Front
DISASSEMBLYNOTE: The front HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator, recirculation-air door, mode-air doors, blend-air doors and linkage.
1. Remove the front HVAC housing (1) and place it on a workbench.
2. Disconnect the HVAC wire harness (2) from the recirculation door actuator (3).
3. Remove the screws (4) that secure the air inlet housing (5) to the HVAC housing.
4. Remove the air inlet housing from the HVAC housing.
5. If required, remove the recirculation door actuator from the air inlet housing.
6. Disconnect the HVAC wire harness (1) from the evaporator temperature sensor (2 ), blend door actuator (3) and the two mode door actuators (4).
7. Remove the the evaporator temperature sensor from the top of the HVAC housing (5).
8. Remove the blend door actuator and the mode door actuators from the HVAC housing.
9. Remove the two actuator couplers (1) from the left end of the HVAC housing (2).
10. Carefully remove the foam seal (1) from the flange on the HVAC housing (2). If the seal is deformed or damaged, it must be replaced.
11. Remove the screw (3) that secures the heater core tube retaining bracket (4) to the top of the HVAC housing.
12. Remove the heater core tube retaining bracket from the HVAC housing.
13. Remove the two screws (1) that secure the HVAC housing retaining bracket (2) to the top of the HVAC housing (3).
14. Remove the HVAC housing retaining bracket from the HVAC housing.
15. Remove the two screws (4) that secure the heater core retaining bracket (5) to the top of the HVAC housing.
16. Carefully remove the heater core (6) from the HVAC housing.
17. Disconnect the HVAC wiring harness (1) from the blower motor (2).
18. Remove the blower motor from the HVAC housing (3).
19. Remove the evaporator temperature sensor.
20. Disconnect the HVAC wiring harness (1) from the blower motor resistor or power module (2), depending on application.
21. If necessary, remove the blower motor resistor or power module, depending on application.
22. Remove the HVAC wiring harness from the HVAC housing (3).
23. Remove the screws (4) that secure the two halves of the HVAC housing together.
24. Separate the two halves of the HVAC housing.
25. If necessary, remove the mode-air doors from the upper half of the HVAC housing.
26. Carefully lift the A/C evaporator (1) and insulator (3) out of the top of the HVAC housing (2).
27. Remove the blend-air doors and linkage (1), mode-air door (2), baffle (3) and the duct plate (4) from the lower half of the HVAC housing (6).
28. If necessary, remove the floor distribution duct (5) from the HVAC housing.
ASSEMBLY
1. If removed, install the floor distribution duct (5) to the HVAC housing (6).
2. Install the blend-air doors and linkage (1), mode-air door (2), baffle (3) and the duct plate (4) into the lower half of the HVAC housing.
3. Install the A/C evaporator (1) into the lower half of the HVAC housing (2). Make sure that the evaporator drain is clean and unrestricted and that the evaporator insulator (3) is properly installed.
4. If removed, install the mode-air doors into the upper half of the HVAC housing (2).
5. Align the ends of the blend-air door pivot shafts (1) to the openings in the upper half of the HVAC housing and install the upper housing half to the lower housing half.
6. Install the screws (4) that secure the two halves of the HVAC housing (3) together. Tighten the screws to 2.2 N.m (20 in lbs.).
7. Install the HVAC wiring harness (1). Make sure the harness is routed through all wiring retainers.
8. If removed, install the blower motor resistor or power module (2), depending on application.
9. Connect the HVAC wire harness to the blower motor resistor or power module, depending on application.
10. Install the blower motor (2) to the HVAC housing (3).
11. Connect the HVAC wire harness (1) to the blower motor.
12. Carefully install the heater core (6) into the top of the HVAC housing (3). Make sure that the heater core insulator is properly positioned.
13. Install the two screws (4) that secure the heater core retaining bracket (5) to the HVAC housing. Tighten the screws to 2.2 N.m (20 in. lbs.).
14. Install the HVAC housing bracket (2) to the top of HVAC housing.
15. Install the two screws (1) that secure the HVAC housing bracket to the HVAC housing. Tighten the screws to 2.2 N.m (20 in. lbs.).
16. Install the heater core tube retaining bracket (4) to the top of the HVAC housing (2).
17. Install the screw (3) that secures the heater core tube retaining bracket to the HVAC housing. Tighten the screw to 2.2 N.m (20 in. lbs.).
18. Install the foam seal (1) to the flange on the HVAC housing.
19. Align the two actuator couplers (1) with the mode-air door pivot shafts and install the couplers into the left side of the HVAC housing. Be sure to install the couplers with the coupler arm located between the two stop tabs on the HVAC housing.
20. Install the blend door actuator (3) and the mode door actuators (4) to the HVAC housing (5).
21. Install the evaporator temperature sensor (2) into the top of the HVAC housing.
22. Connect the HVAC wire harness (1) to the evaporator temperature sensor, blend door actuator and the mode door actuators.
23. If removed, install the recirculation door actuator (3) to the air inlet housing (5).
24. Install the air inlet housing onto the top of the HVAC housing (1).
25. Install the screws (4) that secure the air inlet housing to the HVAC housing. Make sure the HVAC wire harness retainer is properly installed.
26. Connect the HVAC wire harness to the recirculation door actuator (3).
27. Install the HVAC housing.