Overhaul

DISASSEMBLY

Note: This procedure requires removal of the HVAC Unit. For additional information refer to Housing Assembly HVAC.

Distribution Housing:

1. Place distribution housing on workbench.

Heater Core Cover:

2. Remove heater core cover.

Heater Core Tube Plate:

Plate Removal:

3. Remove heater core tube plate.

Heater Core Tube Removal:

4. Remove heater core tubes.
5. Depress heater core retaining clips at housing. When reinstalling core use screws to fasten the heater core to the housing.
6. Slide heater core out of the housing.

Driver's Zone Actuator:

7. Remove driver's zone actuator from distribution housing.

Passenger Zone Actuator:

8. Remove passenger zone actuator from distribution housing.

Distribution Housing:

Blend-Air Door Drive Gear:

9. Using a long thin flat blade tool, insert tool through blend-air opening on top of distribution housing. Depress clip retaining the driver's blend-air door drive gear. Pull out on gear and remove from the housing.
10. Remove mode door motor.

Panel Door Gear:

11. Remove Panel door actuator gear.

Defrost Door Gear:

12. Remove defrost door actuator gear.

Cam Wheel:

13. Remove cam wheel.

Heat Door Gear:

14. Remove heat door actuator gear.

Distribution Housing:

15. Remove distribution housing lower cover screws.

Distribution Housing Half Screws:

16. Remove distribution housing half screws.

Front Cover:

View of Zone Control Doors:

17. Remove distribution housing front cover.
18. Remove weather-strip at fresh-air vent.

Distribution Housing Halves:

19. Separate housing halves.

Defrost Door:

20. Pull up on separator plate and remove defrost door.

Panel Door:

21. Remove upper half Panel door.

Floor Door:

22. Remove upper half of Floor door.

Blend-Air Door:

23. Remove upper half of the blend-air door (slide off of shaft).

Separator Plate:

24. Remove separator plate from distribution housing.

Lower Blend-Air Door:

25. Remove lower half of the blend-air door.

Lower Panel Door:

26. Remove lower half of the Panel door.

Lower Floor Door:

27. Remove lower half of the Floor door.

REASSEMBLY

For reassembly of the distribution housing, reverse the above procedures.

To reassemble the distribution housing actuator gears, an assembly procedure of the gears and cam is necessary.

Actuator Gears Alignment Procedure
1. Install lower FLOOR door actuator gear to housing. Match master spline of FLOOR door actuator gear to master spline on door.
2. Install cam wheel. Align cam wheel track to FLOOR door actuator gear.
3. Align cam wheel slot with the post on the distribution housing marked "1".
4. Install PANEL door actuator gear. Align master spline of PANEL door actuator gear to master spline on PANEL door. Position actuator gear within cam wheel track.
5. Install DEFROST door actuator gear to housing. Match master spline of DEFROST door actuator to master spline on DEFROST door. Position actuator gear within cam wheel track.
6. Reinstall housing in vehicle.
7. Perform the HVAC control Calibration Diagnostic and Cooldown test. Testing and Inspection