE: To remove the Bowden cables, turn the rotary switches as far as they will go to the left.
    Remove the bezel with heater/air conditioning controls (continued).
    • Unclip the Bowden cables.
  1. Remove the lower driver's side footwell trim.
  1. Unclip and remove the air distribution Bowden cables.
  1. Unclip and remove the temperature control Bowden cables.
    • Unclip and remove the temperature control Bowden cables.
Installation
  1. NOTE: Route the new Bowden cables without kinks and check for easy accessibility.
    NOTE: To install the Bowden cables, turn the rotary switches as far as they will go to the left. The mechanism engages easily in this position.
    NOTE: The Bowden cables are identical for RHD and LHD vehicles, although they are fastened to the air flap operating mechanism with the reverse side of their connectors.
    Install the components in reverse order.
  1. Check operation of the Bowden cables.

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