I have a noise inside the heater assembly under the dashboard on the passenger side (first off, what is that whole heater assembly called). I took the motor out and the noise is still there. On the bottom side, behind the motor (toward the firewall) is a vent door. The noise seems to be from an actuator that operates the door. I can "feel" the noise when I touch the door.

I do not see any linkages or anything that operate the door. Can the heater contraption be removed? Is it nessessary? What is the noise?

 

Is it a thumping noise? If so, it is very common and usually a bad actuator. They are a pain to change due to there location, but it can be done. If you just want a quick and easy solution just unplug it. You will only have recirculated air, but the noise will be gone. If you remove the blower motor you can stick your hand in there and see if it is just hung up by pushing in the direction of what setting you have the control panel on (recirculated or fresh air). Most refer to the "heater assembly) as the air plenum. It's basically just a bunch of ductwork and blend doors. The motor in question is on the passenger side and almost right on the firewall. You will have to get down and lay in the passenger floorboard to see and get to it. I have unplugged many - I personally never use the fresh air option anyway. I don't really care to smell the exhaust of the guy in front of me.

 

I have the blower motor out. I stick my hand in and touch the door. It is a door that opens to the floor area or closes. I forced the door open one time. It felt like I should not have done that. But it apparently did not break anything. I then pushed it closed again.

What is the actuator? Can I get to it? Is it a motor or selenoid or a vacuum thingy?
Does the plenum come out without removing the whole dashboard? Etc, etc?

Thanks for replying.