Overhaul

DISSASEMBLY
1. Remove the HVAC housing from the vehicle and place it on a workbench. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, Procedures, HVAC Housing Removal and Installation, Front HVAC Housing, Front HVAC Housing Removal and Installation
2. Remove the heater core tubes from the heater core.
3. Remove and discard the foam seal from the HVAC housing seal flange around the fresh air inlet opening and the expansion valve/evaporator tube opening.
4. Remove the expansion valve from the evaporator inlet and outlet tube fittings.
5. Disconnect the HVAC wire harness connector from the blower motor.
6. Disengage the HVAC wire harness from the routing clips molded into the outside of the HVAC housing.

Distribution Housing - LHD Shown, RHD Typical:

7. Remove the four screws that secure the top of the distribution housing to the HVAC housing.

Distribution Housing Retainers - Typical:

8. Pull the top of the distribution housing away from the HVAC housing far enough to disengage the two hook retainers on the bottom of the distribution housing from the two receptacles on the HVAC housing.
9. Remove the two screws that secure the upper air inlet housing to the lower air inlet housing.
10. Remove the three screws that secure the upper air inlet housing to the top of the HVAC housing. Be certain to remove the screw located just inside the inboard side of the fresh air intake opening.

Upper Intake Air Housing - LHD Shown, RHD Typical:

11. Remove the upper air inlet housing from the top of the HVAC housing to expose the recirculation air door and the blower motor and wheel.
12. Remove the screw and washer from the upper pivot of the recirculation door.
13. Remove the twelve screws that secure the upper HVAC housing half to the lower half.

HVAC Housing - LHD Shown, RHD Typical:

14. Carefully separate and remove the upper half of the HVAC housing from the lower half. Be certain not to lose the rubber grommet for the HVAC wire harness evaporator temperature sensor take out. This grommet is located on the inboard side of the flange around the expansion valve/evaporator tube opening, where it is captured in a notched area between the upper and lower HVAC housing halves.

ASSEMBLY
1. Position the upper half of the HVAC housing onto the lower half. Be certain that the rubber grommet and the HVAC wire harness take out for the evaporator temperature sensor are captured in the notched area between the upper and lower HVAC housing halves.
2. Install the twelve screws around the perimeter of the HVAC housing that secure the upper HVAC housing half to the lower half. Tighten the screws to 2 Nm (17 in. lbs.).
3. Position the upper air inlet housing onto the top of the HVAC housing over the recirculation air door and the blower motor and wheel. Be certain that the upper pivot of the recirculation air door is captured in the pivot receptacle of the upper air inlet housing.
4. Install the three screws that secure the upper air inlet housing to the top of the HVAC housing. Be certain to install the screw located just inside the inboard side of the fresh air intake opening. Tighten the screws to 2 Nm (17 in. lbs.).
5. Install the two screws that secure the upper air inlet housing to the lower air inlet housing. Tighten the screws to 2 Nm (17 in. lbs.).
6. Engage the two hook retainers on the bottom of the distribution housing to the two receptacles on the HVAC housing.
7. Roll the top of the distribution housing up into position against the HVAC housing.
8. Install the three screws that secure the top of the distribution housing to HVAC housing. Tighten the screws to 2 Nm (17 in. lbs.).
9. Engage the HVAC wire harness in the routing clips molded into the outside of the HVAC housing.
10. Reconnect the HVAC wire harness connector to the blower motor.
11. Install the expansion valve onto the evaporator inlet and outlet tube fittings.
12. Install a new foam seal onto the HVAC housing seal flange around the fresh air inlet opening and the expansion valve/evaporator tube opening.
13. Install the heater core tubes into the heater core.
14. Install the HVAC housing into the vehicle. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, Procedures, HVAC Housing Removal and Installation, Front HVAC Housing, Front HVAC Housing Removal and Installation